Instruction Manual 748467-A January 2002 Model MicroCEM Continuous Emissions Monitor http://www.processanalytic.
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.
Instruction Manual 748467-A January 2002 Model MicroCEM TABLE OF CONTENTS PREFACE...........................................................................................................................................P-1 Definitions ...........................................................................................................................................P-1 Intended Use Statement.............................................................................................................
Instruction Manual 748467-A January 2002 2-0 2-1 2-2 2-3 2-4 2-5 3-0 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 ii Contents Model MicroCEM INSTALLATION ....................................................................................................................2-1 Overview................................................................................................................................2-1 a. Limitations .............................................................................
Instruction Manual Model MicroCEM 748467-A January 2002 4-0 4-1 4-2 4-3 4-4 SOFTWARE ..........................................................................................................................4-1 Overview................................................................................................................................4-1 MicroCEM User Interface Software.......................................................................................4-1 MicroCEM Web Server Software .....
Instruction Manual 748467-A January 2002 Model MicroCEM LIST OF ILLUSTRATIONS Figure 1-1. Figure 1-2. Figure 1-3. Figure 1-4. Figure 1-5. Figure 1-6. Figure 1-7. Figure 1-8. Figure 1-9. Figure 1-10. Figure 1-11. Figure 1-12. Figure 1-13. Figure 1-14. Figure 1-15. Figure 2-1. Figure 2-2. Figure 2-3. Figure 2-4. Figure 2-5. Figure 2-6. Figure 2-7. Figure 2-8. Figure 3-1. Figure 3-2. Figure 3-3. Figure 3-4. Figure 3-5. Figure 3-6. Figure 3-7. Figure 3-8. Figure 3-9. Figure 3-10. Figure 3-11. Figure 3-12.
Instruction Manual 748467-A January 2002 Model MicroCEM Figure 5-2. Figure 5-3. Figure 5-4. Figure 5-5. Converter Assembly .............................................................................................. 5-3 Personality Modules and Backplane. .................................................................... 5-4 Chemiluminescense Detector Assembly ............................................................... 5-6 Chemiluminescense Detector Assembly – Exploded View ........................
Instruction Manual 748467-A January 2002 vi Contents Model MicroCEM Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 Model MicroCEM PREFACE The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the MicroCEM. 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.
Instruction Manual 748467-A January 2002 Model MicroCEM INTENDED USE STATEMENT The MicroCEM Continuous Emissions Monitor is intended for use as an industrial process measurement device only. It is not intended for use in medical, diagnostic, or life support applications, and no independent agency certifications or approvals are to be implied as covering such applications. SAFETY SUMMARY If this equipment is used in a manner not specified in these instructions, protective systems may be impaired.
Instruction Manual 748467-A January 2002 Model MicroCEM 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. 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.
Instruction Manual 748467-A January 2002 Model MicroCEM CAUTION. HEAVY WEIGHT Use two persons or a suitable lifting device to move or carry the instrument. P-4 Preface Rosemount Analytical Inc.
Instruction Manual Model MicroCEM 748467-A January 2002 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.
Instruction Manual 748467-A January 2002 Model MicroCEM DOCUMENTATION The following MicroCEM instruction materials are available. cal representative to order (See Section 8). Contact Customer Service Center or the lo- 748467 Instruction Manual (this document) 748468 Instruction Manual, MicroCEM Sample Handling System COMPLIANCES This product may carry approvals from several certifying agencies. The certification marks appear on the product name-rating plate.
Instruction Manual 748467-A January 2002 Model MicroCEM SECTION 1 DESCRIPTION AND SPECIFICATIONS NO2 and oxygen (O2). Some of the NO2 molecules produced are in an electronically excited state (NO2* where the * refers to the excitation). These revert to the ground state, with emission of photons (essentially, red light). The reactions involved are: 1-1 OVERVIEW The MicroCEM Analyzer Module is designed to continuously determine the concentration of O2 , CO, and NOx in a flowing gaseous mixture.
Instruction Manual 748467-A January 2002 Other application-dependent options include a wide range of sample cell materials, optical filters and solid state detectors. The NDIR Microflow detector consists of two chambers, measurement and reference with an interconnected path in which an ultra low flow filament sensor is mounted.
Instruction Manual 748467-A January 2002 Model MicroCEM The signal generation is accomplished with a pyroelectrical (solid-state) detector. The detector records the incoming infrared radiation. This radiation is reduced by the absorption of the gas at the corresponding 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 material.
Instruction Manual 748467-A January 2002 Model MicroCEM 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.
Instruction Manual 748467-A January 2002 Model MicroCEM 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.
Instruction Manual 748467-A January 2002 b. Model MicroCEM be drawn towards the region of greatest magnetic field strength. The oxygen molecules thus exert different forces on the two suspended nitrogen filled quartz spheres, producing a torque which causes the mirror to rotate away from its equilibrium position. 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.
Instruction Manual 748467-A January 2002 Model MicroCEM c. The electric current between the electrodes is proportional to the O2 concentration in the sample gas being measured. The resultant signal is measured as a voltage across the resistor and thermistor, the latter of which is used for temperature compensation. A change in the output voltage (mV) represents oxygen concentration.
Instruction Manual 748467-A January 2002 Model MicroCEM Black Red Lead Wire (Anode) Lead Wire (Cathode) Anode (Lead) O-Ring Plastic Disc Plastic Disk Resistor Thermistor Acid Electrolyte Sponge Disc Cathode (Gold Film) Teflon Membrane Figure 1-6. Electrochemical Oxygen Sensor 1-8 Description and Specifications Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 Model MicroCEM 1-5 CENTRAL PROCESSING UNIT The CPU is an Embedded Pentium-like 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.
Instruction Manual 748467-A January 2002 Model MicroCEM 1-6 ANALOG/DIGITAL I/O BOARD a. The Analog/Digital IO (ADIO) Board is an offthe-shelf, complete data acquisition system in a compact PC/104 packaging. The analog section contains 32 input channels, multiplexed A/D converter with 16 bit resolution and 10uS conversion time. Input ranges are +/-5v or +/- 10V. It also includes on-board DMA support. The analog output section includes two 12 bit D/A converters.
Instruction Manual 748467-A January 2002 Model MicroCEM c. Programmable Input Ranges e. 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 Unipolar Unipolar Unipolar Unipolar Unipolar Bipolar Bipolar Bipolar Bipolar Bipolar d. FullInput Gain scale Range 10V 1 0-10V 5V 1 0-5V 5V 2 0-2.
Instruction Manual 748467-A January 2002 AUTOCALIBRATION CIRCUIT INPUT MUX +15V -15V Model MicroCEM DC/DC 16-BIT A/D CONVERTER +15V X1,2,4,8 ANALOG INPUTS 0-31 SE 0-15 DI PROGRAMMABLE GAIN AMP 1K X8 FIFO 12-BIT A/D CONVERTERS ANALOG OUTPUTS 0-3 TIMING AND CONTROL SIGNALS ADDR MASTER CONTROLLER CTRL 82C54 COUNTER/TIMER 16-BIT DATA 10 MHZ OSCILLATOR 8255 CIRCUIT HIGH CURRENT DRIVE PC/104 BUS 24 DIGITAL I/O BUFFER PORT A BUFFER PORT B BUFFER PORT CH BUFFER PORT CL ACK/STROBE Figure 1
Instruction Manual 748467-A January 2002 Model MicroCEM g. Specifications Analog Inputs Number of inputs ................... 32 single-ended, 16 differential, or 16 SE + 8 DI; user selectable A/D resolution ........................ 16 bits (1/65,536 of full scale) Bipolar ranges ....................... ±10V, ±5V, ±2.5V, ±1.25V, ±0.625V Unipolar ranges ..................... 0-10V, 0-5V, 0-2.5V, 0-1.25V, 0-.625V, Input bias current................... 100pA max Overvoltage protection ..........
Instruction Manual 748467-A January 2002 Model MicroCEM 1-7 PCMCIA ADAPTER a. The PCMCIA adapter board (Figure 1-10) supports Type I, II and III PCMCIA cards. The board is in full compliance with Microsoft FFSII, PCMCIA V.2 and JEIDA 4.1 specifications.
Instruction Manual 748467-A January 2002 Model MicroCEM 1-8 MODEM The PC/104 Modular Modem is a selfcontained modem module that provides the flexibility to include modem functionality into embedded system, with minimal engineering resources. The PC/104 Modular Modem is full featured including high-speed data and fax transmission. The PC/104 Modular Modems support both dial-up and 2-wire leased-line. Figure 1-11 depicts the Modem. a. Features V.90, 56 kbps data (560PC/104) V.34, 33.
Instruction Manual 748467-A January 2002 Model MicroCEM 1-9 FLASH DRIVE Figure 1-12. 128MB Flash Drive a. Specifications System Performance All values quoted are typical at ambient temperature and nominal supply voltage unless otherwise stated. All performance timing assumes the controller is in the default (i.e., fastest) mode. Start-up Time Sleep to Write ................................ 2.5 msec max. Sleep To Read .............................. 2.5 msec max. Reset to Ready............................
Instruction Manual 748467-A January 2002 Model MicroCEM Power Dissipation Sleep mode currently is specified under the condition that all card inputs are static CMOS levels and in a "Not Busy" operating state. The currents specified show the bounds of programmability of the product. Sleep ............................................. 200 µA @3.3 V Read .............................................. 35 mA RMS @3.3 V Write .............................................. 35 mA RMS @3.3 V 500 µA @5.
Instruction Manual 748467-A January 2002 Model MicroCEM 1-10 POCKET PC The Pocket PC acts as an Graphic User Interface to the MicroCEM unit. a. Specifications Processor ..................................... 133MHz 32-bit Hitachi SH3 processor Memory ......................................... 32MB RAM, 16MB ROM Display .......................................... 240 x 320 pixels LCD, Rich-color CSTN, backlit User Interface ...............................
Instruction Manual 748467-A January 2002 Model MicroCEM 1-11 WIRELESS LAN ADAPTER Wireless LAN adapter is an option to allow the user to remove the Pocket PC from the enclosure and to operate the MicroCEM from a distance up to 1000 feet. Figure 1-14 depicts the wireless LAN adapter. Figure 1-14. Wireless LAN Adapter a. Specifications Data Rate ...................................... 11 Mbps send/receive with automatic fallback for extended range Useful Range.................................
Instruction Manual 748467-A January 2002 Model MicroCEM 1-12 500 WATTS POWER SUPPLY The 500 Watts power supply combine high performance midrange power with high power density (4.4 watts/in 3 ),active Power Factor Correction (PFC) and high reliability to meet the requirements of commercial and industrial systems. Providing tightly regulated DC power, the power supply delivers full output performance with only 300 Linear Feet per Minute (LFM) forced air-cooling by utilizing a factory installed fan.
Instruction Manual 748467-A January 2002 Model MicroCEM 1-13 MicroCEM SPECIFICATIONS a. Analyzer Power ............................................ Universal Power Supply 85 – 264 VAC, 50 – 60 Hz, + 10%, 500 Watts Maximum at Start Up. 250 Watts Nominal Microprocessor .............................. Intel Pentium processor, 266MHz, 64MB RAM, PC/104 architecture, Windows NT embedded Platform Pocket PC......................................
Instruction Manual 748467-A January 2002 Model MicroCEM Paramagnetic O2 b.
Instruction Manual 748467-A January 2002 Model MicroCEM SECTION 2 INSTALLATION WARNING ELECTRICAL SHOCK HAZARD 2-1 OVERVIEW a. POSSIBLE EXPLOSION HAZARD Ambient Temperature:-30° to 50° Celsius (-4° to 122° F) Do not open while energized. Do not operate without doors and covers secure. Installation requires access to live parts which can cause death or serious injury. Relative Humidity:5% to 99% b. DANGER.
Instruction Manual 748467-A January 2002 Model MicroCEM 25.2 640.1 11.6 295.3 20.2 513.1 4.3 109.2 1.1 TYP 27.9 17.9 456.9 MOUNTING DIMENSION 1.1 27.9 4.9 124.5 SAMPLE CALIBRATION 1.5 TYP 38.1 GAS 3 GAS 2 GAS 1 OZONE / AIR VENT 25.5 647.7 MOUNTING DIMENSION 24.6 624.8 KEY LOCK HINGE 4.9 124.5 CLEARANCE HOLE FOR 3/8 BOLT (4 PLACES) 1.5 TYP 38.1 AC POWER ANALOG DIGITAL INPUT INTERFACE INTERFACE RS232 LAN RS485 INTERFACE INTERFACE INTERFACE PHONE LINE ANTENNA 7.1 180.3 Figure 2-1.
Instruction Manual 748467-A January 2002 Model MicroCEM 2-3 GASES NOTE For external gas lines, the use of new tubing throughout is strongly recommended. The preferred type is teflon or stainless steel, sealed at both ends. a. Connection The gas conditioning must meet the following conditions: • Free of condensable constituents • Free of dust above 2 µm Besides sample gas, the MicroCEM requires other gases for operation. In most cases, one or more Calibration Standards must be provided.
Instruction Manual 748467-A January 2002 Model MicroCEM Figure 2-2. MicroCEM Gas Connections IN 3-WAY VALVE NDIR DETECTOR 90003225 OUT FLOWMETER W/VALVE CONVERTER 656715 SAMPLE PARAMAGNETIC DETECTOR 90003311 GAUGE 638614 CAL CAL GAS 3 CAL GAS 2 REGULATOR 904017 CAL GAS 1 OZONE AIR 2-WAY VALVE MANIFOLD ASSEMBLY EXHAUST OZONE GENERATOR 659494 VENT CAPILLARY 634398 DETECTOR 659754 Figure 2-3. MicroCEM Flow Diagram 2-4 Installation Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 Model MicroCEM Sample Inlet ½” FPT MicroCEM Analyzer Sample Handling System Stack Sample Flow Power In 115 VAC 60Hz 5A Dry Contact Initiate Auto Calibration Instrument Air 1 3 3 2 Atmospheric Pressure Calibration Line to Analyzer 3 ¼” Teflon tubing. Customer supplied. 2 Drain to safe location. 1 Customer supplied. Electrical connections. See Section 2-4 and Figure 2-5.
Instruction Manual 748467-A January 2002 Model MicroCEM tual electrical connections will be specified in the Application Data package. All connections are not necessary for every application. 2-4 ELECTRICAL CONNECTIONS NOTE Cable length for these signals should not exceed 3,000 feet (914 meters), to avoid excessive capacitance and corresponding signal distortion. The enclosure is a NEMA 4. All entry locations must be sealed.
Instruction Manual 748467-A January 2002 Model MicroCEM EXIO A22 DIGITAL A20 EXTERNAL CONNECTIONS ANTENNA J8 PHONE AC IN ADIO A3 CPU A4 P5 CN15 J6 CN16B J7 J9 J1 J3 PC-104 J4 PC-104 4-20 mA CURRENT LOOPS CO NOx BACKPLANE A2 CN16C J5 LAN RS485 AXX O2 PRIMARY POWER SUPPLY A1 MODEM A5 J4 RS232 CIRCUIT BREAKER 6A J3 J2 ANALOG AXX DIAGNOSTIC OUTPUT VOLTAGE J2 J3 DIGITAL I/O O2 CO NOx AXX LOW RANGE READING O2 CO NOx AXX OVER LIMIT INDICATOR AXX PLC ANALOG I/O AXX TROUBLE
Instruction Manual 748467-A January 2002 a. Model MicroCEM AC Power Connect AC power through a 10A circuit breaker that is to be located close to the MicroCEM. The circuit breaker will provide over current protection as well as a means of disconnecting the power. Maximum power requirements will be 380 watts, with most applications requiring less than this amount. b. 2. Using correct crimp tool and locator, cycle the tool once to be sure the indentors are open. Insert contact and wire into locator.
Instruction Manual Model MicroCEM Contact Insertion 1. Remove hardware from plug or receptacle and slip over wire bundle in proper order for reassembly. 748467-A January 2002 3. Press tool against contact shoulder and, with firm and even pressure, insert wired contact and tool tip into center contact cavity. A slight click may be heard as metal retaining tines snap into place behind contact shoulder. 4. Remove tool and pull back lightly on wire to make sure contact is properly seated.
Instruction Manual 748467-A January 2002 Model MicroCEM Contact Extraction 1. Remove hardware from plug or receptacle and slide hardware back along wire bundle. 4. Hold wire firmly in tool and extract wired contact and tool. Repeat operation for all contacts to be extracted. 2. Using plastic or metal extraction tool with proper color code corresponding to contact size, place wire in tool. 5. Fill any empty wire cavities with wire sealing plugs. 3.
Instruction Manual 748467-A January 2002 Model MicroCEM c. Interface Connections AC Power J1 Shell Size 12 Analog Interface J2 12 Digital Interface J3 RS232 Connection Designator No.
Instruction Manual 748467-A January 2002 Model MicroCEM SIGNAL NAME SPUMPNO SPUMPC SPUMPNC DPUMPNO DPUMPC DPUMPNC PURGNO PURGC PURGNC CALNO CALC CALNC TRBLNO TRBLC TRBLNC O2LR+ O2LRCOLR+ COLRNOxLR+ NOxLREXTDIG1+ EXTDIG1INCAL+ INCALO2OL+ O2OLCOOL+ COOLNOxOL+ NOxOL- DEFINITION Sample Pump Control, Dry contact, 110V 1A Rating Drain Pump Control, Dry contact, 110V 1A Rating Purge Valve Control, Dry contact, 110V 1A Rating Calibration Valve Control, Dry contact, 110V 1A Rating Trouble Indicator, Dry conta
Instruction Manual 748467-A January 2002 Model MicroCEM SIGNAL NAME DCD (pin 1) DSR (pin 6) RxD (pin 2) RTS (pin 7) TxD (pin 3) CTS (pin 8) DTR (pin 4) RI (pin 9) GND (pin 5) DEFINITION Data Carrier Detect Input Data Set Ready Input Receive Data Input Request to Send Output Transmit Data Output Clear To Send Input Data Terminal Ready Output Ring Indicator Input Signal Ground Not Used PIN 1 2 3 4 5 6 7 8 9 10-13 Table 2-5.
Instruction Manual 748467-A January 2002 Model MicroCEM 2-5 ANALYTICAL LEAK CHECK a. If explosive or hazardous gas samples are being measured with the MicroCEM, it is recommended that gas line fittings and components be thoroughly leak-checked prior to initial application of electrical power, bimonthly intervals thereafter, and after any maintenance which involves breaking the integrity of the sample containment system.
Instruction Manual 748467-A January 2002 Model MicroCEM b. 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. Manometer Method Install a water-filled U-tube manometer at the sample gas outlet.
Instruction Manual 748467-A January 2002 2-16 Installation Model MicroCEM Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 Model MicroCEM SECTION 3 OPERATION CAUTION. Do not operate or service this instrument before reading and understanding this instruction manual and receiving appropriate training. Refer to installation drawing supplied with the application data package. 3-1 STARTUP PROCEDURE Once the MicroCEM has been correctly assembled and installed in accordance with the instructions in Section 2, the analyzer is ready for operation.
Instruction Manual 748467-A January 2002 Model MicroCEM Flowmeter Printer Connector 5V Connector Heartbeat LED VGA Connector RS232 Connector Keyboard Connector Mouse Connector Trouble LED USB Connector Reset Button Floppy Connector IDE Connector Power Switch Figure 3-2. MicroCEM Front Panel 3-2 Operation Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 Model MicroCEM b. Main Display The MicroCEM Main Display (Figure 3-3) provides the status of the three emissions channels. The status includes the current reading (updated approximately every 2 seconds), the last 1-minute average, and the last 15minute average. The status column (Sts) indicates the status of the measurement and can be any of the values in listed in Table 3-1. (“Status” shown in order of precedence. Maintenance mode status takes highest precedence.
Instruction Manual 748467-A January 2002 c. Model MicroCEM MicroCEM Menu Clicking on the Tools text in the lower left corner of the display activates the MicroCEM menu. From this menu, all of the MicroCEM user-interface functions can be accessed. d. MicroCEM Alarms The MicroCEM 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)..
Instruction Manual 748467-A January 2002 Model MicroCEM ALARM NAME LEVEL DESCRIPTION O2 Calibration Failed Critical O2 Calibration Failed to meet the maximum Drift requirements CO Calibration Failed Critical CO Calibration Failed to meet the maximum Drift requirements NOx Calibration Failed Critical NOx Calibration Failed to meet the maximum Drift requirements O2 High Limit Critical O2 Sensor reading is above the minimal acceptable limit O2 Low Limit Critical O2 Sensor reading is below th
Instruction Manual 748467-A January 2002 e. MicroCEM Login The login dialog appears (Figure 3-6) when first requesting the MicroCEM Settings or MicroCEM Admin. If a valid user name and password are entered, the user logging in will have permission to use the MicroCEM Settings and/or the MicroCEM Administration (Refer to the User Settings page of the MicroCEM Settings dialog).
Instruction Manual Model MicroCEM 748467-A January 2002 3-3 MicroCEM SETTINGS The MicroCEM Settings dialog is only available to users with MicroCEM Settings permission. If a user is not currently logged in, the login dialog will be displayed. If the current user doesn’t have MicroCEM Settings permission, a message will be displayed which reads “Permission denied”. When the MicroCEM Settings are invoked from the Tools menu or the MicroCEM Settings button, the MicroCEM Settings tabbed dialog is displayed.
Instruction Manual 748467-A January 2002 b. Auto Calibration The Auto-Calibration settings are set on the Auto-Calibration page of the MicroCEM 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 (Section 3-3c). Model MicroCEM c. Auto Calibration Time and Frequency The Auto-Calibration Time and Frequency tab allows specifying time and frequency of the auto-calibration.
Instruction Manual Model MicroCEM d. 748467-A January 2002 Manual Calibration A dry-run Calibration may be initiated from the Manual Calibration page of the MicroCEM Settings. The results of the calibration will not be applied and only provide a dry run of the calibration. If desired a partial calibration may be invoked for one or more of the emission types. While the manual calibration is in process, a calibration progress dialog will be displayed as shown in Figure 3-26.
Instruction Manual 748467-A January 2002 e. Model MicroCEM Limits The emission limits alarms can be set on the Limits page of the MicroCEM 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. f.
Instruction Manual Model MicroCEM g. 748467-A January 2002 Maintenance Mode Maintenance mode may be selected for any of the emission types on the Maintenance Mode page of the MicroCEM Settings. Choosing maintenance mode will invoke an “M” flag” onto the data. Customer can perform routine maintenance while in this setting Figure 3-15. Maintenance Mode Settings Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 3-4 MicroCEM FACTORY SETTINGS A MicroCEM Factory Settings program is available for use by MicroCEM technicians to set parameters in the MicroCEM or a qualified customer technician. Enter the Factory Settings password at the login dialog to enter the Factory Settings. This 3-12 Operation Model MicroCEM password will not be provided to the customer. The list of settings is shown in Table 3-3 and Table 3-4.
Instruction Manual 748467-A January 2002 Model MicroCEM Calibration Setting Description O2ZeroDriftLimit O2 Allowed Zero Drift Limit. COZeroDriftLimit CO Allowed Zero Drift Limit. NOXZeroDriftLimit NOx Allowed Zero Drift Limit. OSMidDriftLimit O2 Allowed Mid Drift Limit. COMidDriftLimit CO Allowed Mid Drift Limit. NOXMidDriftLimit NOx Allowed Mid Drift Limit. O2SpanDriftLimit O2 Allowed Span Drift Limit. COSpanDriftLimit CO Allowed Span Drift Limit.
Instruction Manual 748467-A January 2002 Model MicroCEM General Setting Description O2SensorLowLimit This sets the O2 % low limit, below which a limit alarm will occur. O2SensorHighLimit This sets the O2 % high limit, above which a limit alarm will occur. COSensorLowLimit This sets the CO low limit, below which a limit alarm will occur. COSensorHighLimit This sets the CO ppm high limit, above which a limit alarm will occur.
Instruction Manual 748467-A January 2002 Model MicroCEM a. PID Control Loop Factory Settings These settings can be set for each of the temperature control loops. The temperature control loops include the Zone heater/cooler, Converter Heater, PMT Heater, and PMT Photo Diode Cooler. Table 3-5 shows the section names in the INI file used for each temperature control loop.
Instruction Manual 748467-A January 2002 Model MicroCEM PID Setting Description PSetting Proportional Gain. This parameter is set by using typical PID tuning methods. The P setting is mandatory and is the first parameter to adjust. It provides a command directly proportional to the error. ISetting Integral Gain. This parameter is set by using typical PID tuning methods. The I setting is optional and is used to make small adjustments to correct a small error which persists for a period of time.
Instruction Manual 748467-A January 2002 Model MicroCEM 3-5 MicroCEM ADMINISTRATION The MicroCEM Administration dialog is only available to users with MicroCEM Administration permission. If a user is not currently logged in, the login dialog will be displayed. If the current user doesn’t have MicroCEM Administration permission, a message will be displayed which reads “Permission denied”.
Instruction Manual 748467-A January 2002 Model MicroCEM 3-6 MicroCEM DATA LOGS b. The MicroCEM 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. The second type of log file is the calibration log file, which contains information on each auto calibration done.
Instruction Manual 748467-A January 2002 Model MicroCEM e. Calibration Log File Format The log file contains data in a flat, ASCII, CSV file.
Instruction Manual 748467-A January 2002 f. Model MicroCEM Alarm 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. Name Date/Time Fault Level Fault Type Fault Description The days or months maintained in the Alarm Log depends on how often trouble conditions are recorded. If there are rarely alarm conditions recorded, there is enough space for many years of alarm logs to be recorded.
Instruction Manual 748467-A January 2002 Model MicroCEM croCEM web pages (see Figure 3-18 and Figure 3-19). This page can be used to view the Emissions log. Other pages may be selected to view the calibration log and the alarm log. 3-7 VIEW DATA LOGS View Data Logs will start Internet Explorer and display the Emissions page of the Mi- If Most Recent is selected, the month day and hour do not need to be selected. Select 1 min., 15 min., 1 hour or 24 hour averages.
Instruction Manual 748467-A January 2002 Model MicroCEM 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. The Emission Data-Logs data is shown here. 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.
Instruction Manual 748467-A January 2002 Model MicroCEM 3-8 VIEWING MicroCEM DATA WITH A WEB BROWSER The log files may be accessed using a web browser that has access to the MicroCEM over a Wireless LAN, serial port connection (PPP) or Dialup Connection (RAS). The MicroCEM 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.
Instruction Manual 748467-A January 2002 b. Model MicroCEM Emissions Page The Emissions Page can be used to view emission history in a tabular webpage format. This page is used as part of the MicroCEM User interface as well as by a remote user (probably from a desktop computer). The Emission Data-Logs table is displayed (as shown in Figure 3-19) after selecting the Date and Average Period and pressing the Display button. If desired a bookmark or shortcut may be made to the page displaying the table.
Instruction Manual 748467-A January 2002 Model MicroCEM Figure 3-23. Calibration Table Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 c. Model MicroCEM Download Page The download page of the MicroCEM 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.
Instruction Manual 748467-A January 2002 Model MicroCEM 3-9 VIEWING MicroCEM DATA WITH MS EXCEL The MicroCEM Data may be view with MS Excel using two different methods. The first method is to open the data log files that have been downloaded onto a workstation. The files may then be opened directly with Excel. The second method is to create an Excel workbook, which links to the MicroCEM web page. This is described in the following paragraph.
Instruction Manual 748467-A January 2002 Model MicroCEM 3-10 AUTO CALIBRATION The Auto Calibration dialog is displayed whenever calibration is in process. It dis- plays 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 3-26.
Instruction Manual 748467-A January 2002 Model MicroCEM SECTION 4 SOFTWARE computer. It will not normally run locally since there is no input device or display connected to the MicroCEM processor. 4-1 OVERVIEW The MicroCEM Software includes 3 main components. One component is the MicroCEM 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.
Instruction Manual 748467-A January 2002 Model MicroCEM 4-4 SOFTWARE DEVELOPMENT MANAGEMENT Microsoft Visual SourceSafe is used for version control of all of the MicroCEM software. Compuware’s Track Record is used for change request management and defect tracking. 4-2 Software Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 Model MicroCEM SECTION 5 MAINTENANCE AND SERVICE DANGER. ELECTRICAL SHOCK HAZARD Disconnect power to the module(s) prior to replacing components. WARNING 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 factoryapproved components for repair.
Instruction Manual 748467-A January 2002 Model MicroCEM Converter (Figure 5-2) NDIR Detector Ozone Generator Valve Manifold Assembly Thermoelectric Cooler Paramagnetic Detector Power Relay Regulator 3-Way Valve Chemiluminescense Detector (Figure 5-4) Power Supply Assembly Transistor Fan Personality Modules (Figure 5-3) Figure 5-1. MicroCEM Component Location 5-2 Maintenance and Service Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 Model MicroCEM 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. 5-2 CONVERTER To replace the converter or sensor, disconnect the two pneumatic tubes and two electrical connections.
Instruction Manual 748467-A January 2002 Model MicroCEM ality modules are installed on a custom backplane. See Figure 5-3. 5-3 OZONE GENERATOR To replace the ozonator, remove the two large straps and all tie-wraps, and disconnect the one electrical connection. Reassemble in reverse order. 5-4 PERSONALITY MODULES There are five different personality modules. Depending on your unit, you may have three, four or five modules installed. These person- To remove any on the personality modules.
Instruction Manual 748467-A January 2002 Model MicroCEM 5-5 CHEMILUMINESCENSE DETECTOR ASSEMBLY NOTE Component Positioning. The procedure described above is for the purpose of maintaining the relative positions of windows and O-ring to the Reaction Chamber during installation. Refer to Figure 5-4 and Figure 5-5. a. Reaction Chamber Removal Disconnect the stainless steel tubing lines at the Gyrolok fittings. Remove the (4) nuts holding the Detector Assembly to the chassis.
Instruction Manual 748467-A January 2002 Model MicroCEM position of the O-ring and window in the upper compartment. Replace the lower section of the housing, then the bottom cover, insulator and bracket with the shoulder washers and screws. The new photodiode should be slowly inserted into the housing while gradually rotating the body. This allows the O-ring to properly seat. Continue replacing screws, washers, thermistors, etc.
Instruction Manual 748467-A January 2002 Model MicroCEM M3X0.5 x 25mm Screw (2) 3mm Spring Washer (2) Detector Header Heater* Heater* Retainer Gasket Thermostat* M3X0.5 x 16mm Screw (2) 3mm Spring Washer (2) Reaction Chamber O-Ring 854540 Tubing Cover Sapphire Window Cushioning Gasket O-Ring 876478 Photodiode Cable Lower Cover Photodiode Assembly (see detail below) M3X0.
Instruction Manual 748467-A January 2002 5-8 Maintenance and Service Model MicroCEM Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 Model MicroCEM SECTION 6 TROUBLESHOOTING 6-1 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 tests above.
Instruction Manual 748467-A January 2002 6-2 Troubleshooting Model MicroCEM Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 Model MicroCEM SECTION 7 REPLACEMENT PARTS 1020839-100 1020840-100 1020841-101 1020842-100 1020843-100 1020869-100 1020973-100 1020987-100 42706504 42711801 634398 638614 655216 655250 655289 657716 657719 658157 659754 90003311 902124 905778 905779 905780 905871 PMD Module Assembly NDIR Module Assembly PDD Module Assembly AUX Module Assembly EXIO Module Assembly Thermoelectric Cooler Assembly Thermistor Heater Assembly Desiccant Bulbs Electrical Cable Capillary, V
Instruction Manual 748467-A January 2002 7-2 Replacement Parts Model MicroCEM Rosemount Analytical Inc.
Instruction Manual 748467-A January 2002 Model MicroCEM SECTION 8 RETURN OF MATERIAL 8-1 RETURN OF MATERIAL If factory repair of defective equipment is required, proceed as follows: 1. Secure a return authorization from a Rosemount Analytical Inc. Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted. 2.
Instruction Manual 748467-A January 2002 8-2 Return of Material Model MicroCEM Rosemount Analytical Inc.
WARRANTY Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller.
Instruction Manual 748467-A January 2002 Model MicroCEM 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: gas.csc@emersonprocess.com ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd. 1 Pandan Crescent Singapore 128461 Republic of Singapore Phone: 65-777-8211 Fax: 65-777-0947 EUROPEAN TECHNOLOGY CENTER Fisher-Rosemount GmbH & Co.
