MODEL 2350A GAS CHROMATOGRAPH CONTROLLER __________________________________________ USER GUIDE 2 H S CEM APPLICATION Applies to both: Daniel Danalyzer Gas Chromatographs Rosemount Analytical Process Gas Chromatographs Part Number 3-9005-006 Revision B OCTOBER 2005
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MODEL 2350A GAS CHROMATOGRAPH CONTROLLER __________________________________________
USER GUIDE
2H S CEM APPLICATION
Applies to both:Daniel Danalyzer Gas Chromatographs
Rosemount Analytical Process Gas Chromatographs
Part Number 3-9005-006
Revision BOCTOBER 2005
MODEL 2350A GAS CHROMATOGRAPH CONTROLLER OCT 2005
iPREFACE
2USER GUIDE H S CEMMODEL 2350A GAS CHROMATOGRAPH
CONTROLLER APPLICATION
NOTICE
DANIEL MEASUREMENT AND CONTROL, INC. AND ROSEMOUNT ANALYTICAL, INC. (COLLECTIVELY,
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2The H S CEM (Continuous Emissions Monitoring) application is based on the standard 2350A mode1 application, v1.75, enhanced as described below.
New Functionality:
Automatic Validation
The validation sequence is automatically run once a day at the time specified by the variable named'ValStartTime' (Validation Start Time). Use the Application>User Defined>Numeric menu to accessthe 'ValStartTime' variable.
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The default Validation Start Time is 600 (6:00 a.m. or 0600 in 24-hr time). The 'ValStartTime' iscalculated ((Hours*100)+Minutes). If a validation is needed to run at 7:30 a.m. every day theoperator would calculate the time by:
7*100 = 700 then 700 + 30 = 730.
The value '730' would then be entered into the 'ValStartTime' Value field.
If using 24-hour time, and the validation process was to start at 14:25 in the afternoon, the timewould then be calculated by:
14*100=1400then1400+25=1425
The value 1425 would then be entered into the 'ValStartTime' Value field.
Manual Validation
Start the validation process manually at any time by setting the Option field of the 'StartVal'variable. Use the Application>User Defined>Selection menu to access the StartVal dialog.
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StartVal - 1 = IDLE, 2 = START - manually starts the validation sequence. When the applicationdetects START, it sets 'Discrete Input #5' to ON, which then initiates the auxiliary stream sequencefor the validation.
Click the start option and then click the OK button to apply the change.
Whichever method is used to start the Validation process, Manual or Timed, the Switch field, of'Digital Input #5', labeled 'Run_Aux_Seq' is set to ON, triggering the Validation Process.
Use the Application>User Defined>Selection menu to access the Validation Start process or fromwriting the integer '2' to this register. When the application detects a manual 'Start' from the 'StartVal'variable in the Application>User Defined>Selection menu, this register is set to 2 - (Start), theapplication then sets 'Discrete Input #5' to ON which initiates the validation process by running the'Auxiliary Stream Sequence'.
Sim2251 Register 8018 (Validation Failure Flag) RO - “1" indicates that the last validationsequence failed. Location #1 from Application>Discrete Alarms menu shows the location of thefailure. Discrete Outputs 1 through 3 may be assigned to this alarm at location #1.
The validation process is controlled by the 'Auxiliary Stream Sequence'. Use the Application>Systemmenu to access the Systems dialog. This application, is set up to run in the following stream order:2,2,2,3,3,3,1.
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Numeric Entries:
To access the User Defined Numerics Entries dialog use the Application>User Defined>Numericmenu.
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This is where the variables listed below are assigned values.
ValStartTime - Validation Start Time. ((hrs * 100) + mins) The time each day the validationsequence will begin. If invalid, validation sequence will not be run.
2ValLoStrm - Validation Low Stream. The stream number for the low H S concentration stream (2for this application)
2ValHiStrm - Validation High Stream. The stream number for the high H S concentration stream (3for this application)
ValCalStrm - Validation Calibration Stream. The calibration stream number for the validationprocess to re-calibrate either Stream 2 or 3 when out of limits(3 for this application).
ValAnlStrm - Validation Analysis Stream. The analysis stream number used for determining the
2CDT that will have the response factor of H S updated after the validation calibration run iscompleted (1 for this application).
ValToFail - Validation To Fail. The number of times the validation sequence will run when avalidation calibration fails, before the validation process is aborted and the validation failure alarmis set (1 for this application).
ValLoConc - Validation Low Concentration. Nominal concentration of ValLoStrm (30 ppm for thisapplication)
ValLoDevLim - Validation Low Deviation Limit. Allowable percentage from nominal concentration(±10% for this application)
ValHiConc - Validation High Concentration. Nominal concentration of ValHiStrm (240 ppm forthis application)
ValHiDevLim - Validation High Deviation Limit. Allowable percentage from nominalconcentration (±10% for this application)
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Streams 1 and 4
Both Streams 1 and 4, run on Component Data Table 1 and Timed Event Table 1. Stream 1 is thestandard analysis stream. Stream 4 is the standard calibration stream for Component Data Table 1.Stream 4 is periodically run on a calibration gas bottle and updates the component retention timesand response factors of CDT1 after normal calibrations.
Stream 1 is also the 'ValAnlStrm' (Validation Analysis Stream), the stream used to determine on
2which component data table the H S response factor will be updated when the validation calibrationprocess on Stream 3 is run.
For this application, Stream #1 is assigned to Component Data Table #1. The response factor for
2H S on Component Data Table #1 will be updated when the validation calibration process on Stream#3 is run.
Streams 2 and 3
Streams 2 and 3 are assigned to Component Data Table #2.
2Stream #2 for this application, is the H S low concentration stream, 'ValLoStrm' (Validation LowStream).
2Stream #3 for this application, is the H S high concentration stream 'ValHiStrm' (Validation HighStream).
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Validation Sequence
Validation Streams within Limits
When a validation process has been started manually from the Application>User Defined> Selectionmenu or automatically by the 'StartValTime' setting, 'Discrete Input #5' is set to ON which initiatesthe 'Auxiliary Stream Sequence'. The validation process which is being controlled by the 'AuxiliaryStream Sequence' in the 'System' submenu begins. Running in order the streams 2,2,2,3,3,3,1.
The SIM2251 Modbus bus register 8019 (Operational Status) is set to 4 (Validation). If thevalidation process was started manually by setting the 'StartVal' Option field in theApplication>User Defined>Selection menu to 'Start', SIM2251 Modbus Register 8017 (StartVal)will be set to 2 (Start). Modbus Register 8017 is not changed if the validation process was a timevalidation.
2On the last run of Stream2, the 'ValLoStrm', the calculated Mole % of H S on Stream 2 running the
2low H S calibration bottle is compared to the 'ValLoConc' value assigned to Stream 2 in the numericsubmenu. For this application, the Default 'ValLoConc' value is 30 ppm.
2If the above calculated Mole % of H S on the 'ValLoStrm' (Stream 2) is within the 'ValLoConc'limits specified by the variable 'ValLoDevLim' (±10% for this application, between 27 ppm and 33ppm), then the 'ValHiStrm' (Stream 3) is run.
2On the last run of Stream3, the 'ValHiStrm', the calculated Mole % of H S on Stream 3 from the
2High H S calibration bottle is compared to the 'ValHiConc' value assigned to Stream 3, in theNumeric submenu. For this application, the 'ValHiConc' value is 240ppm.
2If the above calculated Mole % of H S on the 'ValHiStrm' (Stream 3) is within the 'ValHiConc' limitsspecified by the variable 'ValHiDevLim' (±10% for this application, between 216 ppm and 264 ppm),the controller goes to 'Idle' for a short period of time. 'Discrete Input #5' is returned to OFF, Sim2251Modbus registers 8017 (StartVal) is set to 1 (Idle), if it was a manual start. Register 8019 is set to2 (Analysis), and the 2350A Controller resumes normal analyses on Stream 1.
The validation process is initiated. 'Discrete Input #5' is set to 'ON'. SIM2251 Modbus bus register8019 (Operational Status) is set to 4 (Validation). Register 8017 (StartVal) is set to 2 (Start) if thevalidation process was started manually, otherwise register 8017 remains at 1 (Idle). The validationprocess begins running the 'Auxiliary Stream Seq'.
2On the last run of Stream2, the 'ValLoStrm', the calculated Mole Percent of H S on Stream 2 running
2the low H S calibration bottle is compared to the 'ValLoConc' value assigned to Stream 2 in theNumeric submenu. For this application the default 'ValLoConc' value is 30ppm.
2If the above calculated Mole% of H S on the 'ValLoStrm' (Stream 2) is found to be out of the'ValLoConc' limits specified by the variable 'ValLoDevLim' (±10% for this application, between 27ppm and 33 ppm), then the validation sequence is 'Halted'. The system goes to 'Idle' for a short periodof time. Then a calibration sequence is run on the 'ValHiStrm' (Stream 3).
At the end of the calibration sequence on the 'ValHiStrm', if the new calculated response factors fall
2within the component data table's 'Response Factor % Dev' limits, then the H S response factor willbe updated in both component data tables.
2At this time the validation process is repeated, the calculated H S Mole % for the 'ValLoStm' is
2checked against the 'ValLoConc' limits. The calculated H S Mole % for the ValHiStrm' is checkedagainst the 'ValHiConc' Limits, and if both are found to be in Range, the Controller goes to 'Idle' fora short Period. 'Discrete Input #5' is returned to OFF, Sim2251 Modbus registers 8017 (StartVal)is set to 1 (Idle), if the validation process was a manual start. Register 8019 is set to 2 (Analysis), andthe 2350A Controller resumes normal analyses on Stream 1.
High Stream Validation Failure (Calibration Correctable)
The validation process is initiated. 'Discrete Input #5' is set to ON. SIM2251 Modbus bus register8019 (Operational Status) is set to 4 (Validation). Register 8017 (StartVal) is set to 2 (Start) if thevalidation process was started manually, otherwise register 8017 remains at 1 (Idle). The validationprocess begins running the 'Auxiliary Stream Seq'.
2On the last run of Stream2, the 'ValLoStrm', the calculated Mole % of H S on Stream 2 running the
2Low H S calibration bottle is compared to the 'ValLoConc' value assigned to Stream 2 in theNumeric submenu. For this application, the Default 'ValLoConc' value is 30ppm.
2If the above calculated Mole % of H S on the 'ValLoStrm' (Stream 2) is within the 'ValLoConc'limits specified by the variable 'ValLoDevLim' (±10% for this application, between 27 ppm and 33ppm), then the 'ValHiStrm' (Stream 3) is run.
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2On the last run of Stream 3 in the validation process, If the calculated Mole % of H S on the'ValHiStrm' (Stream 3) is found to be out of the 'ValHiConc' limits specified by the variable'ValHiDevLim' ±10% for this application, between 216 ppm and 264 ppm), then the validationsequence is 'Halted'. The system goes to 'Idle' for a short period. Then a calibration sequence is runon the 'ValHiStrm' (Stream 3).
At the end of the calibration sequence, if the new calculated response factors fall within the
2component data table's 'Response Factor % Dev' limits, then the H S response factor will be updatedin both component data tables.
2At this time the validation process is repeated, the calculated H S Mole % for the 'ValLoStm' is
2checked against the 'ValLoConc' limits. The calculated H S Mole % for the ValHiStrm' is checkedagainst the 'ValHiConc' limits, and if both are found to be in range, the controller goes to 'Idle' fora short period pf time. 'Discrete Input #5' is returned to OFF, Sim2251 Modbus registers 8017(StartVal) is set to 1 (Idle) if the validation process was manually started. Register 8019 is set to 2(Analysis), and the 2350A Controller resumes normal analyses on Stream 1.
Low Stream Validation Failure (A Condition Uncorrectable by Calibration)
The validation process is initiated. 'Discrete Input #5' is set to 'ON'. SIM2251 Modbus bus register8019 (Operational Status) is set to 4 (Validation). Register 8017 (StartVal) is set to 2 (Start) if thevalidation process was started manually, otherwise register 8017 remains at 1 (Idle). The validationprocess begins running the 'Auxiliary Stream Seq'.
On the last run of Stream2 during the validation process, the 'ValLoStrm', the calculated Mole % of
2 2H S on Stream 2 running the Low H S calibration bottle is compared to the 'ValLoConc' valueassigned to Stream 2 in the Numeric submenu. For this application the default 'ValLoConc' value is30 ppm.
2If the above calculated Mole % of H S on the 'ValLoStrm' (Stream 2) is found to be out of the'ValLoConc' limits specified by the variable 'ValLoDevLim' (+/-10% for this application, between27 ppm and 33 ppm), then the validation sequence is 'Halted'. The system goes to 'Idle' for a shortperiod. Then a calibration sequence is run on the 'ValHiStrm' (Stream 3).
At the end of the calibration sequence on the 'ValHiStrm', if the new calculated response factors are
2outside the component data table's 'Response Factor % Dev' limits, the H S Response Factor for thecomponent data tables will not be updated. The active 'Excess Response Factor Deviation' alarm willbe set. The validation process is then repeated.
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Before setting the validation failure alarm, the validation process will be repeated the number oftimes specified by the value assigned to the 'ValToFail' variable in the User Defined Numericssubmenu. For this application, the default repeat value is 1.
When this validation process has completed, the controller goes to 'idle' for a short period, and if theout of range condition is found to still exist, the following events take place:
21) The active 'H S Validation Check Failed' alarm is set.
2) If a discrete output has been assigned to the validation alarm In the Discrete Alarmssubmenu, it will be activated.
3) Sim2251 Modbus Register 8017 (StartVal) returns to 1 (Idle) if the validation process wasmanually started.
4) Sim2251 Modbus register 8018 (Validation Failure Flag) is set to '1' (Failed). 5) Sim2251 Modbus registers 8019 (Operational Status) is set to '2' (Analysis).
6) 'Discrete Input #5' is reset to OFF.
7) The controller resumes running Stream 1 analyses.
2The active 'H S Validation Failure' alarm can be cleared in MON. But SIM2251 Modbus register8018 (Validation Failure Flag) and the 'Discrete Output', if one has been assigned to the validationalarm in the Discrete Alarms submenu, will remain set.
The Modbus register 8018 (Validation Failure Flag) and the discrete output will only be clearedwhen the conditions causing the validation failure has been cleared and the validation process passes.
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High Stream Validation Failure (A Condition Uncorrectable by Calibration)
The validation process is initiated. 'Discrete Input #5' is set to ON. SIM2251 Modbus bus register8019 (Operational Status) is set to 4 (Validation). Register 8017 (StartVal) is set to 2 (Start) if thevalidation process was started manually, otherwise register 8017 remains at 1 (Idle). The validationprocess begins running the 'Auxiliary Stream Seq'.
On the last run of Stream2 (the VAlLoStrm) during the validation process, the calculated Mole %
2 2of H S on Stream 2 running the Low H S calibration bottle is compared to the 'ValLoConc' valueassigned to Stream 2 in the Numeric submenu, for this application the default 'ValLoConc' valueis 30 ppm.
2If the above calculated Mole % of H S on the 'ValLoStrm' (Stream 2) is within the 'ValLoConc'limits specified by the variable 'ValLoDevLim' (±10% for this application, between 27 ppm and 33ppm), then the validation process begins on the 'ValHiStrm' (Stream 3).
2On the last run of Stream 3 in the validation process, If the calculated Mole % of H S on the'ValHiStrm' (Stream 3) is found to be out of the 'ValHiConc' limits specified by the variable'ValHiDevLim' (±10% for this application, between 216 ppm and 264 ppm), then the validationsequence is 'Halted'. The system goes to 'Idle' for a short period. Then a calibration sequence is runon the 'ValHiStrm' (Stream 3).
At the end of the calibration sequence on the 'ValHiStrm', if the new calculated response factors are
2outside the component data table's 'Response Factor % Dev' limits, the H S response factor for thecomponent data tables will not be updated. The active 'Excess Response Factor Deviation' alarm willbe set. The validation process is then repeated.
Before setting the validation failure alarm, the validation process will be repeated the number oftimes specified by the value assigned to the 'ValToFail' variable in the User Defined Numericssubmenu. For this application the default repeat value is 1.
When this validation process has completed, the controller goes to 'idle' for a short period, and if theout of range condition is found to still exist, the following events take place:
21) The active 'H S Validation Check Failed' alarm is set.
2) If a discrete output has been assigned to the validation alarm in the 'Discrete Alarms'submenu, it will be activated.
3) Sim2251 Modbus Register 8017 (StartVal) returns to 1 (Idle) if the validation process wasmanually started.
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4) Sim2251 Modbus register 8018 (Validation Failure Flag) is set to '1' (Failed). 5) Sim2251 Modbus registers 8019 (Operational Status) is set to '2' (Analysis).
6) 'Discrete Input #5' is reset to 'OFF'.
7) The controller resumes running Stream 1 analyses.
2The active 'H S Validation Failure' alarm can be cleared in MON. But SIM2251 Modbus register8018 (Validation Failure Flag) and the 'Discrete Output', if one has been assigned to the ValidationAlarm in the Discrete Alarms submenu, will remain set.
The Modbus register 8018 (Validation Failure Flag) and the discrete output will only be clearedwhen the conditions causing the validation failure has been cleared and the validation processpasses.
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Modbus Register Definitions:
(SIM2251) (User-Modbus)Field Strm Component
8007 ValStartTime R/W Cus_Cmp_Data-Field2 1 38008 ValLoStrm R/W Cus_Cmp_Data-Field3 1 38009 ValHiStrm R/W Cus_Cmp_Data-Field4 1 38010 ValCalStrm R/W Cus_Cmp_Data-Field5 1 38011 ValAnlStrm R/W Cus_Cmp_Data-Field1 1 48012 ValToFail R/W Cus_Cmp_Data-Field2 1 48013 ValLoConc RW Cus_Cmp_Data-Field3 1 48014 ValLoDevLim RW Cus_Cmp_Data-Field4 1 48015 ValHiConc RW Cus_Cmp_Data-Field5 1 48016 ValHiDevLim RW Cus_Cmp_Data-Field1 1 58017 StartVal RW Cus_Cmp_Data-Field2 1 58018 Validation failure flag RO Cus_Cmp_Data-Field3 1 58019 Operational status RO Cus_Cmp_Data-Field4 1 58020 Last mod date for 8007 RO Cus_Cmp_Data-Field5 1 58021 Last mod time for 8007 RO Cus_Cmp_Data-Field1 2 18022 Last mod date for 8008 RO Cus_Cmp_Data-Field2 2 18023 Last mod time for 8008 RO Cus_Cmp_Data-Field3 2 18024 Last mod date for 8009 RO Cus_Cmp_Data-Field4 2 18025 Last mod time for 8009 RO Cus_Cmp_Data-Field5 2 18026 Last mod date for 8010 RO Cus_Cmp_Data-Field1 2 28027 Last mod time for 8010 RO Cus_Cmp_Data-Field2 2 28028 Last mod date for 8011 RO Cus_Cmp_Data-Field3 2 28029 Last mod time for 8011 RO Cus_Cmp_Data-Field4 2 28030 Last mod date for 8012 RO Cus_Cmp_Data-Field5 2 28031 Last mod time for 8012 RO Cus_Cmp_Data-Field1 2 38032 Last mod date for 8013 RO Cus_Cmp_Data-Field2 2 38033 Last mod time for 8013 RO Cus_Cmp_Data-Field3 2 38034 Last mod date for 8014 RO Cus_Cmp_Data-Field4 2 38035 Last mod time for 8014 RO Cus_Cmp_Data-Field5 2 38036 Last mod date for 8015 RO Cus_Cmp_Data-Field1 2 48037 Last mod time for 8015 RO Cus_Cmp_Data-Field2 2 48038 Last mod date for 8016 RO Cus_Cmp_Data-Field3 2 48039 Last mod time for 8016 RO Cus_Cmp_Data-Field4 2 48040 Last mod date for 8017 RO Cus_Cmp_Data-Field5 2 48041 Last mod time for 8017 RO Cus_Cmp_Data-Field1 2 58042 Last mod date for 8018 RO Cus_Cmp_Data-Field2 2 58043 Last mod time for 8018 RO Cus_Cmp_Data-Field3 2 5
28076 Stream 3 H S mole % RO Cus_Cmp_Data-Field1 4 28077 Stream 3 BTU RO Cus_Cmp_Data-Field2 4 28078 Stream 3 rel dens RO Cus_Cmp_Data-Field3 4 28079 Stream 3 unnorm conc RO Cus_Cmp_Data-Field4 4 28080 Spare RO Cus_Cmp_Data-Field5 4 28081 Stream 1 date RO Cus_Cmp_Data-Field1 4 38082 Stream 1 time RO Cus_Cmp_Data-Field2 4 38083 Stream 2 date RO Cus_Cmp_Data-Field3 4 3
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8084 Stream 2 time RO Cus_Cmp_Data-Field4 4 38085 Stream 3 date RO Cus_Cmp_Data-Field5 4 38086 Stream 3 time RO Cus_Cmp_Data-Field1 4 4
Note: last modification dates are IEEE floating point numbers formatted as YYMMDD, such YYis the last two digits of the year, MM is the month (1 - 12), and DD is the day of the month. The lastmodification times are stored as HHMMSS where HH is hour (0 - 23), MM is minutes, and SS isseconds.
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