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Instruction Manual
748446-D
April 2002
http://www.processanalytic.com
Model CAT200
Continuous Analyzer Transmitter
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
e-mail: [email protected]
http://www.processanalytic.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and
international standards. Because these instruments are sophisticated technical products, you
MUST properly install, use, and maintain them to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to and integrated into your
safety program when installing, using, and maintaining Rosemount Analytical products. Failure to
follow the proper instructions may cause any one of the following situations to occur: Loss of life;
personal injury; property damage; damage to this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Rosemount Analytical representative
for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance of
the product.
• Install your equipment as specified in the Installation Instructions of the appropriate Instruc-
tion Manual and per applicable local and national codes. Connect all products to the proper elec-
trical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program, and
maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts specified by
Rosemount. Unauthorized parts and procedures can affect the product’s performance, place the safe
operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result
in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except when
maintenance is being performed by qualified persons, to prevent electrical shock and personal
injury.
The information contained in this document is subject to change without notice.
Teflon® and Viton® are registered trademarks of E. I. duPont de Nemours and Co., Inc.
SNOOP® is a registered trademark of NUPRO Co.
Instruction Manual
748446-D
April 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Contents i
Model CAT200
TABLE OF CONTENTS
PREFACE...........................................................................................................................................P-1
Definitions ...........................................................................................................................................P-1
Intended Use Statement.....................................................................................................................P-2
Safety Summary .................................................................................................................................P-2
General Precautions For Handling And Storing High Pressure Gas Cylinders .................................P-5
Documentation....................................................................................................................................P-6
Compliances .......................................................................................................................................P-6
1-0 DESCRIPTION AND SPECIFICATIONS..............................................................................1-1
1-1 Overview................................................................................................................................1-1
1-2 Typical Applications...............................................................................................................1-1
a. Standard Industry Applications .......................................................................................1-2
1-3 Detector Methodologies.........................................................................................................1-2
a. Non-Dispersive Infrared (NDIR)......................................................................................1-2
Opto-Pneum
A
tic Method .................................................................................................1-4
Overall NDIR Method......................................................................................................1-5
b. Paramagnetic Oxygen Method .......................................................................................1-7
c. Electrochemical Oxygen Method ....................................................................................1-8
d. Thermal Conductivity Method .........................................................................................1-10
1-4 Specifications ........................................................................................................................1-12
a. General ...........................................................................................................................1-12
b. CAT200 Detector ............................................................................................................1-13
2-0 INSTALLATION ....................................................................................................................2-1
2-1 Process and Calibration Gas Connection .............................................................................2-1
a. Gas Conditioning.............................................................................................................2-5
b. Internal Gas Paths ..........................................................................................................2-5
2-2 Installation..............................................................................................................................2-7
a. Location...........................................................................................................................2-7
b. Limitations .......................................................................................................................2-7
c. Gas Lines ........................................................................................................................2-7
d. Services ..........................................................................................................................2-7
e. Mounting Options ............................................................................................................2-7
f. Vent Lines .......................................................................................................................2-8
g. Electrical Connections ....................................................................................................2-8
2-3 Analytical Leak Check ...........................................................................................................2-12
a. Flow Indicator Method.....................................................................................................2-12
b. Manometer Method.........................................................................................................2-13
3-0 OPERATION .........................................................................................................................3-1
3-1 Startup and initialization ........................................................................................................3-1
3-2 Display & Operating Keys......................................................................................................3-2
a. Display ............................................................................................................................3-2
b. Keys ................................................................................................................................3-2
c. Menu Lines and Softkey Functionality ............................................................................3-3
d. Common Function Keys..................................................................................................3-4
e. Entering and Changing Variables ...................................................................................3-4
f. Starting a Function..........................................................................................................3-4
g. Main Menu ......................................................................................................................3-5
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April 2002
ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model CAT200
3-3 Basic Setup............................................................................................................................3-8
a. Analyzer Channel Status ................................................................................................3-8
b. Status Details ..................................................................................................................3-9
c. Acknowledge and Clear Failures ....................................................................................3-10
d. Current Operation Parameters........................................................................................3-11
e. Single Component Display..............................................................................................3-12
f. Multi Component Display ................................................................................................3-12
3-4 Calibration..............................................................................................................................3-13
a. Calibration Status............................................................................................................3-13
b. Zero Calibration...............................................................................................................3-14
c. Span Calibration..............................................................................................................3-15
d. Setup Basic Calibration Parameters ...............................................................................3-16
e. Open and Close Valves ..................................................................................................3-16
3-5 Analyzer & I/O, Expert Control & Setup ................................................................................3-17
a. Analyzer Module Setup...................................................................................................3-18
b. Load Factory Configuration.............................................................................................3-19
c. Calibration Parameters ...................................................................................................3-19
d. Span Gas Parameter ......................................................................................................3-20
e. Calibration Tolerances ....................................................................................................3-20
f. Calibration Procedure Setup...........................................................................................3-22
g. Timed Controlled Calibration ..........................................................................................3-24
3-6 Calibration Parameters – Manual Calibration........................................................................3-25
a. Advanced Calibration Methods .......................................................................................3-26
b. Zero Gas Parameters .....................................................................................................3-27
3-7 Alarm Parameters..................................................................................................................3-28
a. Alarm Setup and Control.................................................................................................3-29
3-8 Range Parameters ................................................................................................................3-30
a. Offset and Span of Range ..............................................................................................3-30
b. Response times (t90) ......................................................................................................3-31
c. Autoranging Control ........................................................................................................3-31
3-9 Cross Interference Compensation.........................................................................................3-34
3-10 Linearization ..........................................................................................................................3-36
a. Disable Linearization .....................................................................................................3-36
b. Zero and Sapn Calibration ............................................................................................3-36
c. Calculate Linearization Curve........................................................................................3-37
d. Enable Linearization .......................................................................................................3-37
e. Linearization Verification ................................................................................................3-37
3-11 Programmable Logic Control (PLC) ......................................................................................3-38
a. Disable PLC ....................................................................................................................3-38
b. Input the program............................................................................................................3-38
c. Enable PLC .....................................................................................................................3-38
d. Checking the results .......................................................................................................3-38
e. Example for PLC Programming ......................................................................................3-43
f. Placing the codes into the Program menu......................................................................3-44
g. PLC Output .....................................................................................................................3-44
3-12 Programmable Calculator......................................................................................................3-45
a. Programming the Calculator ...........................................................................................3-45
b. Example for Calculation Programming ...........................................................................3-47
3-13 Measurement Display Configuration .....................................................................................3-48
3-14 Acknowledgement of Status Reports ....................................................................................3-50
3-15 Concentration Measurement Parameters .............................................................................3-50
3-16 Concentration Peak Measurement........................................................................................3-51
3-17 Differential Measurement ......................................................................................................3-52
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Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii
Model CAT200
3-18 Gas flow Setup ......................................................................................................................3-53
3-19 Pressure Compensation ........................................................................................................3-54
3-20 Flow Measurement ................................................................................................................3-55
3-21 Temperature Measurement ...................................................................................................3-55
3-22 Load/Save Analyzer Module Configuration ...........................................................................3-56
3-23 Inputs & Outputs (SIO/DIO)...................................................................................................3-57
a. SIO ..................................................................................................................................3-57
b. DIO..................................................................................................................................3-61
c. DIO Function Codes .......................................................................................................3-62
3-24 Delay and Average ................................................................................................................3-63
3-25 AK-Protocol Communication .................................................................................................3-64
3-26 System Configuration and Diagnostics .................................................................................3-65
a. Diagnostic Menus............................................................................................................3-65
Analyzer Module Diagnostics..........................................................................................3-66
b. Load/Save Module Configuration....................................................................................3-67
c. Date and Time.................................................................................................................3-68
d. Security Codes................................................................................................................3-69
Setting the code numbers ...............................................................................................3-69
Enable the security code.................................................................................................3-69
e. System Reset..................................................................................................................3-71
f. Memory Usage................................................................................................................3-71
3-27 Display Controls ....................................................................................................................3-72
3-28 Measurement.........................................................................................................................3-73
3-29 Shut Down .............................................................................................................................3-73
3-30 Temperature Stabilization......................................................................................................3-74
a. Controller Settings...........................................................................................................3-74
DIP switch settings:.........................................................................................................3-74
Initial menu settings: .......................................................................................................3-75
Final menu settings: ........................................................................................................3-75
4-0 MAINTENANCE AND SERVICE ..........................................................................................4-1
4-1 Overview................................................................................................................................4-1
4-2 Component Removal.............................................................................................................4-1
a. Analyzer Component Removal .......................................................................................4-2
b. Power Supply Assembly Removal ..................................................................................4-2
4-3 Troubleshooting Guide ..........................................................................................................4-3
a. Instrument Not Functioning (LCD Display Is Dark).........................................................4-3
b. No or Incorrect Measurement Screen.............................................................................4-3
c. Error Messages Displayed..............................................................................................4-3
d. Detector Signal Communication Failed ..........................................................................4-4
e. Light Source Failure........................................................................................................4-4
f. Detector Failure...............................................................................................................4-4
g. No Temperature Measurement.......................................................................................4-4
h. No External Input ............................................................................................................4-4
i. No or Incorrect Analog Outputs or Digital I/O .................................................................4-5
j. Calibration not Possible ..................................................................................................4-5
k. Fluctuating or Erroneous Display....................................................................................4-5
l. Response Time Too Long (t90 time) ..............................................................................4-5
4-4 Analyzer Configuration and Adjustment ................................................................................4-7
a. Component Layout..........................................................................................................4-7
b. Circuit Board ICB ............................................................................................................4-12
c. Circuit Board PSV ...........................................................................................................4-12
d. Circuit Board PIC ............................................................................................................4-12
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iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model CAT200
e. Circuit Board ACU...........................................................................................................4-13
f. Analyzer Rear Panel .......................................................................................................4-14
g. Thermal Conductivity Response Time ............................................................................4-17
4-5 Maintenance ..........................................................................................................................4-18
a. Checking & Cleaning of the Analyzer .............................................................................4-18
b. Photometric Components ...............................................................................................4-19
Removal of Photometer Assembly..................................................................................4-19
Light Source Replacement..............................................................................................4-20
Removal of Analysis Cells ..............................................................................................4-21
Cleaning of Analysis Cells & Windows ...........................................................................4-22
Reinstalling Analysis Cells ..............................................................................................4-22
Reinstalling Photometer Assembly .................................................................................4-22
Physical Zeroing..............................................................................................................4-22
c. Replacement of Electrochemical Oxygen Sensor ..........................................................4-23
Check of the Sensor .......................................................................................................4-23
Removal of the Sensor ...................................................................................................4-24
Replacing the Sensor......................................................................................................4-25
Reinstalling the Sensor ...................................................................................................4-25
Basic Calibration for the Oxygen Sensor........................................................................4-25
4-6 Analyzer Service....................................................................................................................4-26
a. Photometer Signal Processing (PCB PSV) ....................................................................4-26
Internal Voltage Supply...................................................................................................4-27
IR Source ........................................................................................................................4-28
Chopper ..........................................................................................................................4-28
Unamplified Signal at Detector .......................................................................................4-29
Signal on PCB “PSV” ......................................................................................................4-29
b. Physical Zero – Paramagnetic Oxygen ..........................................................................4-30
c. Removal of Operator Front Panel ...................................................................................4-30
d. Replacement of Buffer Battery........................................................................................4-31
e. Replacement of Fuses ....................................................................................................4-32
f. Test Points for OXS PC Board........................................................................................4-33
g. Power Supply ..................................................................................................................4-35
h. Wiring of DIO with External Devices ...............................................................................4-36
5-0 RETURN OF MATERIAL ......................................................................................................5-1
5-1 Return Of Material .................................................................................................................5-1
5-2 Customer Service ..................................................................................................................5-1
5-3 Training..................................................................................................................................5-1
Instruction Manual
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April 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Contents v
Model CAT200
LIST OF ILLUSTRATIONS
Figure 1-1. CAT200 Continuous Analyzer Transmitter ............................................................ 1-1
Figure 1-2. Absorption Bands of Sample Gas and Transmittance of Interference Filters ....... 1-3
Figure 1-3. Opto-Pneumatic Gas Detector............................................................................... 1-4
Figure 1-4. Overall NDIR Method............................................................................................ 1-6
Figure 1-5. Paramagnetic Oxygen Analysis............................................................................. 1-7
Figure 1-6. Electrochemical Oxygen Sensor............................................................................ 1-8
Figure 1-7. Reaction of Galvanic Cell ...................................................................................... 1-9
Figure 1-8. Thermal Conductivity Sensor............................................................................... 1-11
Figure 1-9. Response Time vs Flow Rate Dependence ........................................................ 1-11
Figure 2-1. Gas Connections ................................................................................................... 2-2
Figure 2-2. Piping Diagram (Example)..................................................................................... 2-3
Figure 2-3. Outline and Mounting Dimensions......................................................................... 2-4
Figure 2-4. Internal Gas Paths (example) ................................................................................ 2-6
Figure 2-5. Increased Safety Junction Box Terminals ........................................................... 2-11
Figure 2-6. Leak Test - Flow Indicator Method ...................................................................... 2-12
Figure 2-7. Leak Test - Manometer Method........................................................................... 2-13
Figure 3-1. Startup Display ......................................................................................................3-1
Figure 3-2. The Display and Operating Keys........................................................................... 3-2
Figure 3-3. The Display Screen ............................................................................................... 3-3
Figure 3-4. Confirmation Display.............................................................................................. 3-4
Figure 3-5. Main Menu Display ............................................................................................... 3-5
Figure 3-6. Module Manufacturing Data Displays.................................................................... 3-6
Figure 3-7. Main Menu Sub Menus.......................................................................................... 3-7
Figure 3-8. Analyzer Channel Status Menu Display ................................................................ 3-8
Figure 3-9. Status Details Displays .......................................................................................... 3-9
Figure 3-10. List of Possible Failures Menu (Screen 1 of 2)...................................................... 3-9
Figure 3-11. List of Possible Failures (Screen 2 of 2)................................................................ 3-9
Figure 3-12. Confirmation Displays.......................................................................................... 3-10
Figure 3-13. Analyzer Operation Settings Menu...................................................................... 3-11
Figure 3-14. Auto Start Procedures ......................................................................................... 3-11
Figure 3-15. Single Channel Display........................................................................................ 3-12
Figure 3-16. Multi Channel Display .......................................................................................... 3-12
Figure 3-17. Basic Controls and Setup Menu .......................................................................... 3-13
Figure 3-18. Calibration Procedure Status Menu..................................................................... 3-13
Figure 3-19. Calibration Deviations Menu................................................................................ 3-13
Figure 3-20. Set Gas Valves Menu .......................................................................................... 3-16
Figure 3-21. Analyzer and I/O, Expert Controls & Setup Sub Menus...................................... 3-17
Figure 3-22. Analyzer Module Setup and Controls (1/3) Menu (Screen 1 of 3)....................... 3-18
Figure 3-23. Analyzer Module Setup and Controls (2/3) Menu (Screen 2 of 3)....................... 3-18
Figure 3-24. Analyzer Module Setup and Controls (3/3) Menu (Screen 3 of 3)....................... 3-18
Figure 3-25. Load Factory Configuration ................................................................................. 3-19
Figure 3-26. Calibration Parameters Menu .............................................................................. 3-19
Figure 3-27. Span Gas Definition Menu................................................................................... 3-20
Figure 3-28. Tolerances Menu ................................................................................................. 3-20
Figure 3-29. Calibration Procedure Setup Menu ..................................................................... 3-22
Figure 3-30. Zero/Span Calibration Stability Diagram ............................................................. 3-22
Figure 3-31. Analog Output Chart ............................................................................................ 3-23
Figure 3-32. Time Control Menu .............................................................................................. 3-24
Figure 3-33. Auto-Start Procedures Menu ............................................................................... 3-24
Figure 3-34. Calibration Menu.................................................................................................. 3-25
Figure 3-35. Advanced Calibration Menu................................................................................. 3-26
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vi Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model CAT200
Figure 3-36. State of Calibration Procedures Screen .............................................................. 3-26
Figure 3-37. Zero Gas Definition Menu.................................................................................... 3-27
Figure 3-38. Alarm Setup Menu ............................................................................................... 3-28
Figure 3-39. Concentration Alarm Setup Menu ....................................................................... 3-29
Figure 3-40. Range Parameters Menu..................................................................................... 3-30
Figure 3-41. Begin / End of Ranges Menu............................................................................... 3-30
Figure 3-42. Response Times Menu........................................................................................ 3-31
Figure 3-43. Auto-ranging Control Menu.................................................................................. 3-31
Figure 3-44. Hysteresis Between Ranges Graph .................................................................... 3-32
Figure 3-45. Actual Switch Levels Screen ............................................................................... 3-33
Figure 3-46. Cross Interference Compensation Menu............................................................. 3-34
Figure 3-47. Channels Display................................................................................................. 3-34
Figure 3-48. Interference Factors Menu................................................................................... 3-35
Figure 3-49. Multiple Spline Linearization Menu...................................................................... 3-36
Figure 3-50. Linearization Raw Values Menu .......................................................................... 3-36
Figure 3-51. Programmable Logic Control Menu..................................................................... 3-38
Figure 3-52. PLC Program Menu ............................................................................................ 3-44
Figure 3-53. PLC Outputs Menu .............................................................................................. 3-44
Figure 3-54. Programmable Calculator Menu.......................................................................... 3-45
Figure 3-55. Programmable Calculator – Program Menu ........................................................ 3-47
Figure 3-56. Measurement Display Configuration Menu (Screen 1 of 3) ................................ 3-48
Figure 3-57. Measurement Display Configuration Menu (Screen 2 of 3) ................................ 3-49
Figure 3-58. Measurement Display Configuration Menu (Screen 3 of 3) ................................ 3-49
Figure 3-59. Acknowledgement of Status Reports Menu ........................................................ 3-50
Figure 3-60. General Concentration Measurement Parameters Setup Menu ......................... 3-50
Figure 3-61. Concentration Peak Measurement Menu ............................................................ 3-51
Figure 3-62. Differential Measurement Menu........................................................................... 3-52
Figure 3-63. Gas Flow Setup Menu ......................................................................................... 3-53
Figure 3-64. Pressure Compensation Menu ............................................................................ 3-54
Figure 3-65. Flow Measurement Menu .................................................................................... 3-55
Figure 3-66. Pressure Compensation Menu ............................................................................ 3-55
Figure 3-67. Load/Save Analyzer Module Configuration Menu ............................................... 3-56
Figure 3-68. Analyzer Module I/O Modules Menu ................................................................... 3-57
Figure 3-69. Local SIO Configuration Parameters Menu......................................................... 3-57
Figure 3-70. Analog Outputs Menu .......................................................................................... 3-57
Figure 3-71. Analyzer Modules Menu ...................................................................................... 3-58
Figure 3-72. Output Signal If Analyzer Module Fails / Fine Adjustment Menu ........................ 3-59
Figure 3-73. Serial Interface Menu........................................................................................... 3-60
Figure 3-74. Relay Outputs Menu ............................................................................................ 3-60
Figure 3-75. Local DIO Boards Setup Menu ............................................................................ 3-61
Figure 3-76. Delay and Average Menu .................................................................................... 3-63
Figure 3-77. Example Concentration Average......................................................................... 3-63
Figure 3-78. AK-Communication Menu.................................................................................... 3-64
Figure 3-79. System Configuration Menu ................................................................................ 3-65
Figure 3-80. Diagnostic Menus ................................................................................................ 3-65
Figure 3-81. Analyzer Module Diagnostics Menu .................................................................... 3-66
Figure 3-82. Load/Save Analyzer Module Configuration Menu ............................................... 3-67
Figure 3-83. Date and Time Menu ........................................................................................... 3-68
Figure 3-84. Security Setup Menu ........................................................................................... 3-69
Figure 3-85. Define Basic Level Security PIN Menu................................................................ 3-69
Figure 3-86. System Reset Menu ............................................................................................ 3-71
Figure 3-87. Control Module RAM – Memory Usage Menu..................................................... 3-71
Figure 3-88. Display Controls Menu......................................................................................... 3-72
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April 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Contents vii
Model CAT200
Figure 3-89. Front Panel Control Menu.................................................................................... 3-72
Figure 3-90. Temperature Controller........................................................................................ 3-74
Figure 4-1. CAT200 Enclosure Assembly ................................................................................ 4-2
Figure 4-2. Photometer Analyzer Component Layout.............................................................. 4-8
Figure 4-3. Analyzer Component Layout ................................................................................. 4-9
Figure 4-4. Analyzer Component Layout ............................................................................... 4-10
Figure 4-5. Analyzer Component Layout ............................................................................... 4-11
Figure 4-6. Plug Locations PCB PIC...................................................................................... 4-12
Figure 4-7. Analyzer Rear Panel Layout ................................................................................ 4-14
Figure 4-8. SIO/DIO Pin Assignments (Option) (Front View Of Connectors) ........................ 4-15
Figure 4-9. Pin Assignments DC Power Connector............................................................... 4-16
Figure 4-10. TC Sensor Standard (Short) Response Time Setting ......................................... 4-17
Figure 4-11. TC Sensor Long Response Time Setting ............................................................ 4-17
Figure 4-12. Analyzer Photometer Assembly ( 2 Channel IR, Electrochemical Oxygen
Analyzer, Viewed From Top) ............................................................................... 4-19
Figure 4-13. Chopper Housing with IR Light Sources.............................................................. 4-20
Figure 4-14. Photometer Assembly (1 mm to 10 mm cells)..................................................... 4-21
Figure 4-15. Photometer Assembly (30 mm to 200 mm cells)................................................. 4-21
Figure 4-16. PCB OXS Test Points and Connections.............................................................. 4-24
Figure 4-17. Rear View of Front Panel with Oxygen Sensor ................................................... 4-24
Figure 4-18. Photometer Block Diagram.................................................................................. 4-26
Figure 4-19. PCB VVS .............................................................................................................4-27
Figure 4-20. PCB MOP ............................................................................................................ 4-28
Figure 4-21. Detector Signal .................................................................................................... 4-29
Figure 4-22. Controller Board ACU .......................................................................................... 4-31
Figure 4-23. Fuses on PCB LEM ............................................................................................. 4-32
Figure 4-24. PCB OXS Cable Connections Locations............................................................. 4-34
Figure 4-25. Power Supply Connections.................................................................................. 4-35
Figure 4-26. DIO Inductive Loads ............................................................................................ 4-36
LIST OF TABLES
Table 2-1. Analog Output (SIO) Terminal Assignments ......................................................... 2-9
Table 2-2. Digital Input & Output (DIO) Terminal Assignments.............................................. 2-9
Table 2-3. Relay Output Contacts (SIO) Terminal Assignments .......................................... 2-10
Table 2-4. RS232/RS485 Serial Interface (SIO) Terminal Assignments .............................. 2-10
Table 2-5. Power Connections Terminal Assignments......................................................... 2-10
Table 3-1. Available Operators ............................................................................................. 3-39
Table 3-2. Available Commands (Signal Codes 1 – 19): General Signals.......................... 3-39
Table 3-3. Available Commands (Signal Codes 20 – 39): Programmable Calculator.......... 3-39
Table 3-4. Available Commands (Signal Codes 40 – 69): Programmable Logic Controls... 3-40
Table 3-5. Available Commands (Signal Codes 70 – 89): SIO I/O Module.......................... 3-40
Table 3-6. Available Commands (Signal Codes 90 – 109): DIO I/O Module........................ 3-41
Table 3-7. Measurement Channels....................................................................................... 3-42
Table 3-8. Zero And Span Gas For Each Gas Component .................................................. 3-43
Table 3-9. Valve/Gas Sequencing ........................................................................................ 3-43
Table 3-10. Program Steps..................................................................................................... 3-43
Table 3-11. Programmable Calculator Operator Types.......................................................... 3-45
Table 3-12. Programmable Calculator Operand Types.......................................................... 3-46
Table 3-13. Programmable Calculator Program Steps........................................................... 3-47
Table 3-14. Application for Basic Controls Menu Allowable Function Variables .................... 3-49
Table 3-15. System Configuration and Diagnostic Menus Overview ..................................... 3-65
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April 2002
viii Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model CAT200
DRAWINGS
(LOCATED IN REAR OF MANUAL)
659922 Assembly Instructions, Basic CAT200
660210 Installation Drawing, CAT200
660371 Diagram, Power Input and Ground Circuits
661581 Wiring Diagram CAT200
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April 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-1
Model CAT200
PREFACE
The purpose of this manual is to provide information concerning the components, functions, in-
stallation and maintenance of the CAT200 .
Some sections may describe equipment not used in your configuration. The user should become
thoroughly familiar with the operation of this module before operating it. Read this instruction
manual completely.
DEFINITIONS
The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout
this publication.
DANGER .
Highlights the presence of a hazard which will cause severe personal injury, death, or substantial
property damage if the warning is ignored.
WARNING .
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.
CAUTION.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.
NOTE
Highlights an essential operating procedure,
condition or statement.
Instruction Manual
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April 2002
P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model CAT200
INTENDED USE STATEMENT
The CAT200 Continuous Analyzer Transmitter is intended for use as an industrial process meas-
urement 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 applica-
tions.
SAFETY SUMMARY
If this equipment is used in a manner not specified in these instructions, protective systems may be
impaired.
AUTHORIZED PERSONNEL
To avoid explosion, loss of life, personal injury and damage to this equipment and on-site property,
do not operate or service this instrument before reading and understanding this instruction manual
and receiving appropriate training. Save these instructions.
DANGER.
ELECTRICAL SHOCK HAZARD
Do not open while energized. Installation requires access to live parts which can cause death or
serious injury.
For safety and proper performance this instrument must be connected to a properly grounded
three-wire source of power.
DANGER.
POSSIBLE EXPLOSION HAZARD
Do not operate without dome and covers secure. Ensure that all gas connections are made as la-
beled and are leak free. Improper gas connections could result in explosion and death.
Instruction Manual
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April 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3
Model CAT200
WARNING: DEVICE CERTIFICATION(S)
DANGER.
ELECTRICAL SHOCK HAZARD
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.
DEVICE HAZARDOUS AREA CERTIFICATION(S)
Any addition, substitution, or replacement of components installed on or in this device, must 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 device 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).
WARNING.
POSSIBLE EXPLOSION HAZARD
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.
WARNING
TOXIC GAS
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 con-
nections for leakage.
Keep all tube fittings tight to avoid leaks. See Section 2-3 (page 2-12) for leak test information.
Instruction Manual
748446-D
April 2002
P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model CAT200
DANGER
TOXIC GAS PURGE
This device may contain explosive, toxic or unhealthy gas components. Before cleaning or chang-
ing parts in the gas paths, purge the gas lines with ambient air or nitrogen.
WARNING
PARTS INTEGRITY AND UPGRADES
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 modifi-
cation to this instrument.
Contact Rosemount Analytical Inc., Customer Service Center for Return Authorization.
CAUTION
PRESSURIZED GAS
This unit requires periodic calibration with a known standard gas. It also may utilizes a pressur-
ized 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.
CAUTION
HEAVY WEIGHT
Use two persons or a suitable lifting device to move or carry the instrument.
Instruction Manual
748446-D
April 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5
Model CAT200
GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH
PRESSURE GAS CYLINDERS
Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed
Gases" published in 1981
Compressed Gas Association
1235 Jefferson Davis Highway
Arlington, Virginia 22202
Used by Permission
1. Never drop cylinders or permit them to strike each other violently.
2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of
weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the
shade when located in areas where extreme temperatures are prevalent.
3. The valve protection cap should be left on each cylinder until it has been secured against a wall or
bench, or placed in a cylinder stand, and is ready to be used.
4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a
suitable hand-truck.
5. Never tamper with safety devices in valves or cylinders.
6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is
attached to a pressurized system.
7. No part of cylinder should be subjected to a temperature higher than 125
°
F (52
°
C). A flame should
never be permitted to come in contact with any part of a compressed gas cylinder.
8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding,
precautions must be taken to prevent striking an arc against the cylinder.
Instruction Manual
748446-D
April 2002
P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model CAT200
DOCUMENTATION
The following CAT200 instruction materials are available. Contact Customer Service Center or the local
representative to order (See Section 5).
748441 Instruction Manual (this document)
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
T4X
Canada
Ex d e m IIB + H
2
T4X
European Union
ATEX, Category 2, Zone 1, IIB + H
2
T4X
USA/Canada
Certified by Canadian Standards Association, an OSHA Nationally Recog-
nized Testing Laboratory (NRTL) for USA and Canada.
European Union
Conforms with the provisions of the EMC Directive 89/336/EEC, Low Volt-
age 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 Leg-
islation 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 in-
dustrial.
Complies with the NAMUR RECOMMENDATION, Electromagnetic Com-
patibility (EMC) issue 1998.
N96
0081
II 2 G
EEx d e m II B (+H
2
) T4
LCIE 00 ATEX 6009 X
®
CUS
NAMUR
Instruction Manual
748446-D
April 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Model CAT200
SECTION 1
DESCRIPTION AND SPECIFICATIONS
1-1 OVERVIEW
This manual describes the CAT200 Continu-
ous Analyzer Transmitter.
The CAT200 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 CAT200 to be mounted
close to the process instead of in a remote
shelter. This feature greatly reduces installa-
tion and utility costs while improving process
efficiency.
The CAT200 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 sen-
sors. The CAT200 also features an optional
customized sample-handling module.
The CAT200 offers advanced menu and diag-
nostic functionality with the ability to network
multiple analyzers in complex process monitor
and control systems. The high speed micro-
processor architecture of the CAT200 makes
it capable of ultra low range measurements
for CO and CO
2
.
1-2 TYPICAL APPLICATIONS
The CAT200 Continuous Analyzer Transmitter
supports a variety of industry applications,
drawing on more than 40 years of develop-
ment and process expertise in sensors, digital
signal processing and software technologies.
The CAT200 can satisfy the most demanding
single or multi-component analysis require-
ments. 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)
Figure 1-1. CAT200 Continuous Analyzer Transmitter
Instruction Manual
748446-D
April 2002
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model CAT200
a. Standard Industry Applications
Petrochemical Refinery
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 Sepa-
rator
•
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
Petrochemical Complex
•
Ethylene in Primary and Secondary De-
Methanizer Overhead
•
CO
2
in Ethane-Ethylene Splitter
•
Propylene in Splitter Bottoms
Ammonia and Urea
•
H
2
, CO and CO
2
in Synthesis Gas
Utilities
•
H
2
in Cooling Gas in Turbine Generators
Metals
•
H
2
in Endothermic Furnace
All Applications
•
Continuous Emission Monitoring Sys-
tems (CEMS)
1-3 DETECTOR METHODOLOGIES
The CAT200 can employ up to two of four
different measuring methods depending on
the configuration chosen. The methods are:
NDIR, Paramagnetic O
2
, Electrochemical O
2
,
and Thermal Conductivity.
a. Non-Dispersive Infrared (NDIR)
The non-dispersive infrared method is
based on the principle of absorption of in-
frared radiation by the sample gas being
measured. The gas-specific wavelengths
of the absorption bands characterize the
type of gas while the strength of the ab-
sorption gives a measure of the concen-
tration of the gas component being
measured.
An optical bench is employed comprising
an infrared light source, two analysis cells
(reference and measurement), a chopper
wheel to alternate the radiation intensity
between the reference and measurement
side, and a photometer detector. The de-
tector signal thus alternates between con-
centration dependent and concentration
independent values. The difference be-
tween the two is a reliable measure of the
concentration of the absorbing gas com-
ponent.
Depending on the gas being measured
and its concentration, one of two different
measuring methods may be used as fol-
lows:
Interference Filter Correlation Method
With the IFC method the analysis cell is
alternately illuminated with filtered infrared
concentrated in one of two spectrally
separated wavelength ranges. One of
these two wavelength bands is chosen to
coincide with an absorption band of the
sample gas and the other is chosen such
that none of the gas constituents ex-
pected to be encountered in practice ab-
sorbs anywhere within the band.
The spectral transmittance curves of the
interference filters used in the CAT200
Instruction Manual
748446-D
April 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
Model CAT200
analyzer and the spectral absorption of
the gases CO and CO
2
are shown in
Figure 1-2 below. It can be seen that the
absorption bands of these gases each
coincide with the passbands of one of the
interference filters. The forth interference
filter, used for generating a reference sig-
nal, has its passband in a spectral region
where none of these gases absorb. Most
of the other gases of interest also do not
absorb within the passband of this refer-
ence filter.
The signal generation is accomplished
with a pyroelectrical (solid-state) detector.
The detector records the incoming infra-
red radiation. This radiation is reduced by
the absorption of the gas at the corre-
sponding wavelengths. By comparing the
measurement and reference wavelength,
an alternating voltage signal is produced.
This signal results from the cooling and
heating of the pyroelectric detector mate-
rial
Figure 1-2. Absorption Bands of Sample Gas and Transmittance of Interference Filters
Transmittance (%)
0 18 36 54 72 90
Transmittance (%)
0 15 30 54 60 75 90
CO
2
CO
Absorption Band
HC CO
2
CO
Reference
3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600
Wave Length (nm)
Instruction Manual
748446-D
April 2002
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model CAT200
b. Opto-Pneum
A
tic Method
In the opto-pneumatic method, a thermal
radiator generates the infrared radiation
which passes through the chopper wheel.
This radiation alternately passes through
the filter cell and reaches the measuring
and reference side of the analysis cell
with equal intensity. After passing another
filter cell, the radiation reaches the pneu-
matic detector.
The pneumatic detector compares and
evaluates the radiation from the measur-
ing and reference sides of the analysis
cell and converts them into voltage sig-
nals proportional to their respective inten-
sity.
The pneumatic detector consists of a gas-
filled absorption chamber and a compen-
sation chamber which are connected by a
flow channel in which a Microflow filament
sensor is mounted. This is shown in
Figure 1-3 below. In principle the detector
is filled with the infrared active gas to be
measured and is only sensitive to this dis-
tinct gas with its characteristic absorption
spectrum. The absorption chamber is
sealed with a window which is transparent
for infrared radiation. The window is usu-
ally Calcium Fluoride (CaF
2
).
When the infrared radiation passes
through the reference side of the analysis
cell into the detector, no pre-absorption
occurs. Thus, the gas inside the absorp-
tion chamber is heated, expands and
some of it passes through the flow chan-
nel into the compensation chamber.
Figure 1-3. Opto-Pneumatic Gas Detector
Absorption chamber
CaF2 Window
Flow channel with
Microflow sensor
Compensation chamber
/
