7866 Triple Range Digital H2 and CO2 Analyzer/Indicator and Gas Sampling Panel Operation and Maintenance Manual 70-82-25-110 9/06 Industrial Measurement and Control Copyright, Notices, and Trademarks Printed in U.S.A. – © Copyright 2006 by Honeywell Revision D – Sept. 2006 WARRANTY/REMEDY Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact your local sales office for warranty information. If warranted goods are returned to Honeywell during the period of coverage, Honeywell will repair or replace without charge those items it finds defective. The foregoing is Buyer's sole remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a particular purpose. Specifications may change without notice. The information we supply is believed to be accurate and reliable as of this printing. However, we assume no responsibility for its use. While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the customer to determine the suitability of the product in the application. CE Conformity (Europe) This product is in conformity with the protection requirements of the following European Council Directives: 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC Directive. Conformity of this product with any other “CE Mark” Directive(s) shall not be assumed. Attention The emission limits of EN 50081-2 are designed to provide reasonable protection against harmful interference when this equipment is operated in an industrial environment. Operation of this equipment in a residential area may cause harmful interference. This equipment generates, uses, and can radiate radio frequency energy and may cause interference to radio and television reception when the equipment is used closer than 30 meters to the antenna(e). In special cases, when highly susceptible apparatus is used in close proximity, the user may have to employ additional mitigating measures to further reduce the electromagnetic emissions of this equipment. Honeywell Industrial Measurement and Control 1100 Virginia Drive Fort Washington, PA 19034 ii 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 About This Document Abstract This manual describes the installation and operation of the 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator and Gas Sampling Panel and its digital controller. Contacts World Wide Web The following lists Honeywell’s World Wide Web sites that will be of interest to our customers. Honeywell Organization WWW Address (URL) Corporate http://www.honeywell.com Industrial Measurement and Control http://www.honeywell.com/imc Telephone Contact us by telephone at the numbers listed below. Organization United States and Canada 9/06 Honeywell Phone Number 1-800-423-9883 1-800-525-7439 Tech. Support Service 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance iii INSTRUCTIONS (European ATEX Directive 94/9/EC, Annex II, 1.0.6) The following instructions apply to equipment covered by certificate number Sira 05ATEX1249X. 1. The equipment may be used with flammable gases and vapours with apparatus groups IIC with temperature class T6. 2. The equipment is only certified for use in ambient temperatures in the range -10ºC to +50ºC and should not be used outside this range. 3. Installation shall be carried out by suitably trained personnel in accordance with the applicable code of practice, e.g. EN 60074-14:1997. 4. Inspection and maintenance of this equipment shall be carried out by suitably trained personnel in accordance with the applicable code of practice, e.g. EN 60097-17. 5. Repair of this equipment shall be carried out by suitably trained personnel in accordance with the applicable code of practice, e.g. EN 60079-19. 6. See Section 3 of this manual for installation instructions. See Section 4 of this manual for set up instructions. See Section 5 of this manual for calibration instructions. 7. Components to be incorporated into or used as replacement parts of the equipment shall be fitted by suitably trained personnel in accordance with the manufacturer’s documentation. 8. The certification of this equipment relies upon the following material used in its construction: Aluminum Alloy 356 If the equipment is likely to come into contact with aggressive substances, then it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected, thus ensuring that the type of protection provided by the equipment is not compromised. Aggressive substances: Acidic liquids or gases that may attack metals, or solvents that may affect polymeric materials. (All gases specified by Honeywell for use in this equipment are non-corrosive and non-reactive). Suitable precautions: Regular checks as part of routine inspections or establishing from the material data sheets that it is resistant to specific chemicals. 9. A copy of the certification marking can be found on page v of this manual and Honeywell drawing 51452210. 10. Detailed specifications for electrical, environmental and sample gas requirements for this product can be found in Section 2 of this manual. Special Conditions for Safe Use The 7866 Thermal Conductivity Gas Analyzers shall not be used in carbon disulphide gas. The 7866 Thermal Conductivity Gas Analyzers shall not be used to analyze gas samples with an oxygen concentration higher that 21%. The 7866 Thermal Conductivity Gas Analyzers shall not be used to analyze explosive gas mixtures. The 7866 Thermal Conductivity Gas Analyzers shall only be used to analyze gas samples at pressures up to 2 lbf/in2 (13.8 Kpa). iv 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Copy of the certification marking 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance v Symbol Definitions The following table lists those symbols that may be used in this document to denote certain conditions. Symbol Definition This DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. This WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. This CAUTION symbol may be present on Control Product instrumentation and literature. If present on a product, the user must consult the appropriate part of the accompanying product literature for more information. This CAUTION symbol indicates a potentially hazardous situation, which, if not avoided, may result in property damage. WARNING PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms, 42.4 Vpeak, or 60 Vdc may be accessible. Failure to comply with these instructions could result in death or serious injury. ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for handling electrostatic sensitive devices Protective Earth (PE) terminal. Provided for connection of the protective earth (green or green/yellow) supply system conductor. Functional earth terminal. Used for non-safety purposes such as noise immunity improvement. NOTE: This connection shall be bonded to protective earth at the source of supply in accordance with national local electrical code requirements. Earth Ground. Functional earth connection. NOTE: This connection shall be bonded to Protective earth at the source of supply in accordance with national and local electrical code requirements. Chassis Ground. Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements. vi 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Contents 1. INTRODUCTION ................................................................................................... 1 1.1 Overview ........................................................................................................................................ 1 1.2 Sensing Unit ................................................................................................................................... 2 1.3 7866 Digital Controller .................................................................................................................. 4 1.4 Principles of Operation................................................................................................................... 7 1.5 Process Instrument Explorer Software ........................................................................................... 8 1.6 CE Conformity (Europe) .............................................................................................................. 10 2. SPECIFICATIONS AND MODEL SELECTION GUIDE ...................................... 11 2.1 Specifications ............................................................................................................................... 11 2.2 Model Selection Guide ................................................................................................................. 15 3. INSTALLATION .................................................................................................. 19 3.1 Overview ...................................................................................................................................... 19 3.2 Sensing Unit Requirements and Location .................................................................................... 19 3.3 Mounting the Sensing Unit........................................................................................................... 20 3.4 Piping or Tubing Connections...................................................................................................... 20 3.5 Mounting the 7866 Digital Controller/Indicator .......................................................................... 23 3.6 Electrical Considerations.............................................................................................................. 26 3.7 Wiring Between Sensing Unit, Controller, and Indicator ............................................................ 27 3.8 Checklist....................................................................................................................................... 32 4. SET UP MODE.................................................................................................... 33 4.1 Overview ...................................................................................................................................... 33 4.2 Configuration Tips ....................................................................................................................... 33 4.3 Unit Set Up Group........................................................................................................................ 34 4.4 Alarms Set Up Group ................................................................................................................... 36 4.5 Communications Set Up Group.................................................................................................... 36 4.6 Calibration Group......................................................................................................................... 39 4.7 Status Group ................................................................................................................................. 39 4.8 P.I.E. Tool Ethernet and Email Configuration Screens................................................................ 39 4.9 Configuring your Ethernet Connection ........................................................................................ 42 4.9.1 Connecting to the Controller via Infrared Communications ............................................. 42 4.9.2 Connecting to the Controller via Ethernet Communications............................................. 44 5. 9/06 CALIBRATION.................................................................................................... 47 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance vii 5.1 Overview ...................................................................................................................................... 47 5.2 Sensing Unit Calibration Warning ............................................................................................... 47 5.3 7866 Analyzer Input Calibration .................................................................................................. 48 5.4 7866 Remote Indicator Input Calibration..................................................................................... 51 5.5 Restoring Factory-set Input Calibration ....................................................................................... 52 5.6 Output Calibration ........................................................................................................................ 53 5.7 Security Lockout .......................................................................................................................... 54 5.8 Setting the Alarm Limits .............................................................................................................. 56 6. OPERATION ....................................................................................................... 59 6.1 Overview ...................................................................................................................................... 59 6.2 Operating Notes............................................................................................................................ 59 6.3 Operation ...................................................................................................................................... 59 7. MAINTENANCE .................................................................................................. 61 7.1 Routine Maintenance.................................................................................................................... 61 7.2 Parts Replacement ........................................................................................................................ 61 7.2.1 Sensing Unit ...................................................................................................................... 61 7.3 Repacking..................................................................................................................................... 64 7.4 Spare Parts.................................................................................................................................... 65 8. TROUBLESHOOTING ........................................................................................ 67 8.1 Overview ...................................................................................................................................... 67 8.2 Troubleshooting............................................................................................................................ 67 8.2.1 General .............................................................................................................................. 67 8.2.2 Recalibration...................................................................................................................... 67 8.2.3 Fault Isolation Tests........................................................................................................... 69 8.2.4 Additional Troubleshooting............................................................................................... 73 9. APPENDIX A – 7872 GAS SAMPLING PANEL ................................................. 75 9.1 Overview ...................................................................................................................................... 75 9.2 Model Selection Guide ................................................................................................................. 75 9.3 Installation .................................................................................................................................... 76 9.4 Maintenance ................................................................................................................................. 78 10. APPENDIX B – SECURITY BYPASS ................................................................. 79 10.1 11. viii Overview................................................................................................................................... 79 SALES AND SERVICE ....................................................................................... 81 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Tables Table 1-1 Function of Keys ......................................................................................................................... 5 Table 1-2 Relative Thermal Conductivity of Common Gases..................................................................... 7 Table 3-1 Mounting Procedure ................................................................................................................... 25 Table 3-2 Permissible Wiring Bundling .................................................................................................... 27 Table 3-3 Terminals for connecting a UDC to a MDI Compliant Hub or Switch utilizing a cross-over cable..................................................................................................................................................... 31 Table 3-4 Terminals for connecting a UDC directly to a PC utilizing a straight-through cable................. 31 Table 4-1 Configuration Tips..................................................................................................................... 33 Table 4-2 Controller Unit Group Function Prompts.................................................................................. 34 Table 4-3 Indicator Unit Group Function Prompts.................................................................................... 35 Table 4-4 Alarms Group Function Prompts............................................................................................... 36 Table 4-5 Communications Group Function Prompts ............................................................................... 36 Parameter Definition .................................................................................................................................. 36 Table 4-6 Status Group Function Prompts................................................................................................. 39 Table 5-1 Input Calibration for Range 1.................................................................................................... 48 Table 5-2 Input Calibration for Range 2.................................................................................................... 49 Table 5-3 Input Calibration for Range 3.................................................................................................... 50 Table 5-4 PV Input Calibration.................................................................................................................. 51 Table 5-5 Restoring Analyzer’s Factory-set Input Calibration Values...................................................... 52 Table 5-6 Restoring Indicator’s Factory-set Input Calibration Values...................................................... 52 Table 5-7 Output Calibration Procedure.................................................................................................... 53 Table 5-8 Entering the Security Code........................................................................................................ 54 Table 5-9 Changing Security Level ........................................................................................................... 55 Table 5-10 Alarm Adjustment Procedure .................................................................................................. 57 Table 7-1 Sensing Unit Cell Assembly Cable Connections....................................................................... 63 Table 7-2 Recommended Spare Parts ........................................................................................................ 65 Table 8-1 Coarse Zero Adjustment............................................................................................................ 68 Table 8-2 Binary Count Sequence for Coarse Zero Jumper Pattern .......................................................... 68 Table 8-3 Coarse-Zero Jumper Pattern ...................................................................................................... 69 Table 8-4 Troubleshooting Procedures ...................................................................................................... 70 Table 9-1 Replaceable Parts for 7872 Gas Sampling Panel....................................................................... 78 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance ix Figures Figure 1-1 Digital 7866 Analyzer ................................................................................................................ 1 Figure 1-2 Sensing Unit, Showing Removal of Entire Sensing Assembly.................................................. 3 Figure 1-3 7866 Digital Controller, Front View .......................................................................................... 5 Figure 1-4 Triple-Range Hydrogen and Carbon Dioxide Analyzer Controller and Display Logic Chart... 6 Figure 1-5 Screen capture of Process Instrument Explorer running on a Pocket PC................................... 8 Figure 1-6 Depiction of infrared communications........................................................................................ 9 Figure 3-1 Outline and Mounting Dimensions for Sensing Unit............................................................... 22 Figure 3-2 Mounting Dimensions (not to scale) ........................................................................................ 24 Figure 3-3 Mounting Methods .................................................................................................................... 25 Figure 3-4 Mains Power Supply ................................................................................................................ 28 Figure 3-5 Interconnections Between Sensing Unit, Controller, and Indicator ......................................... 29 Figure 3-6 RS-422/485 Communications Option Connections .................................................................. 30 Figure 3-7 Ethernet Communications Option with Adaptor Board ............................................................ 30 Figure 3-8 Ethernet Communications Option without Adaptor Board ....................................................... 31 Figure 4-1 Ethernet Configuration Screen ................................................................................................. 40 Figure 4-2 Email Configuration Screen ..................................................................................................... 41 Figure 4-3 IR Communications Address ................................................................................................... 42 Figure 4-4 Configuration Upload in Progress............................................................................................ 43 Figure 4-5 Ethernet Communications Address .......................................................................................... 45 Figure 4-6 Configuration Upload in Progress............................................................................................ 46 Figure 7-1 Sensing Unit Mother and Daughter Circuit Cards Parts List ................................................... 62 Figure 7-2 Gas Inlet and Outlet Fitting Parts............................................................................................. 64 Figure 9-1 7872 Gas Sampling Panel Mounting Dimensions.................................................................... 77 Figure 9-2 7872 Gas Sampling Panel Exploded View .............................................................................. 78 x 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Introduction 1. Introduction 1.1 Overview The Triple-Range Digital H2 and CO2 Analyzer/Indicator provides three ranges of measurement: • Range 1: CO2 in Air • Range 2: H2 in CO2 • Range 3: H2 in Air – See Table 5-3 The analyzer consists of three basic components: the sensing unit (transmitter), the control unit (receiver)—both shown in Figure 1-1—and a power supply. The sensing unit is located at the sampling site; the 7866 Digital Controller is arranged for panel mounting in a non-hazardous area. The sensing unit receives a continuous flow of the binary or multi-component gas mixture, measures the concentration of the sample gas and transmits an electrical signal to the control unit. The sensing unit is ruggedly constructed to meet most environmental conditions and is designed to be mounted up to 1,000 feet from the control unit with only a single multi-conductor non-shielded cable connecting the two, resulting in greater flexibility and lower installation costs. Figure 1-1 Digital 7866 Analyzer The control unit receives the output signal from the sensing unit at the sampling site by way of the interconnecting cable. The control unit is designed for simplified panel-mounting either at the sampling site if environmental conditions permit, or in a control room. The unit can provide two current output signals to a remote device for monitoring or recording purposes. The control unit is supplied with one or two alarms. When an alarm is detected, the specific relay de-energizes creating an open circuit that can activate an external annunciator or a relay to initiate a shutdown procedure for the process. When power is off the alarm relay is de-energized. An indicator model, which provides a continuous readout of the concentration of the gas under analysis, is also available. The indicator input is connected to the controller's current output. The indicator has no direct connection to the sensing unit. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 1 Introduction 1.2 Sensing Unit The 7866 Thermal Conductivity analyzer’s Sensor Assembly is supplied in an explosion proof housing. The housing consists of a rugged cast aluminum construction that permits reliable operation under adverse ambient conditions. The Sensor Assembly consists of two sections—the cell block assembly and the electronic assembly (Figure 1-2). The Cell Block assembly is constructed of stainless steel with two identical internal cells, the measuring cell and the reference cell. The highly stable thermistor is mounted in each cell. These matched thermistors form the active arms of a bridge circuit; the unbalanced current of the bridge provides the means of measuring the relative ability of the sample and reference gases to conduct the heat away from their respective thermistors to the cell wall, which is held at a constant temperature. The cells in which the thermistors are mounted are dead-ended so the sample gas enters only by diffusion, minimizing the effect of sample flow variations. In addition, the entire cell-block assembly is maintained at a constant optimum temperature through two heaters and a control thermistor that are located in the cell block assembly. The Sensing Unit’s electronics assembly incorporates solid state electrical circuits. These circuits include: • Current Regulator: supplies the constant current to the thermistor cell bridge circuit • Proportional Action Temperature Controller: maintains the entire cell block at a constant temperature • Voltage to Current Converter/Amplifier: its current output is transmitted to the analyzer’s control unit 2 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Introduction Rugged threaded cover seals on gasketed housing Stainless steel handle facilitates removal of sensor assembly Cell-block electronics assembly 12 13 14 9 Stainless steel cell-block assembly Inlet and outlet ports to measuring and reference cells Rugged, general purpose waterproof anddustproof cast-aluminum housing Inlet and outlet ports for sample gas Figure 1-2 Sensing Unit, Showing Removal of Entire Sensing Assembly 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 3 Introduction 1.3 7866 Digital Controller The 7866 Digital Controller shown in Figure 1-3 can provide a current output, a digital display of the measured gas percentage, and up to two alarm circuits. The alarm limits are set using the integral keyboard on the face of the instrument. The SETPOINT SELECT key is used to select the appropriate range. A second current output is available and will supply a value for the selected range data that can be retransmitted to a remote indicator. The unit also provides access to the calibration settings for each range. The zero and span settings are entered using the group prompt CALIB, function prompt RANGE n (n = 1, 2, or 3). Zero and span are "live" readings until the FUNCTION key is pressed, at which time that displayed value is captured. The increment/decrement keys can then be used to change the desired value. These values are normally secured from inadvertent or unauthorized tampering using a four-digit security code. If alarms are in use, the 7866 Digital Controller displays the alarm status. The alarms are listed by number next to the ALM annunciator on the left side of the display. If the Alarm is in force, the number “1” or “2 “ will be lit indicating the respective alarm and process violation. These alarms will de-energize output relays that the user may hardwire to annunciation circuits or to a safety shutdown system depending on the application. Alarm limits are adjusted through the group prompt SETUP, function prompt ALARMS. The security feature can also secure alarm limits. Normal power losses, even over extended time periods, will not affect the configuration of the controller. The controller uses a nonvolatile memory system to secure the controller’s current configuration and calibration settings. This will prevent any loss during outages. The factory calibration constants that can be used with the controller are stored in its nonvolatile memory. If a field calibration is lost, you can quickly restore the "factory calibration" and overwrite any previous field calibration. Protection after calibration is available through the LOCKOUT feature. The controller’s circuit boards are accessible for service and replacement. The modular design permits selective replacement of circuits as required. The removable chassis eliminates the need to remove or change any field wiring for a circuit board or controller change. The rear of the controller has three terminal strips for field wire termination. All field terminations are accessible from the rear of the controller. Stranded wire of 20 to 22 gauge is recommended. See wiring section for more specific instructions. The 7866 Digital Controller features a universal power supply that can be connected to line voltages of 90 Vac to 264 Vac or 24 Vac/dc. The line frequency can be 50 hertz or 60 hertz. Power for the 7866 Sensing Unit is supplied by a separate 30 Volt dc power supply. This power supply is also utilized by the controller to power its interconnections with the sensing unit. 4 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Introduction Upper display – 7 characters ALM 1 or 2 indicated for Range 3 only No other annunciators are used Normal operation – 4 digit process variable w/adjustable decimal point Configuration mode – parameter values or selection Lower display – 8 characters Normal operation – RANGE x (x = 1, 2, 3) or the gas being measured Configuration mode – Group or function prompt Figure 1-3 7866 Digital Controller, Front View Table 1-1 Function of Keys Key Function Setup Func Loop 1/2 SP Select Lower Display • Places the controller in the Configuration Set Up group select mode. Sequentially displays Set Up groups and allows the FUNC key to display individual functions in each Set Up group. • Used in conjunction with the SETUP key to select the individual functions of a selected Configuration Set Up group. • Pressing this key saves, into nonvolatile memory, any changes made to previous function value or selection. • Used during field calibration procedure. • Configuration Mode: Used to scroll through the parameter selections or to increase the selected parameter value.* • Configuration Mode: Used to scroll through the parameter selections or to decrease the selected parameter value.* * Changing Values Quickly: When changing the value of a parameter, you can adjust a more significant digit in the upper display by holding in one key or , and pressing the other or at the same time. The adjustment will move one digit to the left. Press the key again and you will move one more digit to the left. Holding the or keys down will change the value twice as quickly. • Normal Operation: Used to toggle what is shown in the lower display—either the Range being measured or its corresponding Gas. • Normal Operation: Used to scroll through the lower display selections: • If Range was selected (by pressing SP SELECT), selections are RANGE 1, RANGE 2, or RANGE 3. • If Gas was selected (by pressing SP SELECT), selections are CO2inAIR, H2in CO2, H2in AIR (corresponding to Range 1, Range 2, and Range 3 respectively). Man Auto • Unused keys • KEY ERR message will appear in lower display if one of these keys is pressed. Run Hold 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 5 Introduction Lower Display Microampere Signal from Sensor RANGE x = Select Range 1, 2, or 3 OR Gas being measured Upper Display Selected Range 0 -100% Select Range Zero and Span Limits R1 ZERO = Range 1 Zero 0% CO 2 (100% Air) Range 1 = % Carbon Dioxide vs. Air R1 SPAN = Range 1 Span 100% CO 2 (0% Air) R2 ZERO = Range 2 Zero 0% H 2 (100% CO2) Range 2 = vs. CO2 % Hydrogen vs R2 SPAN = Range 2 Span 100% H 2 (0% CO2) R3 ZERO = Range 3 Zero 100% H 2 (0% N2) Range 3 = % Hydrogen vs. Air R3 SPAN = Range 3 Span 75% H 2 (25% N2) Carbon Dioxide Purge 1 Out put Signal 0/4-20mA Hydrogen Fill 2 Range 3 Alarms Hydrogen Monitor 3 Low 98.0 Alarm 1 Low-Low 90.0 Alarm 2 Figure 1-4 Triple-Range Hydrogen and Carbon Dioxide Analyzer Controller and Display Logic Chart 6 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Introduction 1.4 Principles of Operation Thermal Conductivity Principles Although basic thermal conductivity principles need not be included here, it may be appropriate to consider the following expressions. Thermal Conductivity of Gas The thermal-conductivity of a gas mixture is approximately the sum of the products of the mole fractions of each gas mixture. Therefore, using the letter K to represent thermal conductivity, a gas mixture of 15 % CO2 in air can be defined by the following expression: Kmix = 0.85 Kair + 0.15K CO2 Thermal Conductivity of Air Expressing thermal conductivities in air can be defined by the following expression: Kair is 1.00 and KCO2 is 0.704. Therefore Kmix = 0.85 x 1 + 0.15 x 0.704 = 0.91. Temperature Difference Using a thermistor as the detector in a sample gas and another thermistor in the reference gas, the difference in temperature of these two detectors can be estimated when the thermal conductivities of the gas mixture of the sample gas and reference gas are known. This temperature difference can be expressed as follows: t = Kref – Kmix x (t1–t2) Kmix Where t1 is the reference thermistor temperature and t2 is the cell-block temperature. The above expression applies only when the measuring and reference thermistors are heated to at least 120 °C, which is the minimum temperature for which these thermistors will linearly sense thermal conductivity changes. It applies when current input is constant and the heat losses are by thermal conductivity only. Common Gases Table 1-2 lists the common gases which can be measured by this method or can be present as components in the background gas of the mixture being measured. All thermal conductivities are referred to air at 120 °C. Table 1-2 Relative Thermal Conductivity of Common Gases Component 9/06 Thermal Conductivity (K) Component Thermal Conductivity (K) Air 1.000 Cl2 0.342 O2 1.028 SO2 0.350 NH3 1.040 H2S 0.540 CH4 1.450 Ar 0.665 He 5.530 CO2 0.704 H2 6.803 H2O 0.771 CO 0.958 N2 0.989 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 7 Introduction 1.5 Process Instrument Explorer Software Overview Process Instrument Explorer (P.I.E.) lets you configure your instrument on a desktop/laptop or Pocket PC. For details see Process Instrument Explorer Manual #51-52-25-131. See included CD for P.I.E. software. Features • Create configurations with intuitive software program running on a Pocket PC, a Desktop or a laptop computer. • Create/edit configurations live, just connect software to the controller via a communications port. • Create/edit configurations offline and download to controller later via a communications port. • Communication types available on every 7866: o Infrared (optional) o RS 485 (optional) o Ethernet (optional) • Same port types on UDC controllers allow interconnectivity. • This software is available in English, Spanish, Italian, German and French. Figure 1-5 Screen capture of Process Instrument Explorer running on a Pocket PC Infrared communications The infrared connection provides a non-intrusive wireless connection with the instrument and maintains NEMA4X AND IP66 integrity. No need to get access to the back of the controller to communicate with the instrument, no need to take your screw driver to wire the communication cable, no wiring mistake possible. You can now duplicate an 8 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Introduction instrument’s configuration, upload or download a new configuration in a matter of seconds, just by pointing your Pocket PC in the direction of the instrument. It takes just a few seconds to upload a configuration from an instrument. You can then save the configuration file onto your PC or pocket PC for review, modification or archiving. Furthermore, this software also gives you important maintenance information on the controller: instantly, get information on the current operating parameters, digital inputs and alarm status, identify internal or analog input problems. Question: What if I have several controllers on the same panel? How can I be sure I am communicating with the correct one? Answer: The infrared port of the controller is normally “off”. You activate the infrared port by pressing any controller’s key. You can now communicate. After 4 minutes, the port will be shut down again. Each controller may also be assigned a different communications address. Figure 1-6 Depiction of infrared communications 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9 Introduction 1.6 CE Conformity (Europe) This product is in conformity with the protection requirements of the following European Council Directives: 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC Directive. Conformity of this product with any other “CE Mark” Directive(s) shall not be assumed. Product Classification: Class I: Permanently connected, panel-mounted Industrial Control Equipment with protective earthing (grounding) (EN61010-1). Enclosure Rating: This controller must be panel-mounted with the rear terminals enclosed within the panel. The front panel of the controller is rated at NEMA4X and IP66 when properly installed. Installation Category (Overvoltage Category): Category II (EN61010-1) Pollution Degree: Pollution Degree 2: Normally non-conductive pollution with occasional conductivity caused by condensation. (Ref. IEC 664-1) EMC Classification: Group 1, Class A, ISM Equipment (EN61326, emissions), Industrial Equipment (EN61326, immunity) Method of EMC Assessment: Technical File (TF) Declaration of Conformity: 51453681 Deviation from the installation conditions specified in this manual, and the special conditions for CE conformity in section 3.6, may invalidate this product’s conformity with the Low Voltage and EMC Directives. ATTENTION The emission limits of EN61326 are designed to provide reasonable protection against harmful interference when this equipment is operated in an industrial environment. Operation of this equipment in a residential area may cause harmful interference. This equipment generates, uses, and can radiate radio frequency energy and may cause interference to radio and television reception when the equipment is used closer than 30 meters (98 feet) to the antenna(e). In special cases, when highly susceptible apparatus is used in close proximity, the user may have to employ additional mitigating measures to further reduce the electromagnetic emissions of this equipment. WARNING If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. 10 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Specifications and Model Selection Guide 2. Specifications and Model Selection Guide 2.1 Specifications Performance Accuracy ± 2 % of span (output signal) at reference conditions for binary gas mixtures Linearity Within ± 2 % of span for most standard ranges. If linearity exceeds ± 2 % a correction curve is supplied with the analyzer. Meter Accuracy: Digital Indication: Repeatability Short term: ± 0.3 % of span Reproducibility 24 hour: ± 1 % of span Response Time Maximum, for 4 cfh (2000 cc/min.) flow: For H2; initial, less than 1 second; 63 %: 13 seconds 90 %: 23 seconds 99 %: 40 seconds ± 2 % of span ± 0.1 % For CO2; Initial, less than 2 seconds; 63 %: 24 seconds 90 %: 45 seconds 99 %: 80 seconds Maximum Drift Zero: ± 2 % of span per week maximum Span: ± 2 % of span per week maximum Ambient Temperature Influence At sensing unit: Depends on range; typically less than 1 % F.S. over entire temperature range Atmospheric Pressure Influence ± 0.01 % of span per inch H2O (± 0.05 % of span per mm Hg) Sample Flow Rate Influence Less than ± 0.5 % of span over flow range of 0.2 to 4 cfh (100 to 2000 cc/min) Line Voltage Influence Maximum 0.02 % of span for each 1 % change of line voltage Operating Measuring Range Triple Range Analyzer Three ranges—Range 1 measures CO2 in Air, Range 2 measures H2 in CO2, and Range 3 measures H2 in Air Single Range Analyzer One range, as specified. For standard ranges, see Selection Guide Table in the Model Selection Guide. Explosion Proof Applications When measuring flammable gas mixture that contains oxygen, the maximum oxygen concentration must not exceed 21%. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 11 Specifications and Model Selection Guide Output Ranges 0-20 mA maximum load: 800 ohm 4-20 mA maximum load: 800 ohm 0/4-20 mA Output Triple Range Analyzer Range 1: 0 to 100 % CO2 in Air Range 2: 0 to 100 % H2 in CO2 Range 3: 0 to 100 % H2 in Air Single Range Analyzer 0/4 mA at low range limit 20 mA at high range limit Alarm Outputs One or two alarms are available; each uses an SPDT electromechanical relay. Alarm Relay Contacts Rating Resistive Load: 5 amps @ 24 Vdc or 120 Vac or 240 Vac Inductive Load: 50 VA Outputs Single Range: Two relay outputs for Alarm 1 and Alarm 2 One current output to transmit PV information Triple Range: Two relay outputs for Alarm 1 and Alarm 2 Two current outputs to transmit PV and range information Remote Indicator: Two relay outputs for Alarm 1 and Alarm 2 Sample Requirements Sample Temperature: –10 °C to +50 °C (14 °F to 122 °F) Sample Flow: 0.2 to 4.2 cfh (100 cc/min to 2000 cc/min) Sample Pressure: 37 mm Hg (20” H2O) minimum (with filter and flowmeter) Sensor outlets must vent to atmospheric pressure. Reference Gas Requirements Triple Range Analyzer The triple range H2 and CO2 analyzer requires flowing air as the reference gas, 0.02 – 0.2cfh (10 – 100cc/min), 2 psig (13.79kPA) max. Sensor outlets must vent to atmospheric pressure. Single Range Analyzer None required, except for ranges: 080000, 095000, 098000, 506000, and 516000; these require pure hydrogen reference gas flow 103000 and 510000; these require air reference flow Gas Flow Rate: 0.02-0.2 cfh (10-100 cc/min), 2 psig (13.79kPA) max. Sensor outlets must vent to atmospheric pressure. Ambient Requirements Relative Humidity: Temperature Range: Storage Temperature: Power Requirements Control Unit only: Universal supply 90 Vac to 264 Vac (consumption 18 VA maximum) or 24 Vac/dc (consumption 12 VA maximum); 50 Hz to 60 Hz Materials Contacting Sample Gas Sample contacts 316 stainless steel, Buna N, Teflon, glass and Viton Connections Sample inlet and outlet: 1/4” OD tubing (compression fittings supplied) Reference gas inlet and outlet: 1/4” OD tubing (compression fittings supplied) Electrical power inlet: Opening for 1/2” conduit (control unit only) Sensing unit power inlet (24 Vdc from control unit): 1/2” NPT (female conduit) 12 90 % maximum –10 °C to +50 °C (14 °F to 122 °F) 70 °C maximum (158 °F) 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Specifications and Model Selection Guide Communications: RS422/485 Modbus RTU Communications Interface (Optional) Baud Rate: 4800, 9600,19,200 or 38,400 baud selectable Data Format: Floating point or integer Length of Link: 2000 ft (600 m) max. with Belden 9271 Twinax Cable and 120 ohm termination resistors 4000 ft. (1200 m) max. with Belden 8227 Twinax Cable and 100 ohm termination resistors Link Characteristics: Two-wire (half-duplex), multi-drop Modbus RTU protocol, 15 drops maximum or up to 31 drops for shorter link length. Ethernet TCP/IP Communications Interface (Optional) Type: 10Base-T Length of Link: 330 ft. (100 m) maximum. Use Shielded twisted-pair, Category 5 (STP CAT5) Ethernet cable. Link Characteristics: Four-wire plus shield, single drop, five hops maximum IP Address: IP Address is 10.0.0.2 as shipped from the Factory Recommended network configuration: Use Switch rather than Hub in order to maximize UDC Ethernet performance Configuration: Ethernet parameters are configured via the Process Instrument Explorer. Email: The capacity to send two Emails is provided. These must be configured via the Process Instrument Explorer. It is recommended that the Real Time Clock option be purchased for any instrument that needs to send Email. Ethernet Communications is mutually exclusive with the Second Current Output. Infrared Communications (Standard) Type: Serial Infrared (SIR) Length of Link: 3 ft. (1 m) maximum for IrDA 1.0 compliant devices Baud Rate: 19,200 or 38,400 baud selectable 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 13 Specifications and Model Selection Guide Physical Specifications Sensing Unit: Weight: Dimensions: 8.5 kg (18-3/4 lb.) Approximately 150 mm x 150 mm x 325 mm (6 in. x 6 in. x 12-3/4 in.) Control Unit: Weight: Dimensions: Standards – Sensing Unit 1.3 kg (3 lb.) Bezel: 96 mm H x 96 mm W (3.78” H x 3.78” W) Case: 92 mm H x 92 mm W x 192 mm D (3.62” H x 3.62” W x 7.55” D) FM*: Class 1, Div. 1, Groups A,B,C,D Class II, Div. 1, Groups E,F,G Class III, Div.1 T6 @ TA = 50°C; Enclosure Type 4 Note: All conduits must be sealed within 18 inches CSA*: Class 1, Div. 1, Groups A,B,C,D Class II, Div. 1, Groups E,F,G Class III, Div.1 T6 @ TA = 50°C; Enclosure Type 4 Note: All conduits must be sealed within 18 inches ATEX**: II2G, Ex d IIC T6 (-10oC < Ta < +50oC) Note: Not for Carbon Disulfide Gas *: Approvals standard on Triple Range units, optional on Single Range units. **: Only available on Triple Range units See Model Selection Guide for details. This product is in conformity with the protection requirements of the following European Council Directives: 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC Directive. Conformity of this product with any other “CE Mark” Directive(s) shall not be assumed. Standards – Control Unit Miscellaneous 14 Product Classification: Class I: Permanently connected, panel-mounted Industrial Control Equipment with protective earthing (grounding). Enclosure Rating: Panel-mounted equipment. This controller must be panel-mounted. Terminals must be enclosed within the panel. Front Bezel: NEMA3R and IP54, or NEMA4X and IP66 with 4 screws. UL and CSA approved as Type 4 moisture protection when used with 4 screws. Installation Category (Overvoltage Category): Category II: Energy-consuming equipment supplied from the fixed installation, local level appliances, and Industrial Control Equipment. Pollution Degree: Pollution Degree 2: Normally non-conductive pollution with occasional conductivity caused by condensation. (Ref. IEC 664-1) EMC Classification: Group 1, Class A, ISM Equipment (EN55011, emissions), Industrial Equipment (EN61326, immunity) Method of EMC Assessment: Technical File (TF) Declaration of Conformity: 51453681 Analyzer temperature: Sensing unit thermostated at 50 °C (122 °F) 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Specifications and Model Selection Guide 2.2 Model Selection Guide Model Selection Guide 51-52-16-79 Issue 9 Factory configured for triple range applications Monitors CO2 in purge cycle and H2 in fill and operating cycle Utilizes thermal conductivity technology Optional remote range indicator Optional sample panel, see 7872 MSG 51-52-16-36 / GA-3 See Product Spec 70-82-03-46 for further details FM, CSA and ATEX Explosion Proof (Note 1) Control Unit Sensor Instructions Select the desired Key Number. The arrow to the right marks the selection available. Make one selection each from Table I using the column below the proper arrow. A dot ( ) denotes unrestricted availability. Analyzer includes sensor, control unit and power supply Key Number _________ - I _ II - _ III - ___ KEY NUMBER 7866 Digital Thermal Conductivity Analyzer for Hydrogen Cooled Generator Applications consisting of: IV - _ V - _ __ Selection VI - _ _ _ Availability 07866DHH2 a) 07866DHS2 Sensor Assembly (includes housing) b) 07866DHC2 Digital Control Unit 7866 Replacement Digital Control Unit Only 07866DHC2 (for Hydrogen Cooled Generator Applications) 7866 Digital Remote Range Indicator 7866 Replacement Sensor Assembly (electronics only) 07866DRRI 07866HHSS TABLE I - SENSOR POWER SUPPLY & LINE VOLTAGE None Input Voltage 105 -125VAC, 50-400 Hz Input Voltage 210 -250VAC, 47-520 Hz 0 2 4 TABLE II - OUTPUT (PV RANGE) None 0-20 mA 4-20 mA 0 1 2 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 15 Specifications and Model Selection Guide Availability TABLE III - COMMUNICATIONS None MODBUS RS485 10 Base-T Ethernet (Modbus RTU) Selection DHH2 DHC2 DRRI HHSS 000 101 102 TABLE IV - FACTORY USE ONLY None 0 TABLE V - FACTORY USE ONLY Reserved for Use by Fort Washington TABLE VI - TAGGING None Linen Tags: 15 characters max. On each of three lines: Specify legend. One mounted on Control Unit; one on Sensing Unit. Stainless Steel Tags: 15 characters max. On each of three lines: Specify legend. One mounted on Control Unit; one on Sensing Unit. 000 000 206 208 ACCESSORY PARTS Description Replacement Power Supply Input Voltage 105-125VAC, 50-400 Hz Replacement Power Supply Input Voltage 210 -250VAC, 47-520 Hz DIN Adaptor Plate Part Number 51450915-501 51450915-502 30755223-002 Note 1: Warning - When measuring a gas mixture that contains oxygen, the maximum oxygen concentration must not exceed 21%. 16 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Specifications and Model Selection Guide Refer to Appendix A for ordering information on the optional 7872 Gas Sampling Panel. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 17 Specifications and Model Selection Guide 18 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Installation 3. Installation 3.1 Overview This section describes the installation requirements and procedures for the 7866 Triple Range Digital Analyzer/Indicator. 3.2 Sensing Unit Requirements and Location Location Locate the sensing unit as close as possible to the sampling probe to minimize response lag. This should be at a point in the gas stream which best represents the true gas composition. An ac power line is not required. The sensing unit can be located in a protected outdoor area. The housing is watertight; but it should not be exposed to direct rays from the sun. Ambient temperature must not go above 50 °C (122 °F) or below –10°C (14 °F). Connections Provide a three-conductor copper-wire cable (four-conductor if a solenoid calibrate valve is used) to provide the connections between the sensing unit and the 7866 Digital Controller. Connecting cable/conductors must be rated at 90ºC. The required wire size for each conductor is listed in Section 3.7 according to cable length. An adapter is supplied to terminate 1/2 inch threaded conduit and connect to the sensing unit's watertight housing. The explosion-proof housing is tapped for 1/2 NPT conduit. Clearance Provide at least 12 inches clearance above the top of the sensing unit to allow the internal assembly to be removed for servicing. Allow appropriate space below the sensing unit for 1/4 inch or 6 mm inlet and outlet tubing connections. Position the sensing unit on a vertical surface with the inlet and outlet fittings at the bottom. Allow space at the right-hand opening for the solenoid calibrate valve, which, if supplied, is to be mounted here. Sampling System Provide a sampling system to deliver a clean and relatively dry sample at a rate of 100 to 2000 cc per minute. The sample should be free of dust. Calibrating Gases Provide a source of calibrating gases; e.g., cylinders of compressed zero gas and span gas with pressure regulating valves on each. In general, a zero gas contains all gas components in the sample stream except the measured gas. For suppressed-zero ranges, zero gas contains measured gas at or slightly above the lowend value. Concentrations should be those normally present in the stream. A span gas contains all of the gases in the sample stream at expected concentrations with measured gas concentration accurately analyzed. Concentration of water (vapor) in the calibrating gas should be the same as that in the background gas. Therefore, a gas saturator or dryer may be required. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 19 Installation Reference Gas Provide a source of reference gas, if required. If hydrogen or helium, supply at 0.02 cfh to 0.2 cfh (10 cc/min to 100 cc/min). Vent to atmospheric pressure. (If hydrogen, vent to a safe ventilating system.). If flowing air is required, supply at 0.5 cfh to 2.0 cfh (250 cc/min to 1000 cc/min). Vent to atmospheric pressure. 3.3 Mounting the Sensing Unit Explosion-proof Housing EXPLOSION-PROOF SENSING UNIT REQUIREMENTS • When measuring gas mixture that contains oxygen, the maximum oxygen concentration must not exceed 21%. • Always use conduit for electrical wiring and seal all conduits within 18 inches. • Make certain fully qualified personnel make this installation and all local regulations are observed. Failure to comply with these instructions could result in fire caused by explosion inside the housing. The sensing unit is designed as explosion-proof. Dimensions for this unit are shown in Figure 3-1. Electrical conduit must be used for all wiring and the openings are fitted for 1/2-inch conduit. Mount the explosion-proof sensing unit in accordance with Figure 3-1. 3.4 Piping or Tubing Connections Inlet and Outlet Connections The O-ring type compression fittings in the base of the sensing unit will accept plastic or metal tubing having an O.D. between 0.236 inches (6 mm) and 0.255 inches (6.5 mm). Make inlet and outlet connections in accordance with Figure 3-1. Types of Tubing Any metal and most plastic tubing can be used provided it is chemically compatible with the sample gas. Avoid the use of plasticized PVC or other soft tubing at the sensing-unit compression fittings and do not use tubing having an inside diameter less than 4 mm. Outlet Line Connection To maintain the analyzer cell at constant pressure under various flow conditions, the outlet line must be less than two meters (six feet) long and should exit to atmospheric pressure. No restrictions (other than a Rotameter-type flowmeter) can be used in this line. If a longer vent line is required, use larger diameter tubing, e.g., 12 mm (1/2”) O.D. Refer to Appendix A for sampling and venting information. 20 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Installation Making Connections CONNECTION DAMAGE • Excessive tightening on metal tubing may damage the O-ring. • Excessive tightening on plastic tubing may restrict the opening. Failure to comply with these instructions may result in product damage. Step 9/06 Action 1 Cut the tubing squarely and remove all burrs, loosen the compression nut. 2 Push the tubing firmly into fitting until it slips through the O-ring and seats against the metal. 3 Tighten the compression nut by hand; then turn it about 1/8 turn with a wrench. If the entire fitting assembly turns, use a back-up wrench. 4 If a good seal does not result, remove the compression nut and slide it onto the tubing, take out the small O-ring and slip it on the tubing, then assemble the fitting. 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 21 Installation Reference Reference Inlet Outlet 56 2.20 Sample Sample Outlet Inlet 7866 Thermal Conductivity Analyzer (4 port) 250 Clearance required for sensor removal 9.84 92 max. 165 6.50 3.625 max. 148 5.82 154 6.06 80 3.14 12 .472 Internal 4 pt. Terminal Board *6-32 Screws 166 6.53 Removable Threaded Cover 1/2" NPT 9 .35 DIA. 156 6.14 * Sample Sample Inlet Outlet 56 2.20 114 DIA 4.48 DIA 140 5.51 Front View Left Side View *For 1/4” O.D. or 6 mm O.D. Metal or Plastic Tubing NOTE: 1. Weight of unit is approximately 18-3/4 lb. (8.5 kg) 2. Wiring diagram is ID-2071-356. Figure 3-1 Outline and Mounting Dimensions for Sensing Unit 22 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Installation 3.5 Mounting the 7866 Digital Controller/Indicator Introduction The 7866 Controller/Indicator can be mounted on a panel using the mounting kit supplied. Adequate space must be available at the back of the panel for installation and servicing activities. The controller is considered “rack and panel mounted equipment” per the following safety standards: For US, ANSI/ISA S82-1994 For Canada, CAN/CSA – C22.2 No. 1010.1-92 For Europe, EN610101-1 Conformity with these standards requires the user to provide adequate protection against a shock hazard. The user shall install this controller in an enclosure that limits OPERATOR access to the rear terminals. If the controller is used in a manner not specified by Honeywell, the protection provided by the equipment may be impaired. Physical Considerations The controller can be mounted on either a vertical or tilted panel using the mounting kit supplied. Adequate access space must be available at the back of the panel for installation and servicing activities. 9/06 • Overall dimensions and panel cutout requirements for mounting the controller are shown in Figure 3-2. • The controller’s mounting enclosure must be grounded according to CSA standard C22.2 No. 0.4 or Factory Mutual Class No. 3820 paragraph 6.1.5. • The front panel is moisture rated NEMA3 and IP55 rated and can be easily upgraded to NEMA4X and IP66. See Figure 3-3 and Table 3-1 Mounting Procedure. 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 23 Installation Overall Dimensions Max. panel thickness 19,1 9,0 0.75 0.35 mm inches 92,0 + 0,8 - 0,00 3.62 + 0.03 -0.00 90,6 3.57 108,6 4.28 Panel Cutout 92,0 + 0,8 - 0,00 3.62 + 0.03 - 0.00 17,9 0.70 148,0 5.81 Figure 3-2 Mounting Dimensions (not to scale) Mounting Notes Before mounting the controller, refer to the nameplate on the outside of the case and make a note of the model number. It will help later when selecting the proper wiring configuration. Mounting Method Before mounting the controller, refer to the nameplate on the outside of the case and make a note of the model number. It will help later when selecting the proper wiring configuration. 24 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Installation Mounting clips Attach screws and washers here for water protection Figure 3-3 Mounting Methods Mounting Procedure Table 3-1 Mounting Procedure Step Action 1 Mark and cut out the controller hole in the panel according to the dimension information in Figure 3-2. 2 Orient the case properly and slide it through the panel hole from the front. 3 Remove the mounting kit from the shipping container and install the kit as follows: • For normal installation (NEMA 3/IP55) two mounting clips are required. Insert the prongs of the clips into the two holes in the top and bottom center of the case • For water-protected installation (NEMA 4/IP66) four mounting clips are required. There are two options of where to install the mounting clips: 1) Insert the prongs of the clips into the two holes on the left and right side of the top and bottom of the case or 2) on the center on each of the four sides. Tighten screws to 2 lb-inch (22 N•cm) to secure the case against the panel. CAUTION: Over tightening will cause distortion and the unit may not seal properly. • 4 9/06 For water-protected installation (NEMA 4/IP66), install four screws with washers into the four recessed areas in the corners of the front bezel (Figure 3-3). Push the point of the screw through the center piercing the elastomeric material and then tighten screws to 5 lb-in (56 N•cm). 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 25 Installation 3.6 Electrical Considerations Line voltage wiring This controller is considered “rack and panel mounted equipment” per EN61010-1, Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part 1: General Requirements. Conformity with 72/23/EEC, the Low Voltage Directive requires the user to provide adequate protection against a shock hazard. The user shall install this controller in an enclosure that limits OPERATOR access to the rear terminals. Mains Power Supply This equipment is suitable for connection to 90 to 264 Vac or to 24 Vac/dc 50/60 Hz, power supply mains. It is the user’s responsibility to provide a switch and non-time delay (North America), quick-acting, high breaking capacity, Type F (Europe), 1/2A, 250V fuse(s), or circuit breaker for 90-264 Vac applications; or 2 A, 125 V fuse or circuit breaker for 24 Vac/dc applications, as part of the installation. The switch or circuit breaker shall be located in close proximity to the controller, within easy reach of the OPERATOR. The switch or circuit breaker shall be marked as the disconnecting device for the controller. Applying 90-264 Vac to an instrument rated for 24 Vac/dc will severely damage the instrument and is a fire and smoke hazard. When applying power to multiple instruments, make certain that sufficient current is supplied. Otherwise, the instruments may not start up normally due to the voltage drop caused by the in-rush current. Controller Grounding PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is installed shall be in accordance with National and Local electrical codes. To minimize electrical noise and transients that may adversely affect the system, supplementary bonding of the controller enclosure to a local ground, using a No. 12 (4 mm2) copper conductor, is recommended. Control/Alarm Circuit Wiring The insulation of wires connected to the Control/Alarm terminals shall be rated for the highest voltage involved. Extra Low Voltage (ELV) wiring (input, current output, and low voltage Control/Alarm circuits) shall be separated from HAZARDOUS LIVE (>30 Vac, 42.4 Vpeak, or 60 Vdc) wiring per Permissible Wiring Bundling, Table 3-2. Electrical Noise Precautions Electrical noise is composed of unabated electrical signals, which produce undesirable effects in measurements and control circuits. Digital equipment is especially sensitive to the effects of electrical noise. Your controller has built-in circuits to reduce the effect of electrical noise from various sources. If there is a need to further reduce these effects: • Separate External Wiring—Separate connecting wires into bundles (See Permissible Wiring Bundling - Table 3-2) and route the individual bundles through separate conduit metal trays. Use Suppression Devices—For additional noise protection, you may want to add suppression devices at the external source. Appropriate suppression devices are commercially available. ATTENTION For additional noise information, refer to document number 51-52-05-01, How to Apply Digital Instrumentation in Severe Electrical Noise Environments. 26 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Installation Permissible Wiring Bundling Table 3-2 Permissible Wiring Bundling Bundle No. 1 2 3 3.7 Wire Functions • Line power wiring • Earth ground wiring • Line voltage control relay output wiring • Line voltage alarm wiring Analog signal wire, such as: • Input signal wire (thermocouple, 4 to 20 mA, etc.) • 4-20 mA output signal wiring Digital input signals • Low voltage alarm relay output wiring • Low voltage wiring to solid state type control circuits • Low voltage wiring to open collector type control circuits Wiring Between Sensing Unit, Controller, and Indicator Wiring Connections at the Sensing Unit Step Action 1 After the sensing unit is mounted, carefully remove the top threaded cover by turning it counterclockwise. (Loosen the set screw.) 2 Two openings are provided for cable entrance; make certain the plug screw is tightened firmly into the unused right-hand opening. 3 Use 1/2 NPT threaded electrical conduit, and mount the special adapter fitting supplied with the analyzer. 4 Wire as shown in Figure 3-5. EXPLOSION-PROOF SENSING UNIT REQUIREMENTS • Always use conduit for electrical wiring and follow special installation procedures. • Make certain fully qualified personnel make this installation and all local regulations are observed. Failure to comply with these instructions could result in fire caused by explosion inside the housing. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 27 Installation 1 3 AC/DC Line Voltage 2 Earth Ground Hot Neutral 10 19 28 L1 11 20 29 L2/N 12 21 30 4 13 22 31 5 14 23 32 6 15 24 33 7 16 25 34 8 17 26 35 9 18 27 36 1 PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is installed, shall be in accordance with National and local electrical codes. To minimize electrical noise and transients that may adversely affect the system, supplementary 2 bonding of the controller enclosure to local ground using a No. 12 (4 mm ) copper conductor is recommended. Before powering the controller, see “Prelimnary Checks” in this section of the Product Manual. 2 It is the user’s responsibility to provide a switch and non -time delay (North America), quick-acting, high breaking capacity, Type F (Europe), 1/2A, 250V fuse(s), or circuit breaker for 90-264 Vac applications; or 2 A, 125 V fuse or circuit breaker for 2 4 Vac/dc applications, as part of the installation. 3 Applying 90-264 Vac to an instrument rated for 24 Vac/dc will severely damage the instrument and is a fire and smoke hazard. Figure 3-4 Mains Power Supply 28 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Installation Wiring Connections at the Digital Controller The output signal from the 7866 Digital Controller can be configured as a 4-20 milliampere signal or a 020 milliampere signal. This signal is used to drive a recording device or to report to a DCS or PLC. The signal will proportionately reflect the percentage of measured gas. Typically, the signal will be at minimum value (0 mA or 4 mA) when the display reads 0.0 %. The signal will be at 20 mA when the display reads 100.0 %. The analog output can support a total resistive load of 1000 ohms at maximum. Power Supply 30 Vdc/30 Watt 120 Vac/60 Hz Input Power Model Number B30GT110 12 230 Vac/50 Hz Input Power Model Number B30GT110-230 + - 10 PV Output 0-20 or 4-20 mA Range Output 0-20 or 4-20 mA Sensor Range 13 Sensing Unit 14 Terminal Strip (Top View) 9 19 28 20 29 L1 11 L2/N 12 4 13 5 14 6 15 7 16 25 34 8 17 26 9 18 Sensor + 35 Input - 36 Alarm 2 Alarm 1 21 30 22 31 23 32 24 33 27 250 Ohm Digital Controller 10 19 28 L1 11 20 29 L2/N 12 21 30 4 13 22 31 5 14 23 6 15 Range + 32 Input - 33 7 16 8 17 9 18 Alarm 2 24 34 25 Alarm 1 26 27 PV Input 250 Ohm + 35 - 36 250 Ohm Digital Indicator Figure 3-5 Interconnections Between Sensing Unit, Controller, and Indicator REQUIRED WIRE SIZE FOR INTERCONNECTION CABLE 9/06 AWG MAX. COND. LENGTH 18 427 FT (130 M) 16 689 FT (210 M) 14 1082 FT (330 M) 12 1706 FT (520 M) 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 29 Installation COMMUNICATION MASTER D+ (B) SHLD D– (A) UDC3500 1 4 SHLD 2 SHLD 26 D+ (B) D+ 27 D– (A) D– 120 OHMS Connect shield to ground at one end only. TO OTHER COMMUNICATION CONTROLLERS D– D+ 120 OHMS ON LAST LEG 1 Do not run the communications lines in the same conduit as AC power. 2 Use shielded twisted pair cables (Belden 9271 Twinax or equivalent). Figure 3-6 RS-422/485 Communications Option Connections RS-422/485 connections must be “daisy-chained,” T-drop connections are not allowed. 10 19 11 L1 L2/N 12 13 4 14 5 20 21 22 6 7 15 16 8 9 17 18 Tie Wraps (2) 23 24 25 26 27 28 Ethernet 29 Adaptor 30 31 32 33 Ethernet Cable 34 To Hub 35or 24 36 27 Figure 3-7 Ethernet Communications Option with Adaptor Board Instruments equipped with the Ethernet Communications Option come with an Ethernet Adaptor Kit. To use this kit, first remove the four screws on your instrument from Terminal Block positions 24 through 27. Place the Ethernet Adaptor Board on to the terminal block as shown and then secure it in place with the four long screws provided in the kit. Route the long wire on the Ethernet Adaptor Board over to Terminal #4 on your instrument. The RJ-45 connector on the Ethernet Adaptor Board will allow you to use a straight-through cable to connect the controller to a MDI Compliant Hub or Switch. Alternatively, you may use a crossover cable to connect your controller directly to a PC, which is useful for commissioning purposes. Use only Category 5 (STP CAT5) shielded twisted-pair Ethernet cables. For strain relief, secure your Ethernet cable to the controller with the tie wraps included in the kit using the holes in the bottom controller flange. 30 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Installation COMMUNICATION MASTER 3 SHLD TXD - TXD + RXD - RXD + 1 4 SHLD 2 24 RXD + 25 RXD 26 TXD + 27 TXD - 1 Do not run the communications lines in the same conduit as AC power. Direct connection to a PC may require the use of an Ethernet cross-over cable. 2 Use Shielded twisted-pair, Category 5 (STP CAT5) Ethernet cable. 3 Use Switch rather than Hub to maximize performance. Figure 3-8 Ethernet Communications Option without Adaptor Board If you would rather wire your UDC to your Ethernet connection without using the Ethernet Adaptor Board, then Figure 3-8 and Table 3-3 show the connections for a UDC to a MDI Compliant Hub or Switch utilizing a straight-through cable or for connecting a UDC to a PC utilizing a crossover cable. Table 3-4 shows the connections for a UDC to a PC utilizing a straight-through cable (wiring the UDC cable this way makes the necessary cross-over connections). Table 3-3 Terminals for connecting a UDC to a MDI Compliant Hub or Switch utilizing a cross-over cable UDC Terminal UDC Signal Name RJ45 Socket Pin # Switch Signal Name Position 4 Shield Shield Shield Position 24 RXD- 6 TXD- Position 25 RXD+ 3 TXD+ Position 26 TXD- 2 RXD- Position 27 TXD+ 1 RXD+ Table 3-4 Terminals for connecting a UDC directly to a PC utilizing a straight-through cable UDC Terminal UDC Signal Name RJ45 Socket Pin # PC Signal Name Position 4 Shield Shield Shield Position 24 RXD- 2 TXD- Position 25 RXD+ 1 TXD+ Position 26 TXD- 6 RXD- Position 27 TXD+ 3 RXD+ Use only Category 5 (STP CAT5) shielded twisted-pair Ethernet cables. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 31 Installation 3.8 Checklist Check # Action 1 Check all wiring and piping. Make certain all fittings are tight. Replace the top threaded cover on the sensing unit and tighten the set screw, if provided. No operating checks or settings are required in the sensing unit. 2 Shut off or vent the gas flow at the sampling system to make sure sample will not flow into the analyzer during startup. 3 During calibration, it is necessary to read out the analyzer measurements. A milliammeter is used for verification of the readings. The meter should be wired in series with the signal wire between terminal 12 of the sensing unit and terminal 26 of the 7866 Digital Controller. The test meter used, whether for voltage or current output, should be a digital voltmeter or a millivolt potentiometer for best accuracy. It should have an input impedance greater than 2000 ohms. • Do not open the threaded cover of the sensing unit unless the power source is disconnected. Then loosen the set screw to permit threaded cover to be turned. Failure to comply with these instructions could result in death or serious injury. 32 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Set Up Mode 4. Set Up Mode 4.1 Overview This section describes the steps to configure the 7866 Controller/Indicator for your application. 4.2 Configuration Tips Introduction Table 4-1 lists some tips that will help you enter data more quickly. Table 4-1 Configuration Tips Function Tip Displaying Groups Use the SET UP key to display the Set Up groups. Displaying Functions Use the FUNCTION key to display the individual parameters under each group. The prompts are listed in the order they appear in each group. Scrolling If the SET UP key is held in, the Group prompts scroll continuously at a rate of once every 2/3 of a second. Holding in either the or key will increase the scroll rate to once every 1/3 of a second in the forward or reverse direction while viewing Group prompts. Changing Values Quickly When changing the value of a parameter, you can adjust a more significant digit in the upper or , and pressing the other or at the same time. The display by holding in one key adjustment will move one digit to the left. Press the key again and you will move one more digit to the left. Timing Out from Set Up Mode If you are in Set Up mode and do not press any keys for 30 seconds, the controller will time out and revert to normal operation. Key Error When a key is pressed and the prompt "KEY ERROR" appears in the lower display, it will be for one of the following reasons: • Parameter is not available • Not in Set Up mode, press SET UP key first • Key not available for use in 7866 Controller 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 33 Set Up Mode 4.3 Unit Set Up Group Function Prompts Table 4-2 lists all the function prompts in the Controller’s Unit Set Up group. Table 4-3 lists all the function prompts in the Indicator’s Unit Set Up group. Table 4-2 Controller Unit Group Function Prompts Function Prompt (Lower Display) Function Name Selections or Range of Setting (Upper Display) SECURITY Security Code 0000 to 9999 LOCKOUT Configuration Lockout NONE – Permits changes to all functions. Factory Setting 0 NONE CALIB – Calibration group functions are hidden from view. UNIT – Parameters in the Unit Set Up group cannot be changed, but the Alarms and Communications group parameters are changeable. (Calibration parameters cannot be seen.) VIEW – All parameters are read only. (Calibration parameters cannot be seen.) Analyzer Range Type TRIPLE – Read only TRIPLE Output 2 Type Selection 4-20MA 0-20MA 4-20MA RNG3SPAN Current Output 2, Range 3 Span 0 - 100% 75 - 100% 100 - 75% Sets the 4-20mA or 0-20mA for range 3 only to either 0-100%, 75-100%, or 100 - 75%. NOTE: The current output for ranges 1 and 2 is 4-20mA or 0-20mA over the span of 0100%. 0 - 100 PWR FREQ Input Frequency Selection 60 HZ 50 HZ 60 HZ Decimal Point Location XXX.X – One decimal place XX.XX – Two decimal places XXX.X TYPE CUR OUT DECIMAL 34 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Set Up Mode Table 4-3 Indicator Unit Group Function Prompts Function Prompt (Lower Display) Function Name Selections or Range of Setting (Upper Display) SECURITY Security Code 0000 to 9999 LOCKOUT Configuration Lockout NONE – Permits changes to all functions. Factory Setting 0 NONE CALIB – Calibration group functions are hidden from view. UNIT – Parameters in the Unit Set Up group cannot be changed, but the Alarms and Communications group parameters are changeable. (Calibration parameters cannot be seen.) VIEW – All parameters are read only. (Calibration parameters cannot be seen.) Analyzer Range Type TYPE TRIPLE – Read only TRIPLE INDICTR – Read only BIAS R1 Bias of Input Value for Range 1 +10.00 to –10.00 0.00 BIAS R2 Bias of Input Value for Range 2 +10.00 to –10.00 0.00 BIAS R3 Bias of Input Value for Range 3 +10.00 to –10.00 0.00 Selection of Input actuation consistent with analyzer CUR OUT selection 1-5V (4-20mA) 0-5V (0-20mA) 1-5V RNG3SPAN Selection of Input Range 3 to be consistent with similar function in the Analyzer. For Range 3, it applies 1-5V or 0-5V over the range of 0-100%, 75-100%, or 100 - 75%. 0 - 100% 75 - 100% 100 - 75% 0-100 PWR FREQ Input Frequency Selection 60 HZ 50 HZ 60 HZ Decimal Point Location XXX.X – One decimal place XX.XX – Two decimal places XXX.X PV INPUT DECIMAL 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 35 Set Up Mode 4.4 Alarms Set Up Group Function Prompts Table 4-4 lists all the function prompts in the Alarms Set Up group. The alarms are set to operate in Range 3 only. Refer to Section 5.8 Setting the Alarm Limits for the alarm adjustment procedure. Table 4-4 Alarms Group Function Prompts Function Prompt (Lower Display) Function Name Selections or Range of Setting (Upper Display) Factory Setting ALARM1LO Alarm 1 Setpoint, low alarm type 90.0 to 100.0 98.0 ALARM2LO Alarm 2 Setpoint, low alarm type 90.0 to 100.0 90.0 HYSTERiS Alarm Hysteresis 0 to 100.0 0.5 4.5 Communications Set Up Group Introduction The Communications group lets you configure the controller to be connected to a host computer via Modbus® or Ethernet TCP/IP protocol. A controller with a communications option looks for messages from the host computer. Up to 99 addresses can be configured over this link. The number of units that can be configured depends on the link length, with 31 being the maximum for short link lengths and 15 drops being the maximum at the maximum link length. Function Prompts Table 4-5 Communications Group Function Prompts Function Prompt Lower Display Com ADDR Selections or Range of Setting Upper Display 1 to 99 ComSTATE Parameter Definition COMMUNICATIONS STATION ADDRESS—This is a number that is assigned to a controller that is to be used with the communications option. This number will be its address. This value is also used for IR transactions. To communicate with Pocket PC set address to 3. COMMUNICATIONS SELECTION—enables the RS-485 or Ethernet communications port. DISABLE DISABLE—Disables communications option. MODBUS MODBUS—Enables RS-485 Modbus RTU communication port. Appears only when a communications board is installed. ETHERNE ETHERNET—Enables Ethernet communications port. Appears only when a communication board is installed. ATTENTION The PIE Tool will not be able to communicate via this port if it is disabled. 36 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Set Up Mode Function Prompt Lower Display IR ENABLE Selections or Range of Setting Upper Display DISABLE ENABLE Parameter Definition IR ENABLE—Disable/Enables IR communications port. ATTENTION If there are no IR communications transactions for four minutes, then the IR port automatically shuts down. It can be re-enabled by pressing any key on the front panel. BAUD BAUD RATE—Communications transmission speed in bits per second. This value is used for both RS485 and IR Communications, but for IR Communications, values below 19200 baud are interpreted as being 19200 baud. 4800 9600 19200 38400 4800 BAUD 9600 BAUD 19200 BAUD 38400 BAUD Defines word/byte order of floating point data for communications. Byte values: WS FLOAT 0 1 2 3 seeeeeee emmmmmmm mmmmmmmm mmmmmmmm Where: s = sign, e = exponent, m = mantissa bit FP_B FP_BB FP_L FP_LB TX DELAY 9/06 1 to 500 milliseconds 0 1 3 2 1 0 2 3 2 3 1 0 3 2 0 1 TX DELAY—Configurable response-delay timer allows you to force the instrument to delay its response for a time period of from 1 to 500 milliseconds compatible with the host system hardware/software. 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 37 Set Up Mode Function Prompt Lower Display Selections or Range of Setting Upper Display Parameter Definition LOCAL LOOPBACK—Tests the RS-485 communications port. This feature is not used for any other communications port. LOOPBACK (available with RS485 card option) DISABLE DISABLE—Disables the Loopback test. ENABLE ENABLE—Allows RS-485 Loopback test. The instrument goes into Loopback mode in which it sends and receives its own message. The instrument displays PASS or FAIL status in the upper display and LOOPBACK in the lower display while the test is running. The instrument will go into manual mode when LOOPBACK is enabled with the output at the Failsafe value. The test will run until the operator disables it here or until power to the instrument is turned off and on. ATTENTION The instrument does not have to be connected to the external RS-485 communications link in order to perform this test. If it is connected, then only one instrument should run the Loopback test at a time, as the instrument running the Loopback test transmits on the RS-485 bus. The host computer should not be transmitting on the link while the Loopback test is active. 38 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Set Up Mode 4.6 Calibration Group Calibration Data Refer to Section 5 Calibration for complete calibration information and instructions. 4.7 Status Group Status Test Data Table 4-6 lists all the function prompts in the Status group. All prompts are read-only and provide the status of the background diagnostic tests. Table 4-6 Status Group Function Prompts Function Prompt (Lower Display) VERSION Function Name Software Version Read Only Displays (Upper Display) 7866_n The first number set (7866) details the unit class as the 7866 product and the next number set gives the software version. RAM TEST CONFTEST CAL TEST 4.8 Status of RAM test performed in background PASS or FAIL Status of Configuration Checksum test performed in background PASS or FAIL Status of Working Calibration test performed in background PASS or FAIL If status was FAIL, cycle power to see if error clears. If problem persists, the unit is bad and should be replaced. If status was FAIL, completion of test results in re-computation of checksum and a new status of PASS. All configuration parameters should be rechecked for accuracy. If status was FAIL, completion of test results in re-computation of CRC value. All calibration of inputs and outputs should be verified for accuracy. P.I.E. Tool Ethernet and Email Configuration Screens Introduction These screens only appear in instruments that have Ethernet Communications. Ethernet and Email parameters can only be configured via the Process Instrument Explorer (P.I.E. Tool®). The figures in this section show screen-shots of the Configuration Screens from the PC version of the P.I.E. Tool®. Pocket PC Configuration Screens are generally similar in format but smaller. Ethernet Configuration Screen This controller is shipped from the factory with the IP Address set to 10.0.0.2, the Subnet Mask set to 255.255.255.0 and the Default Gateway set to 0.0.0.0. Consult your Information Technologies (IT) 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 39 Set Up Mode representative as to how these should be configured for your installation. The MAC address is printed on the product label located on the instrument’s case. These settings can be changed via the Ethernet Configuration Screen as shown in Figure 4-1. See Section 4.9 – Configuring your Ethernet Connection for more information. Figure 4-1 Ethernet Configuration Screen WARNING After you change the IP Address, you will no longer be able to communicate with the instrument via Ethernet until you change the P.I.E. Tool’s IP Address setting in the “PC COMM SETUP” to match the setting that is now in your controller. Email Configuration Screen This controller may be configured to support up to two Emails. Each Email can be sent to a different address. Emails are sent only when the selected alarm transitions from the OFF to the ON state. 40 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Set Up Mode Figure 4-2 Email Configuration Screen This controller cannot receive Emails, so it is suggested that you configure the “From Email:” window with a non-Email style address that will make it easy for you to determine which controller sent the Email. For Email technical reasons, the entry in the “From Email:” window cannot have spaces. See Figure 4-2. If you do not know your SMTP IP Address for outgoing Email, then contact your Information Technologies (IT) representative. If your PC is on the same LAN that will be used by the controller and which also connects to the Email server, then the SMTP IP Address may generally be found by opening a DOS shell and typing: ping smtp.[your domain name and extension, i.e., “yourisp.com”] The content of the Emails sent by this controller contains the Alarm that triggered the Email, its settings and the current value (if applicable) of the monitored variable. For example, the content of an Email triggered by Alarm 1 Setpoint 1 that is configured to monitor Input 1 would look something like this: Name: Alarm 1 SP1, Type: INPUT1, Event: HIGH/END, Value = 500.00, Actual = 712.69 ATTENTION Instruments will always send Email time-stamped with the date that the Ethernet Software in the instrument was last modified. If the SMTP address on your network is changed, such as can happen when a server is replaced, then you must reconfigure the Email SMTP IP address in this instrument to match. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 41 Set Up Mode 4.9 Configuring your Ethernet Connection Introduction The P.I.E. Tool can connect to your controller via either Infrared (IR) or Ethernet communications port. See sections 4.9.1 and 4.9.2. Only the P.I.E. Tool can be used to configure Ethernet parameters. The figures in this section show screen-shots from the PC version of the P.I.E. Tool® Screens. Pocket PC Screens are generally similar in format but smaller. This controller is shipped from the factory with the address for Infrared (IR) communications set to 3, the Ethernet IP Address set to 10.0.0.2, the Ethernet Subnet Mask set to 255.255.255.0 and the Ethernet Default Gateway set to 0.0.0.0. Consult your Information Technologies (IT) representative as to how these should be configured for your installation. The MAC address is printed on the product label located on the instrument’s case. The EUNPLGED message indicates the unit has an Ethernet card that is not connected to a network. 4.9.1 Connecting to the Controller via Infrared Communications If connecting via IR and assuming that the instrument’s IR address has not been changed from its factory setting of 3, then configure your Communications Type as “Infrared” and your IR address to 3 as shown below. Select “PC COMM Setup”, then select “Infrared”. You cannot configure your Pocket PC for Ethernet. Figure 4-3 IR Communications Address Close the IR configuration window and then single click on the “Online Configuration” button. 42 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Set Up Mode Press any button on the controller’s keyboard to activate the controller’s IR port. Point your IR dongle (if using PC) or your Pocket PC’s IR port (if using Pocket PC) at the IR window on the front of the controller and then click on the “Start” button. The P.I.E. Tool® should start uploading the configuration information from the controller as shown below: Figure 4-4 Configuration Upload in Progress Once the upload is complete, click on the “Ethernet & Email” Group. Configure your Ethernet and Email parameters per Section 4.8. Once you have changed the Ethernet settings and downloaded them to your controller, you will now be able to communicate with it via Ethernet. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 43 Set Up Mode 4.9.2 Connecting to the Controller via Ethernet Communications WARNING Connecting to the Controller via Ethernet Communications requires that you change your PC’s IP settings. If you have never done this before, then it is strongly recommended that you consult with your Information Technologies (IT) representative before proceeding. First, write down the current IP Address, Subnet Mask and Default Gateway settings for your PC. Put these someplace that you can find them later. Connecting to the Ethernet Port in the Controller requires that you have either an Ethernet crossover cable or a MDI-compliant Switch or Hub available with a straight-through cable. The crossover cable can be used to directly connect your PC to the Controller while the Switch or Hub can be used to connect your PC and Controller to the Hub or Switch via straight-through cables. Once you have made an Ethernet connection between your PC and the controller, then change the Local Area Network (LAN) settings on your PC to be as follows: IP Address: 10.0.0.3 Subnet Mask: 255.255.255.0 Default Gateway: 10.0.0.1 44 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Set Up Mode Open your P.I.E. Tool® program and select “PC Comm Setup”. Now configure your “Communication Type” to Ethernet and your Ethernet address to 10.0.0.2 as shown in Figure 4-5. Figure 4-5 Ethernet Communications Address 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 45 Set Up Mode Close the Ethernet configuration window and then single click on the “Online Configuration” button. Then, click on the “Start” button. The P.I.E. Tool® should start uploading the configuration information from the controller as shown below: Figure 4-6 Configuration Upload in Progress Once the upload is complete, click on the “Ethernet & Email” Group. Configure your Ethernet and Email parameters per Section 4.8. Once you have changed the Ethernet settings and downloaded them to your controller, you will no longer be able to communicate with it until you change the IP address in the P.I.E. Tool® to the controller’s new IP Address. You will also need to re-configure the Local Area Network (LAN) settings on your PC back to their original settings. On some PCs and LANs, it is possible to simply allow the PC to get these settings automatically via the DHCP server. Contact your Information Technologies (IT) representative to see if this is available on your PC. 46 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Calibration 5. Calibration 5.1 Overview Analyzer calibration The 7866 analyzer is calibrated at the factory before shipping. The analyzer must be field-calibrated prior to operation. The input calibration procedure includes: • Setting the Zero for Range 1: 100 % Air; 0 % CO2 • Setting the Span for Range 1: 0 % Air; 100 % CO2 • Setting the Zero for Range 2: 100 % CO2; 0 % H2 • Setting the Span for Range 2: 0 % CO2; 100 % H2 • Setting the Zero for Range 3: 100 % H2; 0 % N2 • Setting the Span for Range 3: 75 % H2; 25 % N2 Indicator calibration The 7866 Indicator is calibrated at the factory before shipping. You do not need to recalibrate it before operating it. The PV Input selection is factory set for 1-5V to be consistent with the Analyzer output of 4-20mA. If you change the analyzer output to 0-20 mA you must change the PV Input to 0-5V. Recalibration is not necessary because the indicator automatically rescales the input values. The PV Input calibration procedure includes: • Setting the Zero for the PV Input • Setting the Span for the PV Input Other This section also includes the procedures for: 5.2 • field-calibrating the current output(s), • entering a security code, • changing the security level, and • setting alarm limits. Sensing Unit Calibration Warning • Do not open the threaded cover of the sensing unit unless the power source is disconnected. Then loosen the set screw to permit threaded cover to be turned. • Before making any test with power applied to the sensing unit, either remove the sensing unit to a non-hazardous area or verify that the atmosphere is free from combustible gases. Failure to comply with these instructions could result in death or serious injury. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 47 Calibration 5.3 7866 Analyzer Input Calibration Range 1: Carbon Dioxide Percentage Ratio to Air Range 1 is used to indicate the percentage of Carbon Dioxide (CO2) against a background of air. When the sensor is exposed to 100 % air (0 % CO2), a display should read zero. As CO2 is introduced, the display should progress to 100 %. Table 5-1 Input Calibration for Range 1 Step Press Action Connect the air source to the sensor. 2 3 SET UP FUNCTION until you see: Upper Display: Lower Display: CALIBR RANGE 1 You will see: Upper Display: Lower Display: DISABL (default selection) RANGE 1 4 or Select CALIB to begin manual calibration procedure for Range 1. 5 FUNCTION You will see R1 ZERO in the Lower Display. The value shown in the Upper Display is a "live" reading. Wait until the value becomes stable 6 FUNCTION Captures the displayed value. The display will blink once indicating that you can use the or keys to change to the desired zero value. (This ties the internal counts processed for the input conversion to the desired value for Zero.) 7 FUNCTION Saves Range 1 ZERO data. You will see R1 SPAN in the Lower Display. Connect the CO2 source to the sensor. The value shown in the Upper Display is a "live" reading. Wait until the value becomes stable. 8 FUNCTION Captures the displayed value. The display will blink once indicating that you can use the or keys to change to the desired span value. (This ties the internal counts processed for the input conversion to the desired value for Span.) 9 FUNCTION Saves Range 1 SPAN data and processes the Range 1 calibration calculation. If, after the Zero or Span "live" value has stabilized, no change is made, you should still perform the same key-press sequences. For example, if in Step 5 you make no change to the displayed value, continue to Step 7 by pressing the FUNCTION key twice. 48 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Calibration Range 2: Hydrogen Percentage Ratio to Carbon Dioxide Range 2 is used to indicate the percentage of Hydrogen (H2) against a background of Carbon Dioxide (CO2). When the sensor is exposed to 100 % Carbon Dioxide (0 % H2), the display should read zero. As H2 is introduced, the display should progress to 100 %. Table 5-2 Input Calibration for Range 2 Step Press Connect the CO2 source to the sensor. 1 2 3 Action SET UP FUNCTION until you see: Upper Display: Lower Display: CALIBR RANGE 2 You will see: Upper Display: Lower Display: DISABL (default selection) RANGE 2 4 or Select CALIB to begin manual calibration procedure for Range 2. 5 FUNCTION You will see R2 ZERO in the Lower Display. The value shown in the Upper Display is a "live" reading. Wait until the value becomes stable. 6 FUNCTION Captures the displayed value. The display will blink once indicating that you can use the or keys to change to the desired zero value. (This ties the internal counts processed for the input conversion to the desired value for Zero.) 7 FUNCTION Saves Range 2 ZERO data. You will see R2 SPAN in the Lower Display. Connect the H2 source to the sensor. The value shown in the Upper Display is a "live" reading. Wait until the value becomes stable. 8 FUNCTION Captures the displayed value. The display will blink once indicating that you can use the or keys to change to the desired span value. (This ties the internal counts processed for the input conversion to the desired value for Span.) 9 FUNCTION Saves Range 2 SPAN data and processes the Range 2 calibration calculation. If, after the Zero or Span "live" value has stabilized, no change is made, you should still perform the same key-press sequences. For example, if in Step 5 you make no change to the displayed value, continue to Step 7 by pressing the FUNCTION key twice. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 49 Calibration Range 3: Hydrogen Percentage Ratio to Air Range 3 is used to indicate the percentage of Hydrogen (H2) against a background of Air. When the sensor is exposed to 100 % Hydrogen (0 % Air), the display should read 100 %. As Air is introduced, the display should progress downscale. Some confusion is possible as 100 % H2 is referred to as the span for Range 3 and 75 % H2 is referred to as the Zero. This is a carry over from the original analog circuitry. Range 3 is used during normal operation to detect Hydrogen loss and therefore to detect potentially dangerous process situations. The implication is that air is replacing the Hydrogen in the system. The standard display range is 100 % to 75 % Hydrogen. Since Air represents a significant hazard due to its Oxygen content, a mixture of 75 % Hydrogen and 25 % Nitrogen is used to calibrate the instrument at the low operating range of the scale. Nitrogen is an acceptable substitute since its heat capacity characteristics are very close to Oxygen. Since Air is composed of roughly 80 % Nitrogen and 20 % Oxygen, the error is insignificant. Span and Zero are reversed for this range as the initial input should be the same as the Range 2 Span. Calibration progresses from Span to Zero for this range. Table 5-3 Input Calibration for Range 3 Step Press 1 2 3 Action Connect the H2 source to the sensor. SET UP FUNCTION until you see: Upper Display: Lower Display: CALIBR RANGE 3 You will see: Upper Display: Lower Display: DISABL (default selection) RANGE 3 4 or Select CALIB to begin manual calibration procedure for Range 3. 5 FUNCTION You will see R3 SPAN in the Lower Display. The value shown in the Upper Display is a "live" reading. Wait until the value becomes stable. 6 FUNCTION Captures the displayed value. The display will blink once indicating that you can use the or keys to change to the desired zero value. (This ties the internal counts processed for the input conversion to the desired value for Span.) 7 FUNCTION Saves Range 3 SPAN data. You will see R3 ZERO in the Lower Display. Connect the 75 % H2/25 % N2 source to the sensor. The value shown in the Upper Display is a "live" reading. Wait until the value becomes stable. 8 FUNCTION Captures the displayed value. The display will blink once indicating that you can use the or keys to change to the desired span value. (This ties the internal counts processed for the input conversion to the desired value for Zero.) 9 FUNCTION Saves Range 3 ZERO data and processes the Range 3 calibration calculation. If, after the Zero or Span "live" value has stabilized, no change is made, you should still perform the same key-press sequences. For example, if in Step 5 you make no change to the displayed value, continue to Step 7 by pressing the FUNCTION key twice. 50 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Calibration 5.4 7866 Remote Indicator Input Calibration Disconnect the PV Input terminals from the Analyzer output and connect them to a voltage milliampere source. For zero and span enter values which are consistent with the PV Input selection (1-5 volts or 0-5 volts). NOTE: Input 2 is not used during Calibration of Input 1. Table 5-4 PV Input Calibration Step Press Connect the input source to the PV Input terminals. Set the source value to the zero value. 1 2 3 Action SET UP FUNCTION until you see: Upper Display: Lower Display: CALIBR PVINPUT You will see: Upper Display: Lower Display: DISABL (default selection) PVINPUT 4 or Select CALIB to begin manual calibration procedure for Range 1. 5 FUNCTION You will see INP ZERO in the Lower Display. The value shown in the Upper Display is a "live" reading. Wait until the value becomes stable for the zero reading. 6 FUNCTION Captures the displayed value. The display will blink once indicating that you can use the or keys to change to the desired zero value. (This ties the internal counts processed for the input conversion to the desired value for Zero.) 7 FUNCTION Saves Input ZERO data. You will see INP SPAN in the Lower Display. Set the source to the span value. The value shown in the Upper Display is a "live" reading. Wait until the value becomes stable for the span value. 8 FUNCTION Captures the displayed value. The display will blink once indicating that you can use the or keys to change to the desired span value. (This ties the internal counts processed for the input conversion to the desired value for Span.) 9 FUNCTION Saves Input SPAN data and processes the Range 1 calibration calculation. If, after the Zero or Span "live" value has stabilized, no change is made, you should still perform the same key-press sequences. For example, if in Step 5 you make no change to the displayed value, continue to Step 7 by pressing the FUNCTION key twice. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 51 Calibration 5.5 Restoring Factory-set Input Calibration A field calibration will overwrite any previous calibration values. However, the initial factory-set input calibration parameters can be restored, if desired, using the procedures below. Table 5-5 Restoring Analyzer’s Factory-set Input Calibration Values Step Press 1 SET UP 2 FUNCTION 3 or 4 FUNCTION Action until you see: Upper Display: Lower Display: CALIBR RANGE n You will see: Upper Display: Lower Display: (n = the desired range number) DISABL (default selection) RANGE n Select RESTOR to restore factory calibration for desired Range input parameters. Saves data to the factory-set values. Table 5-6 Restoring Indicator’s Factory-set Input Calibration Values Step Press 1 SET UP 2 52 FUNCTION 3 or 4 FUNCTION Action until you see: Upper Display: Lower Display: CALIBR PVINPUT You will see: Upper Display: Lower Display: DISABL (default selection) PVINPUT Select RESTOR to restore factory calibration for desired Range input parameters. Saves data to the factory-set values. 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Calibration 5.6 Output Calibration Introduction You can calibrate the controller so that the PV output provides the desired milliampere output when read through a meter connected to the desired output terminals. Before doing an output calibration, make sure the PV current output type (CUR OUT) selection in the Unit Set Up group (Table 4-2) is configured properly for either 4-20 mA or 0-20 mA. This selection must agree with what you are measuring for the output current to be calibrated correctly. Table 5-7 Output Calibration Procedure Step Press Connect a milliammeter, with whatever accuracy is required, capable of measuring 0 to 20 milliamps, to the PV output terminals (16 and 17). 1 2 3 Action SET UP FUNCTION until you see: Upper Display: Lower Display: CALIBR CURRENT You will see ZERO VAL in the Lower Display. A four-digit value appears in the Upper Display. Use the or keys to change the value until the milliampere output, on the meter, is at the desired reading (4 mA or 0 mA). 4 FUNCTION Saves the ZERO VAL data. You will see SPAN VAL in the Lower Display. or keys to change A four-digit value appears in the Upper Display. Use the the value until the milliampere output, on the meter, is at the desired reading (20 mA). 5 FUNCTION Saves the SPAN VAL data and terminates the calibration procedure. A field calibration will overwrite the manufacturing values. You cannot restore the factory-set output calibration. The output range of the current output used to transmit ranging data to the Indicator is fixed at 4-20 mA and is not changeable in the field. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 53 Calibration 5.7 Security Lockout Introduction The LOCKOUT feature in the 7866 Controller inhibits changes to certain functions or parameters by unauthorized personnel. There are three different lockout levels: NONE Allows changes to all functions and parameters. CALIB Calibration group functions are hidden from view. UNIT Parameters in Unit group cannot be changed. VIEW All parameter values are read only and calibration is not permitted. To set up a lockout level, refer to Table 5-9. In step 5 change to the desired Lockout phase. Entering a Security Code The level of keyboard lockout may be changed in the Set Up mode. However, knowledge of a fourcharacter security code number [0000 (no security) to 9999] may be required to change from one level of lockout to another. When a controller leaves the factory it has a security code of 0, which permits changing from one lockout level to another without entering any other code number. If you require the use of a security code, select a number from 0001 to 9999 and enter it when the lockout level is configured as NONE. Thereafter, you will need that selected number to change the lockout level from something other than NONE. Table 5-8 Entering the Security Code Step Press 1 SET UP 2 FUNCTION 3 or Action until you see: Upper Display: Lower Display: SETUP UNIT You will see SECURITY in the Lower Display. Enter a four-digit number in the upper display (0001 to 9999). This will be your security code. 4 54 FUNCTION Saves the security code to nonvolatile memory. 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Calibration Changing Security Level If the LOCKOUT feature has been set to anything other than NONE and a security code has been entered, you will have to change the LOCKOUT level to NONE before calibrating. Table 5-9 Changing Security Level Step Press 1 SET UP 2 FUNCTION 3 or Action until you see: Upper Display: Lower Display: SETUP UNIT You will see SECURITY in the Lower Display. to enter the four-digit security code number (0001 to 9999) If the security code is unknown, see Appendix B – Security Bypass. 9/06 4 FUNCTION 5 or 6 FUNCTION You will see LOCKOUT in the Lower Display. Select NONE. Saves selection to nonvolatile memory. 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 55 Calibration 5.8 Setting the Alarm Limits Each 7866 Digital Controller/Indicator can be supplied with two alarms and two alarm relay outputs as a standard. (Second alarm is mutually exclusive with 4-20 mA ranging output.) The alarms are set to operate in Range 3 only. The intention of the alarms is to detect the loss of Hydrogen for the sealed system. The assumption is that the lost Hydrogen will be replaced with atmospheric air. Alarms are indicated on the left side of the display. When an Alarm is “in force,” a number “1” or “2” will be visible. Alarm 1 Ideally the sealed system is filled to 100 % Hydrogen. As the hydrogen percentage falls the first alarm will engage. The default setting is 98.0 %. The alarm setpoint can be adjusted to suit the process requirement. When the alarm trips the normally open relay will de-energize and the relay contact will close. This relay contact can be used to interlock the system with the main process controller or wired to an alarm bell or flasher. See wiring diagram in Section 3.7 for more detail (Figure 3-5) on the alarm terminal configuration. Alarm 1 may also be used to call for make up Hydrogen. The alarm will activate when the measured percentage of hydrogen falls below the setpoint. A deadband, also called “hysteresis”, will prevent clearing of the alarm until the measured Hydrogen is below the setpoint by 0.5 percent. Alarm 2 (mutually exclusive with 4-20 ranging output) When installed, the second alarm is intended to identify significant losses of Hydrogen. Alarm 2 is set to 90.0 percent Hydrogen at the factory. This alarm should be set to warn operators and the main process control system of impending danger. With the inclusion of Air in the hydrogen filled system, there is a serious possibility of combustion. The relay contact that is linked with this alarm should be wired to an alarm annunciating horn, flasher, and/or shutdown safety system. Alarm 2 is connected to Relay Output #1. See wiring diagram in Section 3.7 for more detail (Figure 3-5) on the alarm terminal configuration. Alarm will activate when the measured percentage of hydrogen falls below the setpoint. A deadband, also called “hysteresis”, will prevent clearing of the alarm until the measured Hydrogen is above the setpoint by 0.5 percent. 56 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Calibration Adjustment of the Range 3 Alarm Limits A four-digit password may be required to adjust the Alarm limits. If the password is unknown, consult your designated plant technician for the password. If you have forgotten the password, see Appendix B for the Security Bypass Procedure. Alarm Limits may be adjusted while the 7866 Digital Controller is operating. Care should be taken to minimize the effects of entering out-of-range values. Table 5-10 Alarm Adjustment Procedure Step Press 1 SET UP 2 FUNCTION 3 or 4 FUNCTION 5 or 6 FUNCTION 7 or 8 FUNCTION Action until you see: Upper Display: Lower Display: SETUP ALARMS You will see ALARM1LO in the Lower Display. This is the Alarm 1 setpoint, low alarm type. Enter limit value between 90.0 % to 100.0 %. (Default = 98.0 %) You will see ALARM2LO in the Lower Display. This is the Alarm 2 setpoint, low alarm type Enter limit value between 90.0 % to 100.0 %. (Default = 90.0 %) You will see HYSTERiS in the Lower Display. This is the Alarm Hysteresis which sets the deactivation range for both alarms. Enter hysteresis value between 0 % to 100.0 %. (Default = 0.5 %) Saves selections to nonvolatile memory. The 7866 should be supplemented with additional safety systems where possible and appropriate. Pressure loss detectors and redundant gas loss detectors are recommended in critical applications. The user always assumes the responsibility of the correctness of the safety system design. It is always recommended that the installer, designer, and user consult with their insurance company, local authorities, and industry guidelines on such matters. The alarm will activate when the measured percentage of hydrogen falls below the setpoint. A deadband, also called “hysteresis”, will prevent clearing of the alarm until the measured Hydrogen is above the setpoint by 0.5 percent. Failure to comply with these instructions could result in death or serious injury. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 57 Calibration 58 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Operation 6. Operation 6.1 Overview This section describes operating guidelines and procedures for the 7866 Digital Analyzer. 6.2 Operating Notes All three range readings are displayed in the upper display of the 7866 digital controller/indicator. To select the measured value of a particular range, the operator selects the desired range (1, 2, or 3) by pressing the LOWER DISPLAY key on the instrument’s face. The lower display indicates the selected range. Each range engages a different scaling equation to calculate the correct percentage of gas. If preferred, the lower display can indicate the gas being measured. Pressing SETPOINT SELECT toggles the lower display between the range and the gas being measured. Pressing LOWER DISPLAY selects the desired gas (CO2inAIR, H2in O2, H2in AIR). Caution should be used since the range can be inadvertently changed. The normal mode for operating is RANGE 3 or H2in AIR. In this mode or range, the controller is monitoring the hydrogen content versus air. The alarms are active in this mode only. 6.3 Operation The digital display will indicate measured value to the limit of the design range. If the signal from the sensor is outside the range, the display value will flash a range message. In extreme cases, a recalibration may be required. However, normal variations due to changing gas flow rates and environmental factors may cause signal drift. The alarm relays are normally energized when no alarm condition exists; therefore, the contacts will go to their alarm position upon loss of line voltage to the controller. Alarm limits can be set by pressing the SET UP key to enter the Set Up mode. The Alarms Set Up group can then be entered to adjust the setpoints of Alarm 1 and Alarm 2. Alarm circuits are inoperative when Range 1 and Range 2 are selected. As soon as the controller is switched to Range 3, the alarms are activated. Two alarms can be available, each one with its own separate relay contact. When power is OFF, the relays are de-energized and their normally open contacts are non-conducting (open). When the alarms are operating, but there is no violation of the limits, the relays are energized and the relays’ normally open contacts are conducting (closed). When an alarm limit is violated the specific relay will de-energize and create an open circuit. The open circuit can be used to activate an external device. Alarm 1 is a LOW Alarm type. Alarm 1 will trip and remain on whenever the measured percentage goes below the entered value. Alarm 1 typically is used as a first warning and to signal the need for make-up hydrogen gas. A typical setting may range from 96.0 % to 98.0 %. The setting of Alarm 1's limit is the responsibility of the user to determine. Consult your safety engineer or insurance company for proper operating parameters. Alarm 2 is also a LOW Alarm type. This alarm is typically used to indicate an increasingly dangerous loss of hydrogen from the system. As air replaces hydrogen in the system, the probability of combustion increases. Alarm 2 is typically used to activate an emergency shutdown circuit and/or to activate an annunciating horn or siren. In this situation, the process may need to be purged to achieve a safe gas mixture. The specific alarm limit and proper procedures to handle a low hydrogen situation is the responsibility of the user to determine. Consult your safety engineer or insurance company for proper operating parameters. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 59 Operation To adjust Alarm Limit 1 or 2, refer to Section 5.8 Setting the Alarm Limits. Please note that extreme values will not be accepted by the controller. For example, an illogical value greater than 100.0 will be automatically overwritten by the controller with a “100.0”. Check calibration with zero and span gases about once each week. Always allow enough time (possibly several minutes) for a stable response. If the reading at the output device is not correct, adjust zero and span, using zero and span gases, in accordance with the procedures as described in Section 5.3 7866 Analyzer Input Calibration. If only a slight zero-gas error exists, it can be corrected without rechecking the span gas. However, this must be considered a temporary correction and the calibration must be readjusted using both zero and span gas before another adjustment is made. 60 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Maintenance 7. Maintenance 7.1 Routine Maintenance The only routine maintenance required is the periodic checking and replacement of the calibrating and reference-gas cylinders. Note the supply pressure of flowing reference gas (if used), to avoid interruption of continuous gas analysis if the supply becomes exhausted. Check the sampling system flow rate daily to make certain that no blockage or buildup of particulates has occurred. 7.2 Parts Replacement 7.2.1 Sensing Unit IMPROPER SENSING UNIT DISASSEMBLY • Never open the 7866 Sensing Unit case until the line power has been disconnected at the 7866 Digital Controller. • Always loosen the set screw provided on this model before turning the top threaded cover. Failure to comply with these instructions could result in death or serious injury. To remove the threaded cover, turn it counterclockwise and lift it off to expose all terminal board connections. To remove the sensor assembly from its housing, first remove all connections at the terminal board and loosen the two screws (captive) in the cutouts at either side of the round circuit board. Carefully pull up on the handle as shown in Figure 1-2 to withdraw the entire unit. Circuit Card Remove the sensor assembly as described above. Then loosen the two captive screws on the underside of the plastic platform to free the entire circuit-card assembly. Carefully unsolder the 12 leads connecting the circuit card and cell assembly. The solder posts to which each lead is connected is identified in Table 7-1 by the wire color code and the letters adjacent to each post. Note that two of the leads go to the jumper posts (S&T) on the platform.* *If the circuit card is replaced, note that the standard R18 for most standard ranges is 1.5 K ohms and the new card may require the R18 resistor taken from the old card depending upon the range. Cell-Block Assembly Remove the circuit card as described above. It is necessary to unsolder the interconnecting wires. Remove the two screws in the top platform and carefully separate the parts, sliding the platform along the wires. Remove the two screws in the large plastic sleeve and carefully slide this along the wires. This provides access to the top of the block, allowing removal of heaters and thermistors. Identify the leads before unsoldering them from the bottom of the circuit card. See Table 7-1. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 61 62 C1 10µF 35V L2 1DOW N 30 C7 470 pF I N O UT 7815 VR 1 COM D 14 4. 7V I N4732 R3 8. 25K½ 1. 05K½ R2 8. 25K½ 1% R4 C30 0. 44µF C 2 50 V 10µF 35V L 1 100µH, 0. 160 D13 3 4 5 8 C3 0.1½ F 5 0V I N4004 THERMISTORS ARE SHOWN CONNECTED FOR H2 RANGES. FOR SO2 AND CO2 RANGES, WIRES WG AND WB AT TERMINALS E AND C ARE INTERCHANGED. 13 CO M MO N 14 + 30V DC 12 CURRENT OUTPUT 9 µA 723C A1 7 B 2 6 2N 40 36 W J2 J5 MN MN R5 4 2½ 1% R7 66. 5½ 1% : 00ppm R6 3. 65 K½ 1% C E D HG W R10 2K ½ 0.1% 25 PP M REFERENCE WRB THERMISTOR T T R1 J6 C3 0 0. 4 4µF 50V R5 1 K½ 1 0% R W R E W B A B L58 R1 6 80 ½.0 .1% 5ppm R1 5 80 ½.0 .1% 5ppm R14 80 ½.0 .1% 5ppm R1 3 80 ½. 0 .1% 5ppm R12 80 ½.0 .1% 5ppm MS B R11 80 ½ .0 .1% 5ppm C26 22 µF 50 V R19 K N R 0 Y G 22 1 ½ 1% R20 0 0 1 0 1 0 1 0 1 0 1 1 R1 8 1.5 K .05 % .20 ppm 3 0 K.0.1 % 2 5ppm R3 2 71 4C 3 Z J1 R R 10 2K½ R G 0. 1% 2000½ 25P PM WRB MEASURING THERMISTOR C R4 9 2 2 0½. 3 W .1% 221 0 1% R17 4 7 R2 2 714C 3 30 K ½ 0 . 0.1% 25 p pm R21 C2 5 2 2 µF 50V 6 7 4 6 R51 3.3 K½ 1% R50 3.3 K½ 1% 150KO 0. 1% . 2 0ppm R2 2 150KO 0. 1% . 2 0ppm R2 2 3 2 D 10 D11 R24 I N4446 1µF. 50V C2 3 49. 9K½ 0. 1% . 20ppm C11 100pF 7 A5 70 9C 6 4 50K½ 0. 1% . 20ppm R24 1µF. 50V C 24 B C R 28 8.25K½ 1% R 26 1 000 0. 1% 5ppm C22 68µF 16V W H TR2 2N3053 E R27 390½ 10% 1/ 2W G R 27 390 ½ 10% 1/ 2W W 10 9 12 5 C16 68mF R3 4 8. 25KO 1% A5 709C 10pF R35 5. 6MO 1 0% C14 R 32 1 A5 7 8 709C 6 4 3 2 4. 7 KO 10% C13 10pF 2 49KO 1% R31 R30 8. 25½ 1% TEMP CONTROL THERMISTOR R33 3.3K½ 1% C 27 1 µF 1 00 V D5 I N8 25A 6. 2V R2 9 1. 21K½ 1% 1/ 8W 44564 4 H EAT ER BOARD D8 I N4935 L4 3. 32 H C 12 4. 7 µF 50V 150 10W 150 10W HEATERS F R 36 R3 5 3. 9K½ 2 N3 725 C 10% T R3 B 2N R 37 TR 4 4895 1K½ E R55 10% 270 10% 6 D4 IN4935 + J 5 K1 5 6 7 K1- 1 NO 2 4 3 S HI ELD 3 D9 I N4004 4 1 R9 9 2. 2 K½ 1W. 10% NOT E 3 Maintenance Figure 7-1 Sensing Unit Mother and Daughter Circuit Cards Parts List 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Maintenance Measuring and Reference Thermistors These thermistors are the two larger hex-head assemblies mounted in the top of the thermistor-chamber assembly. Leadwires plug onto terminal pins on each hex-head. Unscrew the entire assembly using appropriate care as the thermistors are mounted in small glass knobs at the end of each of these screw-in plugs. (Thermistors can be cleaned with solvent or detergent, rinsed, and dried.) The two thermistor plug assemblies are identical. The cell chambers are identified M for measure and R for reference. If new thermistors are to be installed, replace both seals because leakage between the Measuring and Reference Cell chambers will cause drift of the cell assembly output. Table 7-1 Sensing Unit Cell Assembly Cable Connections CircuitCard Post Wire Cell-Block Circuit CircuitCard Post Wire Cell-Block Circuit A (2) Green/red F White/black Heater B (1) Blue/red from S J White/black Heater C (1) Blue/green G White Thermistor C (1) White/blue/red H White Thermistor D (1) White/brown from T E (1) Green/light green E (1) White/brown Bridge Circuit Temperature-Sensing Thermistors These thermistors are the small hex-head assemblies. The leads are permanently attached. Unscrew the assembly and remove from the cell block. Coat the threads with silicone grease before reinstalling to insure a good thermal contact. Replacements are complete units, including leadwire. Cartridge Heaters in Cell Block Use a large screwdriver to remove the screw-in retainer, then remove the heater. Replace a pair of heaters rather than a single heater. Be especially careful not to damage the leads or insulation. O-rings at Inlet and Outlet Connectors (Figure 7-2) Unscrew each fitting at the bottom of the cell block. The O-ring can now be removed from the cell-block. To remove the internal O-ring from the inlet or outlet fitting the outer casting, use a socket wrench to remove the retaining nut inside the casting, then pull out the entire fitting assembly and remove the O-ring. The external compression-fitting O-ring can be removed easily without taking out the entire assembly. To remove O-rings and flame-arrestor parts from explosion-proof housing proceed as follows: Use a socket wrench to remove the retaining nut inside the casting. Remove the fitting, the small inside O-ring from the flame-arrestor, and withdraw the flame-arrestor fitting. The large outside O-ring can be removed from the fitting and the three filter elements can be pushed through the flame arrestor body from outside the casting with a length of tubing. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 63 Maintenance 7.3 Repacking When repacking for shipment, seal the sensor assembly inlet and outlet ports with tape to prevent packing material from clogging these ports. 1 1 2 2 3 4 3 6 4 7 8 5 9 Figure 7-2 Gas Inlet and Outlet Fitting Parts 64 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Maintenance 7.4 Spare Parts To facilitate servicing and restore operation as quickly as possible in case of trouble, a stock of spare parts should be considered. If such a stock is desired, include the parts listed in Table 7-2. Table 7-2 Recommended Spare Parts Description Part No. Quantity See Model Selection Guide 1 for every 3 to 5 analyzers in use. Lower O-ring For Gas Fittings, Viton A For G = 3 and range -- Suffix D is 075, use Buna N 31005724 31082102 8 5 Middle O-ring For explosion-proof Gas Fittings, Viton A For G = 3 and range -- Suffix D is 075, use Buna N 082049 31075745 4 4 5001154-001 6 O-ring for Explosion-proof Housing Cap 31082103 1 Thermistor detectors (matched pair) 31130135 1 Plastic washer seals (for above detectors) 31301420 2 Resistor pair for Heater Assembly 31411258 1 Heater control Thermistor 31353402 2 Sensor Assembly Flame Arrestor for Explosion-proof Fittings 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 65 Maintenance 66 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Troubleshooting 8. Troubleshooting 8.1 Overview This section describes various possible problems and the means to correct them. 8.2 Troubleshooting 8.2.1 General If trouble is encountered in the adjustment of zero, refer to Section 8.2.2 Recalibration for adjustment procedures. If current flow in the sensing unit-7866 Digital Controller leads cannot be adjusted for 200 microamperes to 500 microamperes, refer to Step 2 in Table 8-4. Alarm circuit problems can usually be solved by referring to Section 5.8 Setting the Alarm Limits. Note that alarm circuits will not activate unless the controller/indicator is set to Range 3. 8.2.2 Recalibration A routine procedure for checking calibration is presented in Table 8-1 Coarse Zero. Do not open, even when isolated, when a flammable/dust atmosphere is present. SENSING UNIT WITH EXPLOSION-PROOF DESIGN • Never open the threaded cover until the power line is disconnected at the 7866 Digital Controller. • Always loosen the set screw before turning the threaded cover. • Never make any test with power applied to the sending unit until you either remove the sensing unit to a nonhazardous area or verify that the atmosphere is free from combustible gases. Failure to comply with these instructions could result in death or serious injury. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 67 Troubleshooting Coarse Zero Adjustment (R11 and R16) It may be necessary at some time to return the control-unit 20-turn fine ZERO (R16) to its center-of-travel position. To do so requires a jumper-wire change in the sensing unit. Table 8-1 Coarse Zero Adjustment Step Action 1 Open the sensing unit and observe the jumper pattern used at the top of the round circuit card (terminal board at bottom). Note that each pin provided for the six jumpers is identified with a 1 or a 0. Determine the binary number formed by the jumper positions used and record this number. The letters identify the color of the corresponding jumper. 2 If the analyzer output current or voltage is above zero or other low-end value and the ZERO adjuster is at its counterclockwise limit, determine that binary number which is one digit lower than the number recorded and change the necessary jumper positions to form this number. For example, if the jumpers are positioned to form binary number 111001, then the jumpers must be repositioned to form the next lower number binary 111000. Change the sixth jumper from 1 to 0. If the analyzer reading is below the low-end range value and the ZERO is at its clockwise limit, the zero must be shifted upscale. Position the jumpers to form the next higher number, e.g., from binary 011010 to 011011. Move the right-end jumper from 0 to 1. Refer Table 8-2 for the sequence used in binary counting. The card is screened with MSB (Most Significant Bit) and LSB (Least Significant Bit). 3 The above jumper change should permit the return of fine ZERO adjuster R16 to its center-oftravel position and allow completion of the analyzer zero adjustment. If it does not, simply increase or decrease the binary number by one digit more. A change of one binary count is equivalent to one-half travel of control unit ZERO (R16). If jumpers are changed inadvertently before the binary number has been recorded (or if thermistor detectors have been replaced) re-establish the correct jumper pattern. Measure the sensing-unit current output by connecting a meter in series with terminal 12 at the sensing unit while zero-gas flows through the sensing unit. Proceed through the steps in Table 8-3 in numerical sequence only until the current output measures between 250 µA and 240 µA. Jumpers that have been placed in their final positions, not been moved, are marked X. Start with binary 32 (100000). Table 8-2 Binary Count Sequence for Coarse Zero Jumper Pattern 68 MSB LSB MSB LSB MSB LSB MSB LSB 0 000000 16 010000 32 100000 48 110000 1 000001 17 010001 33 100001 49 110001 2 000010 18 010010 34 100010 50 110010 3 000011 19 010011 35 100011 51 110011 4 000100 20 010100 36 100100 52 110100 5 000101 21 010101 37 100101 53 110101 6 000110 22 010110 38 100110 54 110110 7 000111 23 010111 39 100111 55 110111 8 001000 24 011000 40 101000 56 111000 9 001001 25 011001 41 101001 57 111001 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Troubleshooting MSB LSB MSB LSB MSB LSB MSB LSB 10 001010 26 011010 42 101010 58 111010 11 001011 27 011011 43 101011 59 111011 12 001100 28 011100 44 101100 60 111100 13 001101 29 011101 45 101101 61 111101 14 001110 30 011110 46 101110 62 111110 15 001111 31 011111 47 101111 63 111111 Table 8-3 Coarse-Zero Jumper Pattern Jumper Positions Step If current is G Y O R N K 1 above 450 µA below 250 µA 1 0 1 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 2 above 450 µA below 250 µA X X 0 1 1 1 0 0 0 0 0 0 3 above 450 µA below 250 µA X X X X 0 1 1 1 0 0 0 0 4 above 450 µA below 250 µA X X X X X X 0 1 1 1 0 0 5 above 450 µA below 250 µA X X X X X X X X 0 1 1 1 8.2.3 Fault Isolation Tests The troubleshooting guide provided in Table 8-4 can be used in conjunction with the fault-isolation tests to identify and solve most analyzer problems. If the source of trouble is not apparent from the symptoms given in the table, then the following checks may be used to isolate the site of an unknown source of trouble to either the sensing unit or the 7866 Digital Controller. The troubleshooting table can be used to better identify the malfunction, either before or after these isolation tests are performed, according to the specific symptom. When the fault is thus generally located, replace the faulty circuit card with a spare and return the card to Honeywell for repair in order to quickly restore service. The following is a list of test equipment required to perform all of the various tests and troubleshooting procedures described in this section: • Simpson Model 260 Multimeter or equivalent 20,000 ohms-per-volt meter for voltage, current, and resistance measurements. • Resistor 2500 ohms ± 5 % • Resistor 30 ohms, 25 watts • Six-volt battery • Adjustable resistor (up to 20 K ohms) • Span gas mixture equal to full-scale reading 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 69 Troubleshooting 7866 Digital Controller Test At the control-unit terminal board, disconnect the sensing unit leads connected to terminals 9, 12, 13, and 14, and connect a dummy load of 30 ohms, 25 watts across 13 and 14. Voltage measured across this load should be between 24 volts dc and 28 volts dc. Use a six-volt battery, the current meter and an adjustable resistance (up to 20K ohms) in series across terminals 12 (+) and 13 (–). Connect (–) battery terminal to terminal 13. Pass about 350 uA between terminals 12 and 13. The control unit should display 0.0 % for Range 1. Refer to Section 5 for the proper Calibration procedure, if necessary. Leaving the above circuit connected, set the meter to its 20 mA range. Now adjust the current flow and observe the mA reading. The current flow required to obtain a 5-volt reading across terminals 12 and 13 must not exceed 20 mA. The control unit should display 100.0 % for Range 1. Refer to Section 5 for the proper Calibration procedure, if necessary. If either of these values are not achievable, then the controller’s analog input card is suspect. Before drawing that conclusion, check the obvious. Wiring and bad connections often are the cause. Sensing Unit Test Remove the upper housing. The entire cell assembly can be left in the lower housing or removed as desired. Connect the 26 Vdc to 32 Vdc power supply (1 ampere) to terminals 13 (–) and 14 (+) and wait one half hour for warm-up. Connect a current meter in series with 2500 ohms between terminals 12 (+) and 13 (–). Pass the “zero” gas through the sensing unit at a rate of 500 to 1000 cc per minute. (Provide a reference gas flow if required.) The current reading on the test meter should be 200 uA to 500 uA. If not, adjust coarse zero jumpers per the Coarse Zero Adjustment (R11 and R16). Remove the “zero” gas and pass a full-scale gas through the sensing unit at a rate of 500 to 1000 cc per minute and note the current reading on the test meter. The current must increase by at least 1 mA to 2 mA for the change from “zero” gas to full-scale “span” gas. The change may be as much as 20 mA depending on range. If any of these conditions cannot be attained, probably the circuit card or the thermistors are defective. Table 8-4 Troubleshooting Procedures Symptom 1. Blank display Possible Cause 1a. No line voltage. Recommended Checks 1a. Check for correct voltage at terminals L1/H and L2/N. 1b. Replace the display. 2. Cannot adjust for zero signal with “zero” gas. 2a. ZERO adjuster in 7866 Digital Controller is out of adjusting range. 2a. Adjust coarse ZERO in sensing unit in accordance with the Coarse Zero Adjustment. 2b. Open signal circuit. (Causes below-zero signal.) 2b. Check interconnecting wiring between 7866 Digital Controller and sensing unit for continuity. 2c. Detector unbalance is too large. 2c. With “zero” gas flowing, connect a highimpedance voltmeter (on 5 V range) first between pins A and E, then between pins A and C. If (VAE – VAC)/(VAE + VAC) is greater than ± –0.035, replace or clean the pair of detectors in the cell block. 70 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Troubleshooting Symptom 3. Insufficient span with “span” gas flowing and SPAN ADJUSTER turned fully clockwise. 4. Slow response. 5. Noisy output signal or electrical interference. 9/06 Possible Cause Recommended Checks 3a. Faulty current regulator for detector bridge. 3a. Check for 3.75 volts ± 0.4 volts between pin E and terminal 13. (This is equivalent to checking bridge current for 55 mA ± 5 mA.) 3b. Faulty sensing-unit amplifier. 3b. Disconnect the lead at terminal 12 in the sensing unit and connect a 0-1 mA current meter across terminals 12 (+) and 13 (–). Refer to Table 8-2 and increase the coarsezero binary count (on the coarse-zero jumper pattern described in the Course Zero Adjustment procedure) by one number. Current flow should increase about 250 uA. This verifies that gain is normal.* 3c. Damaged measuring detector. 3c. Connect a millivolt meter across circuit points A and D (at center of round card). Make the zero adjustment in accordance with the Recalibration procedure. Pass a span-gas mixture equivalent to a full-scale measurement through the sensing unit. The meter reading for 1% H2 should be at least 10 mV.** If it is less, the detectors must be cleaned or replaced. 4a. Low flow rate. 4a. Increase flow rate to 2000 cc/min. for maximum speed or response. 4b. Sample lines too long; filter volumes too large, etc. for flow rate. 4b. Increase flow rate above 2000 cc/min., venting excess flow above 2000 cc/min. with a by-pass valve upstream of the analyzer. 4c. Measuring detector or cell block is dirty. 4c. Remove detectors and check for flow between inlet and cell before remounting the detectors. 5a. Lack of earth ground 5a. Check that ground wire is connected to ground terminal and that controller case is connected to ground terminal. 5b. Power line not grounded correctly. 5b. Check that terminal L2/N is connected to the neutral or grounded side of power line. If one side of line is not grounded, install an isolation transformer and ground terminal L2/N. 5c. Flow rate too high 5c. Check that flow does not exceed 2000 cc/min.*** 5d. Cracked or dirty measuring detector. 5d. Remove measuring detector, inspect for cracks in glass or loose dirt in cell. 5e. Faulty detector bridge-current regulator. 5e. Replace sensing-unit printed circuit card assembly.**** 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 71 Troubleshooting Symptom 6. Output signal is unstable. 7. Alarm malfunction. Possible Cause Recommended Checks 6a. Temperature control is inoperative. 6a. Check cell block for approximately 50 °C (122 °F) temperature (too hot to hold in the hand for very long). Check heaters for 30 ohms nominal resistance for series pair. Ambient temperature must not exceed 50 °C (122 °F). 6b. Temperature control cycles. 6b. Check that temperature-sensing thermistor is screwed tightly into the cell block and that its tip and threads are coated with silicone grease. Connect a 0 to 1 amp meter in series with one of the heater leads. During warm-up, current should be approximately 800 mA. When 50 °C (122 °F) is reached current will decrease, cycling 2 or 3 times before current stabilizes at a lower value. If cycling continues, replace the sensing unit circuitcard assembly.**** 6c. Sample flow rate or composition varies. 6c. Check stability when operating on zero gas. If stable, check for large sample flow variations, water vapor variations due to unstable drier or cooler operation, etc. 7a. Alarm set point calibration is inaccurate. 7a. Adjust “Alarm 1” or “Alarm 2”. (See Section 5.8.) 7b. Relay contacts worn or damaged. 7b. Replace circuit board if required. 7c. Relay fails to energize (alarm condition always indicated). 7c. Check alarm limits. (See Section 5.8.) 7d. Relay fails to de-energize (alarm condition never indicated). 7d. This is normal while in Range 1 or 2. Check alarms limits while in Range 3. *For hydrogen spans greater than 10 %, current increase should be about 80 uA. **For higher ranges minimum reading is proportionately higher, e.g., for 0 % to 30 % H2, reading should be 30 mV. ***On flowmeters calibrated for air, note that actual flow may exceed that indicated for H2 or other gases. ****Temperature regulator is a high-frequency variable-duty cycle controller and field repair is not recommended. Replace the entire sensing-unit card and return the faulty unit to the factory for repairs. 72 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Troubleshooting 8.2.4 Additional Troubleshooting General Verify that piping of analyzer and flow rates are correct. Verify that wiring of analyzer is correct. Power Supply Fault 30 V supply — Measure voltage between sensing-unit terminals 14 (hot) and 13 (common.). It should read 30 +2, –6 volts. Actual value depends upon current drawn by heaters. Temperature Control Inoperative Heater voltage — Measure voltage between the sensing-unit terminal given below (hot) and terminal 13 (common). Terminal F. Warmed-up (at 50 °C); 19 ± 3 V. Cold start from (25 °C); 2.5 ± 0.5 V Terminal J. Warmed-up (at 50 °C); 30 +2, -4 V. Cold start from (25 °C): 28 ± 3 V. Heater thermistor voltage — Measure voltage between the sensing-unit terminal given below (hot) and terminal 13 (common). Terminal G. Warmed-up (at 50 °C): 6.2 ± 0.2 V. Cold start from (25 °C): 6.2 ± 0.2 V. Terminal H. Warmed-up (at 50 °C): 3.1 ± 0.1 V. Cold start from (25 °C): 1.5 ± 0.5 V. Zero and Span Check — measure current in Sensing-unit Terminal 12 Zero gas (air) – Sensor output current to be between 250 uA and 450 uA. Range 1 – Sensor output current to be approximately 1.5 mA at 100 % CO2 Range 2 – Sensor output current to be approximately 12 mA at 100 % CO2 Range 3 – Sensor output current to be approximately 3 mA at 75 % H2 in N2 Resistance Check (Sensor Card Disconnected) R8 = 2078 ohms ± 0.1 % R10 = 2000 ohms ± 0.1 % Temperature Control Thermistors 50 °C, 122 °F, R= 3.6 K ohms ± 5 % 25 °C, 77 °F, R = 10 K ohms ± 5 % Heaters, R = 30 ± 3 ohms (one pair) Measuring Cell (WR to WB wires) 50 °C, 122 °F, R = 2024 ohms ± 20 % 25 °C, 77 °F, R = 5000 ohms ± 20 % Reference Cell (WR to WG wires) 50 °C, 122 °F, R = 2024 ohms ± 20 % 25 °C, 77 °F, R = 5000 ohms ± 20% Measuring and reference cells resistances should be matched to 1 %. Test for short circuit between leads of each of the above components and case ground. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 73 Troubleshooting 74 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Appendix A 7872 Gas Sampling Panel 9. Appendix A – 7872 Gas Sampling Panel 9.1 Overview This section contains information and drawings to be used with the 7872 Gas Sampling Panel is in use. 9.2 Model Selection Guide 51-52-16-36 Issue 4 KEY NUMBER Description 7872 Sample Panel for Hydrogen Generator Applications - All Stainless Steel Construction TABLE I - SAMPLE MOTIVE FORCE Standard for H2 Cooled Generator Applications - All Stainless Steel Constructions 3 0 TABLE III - ANALYZER COMPATIBILITY For Use with 7866 Analyzer 0 PARTS: Description Replacement Reference Air Regulator Filter Cartridge for Reference Air Regulators Filter Cartridge for Sample Regulator Replacement Sample Regulator Kit Availability 07872 TABLE II - SAMPLE MOISTURE CONTENT For Sampling Dry Sources TABLE IV - TAGGING OPTIONS None Linen Tag - Up to 15 Characters on 3 Lines Stainless Steel Tag - Up to 22 Characters on 3 Lines Engraved Nameplate 9/06 Selection 000 206 208 239 Part Number 51451417-501 072927 51500286-501 51500283-501 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 75 Appendix A 7872 Gas Sampling Panel 9.3 Installation 1 See Figure 9-1 for mounting dimensions of the Gas Sampling Panel. Mount the Analyzer after mounting the Gas Sampling Panel. The three stainless steel tubing connections made to the bottom of the analyzer housing must not be overly tightened. The seal is made by an O-ring in each analyzer fitting that grips the OD of the stainless steel tubing. If the fittings are too tight, O-ring damage may occur. 2 All panel connections along the right side are 1/4 OD tube compression fittings. These connections along the right side are 1/4 OD tube compression fittings. These connections can be tightened one and one quarter turn to affect a seal upon installation of sample, calibration gas and vent-lines. 3 The bypass valve is included to prevent pressure build-up in the sensor housing. The bypass valve is preset at 5 psig. During normal panel operation, the bypass valve remains closed and the bypass flowmeter indicates no flow. If the bypass flowmeter indicates flow, check for clocked sample vent and/or abnormally high pressure setting on sample regulator or calibration gases. (If the bypass valve is to be replaced, note flow direction arrow stamped on valve body.) 4 The reference air regulator and sample regulator should be set at a pressure sufficient to allow control of flow using the flowmeter valves (REF. AIR FLOW, CO2/AIR FLOW, H2 FLOW). The flowmeter settings should be approximately 2 SCFH. 5 Before adjusting the Ref. Air Regulator or Sample Regulator, unlock the adjustment knob by pulling up on the yellow lock ring. After adjustment is made, push down on the lock ring to maintain the setting. For 7866 explosion-proof applications, set regulator pressure no higher than 2 psig The four-way selector valve is used to select from ZERO gas, SPAN gas or SAMPLE gas inlets. The outlet of the four-way valve feeds into the three-way selector valve. The three-way valve is used to direct the gas flow to either the CO2/AIR Flowmeter or the H2 Flowmeter. Whenever sample or calibration gases contain a high content of H2, adjust the 3-way selector valve to direct flow to the H2 flowmeter for accurate flow determination. This will avoid unnecessary consumption of pure H2 gas. 76 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 9/06 5 (127 mm) 0.250 Dia. (6.35 mm) Mounting Holes (4) 18 (457.2 mm) 30 (762 mm) Gas Analyzer to be mounted as shown. Allow 12.875 (327 mm) for cover and sensor removal. 0.625 (15.87 mm) ”A” ”B” ”C” ”A” H2 FLOW CO2/AIR FLOW BYPASS VALVE ”A” REF AIR FLOW BYPASS VENT SAMPLE VENT SAMPLE GAS IN SAMPLE REGULATOR 1.250 (31.75 mm) 5.122 (130.1 mm) Sample Vent Bypass Vent 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 1 to 1000 psig Exhaust to Safe Location at Atmospheric Pressure Customer Connections (6) 14” O.D. Tube Fittings 4.870 (123.7 mm) 3.763 (95.6 mm) 5.219 (132.6 mm) 8.765 (222.6 mm) Front of Panel 2.266 (57.6 mm) 0.687 (17.5 mm) Ref Air In Zero Gas In Span Gas In Sample Gas In SPAN GAS IN ZERO GAS IN REF AIR IN REF AIR REGULATOR BYPASS FLOW 28.750 (730.3 mm) 30.125 (765.2 mm) C D A Zero Gas: 100% Air: Range 1 100% H2: Ranges 2 & 3 Span Gas: 100% CO2: Ranges 1 & 2 75% H2 in N2: Range 3 Calibration Gases Required for Triple Range Analyzer A-Sample Inlet B-Sample Outlet C-Ref Air In D-Ref Air Out (Atmos. Press.) SKETCH “A-A” Analyzer Bottom View Mtg. Boss B 1.125 (28.58 mm) Appendix A 7872 Gas Sampling Panel Figure 9-1 7872 Gas Sampling Panel Mounting Dimensions 77 Appendix A 7872 Gas Sampling Panel SAMPLE VENT BYPASS VENT BYPASS FLOW 5.5 (139.7 mm) REF AIR FLOW A "B" "C" REF AIR REGULATOR "A" 4 (101.6 mm) BYPASS VALVE C REF AIR IN A 3 (76.2) Section “A-A” CO2/AIR FLOW A,B ZERO GAS IN B H2 FLOW SPAN GAS IN SAMPLE REGULATOR B Section “B-B” Partial Side View SAMPLE GAS IN Figure 9-2 7872 Gas Sampling Panel Exploded View 9.4 Maintenance Table 9-1 lists the replaceable parts for the Gas Sampling Panel. Refer to the exploded view in Figure 9-2. Table 9-1 Replaceable Parts for 7872 Gas Sampling Panel Description Filter Cartridge for Sample Regulator 78 Part No. 51500286-501 Ref Air Flowmeter 31098038 Co2/Air Flowmeter 31098038 3-way Selector Valve 31072929 Ref Air Regulator (includes Filter cartridge) 51451417-501 Sample Regulator (includes filter cartridge) 51500283-501 Gas Inlet and Vent Bulkhead Union Connectors 31076870 Bypass Flowmeter 31072935 Bypass Valve (5 psig) 31072926 H2 Flowmeter 31072925 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 Appendix B Security Bypass 10. Appendix B – Security Bypass 10.1 Overview Your controller has a security bypass code. Secured areas cannot be accessed without the use of the Operator or Master codes. If you have forgotten or misplaced the access code, you can enter the factory default code, “7866”. Use the procedure given in Table 5-8 to enter 7866 to override the forgotten code. 9/06 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 79 Appendix B Security Bypass 80 7866 Triple Range Digital H2 and CO2 Analyzer/Indicator - Operation and Maintenance 9/06 11. Sales and Service For application assistance, current specifications, pricing, or name of the nearest Authorized Distributor, contact one of the offices below. ARGENTINA HONEYWELL S.A.I.C. BELGRANO 1156 BUENOS AIRES ARGENTINA Tel. : 54 1 383 9290 ASIA PACIFIC HONEYWELL ASIA PACIFIC Inc. Room 3213-3225 Sun Kung Kai Centre N° 30 Harbour Road WANCHAI HONG KONG Tel. : 852 829 82 98 AUSTRALIA HONEYWELL LIMITED 5 Thomas Holt Drive North Ryde Sydney NSW AUSTRALIA 2113 Tel. : 61 2 353 7000 AUSTRIA HONEYWELL AUSTRIA G.m.b.H. 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