Rosemount CAT 200-Rev C Owner's manual

748446-C

Rosemount Analytical

M

ODEL

CAT 200

C

ONTINUOUS

A

NALYZER

T

RANSMITTER

O

PERATION AND

M

AINTENANCE

M

ANUAL

N

OTICE

The information contained in this document is subject to change without notice.

This manual is based on the production version of the Model CAT 200 Continuous Analyzer

Transmitter. Hardware and/or software changes may have occurred since this printing.

Manual Part Number 748446-C

March 2001

Printed in U.S.A.

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

www.processanalytic.com

Teflon® is a registered trademark of E. I. duPont de Nemours and Co., Inc.

SNOOP® is a registered trademark of NUPRO Co.

C

ONTENTS

748446-C Rosemount Analytical March 2001

i

Model CAT 200 Continuous Analyzer Transmitter

PREFACE

INTENDED USE STATEMENT..........................................................................P1

SAFETY SUMMARY ..........................................................................................P1

SPECIFICATIONS - GENERAL .........................................................................P4

SPECIFICATIONS – CAT 200 DETECTOR.......................................................P5

CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE............P6

RETURNING PARTS TO THE FACTORY.........................................................P6

TRAINING ......................................................................................................P6

DOCUMENTATION............................................................................................P6

COMPLIANCES .................................................................................................P7

SECTION 1. INTRODUCTION

1.1 OVERVIEW.................................................................................................1

1.2 TYPICAL APPLICATIONS ..........................................................................2

SECTION 2. DETECTOR METHODOLOGIES

2.1 NON-DISPERSIVE INFRARED (NDIR).......................................................3

2.1.1 Interference Filter Correlation Method...........................................3

2.1.2 Opto-Pneumatic Method................................................................5

2.1.3 Overall NDIR Method.....................................................................6

2.2 PARAMAGNETIC OXYGEN METHOD.......................................................8

2.3 ELECTROCHEMICAL OXYGEN METHOD ................................................10

2.4 THERMAL CONDUCTIVITY METHOD.......................................................12

C

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March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

SECTION 3. INSTALLATION

3.1 SPECIFICATIONS...................................................................................... 16

3.2 PROCESS AND CALIBRATION GAS CONNECTION ............................... 16

3.2.1 Gas Conditioning........................................................................... 20

3.2.2 Internal Gas Paths......................................................................... 21

3.3 INSTALLATION .......................................................................................... 22

3.3.1 Location ..................................................................................... 22

3.3.2 Limitations..................................................................................... 22

3.3.3 Mounting Options.......................................................................... 22

3.3.4 Vent Lines..................................................................................... 23

3.3.5 Electrical Connections................................................................... 23

3.3.6 Analytical Leak Check................................................................... 28

3.3.6.1 Flow Indicator Method................................................... 28

3.3.6.2 Manometer Method....................................................... 29

3.3.6.3 Troubleshooting Leaks.................................................. 30

SECTION 4. STARTUP AND OPERATION

4.1 STARTUP AND INITIALIZATION ............................................................... 31

4.1.1 Display & Operating Keys.............................................................. 32

4.1.2 Menu Lines and Softkey Functionality........................................... 33

4.1.3 Common Function Keys................................................................ 34

4.1.4 Entering and Changing Variables.................................................. 35

4.1.5 Starting a Function........................................................................ 35

4.1.6 Main Menu..................................................................................... 36

4.2 BASIC SETUP AND CALIBRATION........................................................... 38

4.2.1 Analyzer Channel Status............................................................... 38

4.2.1.1 Status Details................................................................ 39

4.2.1.2 Acknowledge and Clear Failures................................... 41

4.2.1.3 Current Operation Parameters...................................... 43

4.2.2 Single Component Display............................................................ 44

4.2.3 Multi Component Display .............................................................. 45

4.2.4 Calibration Procedure.................................................................... 46

4.2.4.1 Calibration Status.......................................................... 46

4.2.4.2 Zero Calibration............................................................. 48

4.2.4.3 Span Calibration............................................................ 50

4.2.4.4 Setup Basic Calibration Parameters.............................. 52

4.2.5 Open and Close Valves................................................................. 53

4.3 ANALYZER & I/O, EXPERT CONTROL & SETUP..................................... 55

4.3.1 Analyzer Module Setup................................................................. 56

4.3.1.1 Load Factory Configuration........................................... 57

4.3.1.2 Calibration Parameters.................................................. 58

4.3.1.3 Span Gas Parameter..................................................... 59

4.3.1.4 Calibration Tolerances................................................... 60

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748446-C Rosemount Analytical March 2001

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Model CAT 200 Continuous Analyzer Transmitter

4.3.1.5 Calibration Procedure Setup..........................................62

4.3.1.6 Timed Controlled Calibration..........................................65

4.3.1.7 Calibration Parameters – Manual Calibration ................67

4.3.1.8 Advanced Calibration Methods......................................68

4.3.1.9 Zero Gas Parameters ....................................................70

4.3.2 Alarm Parameters..........................................................................71

4.3.2.1 Alarm Setup and Control................................................73

4.3.3 Range Parameters.........................................................................74

4.3.3.1 Offset and Span of Range .............................................76

4.3.3.2 Response times (t

90

)......................................................77

4.3.3.3 Autoranging Control.......................................................78

4.3.4 Cross Interference Compensation.................................................81

4.3.5 Linearization...................................................................................84

4.3.6 Programmable Logic Control (PLC)...............................................88

4.3.6.1 Programming PLC..........................................................89

4.3.6.2 Example for PLC Programming .....................................94

4.3.7 Programmable Calculator..............................................................96

4.3.7.1 Programming the Calculator ..........................................97

4.3.7.2 Example for Calculation Programming...........................99

4.3.8 Measurement Display Configuration..............................................100

4.3.9 Acknowledgement of Status Reports.............................................105

4.3.10 Concentration Measurement Parameters....................................107

4.3.11 Concentration Peak Measurement ..............................................108

4.3.12 Differential Measurement.............................................................109

4.3.13 Gasflow Setup .............................................................................111

4.3.14 Pressure Compensation ..............................................................112

4.3.15 Flow Measurement ......................................................................113

4.3.16 Temperature Measurement.........................................................114

4.3.17 Load/Save Analyzer Module Configuration..................................115

4.3.18 Inputs & Outputs (SIO/DIO).........................................................117

4.3.18.1 SIO...............................................................................118

4.3.18.2 DIO...............................................................................124

4.3.18.3 Function Codes............................................................125

4.3.19 Delay and Average ......................................................................126

4.3.20 AK-Protocol Communication........................................................128

4.4 SYSTEM CONFIGURATION AND DIAGNOSTICS.....................................129

4.4.1 Diagnostic Menus ..........................................................................130

4.4.1.1 Analyzer Module Diagnostics.........................................131

4.4.2 Load/Save Module Configuration...................................................132

4.4.3 Date and Time...............................................................................134

4.4.4 Security Codes...............................................................................135

4.4.5 System Reset.................................................................................137

4.4.6 Memory Usage...............................................................................138

4.5 DISPLAY CONTROLS.................................................................................139

4.6 MEASUREMENT.........................................................................................140

4.7 SHUT DOWN ..............................................................................................140

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March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

4.8 TEMPERATURE STABILIZATION (OPTION)............................................ 141

4.8.1 Controller Settings......................................................................... 142

SECTION 5. MAINTENANCE AND SERVICE

5.1 OVERVIEW ................................................................................................ 145

5.1.1 Component Removal..................................................................... 146

5.1.1.1 Analyzer Component Removal...................................... 147

5.1.1.2 Power Supply Assembly Removal................................. 147

5.2 TROUBLESHOOTING GUIDE AND ERROR MESSAGES....................... 148

5.2.1 Instrument not functioning (LCD Display is dark).......................... 148

5.2.2 No or Incorrect Measurement Screen........................................... 148

5.2.3 Display Messages......................................................................... 149

5.2.3.1 Chopper Fail.................................................................. 149

5.2.3.2 Raw Signal too High or Low.......................................... 149

5.2.3.3 Detector Signal Communication Failed......................... 149

5.2.3.4 Light Source.................................................................. 150

5.2.3.5 Detector......................................................................... 150

5.2.3.6 Temperature Measurement........................................... 150

5.2.3.7 Invalid Pressure Measurement...................................... 151

5.2.3.8 External input ................................................................ 151

5.2.4 No or Incorrect Analog Outputs or Digital I/O................................ 152

5.2.5 Calibration not Possible................................................................. 152

5.2.6 Fluctuating or Erroneous Display.................................................. 153

5.2.7 Response Time too Long (t

90

time) ............................................... 154

5.3 ANALYZER CONFIGURATION AND ADJUSTMENT ................................ 155

5.3.1 Component Layout........................................................................ 155

5.3.1.1 Circuit Board ICB........................................................... 160

5.3.1.2 Circuit Board PSV.......................................................... 160

5.3.1.3 Circuit Board PIC........................................................... 160

5.3.1.4 Circuit Board ACU......................................................... 161

5.3.2 Analyzer Rear Panel ..................................................................... 162

5.3.3 Thermal Conductivity Response Time .......................................... 164

5.4 MAINTENANCE.......................................................................................... 166

5.4.1 Routine and Preventive................................................................. 166

5.4.2 Checking & Cleaning of the Analyzer............................................ 166

5.4.3 Cleaning & Replacement of Photometric Components................. 167

5.4.3.1 Removal of Photometer Assembly................................ 167

5.4.3.2 Light Source Replacement............................................ 167

5.4.3.3 Removal of Analysis Cells............................................. 169

5.4.3.4 Cleaning of Analysis Cells & Windows.......................... 170

5.4.3.5 Reinstalling Analysis Cells............................................. 170

5.4.3.6 Reinstalling Photometer Assembly................................ 171

5.4.3.7 Physical Zeroing............................................................ 171

5.4.4 Replacement of Electrochemical Oxygen Sensor......................... 172

5.4.4.1 Check of the Sensor...................................................... 172

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748446-C Rosemount Analytical March 2001

v

Model CAT 200 Continuous Analyzer Transmitter

5.4.4.2 Removal of the Sensor ..................................................174

5.4.4.3 Replacing the Sensor.....................................................175

5.4.4.4 Reinstalling the Sensor..................................................175

5.4.4.5 Basic Calibration for the Oxygen Sensor.......................175

5.5 ANALYZER SERVICE................................................................................176

5.5.1 Photometer Signal Processing (PCB PSV)....................................176

5.5.1.1 Internal Voltage Supply..................................................177

5.5.1.2 IR Source.......................................................................178

5.5.1.3 Chopper.........................................................................178

5.5.1.4 Unamplified Signal at Detector.......................................179

5.5.1.5 Signal on PCB “PSV”.....................................................180

5.5.2 Physical Zero – Paramagnetic Oxygen..........................................180

5.5.3 Removal of Operator Front Panel..................................................181

5.5.4 Replacement of Buffer Battery.......................................................181

5.5.5 Replacement of Fuses...................................................................182

5.5.6 Test Points for OXS PC Board.......................................................183

5.5.7 Power Supply.................................................................................185

5.5.8 Wiring of DIO with External Devices..............................................186

G

ENERAL

P

RECAUTIONS FOR

H

ANDLING

& S

TORING

H

IGH

P

RESSURE

C

YLINDERS

W

ARRANTY

F

IELD

S

ERVICE AND

R

EPAIR

F

ACILITIES

C

ONTENTS

vi

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

FIGURES

1-1. CAT 200 Continuous Analyzer Transmitter .............................................. 1

2-1. Absorption Bands of Sample Gas and Transmittance of

Interference Filters........................................................................ 4

2-2. Opto-Pneumatic Gas Detector.................................................................. 5

2-3. Overall NDIR Method................................................................................ 7

2-4. Paramagnetic Oxygen Analysis................................................................ 9

2-5. Electrochemical Oxygen Sensor............................................................... 10

2-6. Reaction of Galvanic Cell.......................................................................... 11

2-7. Thermal Conductivity Sensor.................................................................... 12

2-8. Response Time vs Flow Rate Dependence.............................................. 13

3-1. Gas Connections...................................................................................... 17

3-2. Piping Diagram (Example)........................................................................ 18

3-3. Outline and Mounting Dimensions............................................................ 19

3-4. Internal Gas Paths (example)................................................................... 21

3-5. Increased Safety Junction Box Terminals................................................. 27

3-6. Leak Test Flow Indicator Method.............................................................. 28

3-7. Leak Test Manometer Method.................................................................. 29

4-1. Temperature Controller............................................................................. 141

5-1. CAT 200 Enclosure Assembly.................................................................. 146

5-2. Analyzer Component Layout (Two IR channels / oxygen measurement,

combined)..................................................................................... 156

5-3. Analyzer Component Layout (Two IR channels / oxygen measurement,

combined)..................................................................................... 157

5-4. Analyzer Component Layout (Two IR channels / oxygen measurement,

combined)..................................................................................... 158

5-5. Analyzer Component Layout (Card Cage and PCB Locations)................ 159

5-6. Plug Locations PCB PIC............................................................................ 160

5-7. Analyzer Rear Panel Layout..................................................................... 162

5-8. SIO/DIO Pin Assignments (option) (front view of connectors).................. 163

5-9. Pin Assignments DC Power Connector.................................................... 164

5-10. TC Sensor Standard (short) Response Time Setting ............................... 165

5-11. TC Sensor Long Response Time Setting ................................................. 165

5-12. Analyzer Photometer Assembly ( 2 channel IR, electrochemical oxygen

analyzer, viewed from top)............................................................ 167

5-13. Chopper Housing with IR Light Sources................................................... 168

5-14. Photometer Assembly (1 mm to 10 mm cells).......................................... 169

5-15. Photometer Assembly (30 mm to 200 mm cells)...................................... 169

5-16. PCB OXS Measuring Points.................................................................... 173

5-17. Front Panel Rear View with Oxygen Sensor............................................ 174

5-18. PCB OXS Connections & Measuring Points............................................ 175

5-19. Photometer Block Diagram...................................................................... 176

5-20. PCB VVS................................................................................................. 177

F

IGURES

(

CONTINUED

)

C

ONTENTS

748446-C Rosemount Analytical March 2001

vii

Model CAT 200 Continuous Analyzer Transmitter

5-21. PCB MOP.................................................................................................178

5-22. Detector Signal.........................................................................................179

5-23. Controller Board ACU...............................................................................181

5-24. Fuses on PCB LEM..................................................................................182

5-25. PCB OXS Test Points ..............................................................................183

5-26. PCB OXS Plug Locations.........................................................................184

5-27. Power Supply Connections ......................................................................185

5-28. DIO Inductive Loads.................................................................................186

TABLES

3-1. Analog Output (SIO) Terminal Assignments ...............................................24

3-2. Digital Input & Output (DIO) Terminal Assignments...................................25

3-3. Relay Output Contacts (SIO) Terminal Assignments .................................26

3-4. RS232/RS485 Serial Interface (SIO) Terminal Assignments.....................26

3-5. Power Connections Terminal Assignments................................................26

DRAWINGS (LOCATED IN REAR OF MANUAL)

659922 Assembly Instructions, Basic CAT 200

660210 Installation Drawing, CAT 200

660371 Diagram, Power Input and Ground Circuits

C

ONTENTS

viii

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

NOTES

P

REFACE

748446-C Rosemount Analytical March 2001

P1

Model CAT 200 Continuous Analyzer Transmitter

I

NTENDED

U

SE

S

TATEMENT

The Model CAT 200 Continuous Analyzer Transmitter is intended for use as an

industrial process measurement device only. It is not intended for use in medical,

diagnostic, or life support applications, and no independent agency certifications or

approvals are to be implied as covering such applications.

SAFETY SUMMARY

To avoid explosion, loss of life, personal injury and damage to this equipment

and on-site property, all personnel authorized to install, operate and service this

equipment should be thoroughly familiar with and strictly follow the instructions

in this manual. Save these instructions.

If this equipment is used in a manner not specified in these instructions,

protective systems may be impaired.

DANGER is used to indicate the presence of a hazard which will cause severe

personal injury, death, or substantial property damage if the warning is ignored.

WARNING is used to indicate the presence of a hazard which can cause severe

personal injury, death, or substantial property damage if the warning is ignored.

CAUTION is used to indicate the presence of a hazard which will or can cause minor

personal injury or property damage if the warning is ignored.

NOTE is used to indicate installation, operation, or maintenance information which is

important but not hazard related.

Do not operate without dome and covers secure. Servicing requires access to

live parts which can cause death or serious injury. Refer servicing to qualified

personnel. Operating personnel must not remove instrument covers.

For safety and proper performance this instrument must be connected to a

properly grounded three-wire source of power.

WARNING: ELECTRICAL SHOCK HAZARD

P

REFACE

P2

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

WARNING: POSSIBLE EXPLOSION HAZARD

WARNING: TOXIC GAS

WARNING: DEVICE CERTIFICATION(S)

DANGER: TOXIC GAS - PURGE

Any addition, substitution, or replacement of components installed on or in this

device, mucst be certified to meet the hazardous area classification that the

device was certified to prior to any such component addition, substitution, or

replacement. In addition, the installation of such devices or devices must meet

the requirements specified and defined by the hazardous area classification of

the unmodified device. Any modifications to the device not meeting these

requirements, will void the product certification(s).

Do not open instrument when energized.

Ensure that all gas connections are made as labeled and are leak free. Improper

gas connections could result in explosion and death.

This unit’s exhaust may contain hydrocarbons and other toxic gases such as

carbon monoxide. Carbon monoxide is highly toxic and can cause headache,

nausea, loss

of consciousness, and death.

Avoid inhalation of the exhaust gases at the exhaust fitting.

Connect exhaust outlet to a safe vent using stainless steel or Teflon line. Check

vent line and connections for leakage.

Keep all tube fittings tight to avoid leaks. See Section 3.3.6 for leak test

information.

This device may contain explosive, toxic or unhealthy gas components. Before

cleaning or changing parts in the gas paths, purge the gas lines with ambient air

or nitrogen.

P

REFACE

748446-C Rosemount Analytical March 2001

P3

Model CAT 200 Continuous Analyzer Transmitter

CAUTION: PRESSURIZED GAS

WARNING: PARTS INTEGRITY AND UPGRADES

CAUTION: HEAVY WEIGHT

Tampering with or unauthorized substitution of components may adversely

affect the safety of this instrument. Use only factory approved components for

repair.

Because of the danger of introducing additional hazards, do not perform any

unauthorized modification to this instrument.

Return the instrument to a Rosemount Analyiical Service office for service or

repair to ensure that safety features are maintained.

This unit requires periodic calibration with a known standard gas. It also may

utilizes a pressurized carrier gas, such as helium, hydrogen, or nitrogen. See

General Precautions for Handling and Storing High Pressure Gas Cylinders at

the rear of this manual.

Use two persons or a suitable lifting device to move or carry the instrument.

P

REFACE

P4

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

S

PECIFICATIONS

- G

ENERAL

P

OWER

Universal Power Supply 90-264 VAC, 50-60 Hz, ±10% 180 Watts Maximum at Start

Up. Up to 380 Watts with optional case heater.

D

ETECTORS

/N

UMBER

NDIR, PMD, E02, TC, UV/VIS (one channel only). Up to three channels in one

analyzer.

M

OUNTING

4” or 6” Pipe, Rack, or Wall Mount

A

REA

C

LASSIFICATION

See Compliances page P7

C

ORROSION

P

ROTECTION

O

PTION

Instrument grade air is required. Consult factory for requirements

A

MBIENT

R

ANGE

Temperature: -30° to +5° Celsius. (-34° to 122° F)

Relative Humidity: 5% to 95%

I

NPUTS

/O

UTPUTS

Digital: RS232 serial data

Analog Current Outputs: Up to 8 isolated 4-20 ma, 500 ohms max load

Analog Digital Outputs: Up to 16, 5-30 VDC, max current 500 ma

Analog Digital Inputs: Up to 8, 0-30 VDC, 2.2 ma

I

NSTRUMENT

W

EIGHT

120 to 150 lbs. (55-70 kg)

P

REFACE

748446-C Rosemount Analytical March 2001

P5

Model CAT 200 Continuous Analyzer Transmitter

SPECIFICATIONS – CAT 200 DETECTOR

NDIR/UV/VIS

O

2

Paramagnetic

2

O

2

Electrochemical

Thermal

Conductivity

2

NDIR Ultra Low

CO

(0-10ppm)

CO

2(0-20ppm)

D

ETECTION

L

IMIT

≤1%

3,4

≤1%

3

,

4

≤1%

3

,

4

≤2%

3

,

4

≤0.2ppm

4

L

INEARITY

3

,

4

≤1% ≤1% ≤1% ≤1% ≤1%

Z

ERO

D

RIFT

3

,

4

≤2%/week

3

,

4

≤2%/week

3

,

4

≤2%/week

3

,

4

≤2%/week

3

,

4

≤±2%/24-hr

4

S

PAN

D

RIFT

3

,

4

≤1%/week

3

,

4

≤1%/week

3

,

4

≤1%/week

3

,

4

≤1%/week

3

,

4

≤±2%/24-hr

4

R

EPEATABILITY

3

,

4

≤1% ≤1% ≤1% ≤1% ≤±2ppm

R

ESPONSE

T

IME

3s ≤ t

90

≤7s

6

<5-6s 12s 3s ≤ t

90

≤ 20s

6

≤ 10s

S

AMPLE

F

LOW

R

ATE

.2-1.5 l/min .2-1.5 l/min .2-1.5 l/min .2-1.5 l/min .2-1.5 l/min

S

AMPLE

P

RESSURE

≤1500 hPa abs Atm ≤1500 hPa abs ≤1500 hPa abs ≤1500 hPa abs

I

NFLUENCE OF

P

RESSURE

Standard

7

Pres. Comp. Opt.

7

≤0.1%/hPa

≤0.01%/hPa

≤0.1%/hPa

≤0.01%/hPa

≤0.1%/hPa

≤0.01%/hPa

≤0.1%/hPa

≤0.01%/hPa

≤0.1%/hPa

≤0.01%/hPa

I

NFLUENCE OF

T

EMPERATURE

On Zero

3

On Span

3

On Span

3

,8

≤1%

≤5%

≤1%

≤2%

≤1%

≤5%

≤1%

2

≤5%

2

≤2%

2

S

ENSOR

M

ATERIALS IN

C

ONTACT WITH

S

AMPLE

Anodized Alum

Stainless Steel

Optional

Stainless Steel

Teflon

Stainless Steel

Gold Plated

Stainless Steel

W

ARM

-

UP

T

IME

15 to 50 Min

6

50 Min 15 to 50 Min 50 Min

15 - 50 Min

6

2

Temperature change not greater than 10k in 1 hour.

3

Related to fullscale, per 10°K.

4

At constant pressure and temperature.

6

Dependent on sensor.

7

Related to measuring value.

8

With optional temperature stabilization.

P

REFACE

P6

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE

For order administration, replacement parts, application assistance, on-site or factory

repair, service or maintenance contract information, contact:

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

RETURNING PARTS TO THE FACTORY

Before returning parts, contact the Customer Service Center and request a Returned

Materials Authorization (RMA) number. Please have the following information when

you call: Model Number, Serial Number, and Purchase Order Number or Sales Order

Number.

Prior authorization by the factory must be obtained before returned materials will be

accepted. Unauthorized returns will be returned to the sender, freight collect.

When returning any product or component that has been exposed to a toxic, corrosive

or other hazardous material or used in such a hazardous environment, the user must

attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification

that the material has been decontaminated, disinfected and/or detoxified.

Return to:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

USA

T

RAINING

A comprehensive Factory Training Program of operator and service classes is

available. For a copy of the Current Operator and Service Training Schedule contact

the Technical Services Department at:

Rosemount Analytical Inc.

Phone: 1-714-986-7600

FAX: 1-714-577-8006

D

OCUMENTATION

The following Model CAT 200 Continuous Analyzer Transmitter instruction materials

are available. Contact Customer Service or the local representative to order.

748446 Instruction Manual (this document)

P

REFACE

748446-C Rosemount Analytical March 2001

P7

Model CAT 200 Continuous Analyzer Transmitter

COMPLIANCES

This product may carry approvals from several certifying agencies. The certification

marks appear on the product name-rating plate.

AREA CLASSIFICATIONS:

USA

Class I Zone 1

AEx d e m IIB + H

2

T4 X

Canada

Ex d e m IIB + H

2

T4 X

European Union

ATEX, Category 2, Zone 1, IIB + H

2

T4 X

USA/Canada

Certified by Canadian Standards Association, an OSHA

Nationally Recognized Testing Laboratory (NRTL) for

USA and Canada.

European Union

Conforms with the provisions of the EMC Directive

89/336/EEC, Low Voltage Directive 73/23/EEC,

Potentially Explosive Atmospheres Directive 94/9/EC,

including amendments by the CE marking Directive

93/68/EEC.

EC type Examination Certificate, LCIE 00 ATEX 6009 X.

Rosemount Analytical has satisfied all obligations from

the European Legislation to harmonize the product

requirements in Europe.

Australia/New Zealand

Conforms with Electromagnetic Compatibility – Generic

Emission standard and AS/NZS 4251.1 – 1994 Part 1 –

Residential, commercial, and light industrial.

Complies with the NAMUR RECOMMENDATION,

Electromagnetic Compatibility (EMC) issue 1998.

N96

0081

II 2 G

EEx d e m II B (+H

2

) T4

LCIE 00 ATEX 6009 X

®

C

US

NAMUR

P

REFACE

P8

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

NOTES

1

I

NTRODUCTION

748446-C Rosemount Analytical March 2001

1

Model CAT 200 Continuous Analyzer Transmitter

1.1 OVERVIEW

This manual describes the CAT 200 Continuous Analyzer Transmitter.

The CAT 200 is a multi-component, multi-method Continuous Gas Analyzer. Its Class

I, Zone I (IIB) + H

2

T2 X approved enclosure makes it suitable for installation in

hazardous environments. The field mountable housing design allows the CAT 200 to

be mounted close to the process instead of in a remote shelter. This feature greatly

reduces installation and utility costs while improving process efficiency.

The CAT 200 can continuously measure 1, 2 or 3 components in a single analyzer

using a combination of Non Dispersive Infrared (NDIR/UV/VIS), Paramagnetic

Oxygen, Thermal Conductivity, Electrochemical sensors. The CAT 200 also features

an optional customized sample-handling module.

The CAT 200 offers advanced menu and diagnostic functionality with the ability to

network multiple analyzers in complex process monitor and control systems. The high

speed microprocessor architecture of the CAT 200 makes it capable of ultra low range

measurements for CO and CO

2

.

F

IGURE

1-1. CAT 200 C

ONTINUOUS

A

NALYZER

T

RANSMITTER

I

NTRODUCTION

2

March 2001 Rosemount Analytical 748446-CModel CAT 200 Continuous Analyzer Transmitter

1.2 TYPICAL APPLICATIONS

The CAT 200 Continuous Analyzer Transmitter supports a variety of industry

applications, drawing on more than 40 years of development and process expertise in

sensors, digital signal processing and software technologies. The CAT 200 can satisfy

the most demanding single or multi-component analysis requirements. More than 60

gas components can be measured including:

Carbon Monoxide (CO) Carbon Dioxide (CO

2

) Methane (CH

4

)

Hexane (CH equiv.) (C

6

H

14

) Water Vapor (H

2

O) Oxygen (O

2

)

Hydrogen (H

2

) Helium (He) Argon (Ar)

Some standard industry applications include:

P

ETROCHEMICAL

R

EFINERY

Light Naphtha Isomerization

H

2

, CO and CO

2

in make-up Hydrogen Gas to Combined Feed

H

2

in Scrubber Off Gas to Refinery Fuel Gas Header

Catalytic Reforming

H

2

in Recycle Gas from Product Separator

H

2

in Net Gas from Net Gas Knockout Drum

H

2

in CCR Nitrogen Header

H

2

in Surge Hopper Vent

Fluidized Catalytic Cracking

CO and O

2

Monitoring of Fluidized Catalytic Cracking Regenerator Gas

Sulfur Recovery Units

Propylene in Feed to Sulfur Recovery Plant

P

ETROCHEMICAL

C

OMPLEX

Ethylene in Primary and Secondary De-Methanizer Overhead

CO

2

in Ethane-Ethylene Splitter

Propylene in Splitter Bottoms

A

MMONIA AND

U

REA

H

2

, CO and CO

2

in Synthesis Gas

U

TILITIES

H

2

in Cooling Gas in Turbine Generators

Continuous Emission Monitoring Systems (CEMS)

M

ETALS

H

2

in Endothermic Furnace

A

LL

A

PPLICATIONS

Continuous Emission Monitoring Systems (CEMS)

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Rosemount CAT 200-Rev C Owner's manual

Rosemount CAT 200-Rev C Owner's manual

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