Rosemount Analytical MicroCEM TS Analysis Enclosure Micro Continuous Emission Monitor Operation & Maintenance Manual Revision 2.1, Oct.
CONTENTS Preface Intended Use Statement …………………………………………………………………………….. 1 Safety Summary ……………………………………………………………………………………… 1 Specifications – Analysis Enclosure: General …………………………………………………….. 4 Specifications – Probe/Sample Handling Enclosure: General ..………………………………… 5 Customer Service, Technical Assistance and Field Service ………..………………………….. 6 Returning Parts to the Factory………………………………………………………………………. 6 Training ………………………………………………………………………………………………... 7 1. Introduction..................................
CONTENTS 4.2.5 4.2.6 4.2.7 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 1818 4.3.7 4.3.8 4.4 4.4.1 4.4.2 4.5 4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.7 4.8 4.8.1 4.8.2 4.8.3 4.9 4.10 µCEM Login ......................................................................................................................4-8 µCEM Login-Current User Indication................................................................................4-9 Stream Switching Control .................................................
CONTENTS 5.6.4.1 5.6.5 5.6.5.1 5.6.6 5.6.7 5.6.8 5.6.8.1 5.7 5.7.1 5.8 5.9 Features......................................................................................................................... 5-15 Flash Drive........................................................................................................................5-1 Specifications................................................................................................................... 5-1 Pocket PC.......................
PREFACE PREFACE INTENDED USE STATEMENT The µCEM Continuous Emission Monitoring Gas Analyzer 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.
PREFACE DANGER: TOXIC GAS 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. + WARNING: ELECTRICAL SHOCK HAZARD POSSIBLE EXPLOSION HAZARD Do not open while energized. Do not operate without dome and covers secure. Installation requires access to live parts which can cause death or serious injury.
PREFACE 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 modification to this instrument. Return the instrument to a Rosemount Analytical Service office for service or repair to ensure that safety features are maintained.
PREFACE SPECIFICATIONS - GENERAL SPECIFICATIONS – Analysis Enclosure: GENERAL Power: Universal Power Supply 85 – 125 VAC, 50 – 60 Hz, + 10%, 1000 Watts Maximum at Start Up.
PREFACE Digital Outputs: Following are connected directly to the MicroCEM Probe/Sample Handling Box: Sample Pump on/off, Drain Pump on/off, Purge on/off, Calibrate on/off – All are rated 110VAC @ 1amp Dry Contact. Qty. 6 digital Outputs - TTL: 5 VDC Max Current 20 mA *Optional Time Share option – Dry Contact used for Stream Indicator. Digital Inputs: Qty.
PREFACE Instrument Weight: 62 lbs Typical Size: 24“ X 20“ X 12“ (H W D) Ranges: O2: 0 –2 Selectable to 0 –25% (1% increments) CO: 0 –100ppm Selectable to 1000ppm (1ppm increments) NOx: 0 – 10ppm Selectable to 1000ppm (1ppm increments) Sample Temperature: 0 degrees C to 55 degrees C Sample flow rate: .5 to 1.
PREFACE SPECIFICATIONS – Probe/Sample Handling Enclosure: GENERAL Power: Universal Power Supply 85 – 125 VAC, 50 – 60 Hz, + 10% 750 Watts Maximum at Start Up.
PREFACE 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.
INTRODUCTION 1. Introduction 1.1 Overview This manual describes the Rosemount Analytical Micro Continuous Emission Monitoring (µCEM) gas Analyzer Module. The µCEM Analyzer Module is designed to continuously determine the concentration of O2, CO, SO2, and NOx in a flowing gaseous mixture. The concentration is expressed in percent or parts-per-million. The sampled gas is collected from the stack and prepared by the Probe/Sample Handling Enclosure for analysis and processing by the Analysis Enclosure.
INTRODUCTION Figure 1-1.
INTRODUCTION Figure 1-2. µCEM Micro Continuous Emission Monitoring Gas Analyzer with Time Share option. 1.2 Time Shared Option Provides the functionality to monitor and process sample gases from two streams on a time-share scheme. This option allows you to connect one uCEM to two Sample Handling units.
INTRODUCTION TV1 FROM uCEM CAL TO uCEM SAMPLE TV2 TV3 TO SHU1 CAL GAS TO SHU2 CAL GAS TV4 FROM SHU1 SAMPLE FROM SHU2 SAMPLE EXHAUST Figure 1-3.
INTRODUCTION 1.3 Theory of Operation 1.3.1 NOx The NOx analyzer continuously analyzes a flowing gas sample for NOx [nitric oxide (NO) plus nitrogen dioxide (NO2)]. The sum of the concentrations is continuously reported as NOx. The µCEM NOx Analyzer Module uses the chemiluminecence method of detection. This technology is based on NO’s reaction with ozone (O3) to produce NO2 and oxygen (O2). Some of the NO2 molecules produced are in an electronically excited state (NO2* where the * refers to the excitation).
INTRODUCTION 1.3.3 O2 Paramagnetic: The determination of oxygen is based on the measurement of the magnetic susceptibility of the sample gas. Oxygen is strongly paramagnetic, while other common gases are not. The detector used is compact, has fast response and a wide dynamic range. The long life cell is corrosion resistant, heated and may be easily cleaned. It has rugged self-tensioning suspension and is of welded Non-Glued construction.
INTRODUCTION 1.3.4 SO2 The optical bench can selectively measure multiple components in a compact design by using a unique dual optical bench design. Depending on the application, any two combinations of NDIR channels can be combined on a single chopper motor/dual source assembly. Other application-dependent options include a wide range of sample cell materials, optical filters and solid state detectors.
Detector Methodologies 2. Detector Methodologies The µCEM can employ up to three different measuring methods depending on the configuration chosen. The methods are: NDIR CO/SO2, Paramagnetic O2, Electrochemical O2, and chemiluminescent NOx. 2.1 Non-Dispersive Infrared (NDIR) The non-dispersive infrared method is based on the principle of absorption of infrared radiation by the sample gas being measured.
DETECTOR METHODOLOGIES Figure 2-1. Absorption Bands of Sample Gas and Transmittance of Interference Filters 2.1.2 Opto-Pneumatic 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 pneumatic detector.
DETECTOR METHODOLOGIES Absorption chamber Flow channel with Microflow sensor CaF2 Window Compensation chamber Figure 2-2. Opto-Pneumatic Gas Detector When the infrared radiation passes through the open measurement side of the analysis cell into the detector, a part of it is absorbed depending on the gas concentration. The gas in the absorption chamber is, therefore, heated less than in the case of radiation coming from the reference side.
DETECTOR METHODOLOGIES 2.1.3 Overall NDIR Method In the case of dual-channel analyzers, the broadband emission from two infrared sources pass through the chopper wheel. In the case of the Interference Filter Correlation (IFC) method, the infrared radiation then passes through combinations of interference filters. In the case of the opto-pneumatic method, the infrared radiation passes through an optical filter depending on the application and need for reduction of influences.
DETECTOR METHODOLOGIES 2.2 Paramagnetic Oxygen Method The paramagnetic principle refers to the induction of a weak magnetic field, parallel and proportional to the intensity of a stronger magnetizing field. The paramagnetic method of determination of oxygen concentration utilizes nitrogen filled quartz spheres arranged at opposite ends of a bar, the center of which is suspended by and free to rotate on a thin platinum wire ribbon in a cell.
DETECTOR METHODOLOGIES 2.3 Electrochemical Oxygen Method The electrochemical method of determining oxygen concentration is based on the galvanic cell principle shown in Figure 2-4 below. (Black) Lead wire (Anode) Lead wire (Cathode) (Red) Anode (1) (Lead) O-Ring Plastic disc (9) Plastic top (10) Resistor (6) Thermistor (5) Acid electrolyte (3) Spong3 disc (7) Cathode (2) (Gold film) Teflon membrane (4) Figure 2-4.
DETECTOR METHODOLOGIES (Red) V out Thermistor (5) (Black) Resistor (6) (-) (+) Gold Lead Cathode (2) Anode (1) O2 + 4 H + 4 e → 2 H2O 2 Pb + 2 H2O → 2PbO + 4 H + 4 e Electrolyte (3) (ph 6) Summary reaction O2 + 2 Pb → 2 PbO Figure 2-5 Reaction of Galvanic Cell Rosemount Analytical µCEM Continuous Analyzer Transmitter 2–7
INSTALLATION 3. Installation WARNING: ELECTRICAL SHOCK HAZARD Installation and servicing of this device requires access to components which may present electrical shock and/or mechanical hazards. Refer installation and servicing to qualified service personnel. CAUTION: CODE COMPLIANCE Installation of this device must be made in accordance with all applicable national and/or local codes. See specific references on installation drawing located in the rear of this manual. 3.
INSTALLATION Figure 3-1. Dimensional Drawing, Door closed. Shown with Time Share option.
INSTALLATION O2 IN O2 IN CAL GAS IN (CUST) INST AIR BY CUST { ATMOS PRES DRAIN TO SAFE PLACE ELECTRICAL CONNECTIONS CAL GAS OUT O2 IN INST AIR BY CUST { ATMOS PRES DRAIN TO SAFE PLACE Rosemount Analytical ELECTRICAL CONNECTIONS µCEM Continuous Analyzer Transmitter 3–3
INSTALLATION 4" 150 LB ASA RF FLANGE CONNECTION 3 REMOTE OPERATION FROM MCEM CONTROLLER SV1 STACK LOCATION PI1 10 4 10 2 10 ADJUST FOR 10 20-30 PSIG FI1 10 ANALYZER LOCATION 1/4SSBH/ 3/8SSR PR1 1 DE-ENERGIZED=STREAM 1 ENERGIZED=STREAM 2 INSTRUMENT AIR 60-125 PSIG -40°F DEW POINT 1-5 SCFM 1/2 NPT MALE 10 SLOPE 7 BLOW BACK SAMPLE 1/4SSBH/ 3/8SSR ADJUST FOR 3-4 L/MIN D A 7 SP1 10 EOV1 C 3 10 10 B CAL GAS IN 1-2 LITER/MIN CALIB SET FOR 8-12 PSIG RV1 11 6 SAMPLE FLOW 6 F
INSTALLATION Analysis Enclosure Critical settings and control: 1. Set MicroCEM Pressure guage (P1)to 5 psig +/- 0.5psig. Pressure set by BPR located behind gauge in detector section. If CO and NOx response times are sluggish this pressure can be increased. 2. Set Calibration gas cylinder dual stage pressure regulators to 10 to 20 psig. 3. Set Flowmeter (F1) to 500cc to 1500cc per min. 4. TV1 is used to balance the flow between a probe and local calibration. It is located beside the solenoid valve manifold.
INSTALLATION Figure 3-5. Gas Connections 1 – Sample Gas Inlet (From Probe) 2 – Calibration Gas (From Probe) 3 – Gas 3 Inlet (Cal Gas) 5 – Gas 1 Inlet (Cal Gas) 6 – Ozone/Air Inlet (By Cust) 7 – Vent (To Cust vent) 4 – Gas 2 Inlet (Cal Gas) 3.2.1 Gas Conditioning All gases must be supplied to the analyzer as conditioned gases! When the system is used with corrosive gases, it must be verified that there are no gas components which may damage the gas path components.
INSTALLATION values computer by the detectors will then be corrected to eliminate erroneous measurements due to changes in barometric pressure. The gas flow rate must be in the range of 0.5 l/min to a maximum of 1.5 l/min. A constant flow rate of 1 l/min is recommended. NOTE: The maximum gas flow rate for paramagnetic oxygen detectors is 1.
INSTALLATION 3.3 Installation WARNING: ELECTRICAL SHOCK HAZARD Care should be taken if hazardous gases are to be measured or used for calibration. Refer to installation drawing supplied with the application data package. 3.3.1 Location The µCEM is designed to be installed in an outdoor environmental location. It is highly recommended that the analyzer be located out of direct sunlight and direct rain/snow to the extent possible to assure longevity and accuracies.
INSTALLATION J8 SSU J7 SHU 2 J6 SHU 1 J5 EXT I/O J4 LAN J3 COM J2 CPU I/O J1 AC POWER INPUT Figure 3-6 Electrical Connections J1 – AC Power Input J2 – CPU I/O J3 – COM Interface (pocket pc) J4 – Ethernet LAN Port J5 – EXT I/O Interface J6 – SHU #1 Interface J7 – SHU #2 Interface (T/S units only) J8 – SSU Power (T/S units only) 3.3.4.1 Circular Connector Assembly Instructions Refer to Figure 3-7 for instructions.
INSTALLATION Figure 3-7.
INSTALLATION 3.3.4.2 EXT I/O Interface Connector (J5) - MicroCEM inputs and outputs are specific for customer use. The Analog Interface connector has a shell size of 22, 100 contacts. Each pin will accept a wire size of 26, 24, or 22 AWG. Connector and 6’ pigtail by Rosemount.
INSTALLATION 94 Spare VIO 22 32 Shutdown1+ BLK 22 33 Shutdown1- GRY 22 34 O2LR+ O2 Range indicator (0V =range 1, 5V = range 2 ) BRN 22 35 O2LR- RED 22 36 COLR+ CO Range indicator (0V =range 1, 5V = range 2 ) BRN 22 37 COLR- ORG 22 38 NOxLR+ NOx Range indicator (0V =range 1, 5V = range 2 ) BRN 22 39 NOxLR- YEL 22 40 O2OL+ O2 Over Limit Indicator OR Valid (0V = normal, 5V = alarm ) BRN 22 41 O2OL- GRN 22 42 COOL+ CO Over Limit Indicator OR In Calibration (0V =
INSTALLATION 3.3.4.3 SHU #1 / #2 Interface Connector (J6 & J7). These wires are to be connected directly to the MicroCEM sample handling enclosure (SHU) and will control the operation of the sample pump, drain pump, purge valve and calibration valve respetively. All toggle switches in sample handling enclosure should be set to “remote” mode upon hookup of wire so the MicroCEM analysis enclosure will control the full system. The Digital Interface connector has a shell size of 14, 15 contacts.
INSTALLATION 3.3.4.4 COM Interface Connector (J3) – Pocket PC external connection The COM Interface connector has a shell size of 10, 13 contacts. Each pin will accept a wire size of 28, 26, or 24 AWG. Connector and 3’ pigtail by Rosemount.
INSTALLATION J VSYNC BLACK CENTER K GND BLACK SHIELD L DATA DCC DATA M CLK DCC CLK N KBDATA KEYBOARD DATA P KBCLK KEYBOARD CLOCK R GND GROUND S VCC VCC, +5VDC R GND GROUND S VCC VCC, +5VDC T MSDATA MOUSE DATA U MSCLK MOUSE CLOCK Table 3-5. CPU I/O Terminal Assignments 3.3.4.7 SSU Power Connector, T/S units Only (J8) – T/S enclosure can be located away from the Analysis enclosure. This cable serves as the connection and is by Rosemount.
INSTALLATION Figure 3-4.
INSTALLATION 3.3.5 Analytical Leak Check If explosive or hazardous gas samples are being measured with the µCEM, it is recommended that gas line fittings and components be thoroughly leak-checked prior to initial application of electrical power, and at bimonthly intervals thereafter, as well as after any maintenance which involves breaking the integrity of the sample containment system. 3.3.5.1 Flow Indicator Method Figure 3-8.
INSTALLATION UCEM Analyzer Inlet Outlet Overpressure approx. 50 N2 Water Figure 3-9. Leak Test Manometer Method Close the inlet shut-off valve and, following a brief period for pressure equilibrium, verify that the height of the water column does not drop over a period of about 5 minutes. If the water column height drops, the system is leaking and must be corrected before the introduction of any flammable sample gas or application of power.
INSTALLATION 3.3.5.3 Troubleshooting Leaks Liberally cover all fittings, seals, and other possible sources of leakage with a suitable leak test liquid such as SNOOP™ (part 837801). Bubbling or foaming indicates leakage. Checking for bubbles will locate most leaks but could miss some, as some areas are inaccessible to the application of SNOOP. For positive assurance that system is leak free, perform one of the preceding tests. NOTE: Refer to Specification in Preface for maximum pressure limitations.
INSTALLATION 4. Startup and Operation 4.1 Startup Procedure Once the µCEM has been correctly assembled and installed in accordance with the instructions in Section 1.
STARTUP and OPERATION Installation,” the analyzer is ready for operation. Before operating the system, verify that the Leak Checks have been performed and that the sample handling unit is performing correctly. MicroCEM analysis enclosure On/Off switch is located inside the door on the bottom right hand corner. Push switch to the “on” position to start system. The unit will immediately run thru a self diagnostic mode. This may take up to 2 minutes.
STARTUP and OPERATION 1. Plug the external COM cable into J3 circular connector on the bottom of the uCEM. 2. Plug pocket pc RS232 plug into the J1 on the external COM cable. 3. Plug power supply cable into 5V plug on the COM cable. 4. Turn Pocket PC on. 5. In order to assure no other windows are open press the reset button. Reset button is located on the back of the pocket PC. 6. Go to tools menu (Icon in upper left hand corner) and click on µCEMTS. 7. Unit will display data in 3 to 5 seconds.
STARTUP and OPERATION Table 4-1 - Status Values Shown in order of precedence. Maintenance mode status takes highest precedence. Status Description M Indicates that maintenance mode is active. C Calibration in process I Invalid Reading. Indicates that the reading is invalid due to calibration failure or Low Pressure flow alarm.
STARTUP and OPERATION 4.2.3 µCEM Menus Lower left part of the µCEM screen contains three menus, from which all of the µCEM user-interface functions can be accessed. There are three main menus: File, Tools and Advanced, presented on Figures 4-2.1, 4-2.2, and 4-2.3.
STARTUP and OPERATION Figure 4-2.2 - µCEM Tools Menu Figure 4-2.
STARTUP and OPERATION 4.2.4 µCEM Alarms The µCEM Alarms dialog shows all the current alarms. A current alarm is one with an Active status of 1 (active) or an Acknowledged state of 0 (not acknowledged).. To see the historical Alarms for the last 3 months , the web based µCEM interface must be used. If one or more alarms are current, the most recent of them will be displayed on the main display.
STARTUP and OPERATION O2 High Limit Critical O2 Low Limit Critical CO High Limit Critical CO Low Limit Critical NOx High Limit Critical Nox Low Limit Critical 24V Over Max Critical 24 Low Min Critical O2 Emission Limit Warning CO Emission Limit Warning NOx Emission Limit Warning Converter Over Temp Converter Low Temp Zone Over Temp Critical Zone Low Temp Critical PDT Over Temp Critical PDT Low Temp Critical PMT Over Temp Critical PMT Low Temp Critical Low Pressure Critical
STARTUP and OPERATION 4.2.5 µCEM Login The login dialog appears (Figure 4-4) when first requesting the µCEM Settings or µCEM Admin. If a valid user name and password are entered, the user logging in will have permission to use the µCEM Settings and/or the µCEM Administration (Refer to the User Settings page of the µCEM Settings dialog).
STARTUP and OPERATION 4.2.6 µCEM Login-Current User Indication When a user is logged in, the µCEM main display will indicate the user name of the logged in user as shown in Figure 4-5. Current user and Log off button.
STARTUP and OPERATION 4.2.7 Stream Switching Control Typically a dual stream system is in Automatic Stream Switching mode. That means that it runs the timing schedule specified in User Settings Configuration file. If Automatic switching is not desirable, the user may turn it off using Tools-> Stop Auto Switching menu. In this case the system will remain on the current stream indefinitely. When Automatic switching is needed again, user may turn it back on with Tools->Start Auto Switching menu.
STARTUP and OPERATION 4.3 µCEM Settings The µCEM Settings dialog is only available to users with µCEM Settings permission. If a user is not currently logged in, the login dialog will be displayed. If the current user doesn’t have µCEM Settings permission, µCEM will not allow Settings screen to appear. When the µCEM Settings are invoked from the Advanced menu or the µCEM Settings button, the µCEM Settings tabbed dialog is displayed. The Range page (tab) is displayed initially. 4.3.
STARTUP and OPERATION The Tabs allow selection of the µCEM Settings pages. Figure 4.
STARTUP and OPERATION 4.3.2 µCEM Settings-Auto Calibration The Auto-Calibration settings are set on the Auto-Calibration page of the µCEM settings. If auto calibration is turned to the on position, then the user can select time and/or frequency of the auto calibration in the Auto Calibration Frequency tab (4.3.3). Note: Both manual and auto calibration need to be perform with the MicroCEM enclosure door in the closed position.
STARTUP and OPERATION 4.3.3 µCEM Settings - Auto Calibration Time and Frequency The Auto-Calibration Time and Frequency tab allows specifying time and frequency of the auto-calibration. Time field requires military time format. The times are displayed in Military time type. Figure 4.
STARTUP and OPERATION 4.3.4 µCEM Settings-Limits The emission limits alarms can be set on the Limits page of the µCEM Settings. When a measured emission exceeds its limit, the emission will have a limit-exceeded status. This is indicated on the main display and on the Data-Logs display. It is also indicated in the limit exceeded digital output. Figure 4.
STARTUP and OPERATION 4.3.5 µCEM Settings-Calibration Gas The Calibration Gas values and Gas Bottle allocation may be set on the Calibration Gas page of the µCEM Settings. This should be set whenever a Calibration Gas container is replaced or upon Startup of the system. Calibration Gas Values: R1Mid: This is typically used for CGA audits and not for daily calibrations. The specific calibration gas mid value (typically between 40% to 60% of range) is set in this space.
STARTUP and OPERATION Figure 4.
STARTUP and OPERATION 4.3.6 µCEM Settings-Maintenance Mode Maintenance mode may be selected for any of the emission types on the Maintenance Mode page of the µCEM Settings. Choosing maintenance mode will invoke an “M” flag” onto the data. Customer can perform routine maintenance while in this setting This mode is typically used when preventive maintenance is being performed. The M flag signifies to the EPA that the values reported are not valid therefore should not be applied to emissions reporting.
STARTUP and OPERATION 4.3.7 µCEM -Manual Calibration A dry-run Calibration may be initiated from the Manual Calibration page of the µCEM Settings by pressing the Manual Calibrate All icon. A full zero and span calibration will be run by the MicroCEM but the end result corrections of the calibration will not be applied to the O2/Nox/CO measurement values. If desired a partial calibration may be invoked for one or more of the emission types.
STARTUP and OPERATION 4.3.8 Auto Calibration The Auto Calibration dialog is displayed whenever calibration is in process. It displays the current emission values and the status of the calibration. The calibration may be canceled before it completes by pressing the Cancel button. Note: The title of this dialog will read either “Auto Calibration” or “Manual Calibration” to indicate how the calibration process was initiated. Figure 4.
STARTUP and OPERATION 4.4 µCEM Administration The µCEM Administration dialog is only available to users with µCEM Administration permission. If a user is not currently logged in, the login dialog will be displayed. If the current user doesn’t have µCEM Administration permission, a message will be displayed which reads “Permission denied”. When the µCEM Administration is invoked from the Tools menu or the µCEM Administration button, the µCEM Administration tabbed dialog is displayed.
STARTUP and OPERATION 4.4.2 µCEM Administration-Auto Logoff The number of minutes of inactivity after which a user is automatically logged off is set on the Auto Logoff page of the µCEM Administration. Figure 4.
STARTUP and OPERATION 4.5 µCEM Factory and User Settings A µCEM Factory and User Settings files are available for use by µCEM technicians to set parameters in the µCEM or a qualified customer technician. µCEM Settings are separated into two files: Factory Settings and User Settings. Factory Settings should be modified by a Rosemount technician only. Note: Some parameters in this file, if set incorrectly, may cause permanent damage to hardware.
STARTUP and OPERATION Table 4.
STARTUP and OPERATION Table 4.
STARTUP and OPERATION R12O2SpanDriftLimit O2 Allowed Span Drift Limit for Range 2. R2COSpanDriftLimit CO Allowed Span Drift Limit for Range 2. R2NOXSpanDriftLimit NOx Allowed Span Drift Limit for Range 2. 4.6 uCEM Data Logs The µCEM maintains a minimum of 3 months of history in three types of data log files. The first type of log file is the measurement log, which contains emission measurements (at 1 minute intervals), alarm indications and maintenance mode indications.
STARTUP and OPERATION 4.6.4 Measurement Log File Format The log file contains data in a flat, ASCII, CSV file. The following are the fields of the file, in order of occurrence. The log file size will be about 42 bytes per entry.
STARTUP and OPERATION Span O2 R1 Mid Drift O2 R1 Expected Span O2 R1 Measured Span O2 R1 Span Drift O2 R2 Expected Mid Span O2 R2 Measured Mid Span O2 R2 Mid Drift O2 R2 Expected Span O2 R2 Measured Span O2 R2 Span Drift CO Expected Zero CO Measured Zero CO Zero Drift CO Expected R1 Mid Span CO Measured R1 Mid Span CO R1 Mid Span Drift CO R1 Expected Span CO R1 Measured Span CO R1 Span Drift CO Expected R2 Mid Span CO Measured R2 Mid Span CO R2 Mid Span Drift CO R2 Expected Span CO R2 Measured Span CO R2 Sp
STARTUP and OPERATION NOx R2 Span Drift NOx Expected R2 Mid Span NOx Measured R2 Mid Span NOx R2 Mid Span Drift NOx Expected R2 span NOx Measured R2 span NOx R2 Span Drift Percent drift of NOx Range 1 span calibration Measured ppm NOx for Range 2 mid span phase of calibration Measured ppm NOx for Range 2 mid span phase of calibration Percent drift of NOx Range 2 mid span calibration Measured ppm NOx for Range 2 span phase of calibration Measured ppm NOx for Range 2 span phase of calibration Percent drift o
STARTUP and OPERATION Fault Description 24 = Zone Cooler On Failed ** 25 = Zone Cooler Off Failed ** 26 = Heater Fan On Failed ** 27 = Heater Fan Off Failed ** 28 = Cooler Fan On Failed ** 29 = Cooler Fan Off Failed ** 30 = PDT Over Temp 31 = PDT Low Temp 32 = PDT On Failed ** 33 = PDT Off Failed ** 34 = PMT Over Temp 35 = PMT Low Temp 36 = PMT On Failed ** 37 = PMT Off Failed ** 38 = O2 Over Temp ** 39 = O2 Low Temp ** 40 = O2 On Failed ** 41 = O2 Off Failed ** 42 = Warmup Time Limit 55 = Low Pressure 70
STARTUP and OPERATION 4.6.7 Accessing the Real-Time ACSII Data String via Ethernet TCP/IP (DAS) Remote Real-time data acquisition from the uCEM is done through the TCP/IP enabled network via the HTTP (Web transport) protocol. Acquisition software has to request the page form the Web Server running on the uCEM unit with the desired frequency (real update time is 1 sec). URL for the real time data is defined as such: http://[uCEM IP]/fetchData.asp For example: http://127.0.0.1/ fetchData.
STARTUP and OPERATION M – Maintenance C – Calibration P – Process Off O – uCEM Off AlarmsString – is a string data that describes the current Alarms situation with the uCEM module. It is separated from the rest of the data by a semi-colon. AlarmsString usually is not parsed and used for the presentation purposes only. Example: “1,NOx Emission Failed. 13 More ...” Example: 02-05-2002 14:58:53,21.44,1,V,20.09,V,-555.00,V,##.##,0,P,##.##,P,##.##,P,10.37,1,I, 12.45,I,-555.00,I,5.0,3.
STARTUP and OPERATION 4.7 Viewing Data via the Pocket PC Web Browser The Pocket PC Web Browser menu can be accessed via the pocket pc main menu. In the top upper left hand corner of the menu the name of the unit will be displayed (ucem XXXX). Point on this name. A drop down menu will appear. Point on Internet Explorer. A sign on page will then be displayed. User name and password will be the identical as the normal names used on the administration settings.
STARTUP and OPERATION zone may show than the AC/Heater unit fan may have failed or a possible defective thermocouple. *PDD Temp: For systems with NOx a cylindrical NOx detector assy is located in the detector section. Internal to the detector assy a small peltier device is operating and must operate at 0 degrees C. The temperature should never deviate +/- .05 degrees C from the setpoint of zero or the NOx readings may drift. Integral will typically run between 40 to 70%.
STARTUP and OPERATION Note: The Real-time, Config and Download are included in the navigation menu but these pages are intended for remote desktop use. As an enhancement these items could be hidden if the pages are browsed from a Windows CE version of Internet Explorer. Alarms and Calibration data may also be viewed. A Date is shown for 1 min or 15 minute averages. A date range is shown for 1 hour or greater averages. The Emission DataLogs data is shown here. 7Figure 4.
STARTUP and OPERATION 4.8 Viewing µCEM Data with an external PC Web Browser The MicroCEM internal log files may be accessed using a user PC or laptop with a web browser that has access to the µCEM over a LAN, serial port connection (PPP) or Dialup Connection (RAS). The µCEM has Window CE Web Server installed and provides a Web-based interface to select and download the Data-Log files. The downloaded Data-Log files will be in a CSV (comma delineated ASCII) format.
STARTUP and OPERATION Figure 4.
STARTUP and OPERATION 4.8.2 Emissions Page The Emissions Page can be used to view emission history in a tabular web-page format. This page is used as part of the µCEM User interface as well as by a remote user (probably from a desktop computer). If Most Recent is selected, the month day and hour do not need to be selected. Select the ending hour to view (applicable only to 1 minute averages) Select 1 min., 15 min., 1 hour or 24 hour averages. Figure 4.
STARTUP and OPERATION Figure 4.
STARTUP and OPERATION Figure 4.
STARTUP and OPERATION 4.8.3 Download Page The download page of the µCEM allows the selection and download of the three types of Data-Logs. To quickly download recent data, a “Download Most Recent Emissions Data” selection is provided. For more control over the date range, a “Download Emissions by Date Range” selection is available. Once the selection is made, press the Download button to start the HTTP download. The µCEM will create a temporary file that contains the selected data.
STARTUP and OPERATION Download Emissions Log, Calibration Log or Alarm Log Choose from: 1 Minute / 8 Hours 1 Minute / 1 Day 1 Minute / 1 Week 15 Minutes / 1 Day 15 Minutes / 1 Week 15 Minutes / 1 Month 15 Minutes / 3 Months 1 Hour / 1 Week 1 Hour / 1 Month 1 Hour / 3 Months Figure 4.22 - Download Web Page 4.9 Viewing µCEM Data with MS Excel The µCEM Data may be viewed with MS Excel.
MAINTENANCE and SERVICE 5. Maintenance and Service CAUTION: QUALIFIED PERSONNEL This equipment should not be adjusted or repaired by anyone except properly qualified service personnel. WARNING: PARTS INTEGRITY Tampering with or unauthorized substitution of components may adversely affect safety of this product. Use only factory-approved components for repair. WARNING: ELECTRICAL SHOCK HAZARD Disconnect power to the module(s) prior to replacing components.
MAINTENANCE and SERVICE Figure 5-2.
MAINTENANCE and SERVICE 5.2 Converter Refer to Figure 5-1, Item 97, and Figure 5-3. To replace the converter or sensor, disconnect the two pneumatic tubes and two electrical connections. Unlace the heater blanket, and remove the converter. Reassemble in reverse order, ensuring that the converter is oriented with the glass cloth at the bottom and the sensor is oriented correctly inside the heater jacket.
MAINTENANCE and SERVICE Figure 5-4. Personality Modules and Backplane.
MAINTENANCE and SERVICE 5.5 Detector Assembly Refer to Figure 5-5 and Figure 5-6. REACTION CHAMBER REMOVAL: Disconnect the stainless steel tubing lines at the Gyrolok fittings. Remove the (4) nuts holding the Detector Assembly to the chassis. Disconnect the plug from connector J1 on the Signal Board and remove the assembly from the chassis. Note: Heatsink Compound. Care should be taken to avoid getting heatsink compound on optical surfaces.
MAINTENANCE and SERVICE washers from the bracket. Remove the bracket, insulating disk and bottom plate as a unit to minimize the spread of the heatsink compound. Remove the (2) screws holding the lower section of the Detector Housing, then slide the section along the cable and remove. Remove the (2) screws holding the socket, thermistor and photodiode in place, being careful not to lose the washers that are used as shims.
MAINTENANCE and SERVICE M3X0.5 x 25mm Screw (2) 3mm Spring Washer (2) Detector Header Heater* Heater* Retainer Gasket M3X0.5 x 16mm Screw (2) 3mm Spring Washer (2) Thermostat* Reaction Chamber O-Ring 854540 Tubing Cover Sapphire Window Cushioning Gasket O-Ring 876478 Photodiode Cable Lower Cover Photodiode Assembly (see detail below) M3X0.5 x 20mm Screw (2) 3mm Spring Washer (2) Insulator (between Lower Cover and Mounting Bracket) Nylon Shoulder Washers (3) Detector Cover M3X0.
MAINTENANCE and SERVICE 5.6 Central Processing Unit The CPU is an Embedded Pentium-type AT Computer in 5.75” x 8” form factor. The peripherals integrated on board are: SVGA, 4 serial ports and one parallel port, Fast Ethernet ctrl., IDE, Keyboard, Mouse, 2 USB. The module is built around the Intel Tillamook processor and is equipped with 64MB SDRAM.
MAINTENANCE and SERVICE Bus: Power Supply: Connectors: 2 USB ports 4 RS232 serial ports (one can be 485) Parallel port (bi-directional EPP-ECP) Keyboard PS/2 Mouse PS/2 AT bus according to PC/104 spec. AT/ATX COM1-4, SVGA, USB 1 and 2, PS/2 Mouse/Keyboard, ATX Power, Parallel, IDE, Floppy, and Fast Ethernet 5.6.1.2 EMBEDDED ENHANCED BIOS: - Award, 256KB Flash Bios.The Bios is immediately activated when you first turn on the system.
MAINTENANCE and SERVICE Figure 5-9. ADIO Block Diagram 5.6.2.1 Automatic Calibration The ADIO board features automatic calibration of both analog inputs and outputs for enhanced accuracy and reliability. The potentiometers, which are subject to tampering and vibration, have been eliminated. Instead, all A/D calibration adjustments are performed using an octal 8-bit DAC. The DAC values are stored in an EEPROM and are recalled automatically on power up.
MAINTENANCE and SERVICE 5.6.2.3 Programmable Input Ranges A programmable gain amplifier, programmable unipolar/bipolar range, and programmable 5V/10V full-scale range combine to give the ADIO board a total of 10 different possible analog input ranges. All range settings are controlled in software for maximum flexibility. Mode Full- Gain Input Scale Range Resolution Unipolar 10V 1 0-10V 0.153mV Unipolar 5V 1 0-5V 0.076mV Unipolar 5V 2 0-2.5V 0.038mV Unipolar 5V 4 0-1.25V 0.
MAINTENANCE and SERVICE can be disabled at slow sample rates, so there is no lag time between sampling and data availability. The 16-bit interface further reduces software overhead by enabling all 16 A/D bits to be read in a single instruction, instead of requiring 2 8-bit read operations. The net result of this streamlined design is that the ADIO board supports gap-free A/D sampling at rates up to 200,000 samples per second, twice as fast as our previous boards. 5.6.2.
MAINTENANCE and SERVICE trigger/control lines Counter/Timers A/D Pacer clock 32-bit down counter (2 82C54 counters cascaded) Clock source 10MHz on-board clock or external signal General purpose 16-bit down counter (1 82C54 counter) General Power supply +5VD±10%@200mA typ Operating temperature -25 to +85ƒC Weight 3.4oz/96g 5.6.3 PCMCIA Adapter The PCMCIA adapter supports Type I, II and III PCMCIA cards. The board is in full compliance with Microsoft FFS-II, PCMCIA V.2 and JEIDA 4.
MAINTENANCE and SERVICE 5.6.3.1 Features Dimensions: compliant with the PC/104 standard - Compatible with AT PC/104 CPU modules Functions on board: 2 PCMCIA slots Optional remote socket PCMCIA features - Supports PCMCIA V.1.0 and V.2.0 - Supports PCMCIA types I, II and III - Supports both I/O and Memory Card - Supports Hot insertion Operating Systems - Dos and Windows and any other RTOS that supports PCMCIA.
MAINTENANCE and SERVICE Figure 5-11. Modem 5.6.4.1 Features V.90, 56 kbps data (560PC/104) V.34, 33.6 kbps data (336PC/104) 14.4 kbps fax Voice playback and record DTMF decode -40oC to 85oC operation 3.775" x 3.550" x 0.568" (with modular phone jack) 3.775" x 3.550" x 0.435" (without modular phone jack) 8 bit PC/104 bus type V.42 and MNP 2-4 error correction V.
MAINTENANCE and SERVICE 5.6.5 Flash Drive Figure 5-12. 256MB Flash Drive. 5.6.5.1 Specifications Start-up time System Performance *Notes 1 & 2 Start-up Time Sleep to Write Sleetp To Read Reset to Ready Data Transfer Rate to/from host Active to Sleep Delay Controller Overhead Command to DRQ 2.5 msec max. 2.5 msec max. 50 msec typical 400 msec max. 16.0 MB/sec burst Programmable <1.25 msec Power Requirements *Note 1 DC Input Voltage Commercial Industrial Power Dissipation (Notes 3 & 4) @3.3 V 3.
MAINTENANCE and SERVICE Write 35 mA RMS 50 mA RMS Environmental Specifications Temperature: Operating Commerical Operating Industrial Non-Operating Commerical Non-Operating Industrial 0°C to 60°C -40°C to 85°C -25°C to 85°C -50°C to 100°C Humidity: Operating Non-Operating Acoustic Noise 8% to 95%, non-condensing 8% to 95%, non-condensing 0dB Vibration: Operating Non-Operating 15 G peak to peak max. 15 G peak to peak max. Shock: Operating Non-Operating 1,000 G max. 1,000 G max.
MAINTENANCE and SERVICE Physical Specifications Length Width Thickness (Body) Thickness (Removable Edge) Weight 100.2mm ± 0.51mm 69.85mm ± 0.51mm 9.6mm ± 5.0mm N/A 160 g. max Note 1: All values quoted are typical at ambient temperature and nominal supply voltage unless otherwise stated. Note 2: All performance timing assumes the controller is in the default (i.e., fastest) mode.
MAINTENANCE and SERVICE 5.6.6 Pocket PC The Pocket PC acts as an Graphic User Interface to the µCEM unit. Figure 5-13 depicts the Pocket PC. Figure 5-13.
MAINTENANCE and SERVICE Features Serial cable Earphones Removable metal cover Password protected and DMI compatible Physical Specifications 5.2 × 3.1 × 0.6 in (13 × 7.8 × 1.6 cm) 9.1 oz (260 g) with battery Operating Requirements Operating temperature: 32–104° F (0–40° C) Storage temperature: 32–140° F (0–60° C) Humidity: 90% relative humidity at 104° F (40° C) 5.6.
MAINTENANCE and SERVICE Physical Specification: Antenna(s): ETSI - FCC part 15B, CE, ETS 300 328, ETS 300 826, C-Tick (Australia) PC Card: PCMCIA Type II PC Card PCI: 32-bit, 5V Key, Full Plug-N-Play Integrated: Printed dual diversity External: 2.2dBi dipole; additional options for specific installation needs 5.6.8 500 Watts Power Supply The 500 Watts power supply combine high performance midrange power with high power density (4.
MAINTENANCE and SERVICE • Fan Output Voltage and Optional Fan • Optional Isolation Diodes for Parallel or Redundant Operation 5.7 Replacement Parts WARNING: PARTS INTEGRITY Tampering with or unauthorized substitution of components may adversely affect the safety of this product. Use only factory approved components for repair. 5.7.1 Replacement Part list The following is a list of replacement parts for the uCEM analyzer. For other parts or service, contact the factory as indicated in session 6.
MAINTENANCE and SERVICE PARTS LIST Item Vendor 1 CSTS 2 CSTS 3 CSTS 4 CSTS 5 CSTS 6 CSTS 7 CSTS 8 CSTS 9 CSTS 10 CSTS 11 CSTS 12 CSTS 13 CSTS 14 CSTS 15 CSTS 16 CSTS 17 CSTS 18 19 CSTS 20 CSTS 21 CSTS 22 23 CSTS 24 CSTS 25 CSTS 26 CSTS 27 CSTS 28 CSTS 29 CSTS 30 CSTS 31 CSTS 32 CSTS 33 CSTS 34 CSTS 35 CSTS 36 CSTS 37 CSTS 38 CSTS 39 CSTS 40 CSTS 41 CSTS Rosemount Analytical Mfg.
MAINTENANCE and SERVICE 42 CSTS 43 44 CSTS 45 CSTS 46 CSTS 47 CSTS 48 CSTS 49 CSTS 50 CSTS 51 CSTS 52 CSTS 53 CSTS 54 CSTS 55 56 CSTS 57 CSTS 58 CSTS 59 CSTS 60 CSTS 61 62 CSTS 63 CSTS 64 CSTS 65 CSTS 66 CSTS 67 CSTS 68 CSTS 69 CSTS 70 RMT-GMBH 71 RMT-GMBH 72 RMT-GMBH 73 RMT-GMBH 74 RMT-GMBH 75 SNAP-TITE 76 SNAP-TITE 77 SNAP-TITE 78 DWYER INST. 79 80 HOKE/SWAGELOC 81 HOKE/SWAGELOC 82 HOKE/SWAGELOC 83 CRAWFORD/SWGLO 84 HOKE/SWAGELOC 85 HOKE/SWAGELOC 86 INSOL.SUPPLY 87 INSOL.SUPPLY 88 INSOL.
MAINTENANCE and SERVICE 89 Westam Rubber 90 RMT-GMBH 91 Sante Fe Rub. Prod. 92 RAI Marshal Town Mfg. Or 93 Marsh Inst. Co. 94 CSTS 95 RAI 96 SWAGELOC 97 RAI 98 Te Lite 99 RAI 100 RAI 101 HOKE/SWAGELOC 102 HOKE/SWAGELOC 103 HOKE/SWAGELOC 104 HOKE/SWAGELOC 105 HOKE/SWAGELOC 106 107 108 HOKE/SWAGELOC 109 HOKE/SWAGELOC 110 CLIC 111 JACO SIEMENS-MOORE or 112 MOORE PROD.
MAINTENANCE and SERVICE 134 CSTS 135 CSTS 136 CSTS 137 CSTS 138 CSTS 139 CSTS 140 CSTS 141 CSTS 142 CSTS 143 CSTS 144 CSTS 145 Fastener Spec. 146 Fastener Spec. 147 Fastener Spec. 148 Fastener Spec. 149 Fastener Spec. 150 Amphenol (TTI) 151 Amphenol (TTI) 152 Amphenol (TTI) 153 Amphenol (TTI) 154 Amphenol (TTI) 155 KAD 156 KAD 157 KAD 158 KAD 159 KAD 160 KAD 161 KAD 162 KAD 163 KAD 164 KAD 165 KAD 166 KAD 167 KAD 168 KAD 169 KAD 170 KAD 171 KAD 172 KAD 173 Fastener Spec.
MAINTENANCE and SERVICE 181 CSTS 182 CSTS 183 CSTS 184 CSTS 185 CSTS 186 CSTS 187 RICHCO 188 RICHCO 189 CSTS 190 191 CSTS 192 CSTS 193 CSTS 194 EAR 195 CLIC 196 RMT-GMBH 197 E-T-A 198 Amphenol (TTI) 31391-9 31391-10 31391-11 31391-12 31391-1 31391-4 BHKL350-4-01 BHKL750-4-01 1020973-102 Insulation, Enclosure Insulation, Enclosure Insulation, Enclosure Insulation, Enclosure Insulation, Enclosure Insulation, Enclosure Blind Hole Kurly-Lok, .30-.40 dia bundle Blind Hole Kurly-Lok, .70-.
MAINTENANCE and SERVICE Figure 5-16. µCEM Enclosure with door open. 5.9 Trouble LED The Red Trouble LED output is activated whenever there is a critical alarm that has not been acknowledged and adjusted.
SOFTWARE 6. µCEM Software The µCEM Software includes 3 main components. One component is the µCEM control software that interfaces with the instrumentation and records the emissions measurements. A second component is the User Interface Software that provides realtime status and configuration dialogs. A third component is the web server software that uses VB Script or Java Script to provide a web-based interface to the µCEM. 6.
SOFTWARE uCEM User Interface uCEM Computer HTML (TCP/ IP) uCEM Control Software Serial Cable Pocket PC Shared Memory Segment Web Server Script TCP/IP Device Drivers Data-Log & Config Files As an option a Wireless Network may be used. HTML Workstation Ethernet, Modem or serial Digital and Analog IO Sensors and Control Circuitry Figure 6-1 - µCEM Software Block Diagram 6.3 Software Development Management Microsoft Visual SorceSafe is used for version control of all of the µCEM software.
SOFTWARE 6.4 µCEM Pocket PC Connection Failure In the event of the connection with the µCEM failed, a connection failure dialog will be displayed. It will display the following message. Connection with µCEM Lost, Retrying… A Cancel button will be displayed. The µCEM software will continue to attempt to reconnect with the µCEM indefinitely and will stop when a connection is made or the cancel button is pressed.