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Emerson Process Management 755R Oxygen Equipment User Manual

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2. 100 R85 AO OS 2M 50 R102 e 40K O O 25 R86 e NN e 80K O 9 10 Recorder Span e R52 A O Oo Jumper Selectable 200K 5 R87 R50B _AMO O gt 400K NNN 25 20K R534 4A O O e R50C 800K AAN 4 R82 1 20K e MO O 2M TP18 C55 C46 C e gt gt AUF UF E FROM R84 E G 7 To Alarm and V I U10 V R50A 20K U13 e 5V U16 e e e To Recorder 20K a Es d R88 Xd 500 R57 3 83K 1V e Oe E3 E4 Recorder Output R58 Jumper Selectable 909 100mV E5 E6 R59 90 9 10mV E7 E8 R60 10 Figure 5 8 Simplified Analog Recorder Output Circuit 5 12 Circuit Analysis Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 SECTION 6 MAINTENANCE AND SERVICE The information provided in this section will aid in isolation of a malfunction to a particular assembly or circuit board A few detailed checks are included to aide in locating the defective assembly It is recommended that those familiar with cir cuit analysis refer to Section 6 Circuit Analy sis of this manual WARNING ELECTRICAL SHOCK HAZARD Do not operate without doors and covers secure Servicing requires access to live parts which can cause death or serious injury Refer servicing to qualified per sonnel For safety and proper performance this in strument must be connected to a properly grounded three
3. Model 755R GAS EQUIV AS Acetylene C2H2 0 612 Allene C3H4 0 744 Ammonia NH3 0 479 Argon A 0 569 Bromine Br2 1 83 1 2 Butadiene C4H6 1 047 1 3 Butadiene C4H6 1 944 n Butane C4H10 1 481 iso Butane C4H10 1 485 Butene 1 C4H8 1 205 cis Butene 2 C4H8 1 252 iso Butene C4H8 1 201 trans butene 2 C4H8 1 274 Carbon Dioxide CO2 0 623 Carbon Monoxide CO 0 354 Ethane C2H6 0 789 Ethylene C2H4 0 553 Helium He 0 059 n Heptane C7H16 2 508 n Hexane C6H12 2 175 cyclo Hexane C6H12 1 915 Hydrogen H2 0 117 Hydrogen Bromide Hbr 0 968 Hydrogen Chloride HC1 0 651 Hydrogen Fluoride HF 0 253 Hydrogen lodide HI 1 403 Hydrogen Sulphide C2S 0 751 Kryton Kr 0 853 Methane CH4 0 512 Neon Ne 0 205 Nitric Oxide NO 44 2 Nitrogen N2 0 358 Nitrogen Dioxide NO2 28 7 n Octane C8H18 2 840 Oxygen O2 100 0 n Pentane C5H12 1 810 iso Pentane C5H12 1 853 neo Pentane C5H12 1 853 Propane C3H8 1 135 Propylene C3H6 0 903 Water H20 0 381 Xenon Xe 1 340 Rosemount Analytical Inc Table 3 2 Oxygen Equivalent of Common Gases A Division of Emerson Process Management Instruction Manual Rosemount Analytical Inc The Current Output is set at the factor for 4 to 20 mA If a 0 to 20 mA output is required re adjust both the zero and span potentiometers R1 and R2 on the Current Output Board 748213 S Model
4. Maximum 10 psig 68 9 kPa EE Minimum 5 psig vacuum 34 5 kPa vacuum Flow Rate eee 50 cc min to 500 cc min ER OE RO TC Recommended 250 20 cc min Materials in Contact with Sample Glass 316 stainless steel titanium Paliney No 7 epoxy resin Viton A platinum nickel and MgF2 Performance specifications are measured at recorder output and are based on constant sample pressure and deviation from set flow held to within 1096 or 20 cc min whichever is smaller Rosemount Analytical Inc A Division of Emerson Process Management Description and Specifications 1 3 Instruction Manual 748213 S c Electrical Supply Voltage and Frequency selectable when ordered Standard 115 VAC 10 VAC 50 60 Hz Optional 230 VAC 10 VAC 50 60 Hz Power Consumption Maximum 300 watts Outputs iii Standard Field selectable voltage output of 0 to 10mV 0 to 100mV 0 to 1V or 0 to 5VDC Optional Isolated current output of 0 to 20mA or 4 to 20mA with Current Output Board Alarm Optionen aia High Low Alarm Contact Ratings 5 amperes 240V AC resistive 3 amperes 120 VAC inductive 1 amperes 24V DC resistive 5 amperes 30 VDC resistive 5 amperes 120V AC resistive 3 amperes 30 VDC inductive Setpoint ios Adjustable from 1 to 100 of fullscale Deadband sss Adjustable from 196 to 2096 of fullscale Factory set at 1096 of fullscale
5. 2 6 Figure 2 4 Model 755R Connected to Drive Several Current Actuated Output Devices 2 7 Figure 2 5 Relay Terminal Connections for Typical Fail Safe Applications 2 8 Figure 2 6 Typical Alarm SettingS sees ee esser esser esser seer reer neee 2 10 Figure 2 7 Alarm Relay Assembly Schematic Diagram ees ees esse eee eee e 2 11 Figure 3 1 Control Board Adjustment Locations 3 3 Figure 3 2 Dial Settings for Alarm Setpoint Adjustments iese eee eee ee 3 7 Figure 4 1 Functional Diagram of Paramagnetic Oxygen Measurement System 4 3 Figure 4 2 Spherical Body in Non Uniform Magnetic Field ee ee eee 4 4 Figure 4 3 Detector Magnet Assembly sss ee esse ee ee ee ereer nenen meer enne 4 7 Figure 5 1 Two Comparator OR Circuit ie ee ee ee eene nenne 5 2 Figure 5 2 Case Heater Control Circuit ees se ee ee enne 5 3 Figure 5 3 Ramp Generator Circuit ees ee ee ee ee Re eene 5 3 Figure 5 4 Detector Heater Control Circuit ee se seer ereer enne 5 6 Figure 5 5 Detector Light Source Control Circuit ee ee ee ee ee Re ee ee 5 7 Figure 5 6 Detector with First Stage Amplifier sese sees ee ee ee ee ee Re ee Re ee m 5 9 Figure 5 7 Buffer Anticipation and Digital Output Circuit iese ee ee ee ee ee Ge Re Ee ee ee ee 5 10 Figure 5 8 Simplified Analog Recorder Output Circuit ese se ee ee ee ee Re ee ee Re ee 5 12 Figure 6 1 Detector Magnet Assem
6. AAA a a OE OO5DBS CONN DE 901839 C A O Fo 654076 PW DE LU sd LU m Wes S TB2 2 JTA MV MA GRN YEL 654012 CASE BD ASSY es Hai Pas AN FAN COLOR CODES VARY WITH MANUFACTURE USE COLOR CODE THAT APPLIES N UNITS WITH 230V OPTION AND REMOTE RANGE SELECTION REQUIRE RANGE BOARD EN 1546004 JUMPER CONFIGURATION CHANGED FROM A TO B AND E 10 BDB PEL IS EOS 4S A A ee ME 654004 30 EG ou THERMISTOR 654013 632353 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF ROSEMOUNT ANALYTICAL INC AND 15 TENDERED SUBJECT TO THE CONDITIONS THAT THE INFORMATION A BE RETAINED IN CONFIDENCE B NOT BE OR COPIED IN WHOLE OR IN PART AND C NOT BE USED OR INCORPORATED IN ANY PRODUCT EXCEPT UNDER AN EXPRESS WRITTEN AGREEMENT WITH ROSEMOUNT ANALYTICAL INC H 17377 3 29 96 LA JB JR 17023 08 12 9 Kv IGE WE ER Ru od BLK HEATER HRZ BLK GRN 646004 RANGE BD eo A BE JD N SUSPENSION ASS E amp H id H ES H v 646092 646091 Q 00 Q L LO LO ISOLATED V 1 BD ASSY 6204353 OPTIONAL SIGNAL CONTROL BOARD 652830 DISPLAY ROSEMOUNT ANALYTICAL INC LA HABRA CALIFORNIA lt 0631 Rosemount Analytical Inc CHK ANDERSON DSGN 12 90 TITLE DIAGRAM PICTORIAL WIRING ENGR s saman _ 12 20 PARAMAGNETIC O2 ANALYZER J B simpson 12
7. SCHEMATIC 1 gt 6 S1VAC 20K ES C55 2 HIS Y 1 0 63V 415V ANALOG GND Y SIG LH po M GND i SERVICE GND 5 o a Es EM LO lt Ien CO O een a a a a a ae Aa a a A I E Lr HE Lo e oL eb 2 ALL RESISTORS ARE IN OHMS 141 178W ALL CAPACITORS ARE MICROFARADS 50V Saa NOTES UNLESS OTHERWISE SPECIFIED 8 6 0 14 100 50 CR Fi 182K R49 20K TFie RECORDER OUTPUT SELECT E TRF B 2 40 EVEN NO S Jo CD4049CN 2 11 1 4W 20K t1 1 4W C53 120PF 500V t1 1 4W 0 t1 1 4W 2 1 i i Qt PN3569 R72 AI R71 D KS 20K 5 1 74W l 11 1 4W T S R73 39 4K 25 1 40 V 2N4356 R80 7 10K E G 11 R78 39 x 1K SR IAN Y CHK ANDERSON DSGN ENGR RUSSELL J B SIMPSON out U18 IN LM7805 C59 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF ROSEMOUNT ANALYTICAL INC AND IS TENDERED SUBJECT TO THE CONDITIONS THAT THE INFORMATION _ A BE RETAINED IN CONFIDENCE B NOT BE OR COPIED IN WHOLE OR_IN PART AND C NOT BE USED OR INCORPORATED IN ANY PRODUCT EXCEPT UNDER AN EXPRESS WRITTEN AGREEMENT WITH ROSEMOUNT ANALYTICAL INC 45V 11 8 90 1 32082 18 91 GS BG 161 7910 18 8 TL J 22 C 8 50 9 49 40 481 La EE 4 ES l6 5 Zo o A 8 45 9 44 DS 10 43 3918 46 M1 7 Ig 13 10 138 14 al 34 16 40l EXIJO 17 39 30 18 14 2
8. C4 01uF U1 C2 1000pf C3 R4 AT7uF f 1 13K VI DS1 ES AA CURRENT R5 2M imbalance in the detector and the photocells BT1 and BT2 The output current that U2 must provide to re store the dumbbell is a measure of the dis placing force and thus is a function of both a the oxygen concentration of the sample and b the sample pressure The output from the U1 and U2 loop is further amplified by U4 to provide a O to 10 VDC out put that constitutes signal V E21 E22 SIG Vx 0 10V R20 20K 15V R12 200K R13 FRONT VVV 20k PANEL ZERO 15V R10 EK 3 01K Ro DETECTOR e 20K COARSE C8 ZERO 0022uF U2 R7 1 77K e ACT T ATUF R8 1 77K FEEDBACK LOOP o Figure 5 6 Detector with First Stage Amplifier A Division of Emerson Process Management Circuit Analysis 5 9 Instruction Manual e Model 755R 5 7 BUFFER AMPLIFIERS U8 AND U10 WITH Analog output circuits for recorder V I ASSOCIATED ANTICIPATION FUNCTION and alarms See Section 5 9 page 5 11 Refer to Figure 5 8 page 5 12 U8 is a unity 5 8 DIGITAL OUTPUT CIRCUIT gain amplifier that provides zeroing capability and a buffered output for the anticipation cir Refer to Figure 5 7 below The output signal cuit feeding U10 from buffer amplifier U10 is routed through an attenuator and filter netwo
9. Fullscale span is 5 O2 Therefore the 0 0596 O2 error is equal to 196 of fullscale Thus if the exhaust is vented to the at mosphere the pressure effect must be taken into consideration This may be ac complished in various ways including manual computation and computer cor rection of data Operation at Negative Gauge Pres sures Operation at negative gauge pressures is not normally recommended but may be used in certain special applications A suction pump is connected to the analyzer exhaust port to draw sample into the inlet and through the analyzer Such operation necessitates special precautions to en sure accurate readout First is the basic consideration of supplying the standard gases to the analyzer at the same pres sure that will be used for the sample dur ing subsequent operation In addition any leakage in the sample handling system will result in decreased readout accuracy as compared with operation at atmos pheric pressure The minimum permissible operating pres sure is 5 psig vacuum 34 5 kPa vacuum Operation of the analyzer below this limit may damage the detector and will void the warranty Flow Rate Operating limits for sample flow rate are as follows minimum 50 cc min maxi Installation mum 500 cc min A flow rate of less than 50 cc min is too weak to sweep out the detector and associated flow system effi ciently Incoming sample may mix with earlier sample causing an aver
10. I van Ne wae Y Sample Gas Magnetic Susceptibility k Note As percentage of oxygen in sample gas increases displacement force F increases Figure 4 2 Spherical Body in Non Uniform Magnetic Field 4 3 ELECTRONIC CIRCUITRY Electronic circuitry is shown in the Control Board schematic diagram Drawing 652826 and is described briefly in the following sec tions For detailed circuit analysis refer to Section 5 Circuit Analysis a Detector Magnet Assembly A cross sectional view of the optical bench and detector assemblies is shown in Figure 4 3B page 4 7 Source lamp DS1 powered by a supply section within the Power Supply Board assembly See Section 4 3c page 4 5 directs a light beam onto the mirror attached to the test body The mirror reflects the beam onto dual photocell BT1 BT2 The difference between the signals de veloped by the two halves of the photocell constitutes the error signal supplied to the input of amplifier U1 on the Control Board assembly Amplifier U1 drives U2 which 4 4 Theory in turn supplies the restoring current to the titanium wire loop on the test body See Section 4 1 page 4 1 Detector temperature is sensed by ther mistor RT1 an integral part of the detec tor assembly See Figure 4 3B page 4 7 The thermistor provides the input signal to the detector temperature control section of the Power Supply Board assembly HR1 mounted on the top of the magnet
11. XX 020 125 XX E 008 MACH SURE DSGN dw KEE p RE ncque c ERRE THREADS CLASS 2A OR 28 TENISTE E I I TEM it 1 REMOVE BURRS amp SHARP EDGES 020 MAX Lu uam Eom ACH EE E La EE EES MACH SURF FLAT WITHIN 0Q1 IN IN pou KA emit i is n po OTHER SURF FLAT WITHIN 005 INN VR A es CONCENTRICITY MACH SURF ga GN SU N i TLR WITHIN 1 2 SUM OF DIAS TOLS 001 MIN 7 DO NOT SCALE GRAWING E 5 cer TIBU 027 0 1 PES airless R23 ed 150K TP10 Pu 4M C36 E21 E22 Rel S p v d 49 9K p CW 013 R20 R22 V 1000PF 20K s d 15 8K ore c14 reels Y di 15V OS 2M 14 1 4W TP8 2K R276 im 45V SOURCE 15V SOURCE C26 100K RB4 ee 1 4 7 4W C1 R28 45V a 15v Q H fk C46 3 3 15V 1 0 45V R85 R2 CRA 249K R10 CB 20K 1N4448 nm R102 R4 l 0022 1 47 4W 200V 40K 10 45 1 4W 15V EV RECORDER N R86 TPE c10 a DET sic 13 R7 v R52 440K NW 2 7 ae 44 4 4W 2 6 T 1 7748K B7 er 1006PF 4 A 1 1 4 3 07 400K SIG GND 14 a 47 64 7 S 15V 45V GND dar V RS y T R43 FRONT XV 61 s AU 174M NG CW gt 20K PANEL CASE 200K 47 63V 1 43K THERMISTOR E s B 0 QUE RU dd iy 1 77 48k asy 11 e 118K 4 4N m DET LOOP DRIVE J4 C66 45V 22 25V C67 LTE ue 22 25V y JT P4 J4 2 gt 5 81VAC T4 DISPLAY R89 BI Or ELEGTATCAL 180 POWER SUPPLY ut 620423 7 CURRENT n s TE BoaRD d 5 SIG GND
12. ment at 100 i e Position 10 on the dial adjust front panel SPAN Control so that A Typical ALARM 1 Setting When input signal moves upscale through this point the coil of ALARM 1 relay K1 is energized providing continuity between the common and normally closed contacts of the relay 40 INPUT SIGNAL Percent of Fullscale DEADBAND SET FOR 20 OF FULLSCALE 30 ALARM 1 Setpoint When input signal moves downscale through this point the coil of ALARM 1 relay K1 is de energized providing continuity between the common and normally open contacts of the relay 20 B Typical ALARM 2 Setting When input signal moves upscale through this point the coil of ALARM 2 relay K2 is de energized providing continuity between the common and normally open contacts of the relay 55 INPUT SIGNAL Percent of Fullscale DEADBAND SET FOR 50 H 1096 OF FULLSCALE ALARM 2 Setpoint When input signal moves upscale through this point the coil of ALARM 2 relay K2 is energized providing continuity between the common and normally closed contacts of the relay 45 Figure 2 6 Typical Alarm Settings 2 10 Installation Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748213 S Model 755R April 2002 TB4 Y NO 10 S i 9 gt LO com i Or a 5 L larm 15V 4 7 no No 1
13. TE O O i A gt 140 O 43 10 Ya ak 8 Y 15V oe aot Reset Alarm LZ IRIN DIN No 1 l Q Command No 10 x 9 pa com 5 i Alarm CRZ AL NC No 2 gt 14 A 13 oe O A O E 2 124 8 Es ER Reset Alarm E LAKAI ol No 2 6 gt Command 2 CRIAND CR2 ARE ANY 600V 1 AMP DIODE 1 RELAYS SHOWN IN ENERGIZED POSITION NOTES Figure 2 7 Alarm Relay Assembly Schematic Diagram Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 11 Instruction Manual 748213 S April 2002 Model 755R 2 6 REMOTE RANGE CHANGE OPTION The power supply circuitry on the Remote Range Board 646004 must be jumpered for the correct line voltage either 115 VAC or 230 VAC See Drawings 656081 Table 2 and 646090 for correct jumper locations On the Remote Range Board an additional option exists for using either the on board 12 V to drive the range select relays or an exter nal 12 V supply To use an external supply 1 Remove the E to F jumper DWG 646090 2 Apply the external 12 V to J3 5 3 Program the remote controller to pull the range bits J3 1 through J3 4 low See Table 2 1 below To use the internal 12 V supply 1 Verify the E to F jumper is in place 2 Connect the controller s common to J3 6 to reference the instrument s common to the controller s common NOTE DO NOT connect anything to J3 5 3 Connect J3 1 to J3 4 as shown in the truth table below to s
14. d Physical MOUNUNG RE EO eee 19 inch rack IEC 297 1 1986 Case Classification General Purpose Weight eise Ee SE eren cedes 46 Ibs 21 kg Dimensions eere 19 0 x 8 7 x 19 2 inches 482 2 x 221 x 487 mm W xX H x D 1 4 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 SECTION 2 INSTALLATION 2 1 FACILITY PREPARATION Observe all precautions given in this section when installing the instrument a Rosemount Analytical Inc Installation Drawings For outline and mounting dimensions gas connections and other installation infor mation refer to Installation Drawing 654015 at the back of this manual Electrical Interconnection Diagram Electrical interconnection is also shown in drawing 654015 Refer also to Section 2 5 page 2 6 Flow Diagram The flow diagram of Figure 2 1 page 2 3 shows connection of a typical gas selector manifold to the Model 755R Location and Mounting Install the Model 755R only in a non hazardous weather protected area Permissible ambient temperature range is 32 F to 113 F 0 C to 45 C Avoid mounting where ambient temperature may exceed the allowable maximum Magnetic susceptibilities and partial pres sures of gases vary with temperature In the Model 755R temperature induced readout error is avoided by control of t
15. 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 Rosemount CSC will provide the shipping address for your instrument In no event will Rosemount be responsible for equipment returned without proper authorization and identification 2 Carefully pack the defective unit in a sturdy box with sufficient shock absorbing material to ensure no additional damage occurs during shipping 3 In a cover letter describe completely e The symptoms that determined the equipment is faulty e The environment in which the equipment was operating housing weather vibration dust etc e Site from where the equipment was removed e Whether warranty or non warranty service is expected e Complete shipping instructions for the return of the equipment 4 Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in the Rosemount Return Authorization prepaid to the address provided by Rosemount CSC Rosemount Analytical Inc Process Analytical Division Customer Service Center 1 800 433 6076 Rosemount Analytical Inc A Division of Emerson Process Management If warranty service is expected the defective unit will be carefully inspected and tested at the
16. 0 AMP VLOV 15 AMP 240V IOK TES SEAN CRIO C36 RIL GA INAAAB T 8 RI IKE 19 IW JI2 15V El DEM y 4 CWT NSObLD p 1 1 1 1 ic EA 169K d PS TPD Dosis RE sm MeL 1 3 4 1 TP3 6 7 7 gt 56 SUSPENSION HBV C24 7 SEE AVERSA E im j ASSY D51 I C30 2000 EV GND 622356 BD ASSY 29 5M OLL kV VLW ma ERO qm DORUM E vara c Ol 288 OOV CAUTION a THIS DRAWING MAY NOT BE j D UL U FM CSA N 21W Pl HEN 2 EE Crean p DWG NO LQ SIZE dee e TOv DOV i ALARM RELAYS i Low IBN l E PART NO UNLESS wes Sor 7 BY DATE S L BOERE EE Rosemount Analytical Inc Wu deve xu T g l Cirsa 9 03 TITLE SIRE H DIAGENNAS SCHEMATIC mp 4 EAN S a l A o L ALL CAPACITORS ARE IN MICROFARADS fo L ALL RESISTORS ARE IN OHMS X196 1 4 W lao NOTES UNLESS OTHERWISE SPECIFIED 7 MACH SI FLAT WIDAN DUI HL ML OTHE HAT WITH DOS COMCENTRICITY MACH SURF T HIN 1 2 SU OF DU TOLS OOR MEN i DO WOT SCALE Dans E CODE IDENT NO DWG NO MP AA o cu T SCALE INITIAL USE 755A SHEET OF tJ TM 10 82 a gt l S 5 T a l c 1 j han ee See e AR N OE AFRIG e T AE T perie hd a4 c i THAT TE TED IM REO QR WITH e HE COD B NOT
17. 755R April 2002 3 6 SELECTION OF SETPOINTS AND DEAD BAND ON ALARM OPTION The ALARM 1 and ALARM 2 setpoint adjust ments see Figure 3 1 page 3 3 are adjust RANGE PERCENTAGE OXYGEN READOUT able for any desired value from 1 to 100 of versus the fullscale analyzer span The adjustment OXYGEN ALARM SETPOINT DIAL READING screws are graduated from 0 to 10 Percentage Oxygen Readout i s f l 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 Required dial settings for both setpoint ad 0 to 1 EE EE justments may be determined from either Fig 0 1 2 3 4 5 6 7 8 9 10 ure 3 2 or the appropriate equation that Setpoint Dial Reading follows Percentage Oxygen Readout 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 e Zero based operating range T po Rd ER AE N E di N A 02 5 1 4 N N N EE 0 1 23 4 5 6 7 8 9 10 e Required control setting Setpoint Dial Reading desired alarm setpoint 10 Percentage Oxygen Readout 0 0 0 5 10 15 20 25 30 3 5 40 4 5 5 0 fullscale span 0to5 EE EE 0 1 23 4 5 6 7 8 9 10 Figure 3 2 example Setpoint Dial Reading Percentage Oxygen Readout Operating range 0 to 5 oxygen 0 1 2 3 4 5 6 7 8 9 10 ae rs pecie Desired ALARM 1 setpoint 4 oxygen 0 1234 5 6 7 8 9 10 Setpoint Dial Reading Turn potentiometer R64 to 8 Percentage Oxygen Readout 0 25 5 7 5 10 125 15 17 5 20 22 5 25 Desired ALARM 2 setpoint 3 oxygen 0 to 25 YY He 0 1 23 4 5 6 7 8 9 10 Turn potentiometer R68 to 6 Setpoint Dial Reading Percentage Oxygen Readout
18. Connect all products to the proper electrical and pressure sources e To ensure proper performance use qualified personnel to install operate update program and maintain the product e 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 e 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 Paliney No 7 is a trademark of J M Ney Co Hartford CT SNOOP is a registered trademark of NUPRO Co 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 330 lt e mail gas csc EmersonProcess com http www processanalytic com EMERSON Instruction Manual 748213 S Model 755R April 2002 TABLE OF CONTENTS PREFACE ui A A EE P 1 Detinitioris ass P 1 Intended Use Statement sek ee AE EE EA RA AE GR Ee RA Ee ee EE GR EA ede Ge
19. EA TONER 3 9 93 Rosemount Analytical Inc Wi arn ass 3 THE LETTERS NC ON TABLE 1 SIGNIFY NO CONNECTION THERE IS NO WIRE FROM CABLE P N 655089 BEING USED CHK DAN HAAK 9 15 93 FOR THAT RANGE SELECTION OPTION BECA pue TLIPEE A 4 MOUNT RANGE BOARD P N 646004 ON BRACKET ENGR I paee leve NOT RUC TONS REMOTE P N 654806 WITH POWER PLUG ON BOTTOM FACING REAR RANGE SELECTION OF ENCLOSURE SEE DWG 654082 FOR ASSY INSTRUCTIONS S LIFSHUTZ 0 23 93 7 l AN THE RANGE BOARD IS SUPPLIED WITH 115V CONFIGURATION FOR 230V OPTIONAL CONFIGURATION REMOVE CUT JUMPERS A B AND C D ADD JUMPER ITEM B Al B C XSEE TABLE 2 4 3 C DWG NO C O10 656081 SCALE NONE INITIAL USE 755R SHEET 1 OF 4
20. Magnet Components ii se se RA eee 6 5 Ay Source Lamp EE Re bande dt ete eae ies ee eee dle 6 5 Di Phiotocell EE oe a ean lala 6 5 ci Detector muii ole elie ee ee a bue dd 6 7 6 6 Control Board Setup vista aetna nn dium ie tende ia 6 7 a Power Supply Test iis crei oe iter edi attigi lace pho Hp e b e eda sudes 6 7 b IDetector zero ooo eee te aeta dui en cen dec tee ditte edere 6 7 Cx UA Zero EE crime nascente it emet eise ide 6 8 d 8 Zero a ntt pi ed est Seve ed iit dede tt decidi E UE d 6 8 N ES PUO 6 8 t ar T EE ioter er edt enema ddnde Ge Ee Ee OE rae id 6 8 g Recorder Fullscal ie ER EG eed OP DO ete a deter as 6 8 7 0 REPLACEMENT PARTS ien DE Een ct iio 7 1 7 1 Circuit Board Replacement Policy eene 7 1 7 2 Matrix Model 755R Oxygen Analyzer eene nene 7 2 7 3 Selected Replacement Pange 7 3 8 0 RETURN OF MATERIAL EE EE EO OR EO OE Einon ip riani Paa SE 8 1 8 1 Return Of Material is ee ER Res hr etes Ge ee be N EI taia ASERTE GEREEN ge Deep nee 8 1 8 2 Customer Ae os oan A A it ey ee frs 8 1 8 3 ay le EE RE RE ER PR HU qae EE 8 1 LIST OF ILLUSTRATIONS Figure 1 1 Model 755R Oxygen Analyzer Front Panel seen 1 1 Figure 2 1 Interconnect of Typical Gas Manifold to Model 755R sss 2 3 Figure 2 2 Model 755R Rear Panel sees ee se ee ennenen nner nenn 2 5 Figure 2 3 Connections for Potentiometric Recorder with Non Standard Span
21. RQ 7 CURRENT OUTPUT ZERO R1 8 CURRENT OUTPUT SPAN R2 9 ALARM 2 CALIBRATION R67 10 ALARM 2 SETPOINT R68 11 ALARM 2 DEADBAND R78 12 ALARM 1 CALIBRATION R63 13 ALARM 1 SETPOINT R64 14 ALARM 1 DEADBAND R73 652830 SIGNAL CONTROL BOARD Provides selectable output of 10 mV 100 mV 1 V or 5 V for a voltage recorder Calibration of digital readout Initial factory zeroing of amplifier U8 Adjustment of electronic response time Setting fullscale for 1 V 0 1 V and 10 mV outputs Coarse adjustment of detector zero by shifting the position of the detector within the mag netic field It is adjusted during factory checkout and does not require readjustment except if detector is replaced Located on Current Output Board adjustment for zero level current output i e 4mA or OMA Located on Current Output Board adjustment for fullscale current output 20mA Initial calibration of ALARM 2 circuit Continuously variable adjustment of setpoint for ALARM 2 circuit for actuation of external customer supplied control device s Adjustment range is 0 to 100 of fullscale span Adjustment of ALARM 2 deadband circuit from 1 to 20 of fullscale Deadband is essen tially symmetrical with respect to setpoint Initial calibration of ALARM 1 circuit Continuously variable adjustment of setpoint for ALARM 1 circuit for actuation of external customer supplied control device s Adjustment range is 0 to 100 of fullsc
22. Resistor Network It provides a jumper selectable output of 0 to 10 mV 0 to 100 mV 0 to 1 V or 0 to 5 VDC for a potentiometric re corder A Division of Emerson Process Management 2 Current Output Receptacle J1 This connector accepts the optional plug in current output board 3 Dual Alarm Amplifier Circuit This cir cuit drives the optional 654019 Alarm Relay Assembly Oxygen is strongly paramagnetic while most other common gases are weakly diamagnetic The paramagnetism of oxy gen may be regarded as the capability of an oxygen molecule to become a tempo rary magnet when placed in a magnetic field This is analogous to the magnetiza tion of a piece of soft iron Diamagnetic gases are analogous to non magnetic substances With the Model 755R the volume mag netic susceptibility of the flowing gas sample is sensed in the detector magnet assembly As shown in the functional dia gram of Figure 5 1 page 5 2 a dumb bell shaped nitrogen filled hollow glass test body is suspended on a plati num nickel alloy ribbon in a non uniform magnetic field Because of the magnetic buoyancy ef fect the spheres of the test body are subjected to displacement forces result ing in a displacement torque that is pro portional to the volume magnetic susceptibility of the gas surrounding the test body Circuit Analysis 5 11 Instruction Manual 748213 S April 2002 Model 755R
23. V to 1 89 V to 1 7V 15V the temperature bridge at the rate of 120 pulses per second Capacitor C36 is added to the input circuit to delay the incoming AC signal so that the pulses will occur at or just after the line fre quency crossover point Circuits for a ramp generator and a tem perature sensing bridge are part of the case heater control circuit See Figure 5 2 page 5 3 and Figure 5 3 page 5 3 On initial application of power to comparator of Figure 5 2 page 5 3 no potential exists on the inverting terminal because no charge exists on capacitor C37 If the transistor of comparator 3 does not conduct 15V is at the output terminal With 15V at the output the potential on the non inverting terminals will be about 2 3 V because of the resis tance divider R75 R76 100u 159mV Oo COMP 1 1 E Oo 1800 OFF E ON COMP 2 15V R69 2M R71 21 5K ON OFF O OUTPUT 15V R68 3 3K INPUT L C38 T 0 18uF Figure 5 1 5 2 Circuit Analysis Rosemount Analytical Inc 2 E e 15V R73 1 88 VDC Source Two Comparator OR Circuit A Division of Emerson Process Management Instruction Manual 748213 S Model 755R April 2002 15V R78 R69 E R74 2
24. ee ee ee Re ee ee ee ee ee Re ee ee ee ee P 2 Safety SUMMANY OE N nae eva ATTORE P 2 General Precautions For Handling And Storing High Pressure Gas Cylinders P 4 Doeurmentation 2 etudes n t Rc mH deena cee P 5 Gompllarces ERA c se a M e ES e LIE Dee UN d P 5 1 0 DESCRIPTION AND SPECIFICATIONS ee sees ee ee Re ee RR nennen nnne Ee ER RR RE KEER nn nennen 1 1 1 1 DOSGCRIPUOM cnt ER ORR ENG 1 1 1 2 Recorder Output Rang Sior sro EERS tadas 1 1 1 3 MOUNU RR EE EE EE OE AEE EEE 1 1 1 4 Isolated Current Output Option sese sese eee eee eee 1 1 1 5 Alarm Optom esenee ltd ld drid Gee RE ed Se AG N ee 1 2 1 6 Electrical Options eee 1 2 1 7 Remote Range Change OPHON ee ee ee ee Re Re nenen ee nr 1 2 1 8 Specifieati0nst ss SR ee aca T 1 3 a 215 Leya ee esse TEIL T TITULI 1 3 OESTE 1 3 Mite pM 1 4 d Physical 45er EE ER xtd ce itte de E tec e teo tee tb Rees dee 1 4 2 0 INSTALLATION cnica IPS 2 1 2 1 Facility Preparation mc EE EE A a T 2 1 a Installation Drawings oo ssanie zg ores vas cag Re ee nemen ener nnne 2 1 b Electrical Interconnection Diagram esse sesse ee ee AA de ee mmn 2 1 C FON DIA el donet tette ch eet quu N OR eet ads 2 1 d Location ANd MOni iac oon teat oci sema rates 2 1 2 2 Calibration Gas Requirements ertet ete EE t taa 7290 e lat cte oai ee ie 2 2 a Zero Standard G as eid italianas mi bete Ak egg dedita 2 2 b Span Standard Gas ate es i distal N RE RO dign
25. 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 Never tamper with safety devices in valves or cylinders 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 P 4 Preface Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748213 S Model 755R April 2002 DOCUMENTATION The following Model 755R instruction materials are available Contact Customer Service Center or the local representative to order 748213 Instruction Manual this document COMPLIANCES This product satisfies all obligations of all relevant standards of the EMC framework in Australia and New Zealand N96 Rosemount Analytical Inc A Division of Emerson Process Management Preface P 5 Instru
26. magnet when placed in a magnetic field This is analogous to the magnetization of a piece of soft iron Diamagnetic gases are analogous to non magnetic substances With the Model 755R the volume magnetic susceptibility of the flowing gas sample is sensed in the detector magnet assembly As shown in the functional diagram of Figure 5 1 a dumbbell shaped nitrogen filled hollow glass test body is suspended on a plati num nickel alloy ribbon in a non uniform mag netic field Because of the magnetic buoyancy effect the spheres of the test body are subjected to displacement forces resulting in a displace ment torque that is proportional to the volume magnetic susceptibility of the gas surrounding the test body Measurement is accomplished by a null balance system where the displacement torque is opposed by an equal but opposite restorative torque The restorative torque is due to electromagnetic forces on the spheres resulting from a feedback current routed through a titanium wire conductor wound lengthwise around the dumbbell A Division of Emerson Process Management In effect each sphere is wound with a one turn circular loop The current required to restore the test body to null position is directly proportional to the original displacement torque and is a linear function of the volume magnetic susceptibility of the sample gas The restoring current is automatically main tained at the correct level by an elect
27. or Lamp Q 115 VAC Low Alarm Low Control Fail Safe Limit O Fail Safe 2 e Q 2 e Lower N Low Alarm H Indicator Alarm Bell 115 VAC Fail Safe or Lamp ires Solenoid ai Sate I K a Sa N Valve i S Alarm Bell 115 VAC Low Control N or Lamp Fail Safe 115 VAC Solenoid Valve High Control H Fail Safe N 115 VAC Low Control Limi Solenoid imit Q Valve BET R Fail Safe High Q H igher d High Alarm N a t Alarm Bell TIS AC 115 VAC nalsetof or Lam Fail Safe d Figure 2 5 Relay Terminal Connections for Typical Fail Safe Applications Note the following recommendations s A fuse should be inserted into the line between the customer supplied power supply and the alarm relay terminals on the Alarm Relay Assembly e Ifthe alarm contacts are connected to any device that produces radio fre 2 8 Installation Rosemount Analytical Inc quency interference RFI it should be arc suppressed The 858728 Arc Suppressor is recommended If at all possible the analyzer should operate on a different AC power source to avoid RFI A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 Rosemount Analytical Inc Alarm 1 and Alarm 2 output through the 654019 Alarm Relay Assembly is pro vided by two identical single pole dou ble throw relays These relay contacts are rat
28. resistor box to simulate the re sistance of RT1 Also connect an AC voltmeter from the hot side of the line to the neutral side of F2 located inside the detector compartment Set the decade box for 20 2K ohms to simulate RT1 at controlling temperature The voltmeter should show pulses of 1 VAC CAUTION OVERHEATING Avoid prolonged operation with the dec ade box set at 22 2K ohms overheating may result Set the decade box for 22 2K ohms to simulate RT1 resistance at ambient tem perature The voltmeter should show pulses of 120 VAC 6 3 DETECTOR MAGNET HEATING CIRCUIT Heater HR1 is attached to the magnet Heater HR2 is attached to the rear of the de tector Combined resistance of these two parallel connected heaters as measured at Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 pins 15 and 16 of the detector connector J12 should be approximately 89 ohms If resistance is correct and the combined re sistance is incorrect heater HR1 may be open To reach the leads of HR1 remove the circuit board on the heater assembly Resistance of HR1 should be approximately 21 ohms To check operation of the heater circuit con nect a voltmeter across R61 on the Power Supply Board Normally the voltage will be 4 A Detector Magnet Assembly Exploded View Sample Pre Heating Coil Sample Inlet Tube Sample Out let
29. should be steady Disconnect the line power and observe the image when you reconnect the power It should come up from the side and seek a position that equally illuminates the photocells Suspension Turn electrical power to instrument OFF Remove optical bench assembly see Figure 6 1A page 6 3 With 100 nitro gen flowing through the analyzer note position of the suspension Then admit air and note response of the suspension It should rotate clockwise as viewed from the top and to the right as viewed though the window Failure to rotate indicates that the suspension has been damaged and detector assembly must be replaced See Section 6 5c page 6 7 If the suspension has been changed the cause may be improper operating condi tions Rosemount Analytical Inc A Division of Emerson Process Management 6 5 REPLACEMENT OF DETECTOR MAGNET COMPONENTS a Source Lamp Removal Installation The source lamp is held in the optical bench assembly by a set screw see Fig ure 6 1B page 6 3 The two lamp leads are connected to J12 The red line on the lamp base must align with the set screw see Figure 6 4A The base of the lamp should extend from the hole approximately 1 4 inch Tighten set screw when lamp is aligned Realign the photocell per Section 6 5b page 6 5 Photocell Removal Installation Refer to Figure 6 1B page 6 3 Note lo cation of photocell leads in connector J12 Remove leads Remove photoc
30. the 100 microsecond pulse the NPN transistor in the output of comparator 4 ceases to conduct so the signal on the base of Q6 is 15V Q6 ceases to conduct C38 starts to charge driving electrons current through the primary of T2 This induces a pulse into the secondary of T2 and to the gate of Triac Q7 turning it on At the beginning of the next 100 microsecond pulse comparator 4 output is again 15V with zero volts on the base of Q6 Q6 again con ducts discharging C38 At the end of the 100 microsecond pulse Q6 ceases to conduct Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 Rosemount Analytical Inc C38 charges and a pulse appears at the gate of Triac Q7 turning it on again The charging time for C38 is about one half a time constant C38 R87 and ten time con stants R81 C38 are available for discharg ing C38 The above action is repeated as long as the temperature is low causing an error between R82 R83 junction and RT1 R84 junction As the temperature approaches the desired case temperature of 135 F 57 C differences be tween these two junctions will exist for only part of each ramp and the number of pulses operating Q7 will be proportional to the amount of error sensed by the 6 Hz ramp The pulses arrive at Q7 just as the supply AC line voltage is passing the zero volt crossover A Division of Emerson Process Managemen
31. 0 mV 1K 100 mV 10K 1V 100K 5V 2K Figure 2 3 Connections for Potentiometric Recorder with Non Standard Span 2 6 Installation Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 c Potentiometric Output 1 2 3 Insert RECORDER OUTPUT Selector Plug See Figure 3 1 in position ap propriate to the desired output 10 mV 100 mV 1V or 5V Connect leads of shielded recorder cable to REC OUT and termi nals on the I O board Connect the output cable to the appro priate terminals of the recorder or other potentiometric device a For device with span of 0 to 10 mV 0 to 100 mV 0 to 1V or O to 5V connect cable directly to input terminals of the device ensuring correct polarity and range selec tion b For a device with intermediate span i e between the specified values connect the cable to the device via a suitable external voltage divider See Figure 2 3 page 2 6 Isolated Current Output Optional 1 Verify that the optional current output board appropriate to desired output is properly in place in its connector See Figure 3 1 page 3 3 If originally or dered with the analyzer the board is factory installed 2 On I O board connect leads of shielded recorder cable to CUR RENT OUT and terminals 3 Connect free end of output cable to input terminals of recorder or other cu
32. 10 00 V 5mV d U8Zero 2 Monitor TP16 adjust R20 for 10 00 V Monitor TP11 adjust R29 for 0 0 VDC 5mV The display must read 100 00 5mV 5 counts e U10 Zero Recorder Fullscale 1 Monitor TP16 adjust R29 for 0 0 VDC 5mvV NOTE This adjustment requires a long time constant Allow adequate time 6 8 Maintenance and Service 1 Flow nitrogen at 250 cc min monitor TP16 and adjust front panel ZERO potentiometer for 000 VDC 2 Flow 100 oxygen for span gas Re corder output for 1 V 100 mV or 10 mV should read 100 of span gas Adjust R88 if necessary Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 SECTION 7 REPLACEMENT PARTS The following parts are recommended for rou tine maintenance and troubleshooting of the Model 755R Oxygen Analyzer If the trouble shooting procedures do not resolve the prob lem contact Rosemount Analytical Customer Service Center WARNING PARTS INTEGRITY Tampering or unauthorized substitution of components may adversely affect safety of this product Use only factory documented components for repair Rosemount Analytical Inc A Division of Emerson Process Management 7 1 CIRCUIT BOARD REPLACEMENT POLICY In most situations involving a malfunction of a circuit board it is more practical to replace the board than to attempt isolation and replace ment of the individual compone
33. 2 5 5 25 50 05 0 1 2 5 5 25 100 06 0 1 2 5 10 25 100 99 Special Code Feature 00 Features as selected 99 Special ak 5 J Example 7 2 Replacement Parts Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748213 S Model 755R April 2002 7 3 SELECTED REPLACEMENT PARTS 092114 Fuse 1 2A 240VAC Package of 5 711362 Fuse Heater 3A 120VAC Package of 15 777361 Fuse Heater 1 5A 240VAC Package of 15 861649 Thermal Fuse F2 F3 656189 Detector Optical Bench Assembly 0 to 1 616418 Source Lamp Kit 622356 Photocell 621023 Current Output Board 0 to 20mA 4 to 20mA 622351 Connector Board 631773 Power Supply Board 652830 Control Board Kit 654004 Thermistor Case Heater 654022 Display Assembly 654078 Viton Tubing Sample In 654079 Viton Tubing Sample Out 654080 Fan Assembly 654081 Case Heater 809374 Fuse 3 4A Power Transformer 115VAC 860371 Alarm Relay 645407 Shock Mount Package of 4 Rosemount Analytical Inc A Division of Emerson Process Management Replacement Parts 7 3 Instruction Manual 748213 S April 2002 Model 755R 7 4 Replacement Parts Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 SECTION 8 RETURN OF MATERIAL 8 1 RETURN OF MATERIAL If factory repair of defective equipment is required
34. 49K 2M 1 eVe e 120 V TO POWER y 590K ee RMS SUPPLY 3 id e NE 10 CR11 R71 R70 PE A 21 5K DOM C37 EE R79 N 1 0uF 10K Q6 cro A E PA T2 R68 2 P 3 3K R76 c40 R80 NG 9 i 37 4K 2200uF 10K m CR10 EG 20M e R81 um 56 2 C38 15V NV R83 11 0K 20M ABuF 63 4K C39 R87 O1uF 7 RTI 4 gt 10K i 15V Figure 5 2 Case Heater Control Circuit 2 3V OFF OFF bd 2 3V L ml ml l R78 6 Hz 249K JU 15V R74 R77 e e 10K INPUT FROM 590K 143 e MULTIVIBRATOR T P lt A x ed 15V RIS ANN c37 L f A 10uF T R75 ps Q 210K 1s 15V to 1 88V 0 3V Ng E N R80 R76 cao 10K Ne ET L TO 37 4K 2200uF r COMPARATOR a R81 m C38 A8uF R87 10K 15V Figure 5 3 Ramp Generator Circuit Rosemount Analytical Inc A Division of Emerson Process Management Circuit Analysis 5 3 Instruction Manual 748213 S April 2002 Model 755R Capacitor C37 will now start to charge posi tively through R78 When the positive poten tial across C37 and at the inverting terminal of comparator 3 exceeds the potential on the non inverting terminals the transistor con ducts The output is 15 V A full 30 V drop appears across R77 The potential on the non inverting terminal will now be about 2 3 V C37 will not discharge through R78 until its potential exceeds that on the non inverting terminal At that time com parator 3 will switch polarity and start charging C37
35. 90 MODEL 755R 0 B SCALE NONE INITIAL USE 755R 72 A SHEET 1 OF 654014 DWG NO 8 7 221 ZERO SPAN O O Rosemount Analytical OPTIONAL REMOTE RANGE CHANGE SEE MANUAL FOR HOOKUP OPTIONAL ALARM ASSEMBLY CONNECTIONS SEE MARKINGS OR MANUAL FOR CONTACT RATINGS TB2 CUSTOMER HOOK UP FOR RECORDER OUTPUT TBI CUSTOMER HOOKUP FOR POWER SEE NOTE 6 BlZ INCH DIA HOLE FOR POWER CABLE IF MOUNTED IN UNPROTECTED RACK OR PANEL WIRE POWER VIA 3 CONDUCTOR 18 AWG MIN CABLE IN CONDUIT OR ELECTRICAL METAL TUBING IF MOUNTED IN A PROTECTED RACK OR CABINET OR ON A BENCH AN ACCESSORY KIT P N 654008 IS AVAILABLE WHICH CONTAINS A 0 FT NORTH AMERICAN CORD SET AND LIGUID TIGHT FEED THRU GLAND FOR THIS HOLE THIS KIT ALSO CONTAINS FOUR ENCLOSURE SUPPORT FEET FOR BENCH TOP USE ONE 625 DIA HOLE FOR RECORDER OUTPUT CABLE FITTED WITH LIQUID TIGHT GLAND FOR 187 INCH TO 312 INCH DIA CABLE CABLE SUPPLIED BY CUSTOMER 2 CONDUCTOR MIN 18 AWG C ONE 625 DIA HOLE FOR DUAL ALARM OPTION CABLE FITTED WHEN ORDERED WITH LIQUID TIGHT GLAND FOR 187 INCH TO 312 INCH DIA CABLE CABLE SUPPLIED BY CUSTOMER MINIMUM 24 AWG B SAMPLE INLET 25 INCH TUBE FITTING A SAMPLE OUTLET 25 INCH TUBE F ETTING NOTES m D E e z T S RECOMMENDED PANEL CUTOUT Model 755R 4 9 57 4 HOLES 9 5 POWER REQUIREMENT 115 230VAC 50 60 HZ AS SPECIFIED BY CUSTOMER FACTORY SET ELECT
36. AY 2KS S ADC N DRIVER AND EN 3 71C03 R36 410 gt CONTROL L 2093 C36 YM ATuF 7 R49 C40 ZEE 20K 1 0uF R31 2 U18 WV TP16 5V ME sv REGULATOR To Analog Output Circuit Figure 6 8 Figure 5 7 Buffer Anticipation and Digital Output Circuits 5 10 Circuit Analysis Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 5 9 ANALOG OUTPUT CIRCUITS FOR RE CORDER AND ALARMS Refer to Figure 5 8 page 5 12 The analog output circuits utilize two amplifiers first stage amplifier and second stage amplifier a Rosemount Analytical Inc First Stage Amplifier Permits selection of the desired fullscale oxygen range for the recorder via jumper selectable signal amplification for scale expansion This amplifier permits selecting the desired fullscale oxygen range for the recorder by an appropriate jumper selection of one of seven recorder spans The following recorder spans are available 1 2 5 5 10 25 50 and 100 Second Stage Amplifier Provides a a jumper selectable output for a potentiometric recorder and b an output to drive the voltage to current and or alarm option s if used This am plifier is an inverting configuration that provides a signal attenuation of 2X thus reducing the 10 volt fullscale input signal to obtain a 5 volt fullscale output This output is routed to 1 Recorder Output
37. DC at the C28 lead If the specified voltage measurements are ob tained the power supply is working cor rectly 5 3 CASE HEATER CONTROL CIRCUIT The case heater control circuit utilizes four voltage comparators LM339 quad com parator An understanding of how one of these comparators functions is necessary before any circuit analysis can be attempted Rosemount Analytical Inc A Division of Emerson Process Management In Figure 5 1 page 5 2 comparators 1 and 2 are depicted having a comparator within an overall comparator symbol Also within this symbol the base of the NPN transistor is connected to the output of the compara tor A 15 VDC is supplied to the emitter The collector is illustrated as the overall out put for the comparator package When the non inverting terminal of com parator 2 is more positive than the inverting terminal the transistor does not conduct and the collector of the transistor or comparator output is at whatever potential is then pres ent on the collector When the non inverting terminal of com parator 2 is less positive more negative than the inverting terminal the transistor conducts and the output of the comparator is 15 V This value is the output of the OR cir cuit Comparator 2 is biased at O volts on the in verting terminal Comparator 1 is biased at about 159 mV on the non inverting terminal Positive feedback or hysteresis is built into each comparator circuit for stab
38. DING BUT NOT LIMITED TO EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Limitations of Remedy SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE IN NO CASE REGARDLESS OF THE FORM OF THE CAUSE OF ACTION SHALL SELLER S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION BUYER AGREES THAT IN NO EVENT SHALL SELLER S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL DAMAGES CONSEQUENTIAL DAMAGES SHALL INCLUDE BUT ARE NOT LIMITED TO LOSS OF ANTICIPATED PROFITS LOSS OF USE LOSS OF REVENUE COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND OR INDEMNITY COVERAGE PROVIDED TO BUYER ITS ASSIGNS AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER Force Majeure Seller shall not be liable for failure to perform due to labor strikes or acts beyond Seller s direct control Instruction Manual 748213 S April 2002 Model 755R 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
39. E gas csc emersonprocess com ASIA PACIFIC Fisher Rosemount Singapore Private Ltd 1 Pandan Crescent Singapore 128461 Republic of Singapore T 65 777 8211 F 65 777 0947 http www processanalytic com Fisher Rosemount GmbH amp Co Industriestrasse 1 63594 Hasselroth Germany T 49 6055 884 0 F 49 6055 884209 EUROPE MIDDLE EAST AFRICA Fisher Rosemount Ltd Heath Place Bognor Regis West Sussex PO22 9SH England T 44 1243 863121 F 44 1243 845354 LATIN AMERICA Fisher Rosemount Av das Americas 3333 sala 1004 Rio de Janeiro RJ Brazil 22631 003 T 55 21 2431 1882 EMERSON Rosemount Analytical Inc 2001 wey E qe EE N s M 9 Ee an epi en EE M Ml M oe EE EE EE Mg aa A igi ni A oe e T PRA E wE AT TT iat ek k 5 Ran EJ y a 7 6 5 A 3 e 1 H f S s t i i 7 MA ME e c ur 7 i a THIS DOCUMENT CONTADA amp TATI INF ORATION OF ROSEMOUNT Me YT KOM H M INC MO IS TOCLRED BRETT TQ TE COITO TA T DE INTOPPATION d A f RETAINED N COM LENE 5 OT ME MEPRCDUCED ON COPIED de i act 3 DM an EXPRESE dal IEN ADS ENENT WITH ROSEMOUNT WAL TIG I 7 i CHG E O NO DATE BY CHK T I ias DEUM FEES E 13574 12 27 91 L A T4 C238 J RBI DA 11 VLW ME UV 14 F E ZEE Is end m DR fu PART MO IC MOT AC LEED M DXCOPOWIED IK xR ACT OKET f T gi EE EE TASIE 119 1 8w 2 3
40. Instruction Manual 748213 S April 2002 Model 755R Oxygen Analyzer wa a Rosemount Analytical Model 755R ROSEMOUNT E Analytical EMERSON 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 s Read all instructions prior to installing operating and servicing the product e f you do not understand any of the instructions contact your Rosemount Analytical representative for clarification e Follow all warnings cautions and instructions marked on and supplied with the product e Inform and educate your personnel in the proper installation operation and maintenance of the product e Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes
41. NOT EE UD R ANY PRODUCT EXCEPT UNDER AN EXPRESS WHITTEN OR IN PART MO C INFORMATION A BE RETAINED IN ANALYTIC INC ND IS TENSE BET TO THE HIS DOLENT CONTADS PROPRIETARY BEGIN OF i t t nia i DR SASS RE CA O E e O DE NEE EE UENO EEE PEE EE EE EE CER i El i i i i i 1 7 i i i i EER EE ee Ree gr E EE NEE AE eae EE N N EE tt REA ie Lm X amp H N PA rd rd LTT OT EG OO ed mmm F BO ya m na soe pe m 3830 Ma MEME MEM 19 OF CN UN mm P g See y PR ii E wat OM EE r esas ERIE HEUTE A A N eed ARE OE N EN DESCRIPTION CODE IDENT NO IDWG NO PART NO BERE EE CE C Qu mm T oT UNLESS OTHERWISE SPECIFIED l MATERIAL ANGULAR 0 30 125 MACH SURF TOLERANCES CONCENTRICITY MACH SURF LLR WITHIN 1 2 SUM OF DIAS TOLS 001 MIN DIMENSIONS ARE IN INCHES THREADS CLASS 2A OR 2B REMOVE BURRS amp SHARP EDGES 020 MAX MACH FILLET RADI
42. NT WITH ROSEMOUNT ANALYTICAL INC 646004 RANGE BD CONNECTOR MOUNT_TO SMALL HOLE PA 161259 9 93 _ L IN OPTION CONNECTION 3 toa OF PLATE P N 6554643 E 12 20 93 DF N Z SIGNAL WIRE COLOR PI a RANGE 1 RANGE 2 RANGE 3 RANGE 4 RANGE BD 646004 646091 646092 d ds CUT OFF NOT USE NOT USED COMMON 3 ORANGE EE EE ON GND 2 RED O GREEN e L TO 1 BLACK i TS JS 9l Sd 4 GREEN SS RANGE BD 646004 e RANGE BD SS 546004 gt m 9 BLUE ly E LO 0 PART NO UA l zx 555093 0 5 10 25 50 100 X BLU GRN BLK NC NC eee o NR ae STD RANGE SET UP Sc N p SEXE ASS Y ENE TA i j f E 656324 0 1 2 5 5 10 50 EXT NC GRN ORN RED BLK po Ine UA 00 l l 656325 0 1 2 5 5 25 50X EXT RED BLK STR e i l 656326 0 1 2 5 5 25 100 EXT BLK i I py 02 Meee J 4 Os 656527 oo SIGNAL CONTROL E49 ra l BOARD 652830 O O NOTES w C o N SEE TABLE 1 FOR CABLE CONNECTIONS 2 RANGE SELECTION AT THE TOP OF THE CONTROL BOARD P N 652830 ol EE ARE TWO ROWS OF CONNECTOR PINS eeeoccccooccceceos THE TOP ROW E9 E23 THRU E19 HAS PLUG IN CONNECTORS USED TO ACHIEVE THE DESIRED RANGE SELECTION THE BOTTOM ROW E40 E24 THRU E20 ARE COMMON WITH ALL PINS CONN CTED TO EACH OTHER IN THAT ROW HE WHITE WIRE OF CABLE P N 655089 IS ALWAYS Sv DATE CONNECTED TO E10 OF i
43. RICAL INSTALLATION MUST BE IN COMPLIANCE WITH NATIONAL ELECTRICAL CODE ANSI NFPA 70 AND OR ANY APPLICABLE NATIONAL DR LOCAL CODES FOR SAFETY AND EQUIPMENT PROTECTION ALL UNUSED OPENINGS MUST BE PLUGGED WITH FACTORY INSTALLED PLUGS OR EQUIVALENT INSTRUMENT IS NOT WEATHERPROOF APPROXIMATE WEIGHT 46 LBS 20 9 kg STANDARD 19 INCH RACK MOUNT P WE 448 H REAR VIEW DIMENSIONS INCH MILLIMETER THIRD ANGLE PROJECTION REAR TERMINAL COVER REMOVED FOR CLARITY TT BY JDATE 5 27 90 DR D RICHARDSON J B SIMPSON 1 28 90 CHK ANDERSON 11790 N G RS SALIMIAN 1 28 90 28 90 THIS DEEN CONTAINS PROPRIETARY INFORMATON OF TENDERED SUBJE ES BE ETATS IN CONFIDENCE 8 NOT BE REPRODUCED OR COPIED IN OR IN PART AND C NOT BE ay OR INCORPORATED IN ANY PRODUCT Boe T UNDER WRITTEN ROSEMOUNT ANALYTICAL INC ENS ET Y DATE BY CHK ENGR E 118170 Q 06 93DF HI JB JR F 1625 0l 06 93DF H AT S TO NI OE F POWER HOOKUP G RECORDER HOOKUP TITLE Roseme nt Analytical ING us curada eni INSTALLATION DRAWING RACK MOUNT MODEL 755R D IDENT NO D E E SCALE DWG NO OIO 654015 D SIZE olo 654015 E CT TO THE GON TT lons THAT THE FORMATION NO DWG 4 S A e OR IN PART AND C NOT BE USED OR INCORPORATED IN ANY PRODUCT UNDER AN EXPRESS WRITTEN AGREEME
44. The desired deadband may be selected via the appropriate trimming potentiometer R73 AE MD e det dE NN AE for ALARM 1 deadband adjustment and R78 91090 TER a a de E for ALARM 2 deadband adjustment For any Re h E ES 5 2 7 9 159 10 setpoint deadband is adjustable from 1 of Setpoint Dial Reading fullscale counterclockwise limit to 20 of Percentage Oxygen Readout fullscale clockwise limit Deadband is es 0 10 20 30 40 50 60 70 80 90 100 sentially symmetrical with respect to setpoint 0 to 100 SS SS St SS SS oS R 0 1 23 4 5 6 7 8 9 10 3 7 CURRENT OUTPUT BOARD OPTION Setpoint Dial Reading A Division of Emerson Process Management Figure 3 2 Dial Settings for Alarm Setpoint Adjustments Operation 3 7 Instruction Manual Aa Model 755R 3 8 ROUTINE OPERATION 3 10 CALIBRATION FREQUENCY After the calibration procedure of Section 3 4 page 3 1 admit sample gas to the analyzer at the same pressure and the same flow rates used for the zero and span gases The in strument will now continuously indicate the oxygen content of the sample gas 3 9 EFFECT OF BAROMETRIC PRESSURE CHANGES ON INSTRUMENT READOUT If the analyzer exhaust port is vented through a suitable absolute backpressure regulator barometric pressure changes do not affect the percent oxygen readout However if the ana lyzer exhaust port is vented directly to the at mosphere any change in barometric pressure after instrument standardization will r
45. Tube Magnet Detector Assembly Assembly Mounting Screws 2 VDC when cold and will drop to approximately 0 4 VDC at control temperature Temperature sensor RT1 is mounted in the detector with leads accessible at pins 10 and 11 of detector connector J12 The sensor resistance should be 1M ohms at 25 C and approximately 149K ohms at operating temperature of 65 C B Optical Bench Exploded View Connector Photocell Lock Screws 2 Dual Photocell gt Lamp Retaining Set Screw Lamp Viewing 297 Source Lam Hole 7 p Assembly Figure 6 1 Detector Magnet Assembly Rosemount Analytical Inc A Division of Emerson Process Management Maintenance and Service 6 3 Instruction Manual 748213 S April 2002 Model 755R 6 4 DETECTOR CHECK To isolate the detector as the problem it is necessary to check the source lamp photo cells and suspension see Figure Figure 6 1B page 6 3 These components are con nected via J12 on the optical bench assembly Pin leads may be removed from connector J12 by use of an improvised pin removal tool such as a paper clip see Figure 6 2 below Upper Slot Connect J12 has slots at top and bottom To remove a connector pin lead insert the tool into the upper or lower slot and push down on the end to release the keeper on the pin When inserting a pin lead its keeper must face toward the slot opening in the connector in order to lock in If inserted o
46. US 020 MAX MACH SURF FLAT WITHIN 001 1N IN OTHER SURF FLAT WITHIN 005 IN IN SS EG EE rts apr meee ne ements TE DRE SRS Wr aS EES FO ESSE SAN AN A AEN cS SES AAA E f i 9 b i i i i i i i SS nn PETTERS CE AAA EE oa EE EE SET ETE EOE LES EE DES PP SEBO SN EN SRS CISNEROS MES EE BE ona SO NEO EE N SPS ENS ESE ARE TESA EE EE TT ED EE p i U E O OE OE EE EE CRINE TEE OO OO EE TE X um i i Ln Fs N gem 1 b AAA a TA EE N M Ps E a OF dot a A Z ta Bi TINITIAL USE Z DO NOT SCALE DRAWING HS Ra aiie BERE arp OF wm ee j HE CONDITIONS THAT THE Thao d BE RETAINED IN ree cu s NOT BE REPRODIKED OR COPIED IN WHOLE OR IN AAT AND CI NOT BE OR INCORPORATED IN 3 PRODUCT EXCEPT UNDER A AN TYEN AGREEMENT WITH ATA TNC l DATE J E A T P L RANGE 1 1 Z E E annaran f f b geseen Gee lo E ie i o X ot A ae j rH 2 EE d p Tres i grues i E f FX Ta em Z RANGE 2 ik A 1 Aa e er sr o finns E Fi E um A orm RANGE COMM MM A PART NO DESCRIPTION xs D rs OTHERWISE SPECIFIED Ec ROSEMOUNT ANALYTICAL INC LA HABRA CALIFORNIA 90831 DIMENSIONS ARE IN INCHES TOLERANCES A ct 050 ANGULAR O 30
47. a ER SE EE do tr e de EG a e De ER foal ot 3 1 a Calibration with Zero and Span Standard Gases ii eee 3 1 3 5 Compensation For Composition Of Background Gas sss eee 3 2 a Oxygen Equivalent Value of Gases ie ee ee ee Ge ee Re eene mener enne 3 4 b Computing Adjusted Settings for Zero and Span Controls is se ee Re ee 3 4 3 6 Selection Of Setpoints And Deadband On Alarm OPHON ee ee ee ee AR Ge ER RR nono 3 7 3 7 Current Output Board Option seen eene enne 3 7 3 8 RoutineOperation cin aetema a t ccu intei itt doubt aden eu eue 3 8 3 9 Effect of Barometric Pressure Changes on Instrument Readout ies see dee eee 3 8 3 10 Calibration Frequency ien Eee it 3 8 4 0 THEORY EE N RR OE EE ER EE EE 4 1 4 1 Principles of eleis 4 1 4 2 Variables Influencing Paramagnetic Oxygen Measurements eee 4 2 a Pressure Effects ed ive Ai ds 4 2 4 3 Electronic Circultry coccion EE EE EE e etd d e thoes es te e aed v tene ada 4 4 a Detector Magnet Assembly sese ee ee cesse ereer ereenn enen eene enne 4 4 b Control Board and Associated Circuitry sse enne 4 4 c Power Supply Board Assembly se eee eee eee 4 5 d Isolated Current Output Board Optional 4 6 5 0 CIRCUIT ANALYSIS EE N EE N airis 5 1 5 1 retire OR EE EE ARE 5 1 5 2 15 VDC Power Supply sse nnne ee ee Re Re trit enin entente ee ee nnn 5 1 5 3 Case Heater Contro
48. again The result is that the potential across C37 will vary almost linearly with time and form a ramp signal of about 6 Hz As the potential across C37 increases and decreases linearly it affects the potential at the top of the bridge circuit between R82 and R83 through R74 Because of the ramp action charging and discharging C37 the potential between R82 and R83 varies approximately from 1 85 V to 1 92 VDC The temperature sensing device RT1 in the bridge circuit is a thermistor The bridge is de signed to control the temperature in the case at 135 F 57 C When the temperature is 135 F 57 C the resistance of the thermistor RT1 will be at its lowest and the potential at the junction of RT1 and R84 should be the same as the junction of R82 and R83 Com parator 4 See Figure 5 4 page 5 6 does not allow pulses from the OR circuit comparators 1 and 2 to operate Q6 or Triac Q7 in the case heater See Figure 5 5 page 5 7 Theoretically at 135 F 57 C the potential at the junction of RTR1 and R84 is 1 85VDC This is equivalent to a resistance of 21 2 K By substituting a decade box for the thermistor and placing 20 2 K into the bridge the heater should be off With 22 7 K the heater should be full on Since the potential at the junction of R82 and R83 can vary between 1 85V and 1 92V ac cording to the 6 Hz ramp and the potential at the junction of RT1 and R84 may vary around or within these limits depending on
49. aging or damping effect Too rapid a flow will cause back pressure that will affect the readout accuracy The optimum flow rate is between 200 and 300 cc min Deviation from the set flow should be held to within 1096 or 20 cc min whichever is smaller If deviation is held to within these parameters and operating pressure re mains constant zero and span drift will remain within specification limits The analyzer should be installed near the sample source to minimize transport time Otherwise time lag may be appreciable For example assume that sample is sup plied to the analyzer via a 100 foot 30 5 m length of 1 4 inch 6 35 mm tubing With a flow rate of 100 cc min sample transport time is approximately 6 minutes Sample transport time may be reduced by piping a greater flow than is required to the analyzer and then routing only the appropriate portion of the total flow through the analyzer The unused portion of the sample may be returned to the stream or discarded Materials in Contact with Sample Within the Model 755R the following materials are exposed to the sample 316 stainless steel glass titanium Paliney No 7 epoxy resin Viton A platinum nickel and MgF2 coating on mirror Corrosive Gases In applications where the sample stream contains corrosive gases a complete drying of the sample is desirable as most of these gases are practically inert when totally dry For corrosive applications consult t
50. al Bench Assembly Detector Assembly Lamp Viewing Hale y Source Lamp Assembly B Sectional Top View of Optical Bench and Detector Assemblies C Exploded View of Optical Bench Assembly Figure 4 3 Detector Magnet Assembly Rosemount Analytical Inc A Division of Emerson Process Management Theory 4 7 Instruction Manual 748213 S April 2002 Model 755R 4 8 Theory Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 SECTION 5 CIRCUIT ANALYSIS 5 1 CIRCUIT OPERATION The electronic circuitry of the Model 755R Oxygen Analyzer consists of the following e A detector compartment heater circuit e A detector heater circuit e A 15 VDC power supply e A voltage regulating circuit for a stable light source e Adetector circuit with a first stage am plifier to provide a feedback current for mechanical feedback to the detector and a scaling amplifier circuit to give an output change of 0 to 2 5 V for a 0 to 10096 change of the operating span e Adigital output circuit for the digital read out e An analog output circuit for recorder optional alarms and current output 15 VDC POWER SUPPLY Refer to Drawing 617186 The components of the VDC power supply circuit are located in the lower left hand corner of the Power Supply Board 19 VAC should be measured with respect to ground at CR5 WO4 15 VDC should be measured at the C27 lead and 15 V
51. al display gives overrange indi cation the probable cause is the suspen sion in the detector is hung up To correct this condition turn power OFF tap detector compartment with fingers wait 30 seconds turn power ON When on scale reading is obtained allow analyzer to warm up for a minimum of one hour with gas flowing This warm up is necessary because a reliable calibration is obtainable only after the analyzer reaches temperature stability Moreover the resul tant elevated temperature will ensure against condensation within and possible damage to the detector assembly After warm up the digital display or recorder should give stable drift free readout If so Rosemount Analytical Inc A Division of Emerson Process Management proceed to Section 3 4 below Otherwise refer to Section 6 Maintenance and Serv ice 3 4 CALIBRATION Calibration consists of establishing a zero calibration point and a span calibration point see Table 3 1 page 3 4 Zero and span calibration should be performed on the range that will be used during sample analysis In some applications however it may be desirable to perform span calibra tion on a range of higher sensitivity i e more narrow span and then move the jumper to the desired operating range For example if the operating range is to be 0 to 50 oxygen span calibration may be per formed on the 0 to 25 range to permit use of air as the span standard gas a Calibration wit
52. ale span Adjustment of ALARM 1 deadband circuit from 1 to 20 of fullscale Deadband is essen tially symmetrical with respect to setpoint Selectable fullscale output range For servicing and testing of the Control Board Display viewed on front panel indicates oxygen content of sample Accessible on front panel use to establish zero calibration point Accessible on front panel use to establish span calibration point Figure 3 1 Control Board Adjustment Locations Rosemount Analytical Inc A Division of Emerson Process Management Operation 3 3 Instruction Manual 748213 S RECOMMENDED ZERO RECOMMENDED SPAN 0 RANGE X OXYGEN STANDARD GAS STANDARD GAS 0 to 1 Nitrogen 0 9 O2 balance N2 0 to 2 5 Nitrogen 2 3 O2 balance N2 0 to 5 Nitrogen 4 596 O2 balance N2 0 to 10 Nitrogen 9 O2 balance N2 0 to 25 Nitrogen Air 20 9396 O2 0 to 50 Nitrogen 45 O2 balance N2 0 to 100 Nitrogen 10096 O2 Table 3 1 Calibration Range for Various Zero Based Operating Ranges a Oxygen Equivalent Value of Gases In equation form 3 4 For computation of background correc tions the analyzer response to each Analyzer Response to Gas component of the sample must be shown Table 3 2 page 3 6 lists the percentage oxygen equivalent values for many com 02 Equivalent of Gas 0 Analyzer Response to O X To select a random example from Table mon gases 3 2 if analyzer response to oxygen is l 100
53. and HR2 mounted permanently on the rear of the detector assembly b Control Board and Associated Cir cuitry The Control Board consists of signal con ditioning and control circuitry This circuitry includes the following Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 Input Amplifier U1 This amplifier receives the error signal from the dual photocell of the detector as sembly and drives amplifier U2 Amplifier U2 and Associated Zero Ad justment Amplifier U2 supplies the restoring current to the titanium wire loop of the test body within the detector assembly Front panel ZERO Control R13 applies an adjustable zero biasing signal to the input of U2 to permit establishing a zero calibration point on the display or recorder With zero standard gas flowing through the ana lyzer the ZERO control is adjusted for the appropriate reading Amplifier U4 and Associated Span Adjustment Amplifier U4 and associated feed back resistors provide a signal amplification of X4 Front panel SPAN adjustment R20 modifies the value of the input resistance and hence the signal amplification factor Adjustment range is approximately 30 Amplifier U8 This unity gain amplifier provides zeroing capability and a buffered output for the anticipation circuit feeding U10 Amplifier U10 U10 is an inverting buffer amplifier that in corporates an anticipati
54. as 2 2 2 3 SAM rH R 2 2 a Temperature Requitermierits c teretes et bec tetas veg idi tune d age Muse ee 2 2 b Pressure Requirements General eee eee ee eee eee 2 3 c Normal Operation at Positive Gauge PressureS is ee se ee ee ee eee 2 3 d Operation at Negative Gauge Dressures esse esse ee sees rees esse eee reer ee neee eenn mene 2 4 CL BOW RAG sn AG 2 4 f Materials in Contact with Sample eee eee eee 2 4 GO See de tirada ceeds 2 4 2 4 EGA OSU E E 2 5 2 5 Electrical Connectlons ero cte bared ds tte b a a ra ARA GE ea rea RR Res aea Ra 2 6 a Line Power Connection T 2 6 b Recorder Output Selection and Cable Connections sss 2 6 c Potentiometric OULDUL iet ruens ner Ma GER He E EE ERG RE EA Re Ee es si 2 7 d Isolated Current Output Optional ee ee ee ee Re neee Re ee ee nnn 2 7 e Output Connections and Initial Setup for Dual Alarm Option sesessssss 2 8 2 6 Remote Range Change Option sssssssssee eene nemen 2 12 Rosemount Analytical Inc A Division of Emerson Process Management Contents Instruction Manual ene Model 755R 3 0 OPERATION iii ii iii 3 1 3 1 MIR 3 1 3 2 Operating Range Selection ee ee Re AR Re ee GR Re canon nc cnn nan ee ek Re ee ee nennen 3 1 3 3 Startup se l ert ee ta EE c tai 3 1 3 4 Calibrations sce
55. assembly HR1 mounted on the top of the magnet and HR2 permanently mounted on the rear of the detector assembly Theory Detector Compartment Temperature Control Section This section maintains the interior of the detector compartment at a controlled temperature of 140 F 60 C Tempera ture is sensed by a thermistor located in the detector compartment and plugged into the Control Board assembly The circuit provides an on off control of heater element HR3 via TRIAC element Q7 Heater HR3 is a part of the heater fan assembly Isolated Current Output Board Op tional An isolated current output is obtainable by insertion of an optional plug in circuit board into receptacle J1 on the Control Board see Figure 3 1 page 3 3 The current outputs available by this board are 0 to 20 mA or 4 to 20 mA Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model 755R ee Sample Pre Heating Coil Sample Inlet Tube Sample Outlet Tube X Detector Assembly Optical Bench Assembly Ex Mounting Screws 2 A Exploded View of Detector Magnet Assembly d Connector J12 Integral Heater HR2 Sensor RT1 S S elders Se mj Integral 5 Micron Diffusion Screen Photocell Lock Screws 2 E EL Test Body 3 o O S 2 Mirror 5 7 a Lamp Retaining oA Dual Photocell Dual Photocell Set Screw Source Lamp Optic
56. ble supplied by customer conductor minimum 24 AWG 13 16 diameter hole for Power Cable Cable supplied by customer 3 conductor minimum 18 AWG TB1 Customer hook up for Power TB2 Customer hook up for Recorder Output Optional Dual Alarm connections Connections for Optional Remote Range Change UOU gt romm Figure 2 2 Model 755R Rear Panel Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 5 Instruction Manual 748213 S April 2002 Model 755R 2 5 ELECTRICAL CONNECTIONS WARNING ELECTRICAL SHOCK HAZARD For safety and proper performance this instrument must be connected to a prop erly grounded three wire source of supply Cable connections for AC power recorder output and alarm output are shown in In stallation Drawing 654015 and are ex b plained in the following sections a Line Power Connection The analyzer is supplied as ordered for operation on 115 VAC or 230 VAC 50 60 Hz Ensure that the power source con forms to the requirements of the individual instrument as noted on the name rating plate Electrical power is supplied to the ana lyzer via a customer supplied three conductor cable type SJT mini mum wire size 18 AWG Route power ca ble through conduit and into appropriate opening in the instrument case Connect power leads to HOT NEUT and GND terminals on the I O board Connect ana lyzer to power source via an externa
57. bly ee se ee ee Re Re ereenn nne nnn 6 3 Figure 6 2 Pin Lead 1 Removal ee ke ee aea Re ee ek Re ee ee ke ee ee ke ee ee ke ee ee ee ke ee 6 4 Figure 6 3 Detector Optical Bench ie ee ee ee ZTE Saa nennen ee ee 6 4 Figure 6 4 Lamp Replacement see eee ee eee ee Ee GR ER RA Ee ee ee GR Re Re ee ee ee ee ee ee Re Re ee ee ee ee ee nt 6 6 Rosemount Analytical Inc A Division of Emerson Process Management Contents Instruction Manual 748213 S LIST OF TABLES Table 2 1 Remote Range Switching Truth Table ee eee 2 12 Table 3 1 Calibration Range for Various Zero Based Operating Ranges 3 4 Table 3 2 Oxygen Equivalent of Common Gases sse 3 6 DRAWINGS LOCATED IN REAR OF MANUAL 617186 Schematic Diagram Case Board 620434 Schematic Diagram Isolated Current Output Board 646090 Schematic Diagram Remote Range Board 652826 Schematic Diagram Control Board 654014 Pictorial Wiring Diagram Model 755R 654015 Installation Drawing Model 755R 656081 Instructions Remote Range Selection iv Contents Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748213 S Model 755R April 2002 PREFACE The purpose of this manual is to provide information concerning the components functions installation and maintenance of the 755R Some sections may describe equipment not used in your configuration The user should become thoroughly familiar with the operation of th
58. ction Manual ene Model 755R P 6 Preface Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748213 S Model 755R April 2002 SECTION 1 DESCRIPTION AND SPECIFICATIONS 1 1 DESCRIPTION Board assembly and the Power Supply Board assembly The Control Board has receptacles The Model 755R Oxygen Analyzer provides that accept optional plug in current output continuous readout of the oxygen content of a board and alarm features flowing gas sample The determination is based on measurement of the magnetic sus 1 2 RECORDER OUTPUT RANGES ceptibility of the sample gas Oxygen is strongly paramagnetic while most other com Seven zero based ranges are available with mon gases are weakly diamagnetic the Model 755R 0 to 1 0 to 2 5 0 to 5 0 to 10 0 to 25 0 to 50 and 0 to 100 The instrument provides direct readout of 0 to Each range is jumper selectable 100 oxygen concentration on a front panel digital display In addition a field selectable 1 3 MOUNTING voltage output is provided as standard An isolated current output of 0 to 20 mA or 4 to The Model 755R is a rack mounted instru 20 mA is obtainable through plug in of an op ment standard for a 19 inch relay rack Refer tional circuit board Current and voltage out to IEC Standard Publication 297 1 1986 puts may be utilized simultaneously if desired An alarm option is also available by way of a 1 4 ISOLATED CURRENT OUTPUT OPTION relay asse
59. cts Although normally calibrated for readout in percent oxygen the Model 755R actu ally responds to oxygen partial pressure The partial pressure of the oxygen com ponent in a gas mixture is proportional to the total pressure of the mixture Thus readout is affected by pressure variations For instance assume that an instrument is calibrated for correct readout with a standard gas containing 5 oxygen ad mitted at the normal sea level atmos pheric pressure of 14 7 psia 101 3 kPa Ifthe operating pressure now drops to one half the original value i e to 7 35 psia 50 65 kPa and the calibration con trols are left at the previously established settings the display reading for the stan dard gas will drop to 2 5 4 2 Theory It is therefore necessary to calibrate the instrument at the same pressure that will be used during subsequent operation and to maintain this pressure during op eration Typically the sample gas is supplied to the analyzer inlet at slightly above ambi ent pressure and is discharged to ambi ent pressure from the analyzer outlet However in some applications it is nec essary to insert an absolute back pres sure regulator into the exhaust line to prevent the readout error that would oth erwise result from fluctuations in exhaust pressure The regulator must be mounted in a temperature controlled housing See Section 2 3c page 2 3 Operation at negative gauge pressure is not normally
60. d d ee S 20 14 27 24 43 EAN 22 37 19 l23 36 20 24 35 21 7 26 15 25 16 23 F5 MED 181 33 d5 4 R75 56 t54 1 2W 15 VDC lt AS VDC lt R81 56 154 1 2W 1 J4 DATE 10 1 90 TITLE lao DIAGRAM SCHEMATIC CONTROL BOARD 755R D CODE IDENT NO DWG NO m SIZE O20 652826 SCALE NONE INITIAL USE 7 558 SHEET 1 OF 1 Rosemount Analytical Inc 55 uo aes 020 652826 Ber DWG NO SIZE A E p 7 ees gt OOO 1 O ees Ges ee Teh a EE qud de ee 2 NO ALARM COM NO 4 Ne RESET _ Lina NO ALARM COM NO 2 Nc RESET 654019 ALARM ASSY OPTIONAL 654077 N O Z OD RE Ly 4 NEL TZL D UD 654007 I O BOARD CUSTOMER POWER CONN 250V OPTIONA n m e ME EE Ma M MR ee Em e r r m ME T DT EMI BOARD y SCHEMATIC 3 rra m e me e re e A 654013 654077 MO CI ETER 657745 OPTION 697 755 OPTION SCHEMATIC 657741 697 34 d E GRN GND WHT f DIS HT 6 79684 si SE WHT VIO BLK 654076 WHT I CD ORE ma ad BLK VIO BLK BLK 649685 230V OPTIONAL eaer waa wa met weur ween ena aa a eee mag paar anr vanc s paa r mar ogas ezr was evn a a FUSE TEIERMISTONS THERMAL
61. e ratio The thermistor resistance is 149 K at 150 EF 65 5 C and increases rapidly as the tem perature decreases R59 in this bridge circuit represents the setpoint value for temperature Suppose that at temperature resistance of the bridge R55 R56 R59 and RT1 equals 149 K in resistance and causes the junction of RT1 and R59 to go positive in voltage value Since R55 and R56 are of equal resistance their junction is at zero volts Therefore terminal 3 of AR6 is more positive than terminal 2 and the base of Q2 is positive Q2 conducts al lowing alternating current to flow through heaters 1 and 2 The voltage drop across the heaters when completely cold would be about 20 VAC and when controlling would be AC of very low amplitude As the temperature increases the resistance of RT1 decreases and the junction point be tween RT1 and R59 becomes less positive Terminal 3 of AR6 becomes less positive with respect to terminal 2 The output of AR causes Q2 and Q3 to conduct less When terminal 3 equals terminal 2 or is less than terminal 2 the output of AR6 is zero or less Q2 and Q3 do not conduct and the heater would not be supplying heat energy to the detector HR1 2 F1 ALO CR6 wo4 170 3 25 VAC RMS j NA R60 100 R58 5M 6 15V Pad R62 Q3 e 1K R61 2 0 Figure 5 4 Detector Heater Control Circuit Circuit Analysis Ro
62. ecorder scaling It disables the single pole double throw relays one internal recorder fullscale range select without each for the ALARM 1 and ALARM 2 affecting the front panel display 1 2 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748213 S Model 755R April 2002 1 8 SPECIFICATIONS a Performance Operating Range Standard 0 to 5 0 to 10 0 to 25 O to 50 and 0 to 100 oxygen Operating Range Optional 0 to 1 0 to 2 5 0 to 5 O to 10 O to 25 O to 50 and 0 to 100 oxygen Response Time 909 of fullscale 20 seconds Reproducibility 0 01 oxygen or 1 of fullscale whichever is greater Ambient Temperature Limits 32 F 0 C to 113 F 45 C Zero Drift err torni 1 fullscale per 24 hours provided that ambient temperature does not change by more than 20 F 11 1 C 2 5 of fullscale per 24 hours with ambient temperature change over entire range Span Drift uenti 1 fullscale per 24 hours provided that ambient temperature does not change by more than 20 F 11 1 C 2 5 of fullscale per 24 hours with ambient temperature change over entire range Sample Dryness i ioni ee es Sample dewpoint below 110 F 43 C sample free of entrained liquids Temperature Limits 50 F 10 C to 150 F 65 C Operating Pressure
63. ect to lowest range or use zero and span gases When checkout complete re install De tector Isolation Plug Configure Control Board to original setup If the Control Board functions correctly the problem is either located in the De tector Magnet Assembly or related to temperature control 6 2 HEATING CIRCUITS To ensure against damage from overheating in the event of malfunction the heating cir cuits receive power via thermal fuses F2 and F3 If temperature of a heated area exceeds the permissible maximum the associated fuse melts opening the circuit NOTE The thermal fuses should be plugged in NOT SOLDERED as the fuse element might melt and open the circuit a Case Heater Control Circuit The case heater control circuit receives power via thermal fuse F2 setpoint Maintenance and Service 75 C This fuse accessible on the Power Supply Board may be checked for continuity Detector compartment heater element HR3 mounted on the heater fan assem bly has a normal resistance of 20 ohms To verify heater operation carefully place a hand on top of detector compartment Heat should be felt If not check the case heating circuit Temperature sensor RT1 has a cold re sistance of 22 7K ohms and a normal op erating resistance of 20 2K ohms indicating normal operating temperature As a further check disconnect plug P6 on the Control Board thus disconnecting temperature sensor RT1 Substitute a decade
64. ed at the following values 5 amperes 240 VAC resistive 1 ampere 240 VAC inductive 5 amperes 120 VAC resistive 3 amperes 120 VAC inductive 5 amperes 30 VDC resistive 3 amperes 30 VDC inductive Removal of AC power from the analyzer such as power failure de energizes both relays placing them in alarm condition Switching characteristics of the Alarm 1 and Alarm 2 relays are as follows The Alarm 1 relay coil is de energized when the display moves downscale through the value that corresponds to setpoint minus deadband This relay coil is energized when the display moves up scale through the value that corresponds to setpoint plus deadband The Alarm 2 relay coil is de energized when the display moves upscale through the value that corresponds to the setpoint plus deadband This relay coil is ener gized when the display moves downscale through the value that corresponds to setpoint minus deadband Both the ALARM 1 and ALARM 2 func tions generally incorporate automatic rest When the display goes beyond the pre selected limits the corresponding relay is de energized When the display returns within the acceptable range the relay is turned on The ALARM 1 and or ALARM 2 alarm functions may be converted to manual re set The conversion requires the substitu tion of an external pushbutton or other momentary contact switch for the jumper that connects the RESET terminals on the Alarm Relay Assembly If the corre sponding
65. ell lock screws 2 slide photocell out Reverse the removal procedure for in stallation Align photocell see below Alignment The adjustments in this procedure are made on the Control Board With zero gas flowing 1 Place a digital voltmeter between the wiper of zero potentiometer R13 and TP7 ground Adjust for 0 VDC 2 Remove the voltmeter from R13 and place on R10 see Figure 6 4B page 6 6 Adjust R9 for 0 VDC 3 Remove the voltmeter from R10 and place on TP8 Move the photocell to obtain a DC voltage as close to 0 mV as possible but no more than 750 mV Maintenance and Service 6 5 Instruction Manual 748213 S April 2002 Model 755R 4 Apply power to instrument and allow 7 Connect the voltmeter between TP10 to warm up approximately one hour and circuit ground TP7 Adjust front panel ZERO for reading of exactly 5 Set front panel ZERO at mid range zero on voltmeter i e five turns from either end All internal adjustments are now properly 6 Connect digital voltmeter from slider set The instrument may be calibrated of R9 to chassis ground With a per Section 3 4 page 3 1 steady flow of 50 to 500 cc min of ni trogen zero gas going through instru ment adjust R9 for 0 V DETAIL A E 1 4 7 Set Screw AA Re IN mo NU EA L Red Mark for Alignment DETAIL B Vo
66. emperatures in the following areas 1 Interior of the analyzer is maintained at 140 F 60 C by an electrically controlled heater and associated fan 2 Immediately downstream from the inlet port prior to entry into the de tector the sample is preheated by passage through a coil maintained at approximately the same temperature as the detector See Figure 4 3A page 4 7 3 The detector is maintained at a con trolled temperature of 150 F 66 C Also avoid excessive vibration To mini mize vibration effects the detec tor magnet assembly is contained in a shock mounted compartment WARNING POSSIBLE EXPLOSION HAZARD This analyzer is of a type capable of analy sis of sample gases which may be flam mable If used for analysis of such gases internal leakage of sample could result in an explosion causing death personal in jury or property damage Do not use this analyzer on flammable samples Use ex plosion proof version instruments for analysis of flammable samples A Division of Emerson Process Management Use reasonable precautions to avoid ex cessive vibration In making electrical connections do not allow any cable to touch the shock mounted detector as sembly or the associated internal sample inlet and outlet tubing This precaution ensures against possible transmission of mechanical vibration through the cable to the detector which could cause noisy readout Installation 2 1 In
67. esult in a directly proportional change in the indicated percentage of oxygen This effect may be compensated in various ways If desired cor rection may be made by the following equa tion True Oxygen Pst Pan Indicated Oxy gen Where Pst Operating pressure during stan dardization Pan Operating pressure sample analy sis Example U S Units Pst 760 mm Hg Pan 740 mm Hg Indicated O2 True O2 760 740 40 41 1 O2 Example S l Units Pst 101 kPa Pan 98 2 kPa Indicated O2 40 True O2 101 98 2 40 41 1 02 Operation The appropriate calibration interval will de pend on the accuracy required in the particu lar application and is best determined by keeping a calibration log If the analyzer ex haust port is vented directly to the atmos phere the greatest source of error is normally the variation in barometric pressure If de sired effects of barometric pressure variation can be minimized by calibrating immediately before taking readings for example at the beginning of each shift Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model 755R ie SECTION 4 THEORY 4 1 PRINCIPLES OF OPERATION Rosemount Analytical Inc Oxygen is strongly paramagnetic while most other common gases are weakly diamagnetic The paramagnetism of oxygen may be re garded as the capability of an oxygen mole cule to become a temporary
68. ey are filled and sealed with pure dry nitro gen Around the test body a titanium wire is chemically etched in order to form a feedback loop that can create a counteracting magnetic force to the test body displacement caused by oxygen concentration in the test assembly magnetic field Attached to the center arm of the test body dumbbell is a diamond shaped mirror At tached to the mirror are two separate platinum wires in tension with the supports for the test body The supports are isolated from ground and are electrically connected to the feedback loop and the electronics for that loop The platinum wires form a fulcrum around which the test body pivots The detector operates in the following fashion If the sample gas contains oxygen it collects in the non uniform magnetic field around the test body Oxygen because of its paramag netic qualities gathers along the magnetic lines of flux and forces the dumbbell of the test body out of the magnetic field A light source is focused on the test body mir ror As the test body moves out of the mag netic field the mirror distributes light unevenly on two photocells BT1 and BT2 The photo cells create a current proportional to light This current is converted to a voltage by U1 and U2 located on the connector board in the de tector housing This voltage is then presented to comparator U1 on the controller board The output of U1 goes to U2 The output of U2 causes current to f
69. factory If the failure was due to the conditions listed in the standard Rosemount warranty the defective unit will be repaired or replaced at Rosemount s option and an operating unit will be returned to the customer in accordance with the shipping instructions furnished in the cover letter For equipment no longer under warranty the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions 8 2 CUSTOMER SERVICE For order administration replacement Parts application assistance on site or factory repair service or maintenance contract information contact Rosemount Analytical Inc Process Analytical Division Customer Service Center 1 800 433 6076 8 3 TRAINING A comprehensive Factory Training Program of operator and service classes is available For a copy of the Current Operator and Service Training Schedule contact the Technical Services Department at Rosemount Analytical Inc Customer Service Center 1 800 433 6076 Return of Material 8 1 Instruction Manual 748213 S April 2002 Model 755R 8 2 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management 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 me
70. ght but is not in all cases negligible During initial installation of an instrument in a given appli cation effects of the background gas should be calculated to determine if any correction is required See Section 3 4 page 3 1 2 2 Installation a Zero Standard Gas In the preferred calibration method de scribed in Section 3 4a page 3 1 a suit able zero standard gas is used to establish a calibration point at or near the lower range limit Composition of the zero standard normally requires an oxy gen free zero gas typically nitrogen b Span Standard Gas A suitable span standard gas is required to establish a calibration point at or near the upper range limit If this range limit is 2196 or 2596 oxygen the usual span standard gas is air 20 9396 oxygen 2 3 SAMPLE Basic requirements for sample are 1 A2 micron particulate filter inserted into the sample line immediately upstream from the analyzer inlet 2 Provision for pressurizing the sample gas to provide flow through the analyzer 3 Provision for selecting sample zero stan dard or span standard gas for admission to the analyzer and for measuring the flow of the selected gas a Temperature Requirements Sample temperature at the analyzer inlet should be in the range of 50 F to 150 F 10 C to 66 C Normally however a maximum entry temperature of 110 F 43 C is recom mended so that the sample temperature will rise during passage of t
71. h Zero and Span Standard Gases NOTE The same flow rate must be main tained for zero span and sample to avoid measure error The exhaust is vented to the atmosphere to avoid back pressure The following pro cedure is based on the standards in Table 3 2 page 3 6 Performance specifications are based on recorder output Set Zero Calibration Point Inject nitrogen zero standard gas through analyzer at suitable flow rate preferably 250 cc min Allow gas to purge analyzer for a minimum of three minutes Adjust ZERO control so that the read ing on the digital display or recorder is zero Operation 3 1 Instruction Manual 748213 S April 2002 Model 755R Set Span Calibration Point Inject span standard gas see Table 3 1 page 3 4 through the analyzer at the same flow rate as was used for zero standard gas Allow gas to purge analyzer for a minimum of three min utes Adjust SPAN control so that reading on display or recorder is appropriate to the span standard gas 3 5 COMPENSATION FOR COMPOSITION OF BACKGROUND GAS Any gas having a composition other than 100 oxygen contains background gas The background gas comprises all non oxygen constituents Although instrument response to most gases other than oxygen is comparatively slight it is not in all cases negligible The contribution of these com 3 2 Operation ponents to instrument response is a func tion of the span and range used and can be c
72. he factory Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748213 S Model 755R April 2002 2 4 LEAK TEST For proper operation and safety system leak age must be corrected particularly before in WARNING troduction of toxic or corrosive samples and or application of electrical power TOXIC OR CORROSIVE HAZARD The sample containment system must be carefully leak checked upon installation and before initial start up during routine maintenance and any time the integrity of the sample containment system is broken to ensure the system is in leak proof con dition To check system for leaks liberally cover all fittings seals and other possible sources of leakage with suitable leak test liquid such as SNOOP P N 837801 Check for leak indica tive bubbling or foaming Leaks that are inac cessible to SNOOP application could evade detection by this method Internal leaks resulting from failure to ob serve these precautions could result in personal injury or property damage L1 HOT L2 NEUT ewp O CUR VOLT OUTPUT OUTPUT elelelela Rear terminal cover removed for clarity Sample outlet 1 4 O D tube fitting Sample Inlet 1 4 O D tube fitting 5 8 diameter hole for optional Dual Alarm Cable Cable supplied by customer minimum 24 AWG 5 8 diameter hole fitted with liquid tight gland for Recorder Output Cable Ca
73. he sample through the analyzer This precaution prevents cooling of the sample and possi ble analyzer damaging condensation With a thoroughly dry sample entry tem perature can be as high as 150 F 66 C without affecting readout accuracy Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 Needle Valves Sample In a Zero Standard Gas _ _ _ _ _ __ _ _ Model 755R Oxygen Analyzer Two Micron To Vent Filter Flowmeter Span Standard Gas Figure 2 1 Interconnect of Typical Gas Manifold to Model 755R b Pressure Requirements General Operating pressure limits are as follows maximum 10 psig 68 9 kPa minimum 5 psig vacuum 34 5 kPa vacuum CAUTION RANGE LIMITATIONS Operation outside the specified pressure limits may damage the detector and will void the warranty c Normal Operation at Positive Gauge Pressures Normally the sample is supplied to the analyzer inlet at a positive gauge pres sure in the range of 0 to 10 psig 0 to 68 9 kPa Rosemount Analytical Inc The basic rule for pressure of sample and standard gases supplied to the inlet is to calibrate the analyzer at the same pres sure that will be u
74. ility or posi tive action This is achieved by the 20 M re sistances R70 and R73 An approximate 8 V peak to peak AC signal is applied to comparators 1 and 2 As the signal starts going positive comparator 2 transistor ceases conducting and compara tor 1 transistor is off When the signal exceeds the 159 mV on the non inverting terminal it turns on com parator 1 and the output is 15 V Com parator 1 stays on until the signal drops below 159 mV at which time the output will be the value of the OR bus As the AC signal goes negative with respect to ground the transistor of comparator 2 conducts and the output is again 15 V The Circuit Analysis 5 1 Instruction Manual 748213 S April 2002 Model 755R output remains at 15 VDC until the incom ing signal crosses zero value and the posi tive signal causes the comparator 2 transistor to cease to conduct Summing the effects of the two comparators in the OR circuit results in no output from the comparators for about 4 of the sine wave 2 after the signal goes positive 0 to 2 and 2 before the positive signal reaches 180 178 to 180 During the period that neither comparator is conducting the value on the OR bus is the potential from the temperature sensing bridge plus the effect of the ramp generator probably 1 88 0 03 V The on off effect of the comparators to the OR circuit results in application of a posi tive going pulse from 15
75. is equipment and on site property all personnel authorized to install operate and service the this equipment should be thoroughly familiar with and strictly follow the instructions in this manual SAVE THESE INSTRUCTIONS DANGER ELECTRICAL SHOCK HAZARD Do not operate without doors and covers secure Servicing requires access to live parts which can cause death or serious injury Refer servicing to qualified personnel For safety and proper performance this instrument must be connected to a properly grounded three wire source of power Optional alarm switching relay contacts wired to separate power sources must be disconnected before servicing WARNING POSSIBLE EXPLOSION HAZARD This analyzer is of a type capable of analysis of sample gases which may be flammable If used for analysis of such gases internal leakage of sample could result in an explosion causing death per sonal injury or property damage Do not use this analyzer on flammable samples Use explosion proof version instruments for analysis of flammable samples P 2 Preface Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748213 S Model 755R April 2002 WARNING PARTS INTEGRITY Tampering or unauthorized substitution of components may adversely affect safety of this product Use only factory documented components for repair CAUTION PRESSURIZED GAS This module requires peri
76. is module before operating it Read this instruction manual completely DEFINITIONS The following definitions apply to DANGERS WARNINGS CAUTIONS and NOTES found throughout this publication Highlights the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored 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 Rosemount Analytical Inc A Division of Emerson Process Management Preface P 1 Instruction Manual ene Model 755R INTENDED USE STATEMENT The Model 755R 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 application 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 th
77. l Circus esse eee eee 5 1 5 4 Detector Heater Control Circuit ee ee AR AE GR Re Re erre nennen 5 6 5 5 Detector Light Source Control Circuit ees ee inn ee nennen 5 7 5 6 Detector with First Stage Amplifier iese ee ee ee ee eene enne 5 8 5 7 Buffer Amplifiers U8 and U10 with Associated Anticipation Function 5 10 5 8 Digital Output Circ coco ice Ee ed GEN e ene eee e tee SR iie d d ine 5 10 5 9 Analog Output Circuits for Recorder and Alarms sess en 5 11 a First Stage Amplifier ciet iie rae e uec iue iaa e uc e 5 11 b Second Stage Amplifier econ ete tek ede ttd Jes tue ed te ed ed i 5 11 6 0 MAINTENANCE AND SERVICE eese ek RE Re ee nenne erre 6 1 6 1 Initial Checkout With Standard GaseS iis se ee ee ee GR AR Re ee ee ee GR AR AA ee ee ee ee ee ee Re Re ee ee ee 6 1 a Control Board Glhieckout 5 i iir t artt dite te 6 1 6 2 Heating CIECUIEs AR EE OE EO EE OE 6 2 a Case Heater Control Circuit essere ee ee ee nnne 6 2 6 3 Detector Magnet Heating Circuit ees ee ee ee Ge ee Ge enne nennen 6 2 6 4 Detector Chick n OER e ub ee Ed ee Lm LES 6 4 a tdi nce Res Ir 6 5 b iPhotocellz EES EER Lue Ei E LIE 6 5 C SUSPENSION EE RR EE RE EE EAE Ge aci 6 5 ii Contents Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748213 S Model 755R April 2002 6 5 Replacement Of Detector
78. l fuse or breaker in accordance with local codes Do not draw power for associated 755R Analyzer Input c Terminals equipment from the analyzer power cable Refer to Figure 2 3 below If the analyzer is mounted in a protected rack or cabinet or on a bench an acces Sory kit P N 654008 is available which provides a 10 foot North American power cord set and a liquid tight feed through gland for the power cable hole The kit also contains four enclosure support feet for bench top use Recorder Output Selection and Cable Connections If a recorder controller or other output device is used connect it to the analyzer via a number 22 or number 24 AWG two conductor shielded cable Route the cable into the case through the liquid tight feed through gland in the Recorder Out put opening See Installation Drawing 654015 Connect the shield only at the recorder end or the analyzer end not to both at the same time because a ground loop may occur NOTE Route recorder cable through a separate cable gland P N 899329 or conduit not with power cable or alarm output cable Cable connections and output selection for potentiometric and current actuated devices are explained below Potentiometric Recorder 5 Verify polarity yO Voltage Divider is correct Customer Supplied Position of Recorder Output Minimum Permissible Selector Plug Resistance for R1 R2 ohms 1
79. low through the feedback loop attached to the dumbbell This feedback current creates an elec tro magnetic field that attracts the dumbbell and mirror into the test assembly magnetic field until the mirror reflects light almost uni 5 8 Circuit Analysis formly on each photocell A current propor tional to the oxygen concentration in the mag netic field of the test assembly has to be flowing through the feedback loop in order to maintain balance and provide a reading of the oxygen content of a sample Resistances R7 R8 and the resistance of the wire in the feedback loop determine the gain of amplifier U2 The mirror on the dumbbell is positioned by the amount of current in the feedback loop The mirror reflects light from the source DS1 to the photocells BT1 BT2 This repositioning of the mirror is a form of mechanical feedback to the input of the amplifier U1 The net result is that the output of U1 could vary from 0 to 70 mV or 0 to 7 0 V de pending on the range of the instrument R4 C3 and R5 C7 form damping circuits for the input amplifier U1 and to smooth out noise that might be introduced by the measurement source Diode CR2 is a low leakage device Its pur pose in the circuit is to ensure that the dumb bell and mirror are positioned correctly with respect to the photocells on initial application of power If the dumbbell was out of position on start up the mirror might reflect light from the source ont
80. ls Adjusted O2 for standard gas A 100 B C 100 B C 100 Where A true O2 of standard gas B BGGs C BGGst Example Background gas in sample is CO2 oxygen equivalent 0 623 Zero gas is 100 N2 Span standard gas is air 21 O2 79 N2 Background gas in zero and span standard gases is N2 oxygen equivalent 0 358 With N2 zero standard gas flowing ZERO control is adjusted so digital display reads 0 100 0 623 0 358 100 0 623 0 358 100 0 265 O With air flowing SPAN control is adjusted so the digital display reads 21 100 0 265 100 0 265 21 209 O 21 21 100 In two limiting cases the general equation is reduced to simpler forms 1 If the span standard gas is 100 oxygen the adjusted oxygen value for setting the SPAN control is the same as the true value i e 100 oxygen 2 If the zero standard is an oxygen free zero gas the adjusted value for setting the ZERO control BGGst BGGs If the oxygen free zero gas is more diamagnetic than the background gas in the sample this difference is negative The negative value may be set on the digital display or the re corder if provided with below zero capability Rosemount Analytical Inc A Division of Emerson Process Management Operation 3 5 Instruction Manual 748213 S April 2002 3 6 Operation
81. ltmeter Lead R10 C8 d C1 R8 Ml id Figure 6 4 Lamp Replacement 6 6 Maintenance and Service Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 Rosemount Analytical Inc Detector Removal Prior to removal of the detector remove power from instrument and stop flow of sample gas 1 Remove the four screws securing the detector cover plate 2 Disconnect cable from J12 on the detector assembly NOTE Note how the rubber sample lines are looped into a long coil When rein stalling the sample lines they must be configured in the same way This pre caution isolates the detector from the effects of mechanical vibration Oth erwise vibration waves could travel upward along the tubing walls result ing in noisy readout 3 Refer to Figure 6 1 page 6 3 Using needle nose pliers squeeze the hose clamps to disconnect the rubber sam ple lines from the metal inlet and out let tubes of the detector assembly 4 Remove the two screws at the bottom of the detector assembly slide de tector out Installation 1 Install replacement detector assembly and connect cable to J12 2 Seat the detector assembly firmly against the magnet pole pieces and tighten attaching screws 3 Reconnect rubber sample lines to metal inlet and outlet tubes on detec tor assembly 4 Apply power to instrument and allow to warm up approximately o
82. mbly that mounts at the rear of the case with a cable that plugs into the Control An isolated current output is obtainable by Board Customer connections are available on using an optional current output board either this assembly during factory assembly or subsequently in the field The board provides ranges of 0 to 20 The basic electronic circuitry is incorporated or 4 to 20 mA into a maximum resistive load into two master boards designated the Control of 1000 ohms Digital Display 8 o NENNEN ZERO SRAN Roseinount Analytical Model 755R Zero Control Span Control Figure 1 1 Model 755R Oxygen Analyzer Front Panel Rosemount Analytical Inc A Division of Emerson Process Management Description and Specifications 1 1 Instruction Manual eee Model 755R 1 5 ALARM OPTION contacts These relays may be used to drive external customer supplied alarm The alarm option contains and or control devices e Analarm circuit incorporating two com 1 6 ELECTRICAL OPTIONS parator amplifiers one each for the ALARM 1 and ALARM 2 functions Each The analyzer is supplied as ordered for op amplifier has associated setpoint and eration on either 115 VAC 50 60 Hz or 230 deadband adjustments Setpoint is ad VAC 50 60 Hz justable from 1 to 100 of fullscale Deadband is adjustable from 1 to 20 1 7 REMOTE RANGE CHANGE OPTION of fullscale This option allows the customer to remotely e An alarm relay assembly containing two control the r
83. mbranes 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 Goods part s and consumables proven by Seller to be defective in workmanship and or material shall be replaced or repaired free of charge F O B Seller s factory provided that the goods part s or consumables are returned to Seller s designated factory transportation charges prepaid within the twelve 12 month period of warranty in the case of goods and part s and in the case of consumables within the ninety 90 day period of warranty This warranty shall be in effect for replacement or repaired goods part s and the remaining portion of the ninety 90 day warranty in the case of consumables A defect in goods part s and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods part s and consumables are capable of being renewed repaired or replaced The Seller shall not be liable to the Buyer or to any other person for the loss or damage directly or indirectly arising from the use of the equipment or goods from breach of any warranty or from any other cause All other warranties expressed or implied are hereby excluded IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY NO OTHER WARRANTIES ARE GRANTED INCLU
84. ne hour A Division of Emerson Process Management Calibration 1 On the Control Board set the front panel ZERO control R13 at mid range i e five turns from either end 2 Connect a digital voltmeter from the slider of R9 to chassis ground With a steady flow of 50 to 500 cc min of ni trogen gas passing through the in strument adjust R9 for zero volts 3 Connect the voltmeter between TP10 and circuit ground TP7 Adjust front panel ZERO control R13 for reading of exactly zero on voltmeter 4 With all internal adjustments now properly set the instrument may be calibrated per Section 3 4 page 3 1 6 6 CONTROL BOARD SETUP a Power Supply Test 1 TP7 circuit ground is ground point for all voltage tests 2 Counterclockwise end of front panel ZERO potentiometer R13 on Control Board 15 VDC x0 5 VDC 3 Clockwise end of ZERO potentiome ter 15 VDC 5 VDC 4 Set ZERO potentiometer to obtain a reading of 0 VDC 10 mV at slider 5 Measure TP19 5 VDC 0 25 VDC Detector zero 1 Flow 250 cc min nitrogen 2 Monitor TP8 adjust R9 for 0 VDC 2mvV Maintenance and Service 6 7 Instruction Manual 748213 S April 2002 Model 755R c U4 Zero 2 Adjust R29 to obtain a reading of 00 00 5 counts on the display 1 Monitor TP5 adjust R100 for 1 VDC 2mV Fullscale 2 Monitor TP10 adjust R13 ZERO for 1 Monitor TP11 Flow 100 oxygen 0 0 VDC 5mV adjust SPAN potentiometer R20 for
85. ngs with standard gases as well as sample gas If Zero and span standard gases give noisy or drifting readings the problem is probably in the detector or the temperature control cir cuits Proceed with checks of the detector and electronics In general before concluding that the detector is defective and must be re placed verify correct operation of all circuits that could cause erratic readings a Control Board Checkout The Detector Isolation Plug located on the Control Board Figure 3 1 page 3 3 re moves the detector signal allowing the input voltage to go to zero The display should register near zero or on scale and TP20 should read zero voltage To test the remainder of the measuring circuit do the following Voltage 1 Set RANGE Select to lowest range Maintenance and Service 6 1 Instruction Manual 748213 S April 2002 Model 755R 2 Adjust R29 clockwise and counter clockwise The display should follow accordingly and remain steady within the adjustment limits of R29 If this condition is met refer to Section 6 6a page 6 7 for Control Board setup Before replacing the Control Board test for 15V at the junction of C1 J4 7 Use the junction of CR1 R2 for 15V or any source of 15V on the board for the respective voltages 3 If adjustment of R29 is not possible replace the Control Board Alarms Set RANGE Select to lowest range or use zero and span gases Current Output Set RANGE Sel
86. nt The cost of test and replacement will exceed the cost of a rebuilt assembly As standard policy rebuilt boards are available on an exchange basis Because of the exchange policy covering cir cuit boards the following list does not include individual electronic components If circum stances necessitate replacement of an indi vidual component which can be identified by inspection or from the schematic diagrams obtain the replacement component from a lo cal source of supply Replacement Parts 7 1 Instruction Manual 748213 S April 2002 Model 755R 7 2 MATRIX MODEL 755R OXYGEN ANALYZER 755R Model 755R Oxygen Analyzer Code Ranges 01 0 5 10 25 50 and 100 Oz Standard 02 0 1 2 5 5 10 25 50 and 100 O Extended 99 Special Code Output 01 0 10 mV 0 100 mV 0 1 V or 0 5 VDC Standard 02 0 4 20 mA Current 99 Special Code Alarm Relays 00 No Alarm 01 Dual Alarm 99 Special Code Case 01 Standard 02 Standard with Tropicalization 03 EMC Kit 04 EMC Kit with Tropicalization 99 Special Code Operation 01 115 VAC 50 60 Hz Standard 02 230 VAC 50 60 Hz 99 Special Code Remote Range 00 None 01 Standard 0 5 10 25 50 100 02 Extended 0 1 2 5 5 10 25 03 0 1 2 5 5 10 50 04 0 1
87. ntrol function as follows a With ALARM 1 Setpoint Adjust ment at 100 i e position 10 on dial adjust front panel SPAN Control so that the display or re corder reads exactly fullscale b Set ALARM 1 Calibrate Adjust ment R63 to its clockwise limit Installation 2 9 Instruction Manual Model 755R Carefully rotate R63 counter clockwise the minimum amount required to obtain energization of ALARM 1 Relay K1 See Figure 2 6 below and Figure 3 1 page 3 3 Energization may be verified by connecting an ohmmeter to relay terminals on 654019 Alarm Relay Assembly c To verify correct adjustment of R63 adjust front panel SPAN Control so that the display or re corder reads 99 of fullscale b the display or recorder reads ex actly fullscale c Set ALARM 2 Calibrate Adjust ment R67 to its clockwise limit Carefully rotate R67 counter clockwise the minimum amount required to obtain energization of ALARM 2 Relay K2 See Figure 2 5 page 2 8 d To verify correct adjustment of R67 adjust front panel SPAN Control so that the display or re corder reads 99 of fullscale Relay K2 should now be DE ENERGIZED Relay K1 should now be DE ENERGIZED 5 Adjust ALARM 2 control function as follows The ALARM 1 and ALARM 2 Setpoint Adjustments are now properly calibrated and may be used to select the desired alarm setpoints as described in Section 3 6 page 3 7 a With ALARM 2 Setpoint Adjust
88. o one of the photocells If the photocell output was positive the current in the feed back loop would be in the wrong direction and its electromagnetic field would cause the dumbbell to be further repelled from the per manent magnetic field The result would be error not balance On application of AC power capacitor C1 has no charge The current will have to flow through R2 Initially the full 30 V drop the difference between the 15 VDC and 15 VDC power will appear cross R2 The cath ode of CR2 will be initially at 15 VDC The anode of CR2 will be some value more posi tive than 15 VDC CR2 will conduct The in put terminal of U1 will be negative and the current through the feedback loop around U2 Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 Rosemount Analytical Inc will cause the dumbbell and mirror to be posi tioned correctly in the test body As the charge on C1 increases the cathode of CR2 becomes more positive When it ex ceeds that on the anode CR2 ceases to con duct and isolates the 15 VDC and 15 VDC power supply from the input circuit The front panel zero potentiometer R13 and detector coarse zero potentiometer add or subtract current to the input of U2 to offset any currents that may occur because of any DETECTOR CONTROL HOUSING BOARD R1 10 15V R2 249K n 188 Y R2 3 3uF u2 TP6 R3 110
89. odic use of pressurized gas See General Precautions for Handling and Storing High Pressure Gas Cylinders page P 4 CAUTION TOPPLING HAZARD This instrument s internal pullout chassis is equipped with a safety stop latch located on the left side of the chassis When extracting the chassis verify that the safety latch is in its proper counter clockwise orienta tion If access to the rear of the chassis is required the safety stop may be overridden by lifting the latch however further extraction must be done very carefully to insure the chassis does not fall out of its enclosure If the instrument is located on top of a table or bench near the edge and the chassis is extracted it must be supported to prevent toppling Rosemount Analytical Inc A Division of Emerson Process Management Preface P 3 Instruction Manual ene Model 755R 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 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
90. omputed for each individual case Ifthe zero and span standard gases con tain the same background gas as the sam ple the routine standardization procedure automatically compensates for the back ground components Therefore the zero and span standard gases would introduce no error If the background gas in the sample is dif ferent from that in the zero and or span standard gas es background effects must be taken into consideration to ensure cor rect readout During adjustment of the front panel ZERO and SPAN controls see Fig ure 1 1 page 1 1 the instrument is not set to indicate the true oxygen content of the zero and span standard gases It is set to indicate a slightly different value relative to background gas calculated to provide cor rect readout during subsequent analysis of the sample gas Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 15 8 7 sg EX EM PAN E10 E24 E12 100 50 25 0 5 15 1 E15 17 E19 TP5 TP6 TP7TP8 TP9 TP10 TP11 TP16 TP17 TP18 TP19 TP20 74 vA al Eo o eo ne o a JEJEJE ER e e e e e e e er R89 214 E16 118 E20 ee el Lel o o e a R a 12 ee 5 4 3 2 6 1013 jooe _
91. on arrangement in its input network thus providing slightly faster response on the readout device s Potentiometer R30 provides a continu ously variable adjustment of 5 to 25 sec onds for the electronic anticipation time and is factory set for 20 seconds Since the anticipation network attenuates the signal a gain of 10 is provided in U10 to restore the signal to the desired full scale range of 0 to 10 VDC Rosemount Analytical Inc A Division of Emerson Process Management The output signal from U10 is routed to two output circuits a digital and an ana log In the Digital Output Circuit the signal from U10 passes to an integrating ana log to digital converter The resulting digital signal drives the liquid crystal dis play In the Analog Output Circuit the output from U10 is provided as an input to the recorder output amplifier This circuitry provides scale expansion and amplifica tion preparatory to use for potentiometric recorder voltage to current conversion for current recorder and or alarm functions Potentiometric output is strap selectable for 0 to 10 mV 0 to 100 mV 0 to 1 V or 0 to 5VDC Potentiometer R88 permits ad justment of recorder span on 0 to 1 V 100 mV and 10 mV outputs Power Supply Board Assembly The Power Supply Board assembly con tains power supply and temperature con trol circuitry The assembly is mounted within the analyzer case As shown in DWG 617186 the various circ
92. potential to terminal 2 of AR7 Now the output AR7 will increase causing Q4 to conduct more current through R66 As the potential across R66 increases Q5 will con duct more current causing a further increase in current flow through DS1 The net result is that the voltage across DS1 will remain uni form and the operation of Q4 and Q5 will ad just the gain of AR to maintain the light emission from DS1 uniform for a long period of time Voltage fluctuations in the 115 VAC supply could cause some variation in the amount of current flowing through the bulb DS1 How ever the voltage drop across DS1 would cause ART to adjust Q4 and the voltage drop across R66 to adjust Q5 The net result would still be uniform current flow through DS1 and uniform light emission EA EE AE 1 a 8 5V BUS i i 15V i 120 V R63 Gor 7 5K i RMS 2 T 01uF i R64 VR3 14K AR OER 9 0V a2 2V EA 01uF C31 It PE R65 2000uF o E Figure 5 5 Detector Light Source Control Circuit A Division of Emerson Process Management Circuit Analysis 5 7 Instruction Manual 748213 S April 2002 Model 755R 5 6 DETECTOR WITH FIRST STAGE AMPLIFIER Refer to Figure 5 6 page 5 9 The detector assembly consists of a test body suspended on a platinum wire and located in a non uniform magnetic field The test body is constructed of two hollow glass spheres forming a dumbbell shape Th
93. recommended but is used in certain special applications See Section 2 3d page 2 4 CAUTION PRESSURE MINIMUM Never subject the sensing unit to an ab solute pressure of less than 500 mm Hg 66 7 kPa Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model 755R ie Displacement gt Torque A Electromagnetic S Restoring Axis Torque qe wt Balancing Weight Restoring Current 1 M Mirror Restoring U Current Electromagnetic Axis N Nitrogen Filled Hollow Glass Test Body Titanium Wire Conductor Balancing Weight Platinum Nickel Alloy Suspension Ribbon TEST BODY DETAIL Displacement Torque hor SENE Restoring Torque d gt Restoring Magnet up Current Test Body gt D 9 DETECTOR MAGNET 1 Pap Source Lamp ASSEMBLY RA DS1 CONTROL 1 _ ASSEMBLY Shaded Pole Pieces 4 Zero we Span dy Oxygen Dual Photocell Readout BT1 BT2 Figure 4 1 Functional Diagram of Paramagnetic Oxygen Measurement System Rosemount Analytical Inc A Division of Emerson Process Management Theory 4 3 Instruction Manual 748213 S April 2002 Model 755R Shaded Z Pole US Ys pu Piece NO 78 am Z EET Sphere pus poc Magnetic Susceptibility k Ba E I N SS ENT gt E EET 3 gt esis TSE SS s zu 2 Es SA ZA S re C
94. relay is now de energized i e in alarm condition the relay remains A Division of Emerson Process Management de energized until the operator momen tarily closes the switch By appropriate connection to the dou ble throw relay contacts it is possible to obtain either a contact closure or a con tact opening for an energized relay Also either a contact closure or a contact opening may be obtained for a de energized relay It is important for fail safe applications that the user under stands what circuit conditions are desired in event of power failure and the resultant relay de energization Relay contacts should then be connected accordingly See Figure 2 5 page 2 8 The ALARM 1 and ALARM 2 circuits have independent setpoint and deadband ad justments See Figure 3 1 page 3 3 Ini tially the ALARM 1 and ALARM 2 Setpoint Adjustments must be calibrated by means of the ALARM 1 and ALARM 2 Calibration Adjustments by the following procedure 1 Set RANGE Select in a position ap propriate to the span standard gas 2 Inject span standard gas through ana lyzer at 50 to 500 cc min 3 Verify that ALARM 1 and ALARM 2 Deadband Adjustments See Figure 3 1 page 3 3 are set for minimum value turned fully counterclockwise These potentiometers should be fac tory set for minimum deadband Both potentiometers MUST REMAIN at this setting throughout calibration of the alarm setpoint adjustments 4 Adjust ALARM 1 co
95. rk to an integrating U10 is an inverting buffer amplifier that incor analog to digital converter It converts the sig porates an anticipation arrangement in its in nal into an equivalent digital value in the put network thus providing slightly faster range of 0 00 to 99 99 Any value above response on the readout device s 99 99 will be preceded by an over range bit for example 1 1123 Potentiometer R30 provides a continuously variable adjustment of 5 to 25 seconds for the The output of the ADC consists of bi electronic response time 90 of fullscale nary coded decimal characters that are input and is factory set for 20 seconds to the liquid crystal controller and display chip characters sequentially in time The BCD Since the anticipation network attenuates the characters are converted into seven line signal a gain of 10 is provided by the feed codes to drive the bar segments of the liquid back network associated with U10 to restore crystal display the signal to the desired fullscale range of 0 to 10 VDC A separate regulator circuit which operates from the 15 VDC supply provides a regu The output signal from U10 is routed to two lated 5 VDC for the digital functions associ output circuits ated with the display Digital output circuit See Section 5 8 page 5 10 R37 R38 2M 100K C38 TP11 22UF R39 REF 8052A O C31 n ue 1 0uF d DIGITAL R30 DISPL
96. ro optical feedback system A beam of light from the source lamp is reflected off the square mirror attached to the test body and onto the dual photocell The output current from the dual photocell is equal to the difference between the signals developed by the two halves of the photocell This difference which constitutes the error signal is applied to the input of an amplifier circuit that provides the restoring current When the test body is in null position both halves of the photocell are equally illuminated the error signal is zero and the amplifier is unequal This condition results in application of an error signal to the input of the amplifier circuit The resultant amplifier output signal is routed through the current loop thus creating the electromagnetic forces required to restore the test body to null position Additionally the output from the amplifier is conditioned as required to drive the digital display and recorder if used The electronic circuitry involved is described briefly in Sec tion 4 3 page 4 4 and in greater detail in Section 5 Theory 4 1 Instruction Manual 748213 S April 2002 Model 755R 4 2 VARIABLES INFLUENCING PARAMAG NETIC OXYGEN MEASUREMENTS Variables that influence paramagnetic oxygen measurements include operating pressure See Section 4 3a page 4 4 sample tem perature interfering sample components and vibration See Section 2 1d page 2 1 a Pressure Effe
97. rrent actuated device making sure that polarity is correct If two or more current actuated devices are to be used they must be connected in se ries See Figure 2 4 below Do not exceed the maximum load resistance of 1000 ohms Current and voltage outputs may be util ized simultaneously if desired Or mA O 755R Analyzer Note Total series resistance of all devices is not to exceed 1000 ohms Recorder OF Controller O Remote Indicator Figure 2 4 Model 755R Connected to Drive Several Current Actuated Output Devices Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 7 Instruction Manual 748213 S April 2002 Model 755R The alarm output provides two sets of re lay contacts for actuation of alarm and or process control functions Leads from the customer supplied external alarm system connect to terminals on the 654019 Alarm Assembly See Figure 2 5 below and In terconnect Drawing 654014 e Output Connections and Initial Setup for Dual Alarm Option If so ordered the analyzer is factory equipped with alarm output Alternatively the alarm feature is obtainable by subse quent installation of the 654019 Alarm Kit TYPICAL CONNECTIONS Solenoid REQUIREMENT TYPICAL CONNECTIONS REQUIREMENT O N Valve H H O Alarm Bell 115 VAC QD N Q
98. sed during subsequent operation and to maintain this pressure during operation The arrangement re quired to obtain appropriate pressure control will depend on the application When inputting sample or calibration gases use the same pressure that will be used during subsequent operation Refer to Section 2 3c page 2 3 Normal Op eration at Positive Gauge Pressures or Section 2 3d page 2 4 Operation at Negative Gauge Pressures CAUTION HIGH PRESSURE GAS CYLINDERS Pressure surges in excess of 10 psig dur ing admission of sample or standard gases can damage the detector A Division of Emerson Process Management Maximum permissible operating pressure is 10 psig 68 9 kPa To ensure against over pressurization insert a pressure re lief valve into the sample inlet line In ad dition a check valve should be placed in the vent line if the analyzer is connected to a manifold associated with a flare or other outlet that is not at atmospheric pressure If the detector is over pressurized damage will result The analyzer exhaust port is commonly vented directly to the atmosphere Any change in barometric pressure results in a Installation 2 3 Instruction Manual ene Model 755R directly proportional change in the indi cated percentage of oxygen Example Range 0 to 5 O2 Barometric pressure change after calibration 196 Instrument reading 5 Oz Readout error 0 01 x 5 O2 0 05 O2
99. semount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 5 5 DETECTOR LIGHT SOURCE CONTROL CIRCUIT Rosemount Analytical Inc Refer to Figure 5 5 below The detector light source control circuit maintains the light out put from the bulb DS1 as uniform as possi ble regardless of voltage fluctuations or aging of the bulb The power source for the light bulb is a cen ter tapped secondary of transformer T1 This AC voltage is rectified by CR7 and CR8 and filtered C32 presenting an approximate 8 5 V bus to the current limiting Darlington con figuration of Q4 Q4 controls the basic amount of current through DS1 Amplifier AR7 has a fixed value approxi mately 2 2 VDC on terminal 3 The output of ART is positive causing Q4 to conduct As Q4 conducts electrons flow from the center tap of T1 to ground and from ground through DS1 for an input voltage to terminal 2 of ART through R66 to develop a bias on the base of Q5 through Q4 to the 8 5 V bus and back to the secondary As Q5 conducts some of the current going through DS1 is shunted from the main current path and goes through Q5 which acts as a variable feedback resistance goes to the positive output potential of ART As DS1 ages its light emission decreases and its resistance increases The current through DS1 tends to decrease causing a decrease in the voltage drop across DS1 and the input
100. struction Manual 748213 S April 2002 Model 755R 2 2 CALIBRATION GAS REQUIREMENTS WARNING HIGH PRESSURE GAS CYLINDERS Calibration gas cylinders are under pres sure Mishandling of gas cylinders could result in death injury or property damage Handle and store cylinders with extreme caution and in accordance with the manu facturer s instructions Refer to GENERAL PRECAUTIONS FOR HANDLING amp STOR ING HIGH PRESSURE CYLINDERS page P 4 Analyzer calibration consists of establishing a zero calibration point and a span calibration point Zero calibration is performed on the range that will be used during sample analysis In some applications however it may be desir able to perform span calibration on a range of higher sensitivity i e more narrow span and then jumper to the desired operating range For example if the operating range is to be O to 50 oxygen span calibration may be per formed on the 0 to 25 range to permit use of air as the span standard gas Recommendations on calibration gases for various operating ranges are tabulated in Ta ble 3 1 page 3 4 and are explained in Sec tions 2 2a page 2 2 and 2 2b page 2 2 Each standard gas should be supplied from a cylinder equipped with dual stage metal dia phragm type pressure regulator with output pressure adjustable from 0 to 50 psig 0 to 345 kPa Instrument response to most non oxygen sample components is comparatively sli
101. t point The purpose of C36 is to delay the tim ing pulse relative to line frequency so that a pulse arrives at the gate of Triac Q7 as the line potential just passes the zero volt cross over point 0 and 180 of line phase Varistor RV1 is a temperature sensitive re sistance device When case temperature is low such as ambient the value of RV1 is low Applying power at that temperature might cause a current surge to damage Triac Q7 RV1 with its low initial value of resistance acts as a bypass and most of the current is shunted through it As the temperature in creases and approaches the desired case temperature the resistance of RV1 increases to a large value This limits the current through it and gives fine control of the heater to Triac Q7 and the temperature sensing cir cuit Circuit Analysis 5 5 Instruction Manual 748213 S April 2002 Model 755R 5 4 DETECTOR HEATER CONTROL CIRCUIT If the temperature goes down RT1 increases Figure 5 4 below is a simplified heater control circuit drawing for the detector Heaters 1 and 2 are actually connected in parallel and have a combined resistance of about 17 ohms The thermistor resistance RT1 in the resis tance bridge varies inversely with tempera ture The bridge is designed to maintain the temperature of the detector at 150 F 65 5 C The junction point between R55 and R56 is maintained at a specific voltage since these resistances maintain a definit
102. tempera ture the error signal to comparator 4 may Circuit Analysis vary from OmV to some absolute value The polarity of the error signal will depend on the deviation from the desired temperature and the ramp value at the function of R82 and R83 The input from the OR circuit comparator See Figure 5 1 page 5 2 is either 15 VDC or the ramp effect on the bridge When 15V the junction of R82 and R83 is also this value The error signal into comparator 4 is nega tively large to the inverting terminal Com parator 4 output transistor does not conduct The base of Q6 is positive therefore Q6 does not conduct and a charge builds up on ca pacitor C38 The input from the OR comparators 1 and 2 form multivibrator circuit pulses 120 times a second For about 100 microseconds the junction of R82 and R83 is some value be tween 1 85 V and 1 92 V depending on the ramp generator For this brief period of time one pulse comparator 4 compares the po tential of junction R82 R83 with junction RT1 R84 of the bridge circuit If the temperature at RT1 is low the potential at the non inverting terminal of comparator 4 is more negative and the output is 15 V The base of Q6 is zero because of the volt age drops across R79 and R80 Therefore Q6 conducts Energy stored in C38 flows through Q6 as current and capacitor C38 dis charges to zero potential No current flows through the primary winding of transformer At the end of
103. the response to xenon would be The percentage oxygen equivalent of a 1 34 gas is the instrument response to the given gas compared to the response to oxygen assuming that both gases are supplied at the same pressure The oxygen equivalent of a gas mixture is the sum of the contribution of the individ ual gas components Example Zero Based Range At lower range limit i e 0 oxygen composition of sample is 80 CO2 20 N2 From Table 3 1 page 3 4 the oxygen equivalents are CO2 0 623 and N2 0 358 oxygen equivalent of mixture 0 8 x 0 623 0 2 x 0 358 0 4984 0 0716 0 570 Oxygen b Computing Adjusted Settings for Zero and Span Controls During instrument calibration adjusted values may be required in setting the ZERO and SPAN controls to correct for the magnetic susceptibility of the background gas The quantities are defined as follows Operation BGGst Oxygen equivalent of background gas in standard gas see Table 3 2 page 3 6 BGGs Oxygen equivalent of background gas sample see Table 3 2 page 3 6 OP operating pressure Unless special pressure corrections are to be made the zero stan dard span standard and sample gases must all be admitted at the same pressure Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748213 S Model 755R April 2002 Use the following equation to compute the adjusted settings for the ZERO and SPAN contro
104. therwise the pin lead will be forced out when the two con nectors are joined Side View of Connector IIT Lower Slot Va a Y L EER Connector Pin Removed Connector Pin Leads in Place Improvised Pin Removal Tool Such as a Paper Clip Figure 6 2 Pin Lead Removal WHT wur JO RTI BLK HR2 BLK Suspension Heater PUR Suspension GRN Terminals 10 18 ddooddddo J142 000000000 1 When dual photocell is installed the gap between the two photocells should be in position IN indicated by this line 1 s O Hole for Source Lamp Optical Bench Figure 6 3 Detector Optical Bench 6 4 Maintenance and Service Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 Source Lamp The simplest check of the source lamp is to verify that it is lit Another check is done by removing the housing cover and viewing the lamp through the photocell alignment hole see Figure 6 3 page 6 4 If the photocell is not illuminated test the voltage across TP2 to TP5 ground This voltage should be 2 2 V 0 2 VDC If reading is correct the lamp may be burned out also inspect the cable for continuity If voltage reading is not 2 2 V 0 2 VDC the Power Supply Board must be replaced Photocell If the photocells are on observe through the photocell alignment hole The image
105. uits operate on main power trans former T1 During instrument assembly the two primary windings of T1 are fac tory connected for operation on either 115 VAC or 230 VAC as noted on the name rating plate The same circuit board contains the fol lowing Source Lamp Power Supply Section This circuit provides a regulated output of 2 20 VDC to operate incandescent source lamp DS1 within the optical bench as sembly One secondary of main power transformer T1 drives a fullwave rectifier consisting of CR7 and CR8 The output of DS1 is held constant by a voltage regu lator circuit utilizing U7 Q4 and Q5 Theory 4 5 Instruction Manual 748213 S April 2002 Model 755R 4 6 15 V Power Supply Section This section provides DC voltage required for various amplifiers and other circuits Fullwave rectifier bridge CR5 provides both positive and negative outputs Each is routed through an associated series type integrated circuit voltage regulator providing regulated outputs of 15 V and 15 V Detector Temperature Control Section This section maintains the detector at a controlled temperature of 150 F 66 C Temperature is sensed by RT1 a resis tance element permanently attached to the detector assembly The signal from the sensor is applied to amplifier AR6 which drives transistors Q2 and Q3 thus controlling application of DC power from full wave rectifier bridge CR6 to two heat ers within the detector magnet
106. wire source of power Optional alarm switching relay contacts wired to separate power sources must be disconnected before servicing WARNING PARTS INTEGRITY Tampering or unauthorized substitution of components may adversely affect safety of this product Use only factory docu mented components for repair Rosemount Analytical Inc INITIAL CHECKOUT WITH STANDARD GASES If instrument readings do not meet specifica tions the first step in troubleshooting is to isolate the analyzer from the sample stream and the sample handling system Admit zero and span standard gases to the analyzer Observe readout on digital display and on recorder if used A Division of Emerson Process Management Digital display gives correct reading with standard gases but not with sample gas The sample and the sample handling system are suspect Check these areas Digital display gives correct readings with standard gases but the alarm or output devices do not Check these devices individually Digital display gives overrange readings with standard gases as well as sample gas The problem is likely with detector or the electronic circuitry Turn power OFF Tap detector compartment with fingers wait 30 seconds reapply power If the suspension within the detector assembly is hung up this may correct the problem If not proceed with checks of the detector and electronic circuitry Digital display gives erratic readi
107. witch ranges Remember that you are dealing with inverse logic and not normal binary addresses Also this process switches the recorder output only and does not affect the front panel dis play J3 4 J3 3 J3 2 J3 1 Hex Range 1 1 1 1 0 E Range 2 1 1 0 1 D Range 3 1 0 1 1 B Range 4 0 1 1 1 7 Note 1 12V 0 lt lt 1 V Table 2 1 Remote Range Switching Truth Table 2 12 Installation Rosemount Analytical Inc A Division of Emerson Process Management Model 755R Instruction Manual 748213 S April 2002 SECTION 3 OPERATION 3 1 OVERVIEW Preparatory to operation a familiarization with Figure 3 1 page 3 3 is recom mended This figure gives locations and summarized descriptions of operating ad justments of the Model 755R Oxygen Ana lyzer 3 2 OPERATING RANGE SELECTION The Model 755R is designed to operate on a single field selectable range A new range may be selected any time the ana lyzer application changes or any time cali bration may require a range change To select the operating range reposition the jumper shown in Figure 3 1 page 3 3 to the desired location Each position is la beled as to its fullscale range Only the analog output voltage and optional current is affected by range selection The digital display always reads 100 oxygen 3 3 STARTUP PROCEDURE Inject a suitable on scale gas not actual sample through the analyzer Turn power ON If digit

Emerson Process Management 755R Oxygen Equipment User Manual

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