Emerson NGA2000 PMD User Manual
Instruction Manual
760007-A
July 2003
Model NGA2000 PMD
Paramagnetic Detector Analyzer Module
http://www.processanalytic.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly
install, use, and maintain them to ensure they continue to operate within their normal specifications.
The following instructions MUST be adhered to and integrated into your safety program when installing,
using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may
cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage
to this instrument; and warranty invalidation.
• Read all instructions
prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Rosemount Analytical representative
for clarification.
• Follow all warnings, cautions, and instructions
marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance of
the product.
• Install your equipment as specified in the Installation Instructions of the appropriate Instruc-
tion Manual and per applicable local and national codes. Connect all products to the proper elec-
trical and pressure sources.
• To ensure proper performance, use qualified personnel
to install, operate, update, program, and
maintain the product.
• When replacement parts are required, ensure that qualified people use replace ment parts specified by
Rosemount. Unauthorized parts and procedures can affect the product’s performance, place the safe
operation of your process at risk, and VOID YOUR WARRANTY
. Look-alike substitutions may result
in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except when
maintenance is being performed by qualified persons, to prevent electrical shock and personal
injury.
The information contained in this document is subject to change without notice.
Viton-A® is a registered trademark of E.I. duPont de Nemours & Co.
Paliney No. 7™ is a trademark of J.M. Ney Co.
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com
Model NGA2000 PMD
TABLE OF CONTENTS
PREFACE...........................................................................................................................................P-1
Intended Use Statement.....................................................................................................................P-1
Definitions...........................................................................................................................................P-1
Safety Summary.................................................................................................................................P-2
General Precautions For Handling And Storing High Pressure Gas Cylinders .................................P-4
Documentation....................................................................................................................................P-5
Compliances.......................................................................................................................................P-5
Glossary Of Terms ...........................................................................................................................P-6
1-0 DESCRIPTION AND SPECIFICATIONS..............................................................................1-1
1-1
Overview................................................................................................................................1-1
1-2 Typical Applications...............................................................................................................1-1
1-3 Theory Of Technology...........................................................................................................1-1
1-4 Features.................................................................................................................................1-2
1-5 Specifications.........................................................................................................................1-3
a. General ...........................................................................................................................1-3
b. Sample............................................................................................................................1-3
c. Physical...........................................................................................................................1-3
Instruction Manual
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July 2003
2-0 INSTALLATION ....................................................................................................................2-1
2-1 Unpacking..............................................................................................................................2-1
2-2 Assembly...............................................................................................................................2-1
2-3 Location.................................................................................................................................2-2
2-4 Gases ....................................................................................................................................2-2
a. Requirements..................................................................................................................2-2
b. Connections....................................................................................................................2-3
c. Leak Test ........................................................................................................................2-3
2-5 Electrical Connections...........................................................................................................2-6
3-0 OPERATION .........................................................................................................................3-1
3-1 Overview................................................................................................................................3-1
3-2 Displays.................................................................................................................................3-1
a. Run Mode Display...........................................................................................................3-1
b. Menu Displays.................................................................................................................3-1
c. Help Displays..................................................................................................................3-1
3-3 Startup Procedure .................................................................................................................3-5
3-4 Binding...................................................................................................................................3-5
3-5 Calibration..............................................................................................................................3-5
3-6 Background Gas Compensation ...........................................................................................3-8
3-7 Barometric Pressure Compensation .....................................................................................3-11
4-0 MAINTENANCE AND SERVICE ..........................................................................................4-1
4-1 Overview................................................................................................................................4-1
4-2 Printed Circuit Board Replacement.......................................................................................4-1
4-3 Module Fan Replacement.....................................................................................................4-2
4-4 Thermal Fuse Replacement..................................................................................................4-3
4-5 Flow Sensor Replacement ....................................................................................................4-4
4-6 Power Fuse Replacement.....................................................................................................4-4
Rosemount Analytical Inc. A Division of Emerson Process Management Contents i
Instruction Manual
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July 2003
5-0 REPLACEMENT PARTS......................................................................................................5-1
5-1 Matrix.....................................................................................................................................5-1
5-2 Replacement Parts................................................................................................................5-2
6-0 RETURN OF MATERIAL......................................................................................................6-1
6-1 Return Of Material.................................................................................................................6-1
6-2 Customer Service..................................................................................................................6-1
6-3 Training..................................................................................................................................6-1
7-0 APPENDIX A. MENU DISPLAYS.........................................................................................7-1
Figure 1-1. Spherical Body in Non-Uniform Magnetic Field..................................................... 1-1
Figure 1-2. Trace Oxygen Detector Coulometric Principle........................................................ 1-2
Figure 2-1. Analyzer Module Installation Into Instrument Platform.......................................... 2-1
Figure 2-2. PMD Front Panel Connections.............................................................................. 2-4
Figure 2-3. PMD Back Panel Connections............................................................................... 2-4
Figure 2-4. Interconnection of Typical Gas Manifold to PMD Analyzer Module ...................... 2-5
Figure 2-5. PMD Wiring Diagram............................................................................................. 2-6
Figure 2-6. PMD Outline and Mounting Dimensions................................................................ 2-7
Figure 3-1. Run Mode Display ................................................................................................. 3-3
Figure 3-2. Main Menu Display ................................................................................................ 3-3
Figure 3-3. Basic Controls Menu.............................................................................................. 3-3
Figure 3-4. Expert Controls and Setup Menu........................................................................... 3-4
Figure 3-5. Technical Level Configuration Menu..................................................................... 3-4
Figure 3-6. Typical Help Screen............................................................................................... 3-4
Figure 4-1. PMD Module – Major Components ....................................................................... 4-1
Figure 4-2. Module Fan Assembly........................................................................................... 4-2
Figure 4-3. Detector Assembly................................................................................................. 4-3
Model NGA2000 PMD
LIST OF ILLUSTRATIONS
LIST OF TABLES
Table 3-1. PMD Analyzer Module Alarms............................................................................... 3-2
Table 3-2. Calibration Range for Various Zero Based Operating Ranges ............................. 3-6
Table 3-3. Calibration Range for Various Suppressed Range Operations.............................3-6
Table 3-4. Oxygen Equivalents of Common Gases.............................................................. 3-10
ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA2000 PMD
PREFACE
INTENDED USE STATEMENT
The purpose of this manual is to provide information concerning the components, functions, installation and
maintenance of the Model NGA2000 PMD and the System Accessories of the NGA2000 System.
DEFINITIONS
The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout
this publication.
DANGER .
Highlights the presence of a hazard which will cause severe personal injury, death, or substantial
property damage if the warning is ignored.
760007-A
July 2003
WARNING .
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.
CAUTION.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.
NOTE
Highlights an essential operating procedure,
condition or statement.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-1
Instruction Manual
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July 2003
Model NGA2000 PMD
SAFETY SUMMARY
Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.
DANGER.
ELECTRICAL SHOCK HAZARD
Do not operate without covers secure. Servicing requires access to live parts which can cause
death or serious injury. Refer servicing to qualified personnel.
For safety and proper performance this instrument must be connected to a properly grounded
three-wire source of power.
DANGER.
POSSIBLE EXPLOSION HAZARD
This equipment is not designed and should not be used in the analysis of flammable samples. Use
of this equipment in this way could result in explosion and death.
NOTE
Apply leak test liquid to cell or detectors only as a last resort.
WARNING
POSSIBLE EXPLOSION HAZARD
Verify that all gas connections are made as labeled and are leak free. Improper gas connections
could result in explosion or death. See Section 2-4c on page 2-3 for Leak test procedure.
WARNING.
HIGH PRESSURE GAS CYLINDERS
This analyzer requires use of pressurized gas. See General Precautions for Handling and Storing
High Pressure Cylinders, page P-4.
WARNING.
PARTS INTEGRITY
Tampering or unauthorized substitution of components may adversely affect safety of this product.
Use only factory documented components for repair.
P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA2000 PMD
WARNING
OVER-VOLTAGE SPIKING
If this Analyzer Module is used with a non-Rosemount Analytical po wer supply, adding Rosemo unt
Analytical PN 90331 Current Protector in series with the 24 V positive line will prevent over-voltage
spiking and resultant fuse flowing when powering up the instrument.
CAUTION
HAND INJURY HAZARD
Do not place hands or fingers in Platform front handles when the front panel is open. Dropping
front panel while hand or fingers are inside either handle can cause serious injury.
CAUTION
OVERBALANCE HAZARD
760007-A
July 2003
This Analyzer Module may tip instrument over if it is pulled out too far and the Platform is not properly supported.
NOTICE
Software compatibility is necessary for all NGA2000 components in your system to work together.
The version of your Platform's software must be equal to or greater that the version of any other
module(s) for successful compatibility. If it is not, contact Rosemount Analytical at 800-433-6076 to
order software upgrade kit PN 657150 for the Platform.
You can locate the version of each NGA2000 component as follows:
Platform Controller Board
Turn power ON.
The display will show "Control Module V2. ...". This is the software version.
Analyzer Module
Located on the right side of the Analyzer Module case.
I/O Module
Located on the backplane connector of the module. If no label is present, the module is Version
2.0.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3
Instruction Manual
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July 2003
Model NGA2000 PMD
GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH
PRESSURE GAS CYLINDERS
Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed Gases" published in 1981
Compressed Gas Association
1235 Jefferson Davis Highway
Arlington, Virginia 22202
Used by Permission
1. Never drop cylinders or permit them to strike each other violently.
2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of
weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the
shade when located in areas where extreme temperatures are prevalent.
3. The valve protection cap should be left on each cylinder until it has been secured against a wall or
bench, or placed in a cylinder stand, and is ready to be used.
4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a
suitable hand-truck.
5. Never tamper with safety devices in valves or cylinders.
6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is
attached to a pressurized system.
7. No part of cylinder should be subjected to a temperature higher than 125
never be permitted to come in contact with any part of a compressed gas cylinder.
8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding,
precautions must be taken to prevent striking an arc against the cylinder.
°
F (52°C). A flame should
P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
9
6
Model NGA2000 PMD
DOCUMENTATION
The following NGA2000 PMD instruction materials are available. Contact Customer Service Center or
the local representative to order.
760007 Instruction Manual (this document)
COMPLIANCES
This product may carry approvals from several certifying agencies, including Factory Mutual and the Canadian Standards Association (which is also an OSHA accredited, Nationally Recognized Testing Laboratory), for use in non-hazardous, indoor locations.
760007-A
July 2003
Rosemount Analytical Inc. has satisfied all obligations from the European Legislation to harmonize the
product requirements in Europe.
These products comply with the standard level of NAMUR EMC. Recommendation (May 1993).
This product satisfies all obligations of all relevant standards of the EMC framework in Australia and New
Zealand.
NRTL /C
®
97-C219
NAMUR
N
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5
Instruction Manual
760007-A
July 2003
Model NGA2000 PMD
GLOSSARY OF TERMS
Analyzer Module
The module that contains all sensor/detector components for development of a Primary Variable signal; includes all signal conditioning and temperature control circuitry.
Backplane
The interconnect circuit board which the Controller Board, Power Supply, Analyzer Module power and network cables, I/O Modules and Expansion Modules plug into.
Control Module
The Operator Interface plus the Controller Board.
Controller Board
The computer board that serves as the Network Manager and operates the Display and Keypad.
Distribution Assembly
The Backplane and the card cages that hold I/O and Expansion Modules.
Expansion Module
A circuit board that plugs into the Backplane from the front of the Platform and performs special features
not related to I/O functions.
I/O Module
A circuit board that plugs into the Backplane from the rear of the Platform. Has a connector terminal for
communication with external data acquisition devices and provides an input/output function.
Operator Interface
The Display and Keyboard.
Platform
Any workable collection of the following: Controller Board, Power Supply, Distribution Assembly, Enclosure
and Operator Interface.
Power Supply
Any of a variety of components that provides conditioned power to other NGA2000 components, from the
Power Supply Board that plugs into the front of the Backplane in a stand-alone instrument to several larger
ones that can power larger collections of modules and components.
Primary Variable
The measured species concentration value from an Analyzer Module.
Secondary Variable
Data placed on the network by a module regarding current status, e.g., sample flow, source voltage and
other diagnostic information.
P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA2000 PMD
Softkeys
The five function softkeys located below the front panel display; they assume the function displayed directly
above each on the display, a function dictated by software.
System
Any collection of Analyzer Module(s), Platform(s), I/O Module(s) and Expansion Module(s).
760007-A
July 2003
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-7
Instruction Manual
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Model NGA2000 PMD
P-8 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 PMD
DESCRIPTION AND SPECIFICATIONS
Instruction Manual
760007-A
July 2003
SECTION 1
1-1 OVERVIEW
This manual describes the Paramagnetic Detector (PMD) Analyzer Module of Rosemount
Analytical's NGA2000 Series of gas analysis
components.
The PMD Analyzer Module is designed to
continuously determine the concentration of
oxygen in a flowing gaseous mixture. The
concentration is expressed in ppm or percent
volume O
2.
The entire Analyzer Module is designed as a
slide-in module (if configured in stand-alone
instrument fashion), removable from the front
of the Platform, with gas connections made
from the rear. All electronics relative to sample detection and conditioning are included in
this module.
1-2 TYPICAL APPLICATIONS
PMD Analyzer Module applications include:
• process control
• continuous emissions monitoring sy st ems
(CEMS)
• industrial gas production
• fermentation process monitoring
1-3 THEORY OF TECHNOLOGY
Oxygen is strongly paramagnetic (i.e., capable of becoming a temporary magnet when
placed in a magnetic field) while most other
common gases are weakly diamagnetic (i.e.,
tend to be non-magnetic). See Figure 1-1
below.
The Magnetic susceptibility of the flowing gas
sample is sensed in the detector/magnet assembly. As shown in Figure 1-2 on page 1-2,
a dumbbell shaped, nitrogen-filled, hollow gas
test body is suspended on a platinum/nickel
alloy ribbon in a non-uniform magnetic field.
Because of a "magnetic buoyancy" effect, the
spheres of the test body are subjected to displacement forces, resulting in a displacement
torque proportional to the magnetic susceptibility of the gas surrounding the test body.
Measurement is accomplished by a nullbalance system, whereby the displacement
torque is opposed by an equal and opposite
restorative torque. The restoring current is
automatically maintained at the correct level
by an electro-optical feedback system. A
beam of light from the source LED is reflected
off the square mirror attached to the test body
onto a bi-cell (dual photodiode).
The current required to keep the test body to
the null position is a linear function of the total
magnetic susceptibility of the sample gas.
See Figure 4-1 on page 4-1, Figure 4-2 on
page 4-2, and Figure 4-3 on page 4-3 for
component configuration.
Shaded
Pole
Piece
Sphere
(Magnetic Susceptibility = ko )
F
k
Sample Gas
(Magnetic Susceptibility = k )
As percentage of oxygen in sample gas increases,
displacement force (F
Note:
) increases.
k
Figure 1-1. Spherical Body in Non-Uniform
Magnetic Field
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Instruction Manual
q
A
A
q
SS
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Model NGA2000 PMD
1-4 FEATURES
Among the features incorporated into the
PMD Analyzer Module is a flow splitter (≈2:1)
that allows for greater sample flow, decreased
lag time and faster analyzer response.
Balancing
Weight
Electromagnetic
xis
Displacement
Restoring
Current
Restoring
Current
Current Loop
Mirror
Platinum/Nickel Alloy
Suspension Ribbon
TEST BODY DETAIL
Tor
Restoring
Torque
The "Time Alignment" feature can be used to
delay sending the Primary Variable from the
PMD Analyzer Module for up to 30 seconds in
0.1 second intervals. This feature allows Primary Variables form more than one PMD
Analyzer Module to be "time aligned" if necessary.
ue
Electromagnetic
xis
Balancing Weight
Nitrogen-Filled Hollow Gl ass
Test Body
Shaded Pole Pieces (4)
Displacement
Tor
ue
Restoring
Torque
Magnet
Test Body
LED Source
Dual Photocell
NULL BALANCE SYSTEM
Restoring
DETECTOR/MAGNET
A
EMBLY
SIGNAL CONDITIONING
Zero
ASSEMBLY
Span
Figure 1-2. Trace Oxygen Detector Coulometric Principle
SIGNAL OUTPUT
TO NETWORK
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 PMD
Instruction Manual
760007-A
July 2003
1-5 SPECIFICATIONS
a. General
Measurement Species................... Oxygen
Ranges.......................................... 0 to 100% oxygen; four fullscale selections, including suppressed
Repeatability.................................. ±1% of fullscale (at constant temperature)
Minimum Detectable Level............ 0.01% oxygen
Noise ............................................. <1% of fullscale, peak-to-peak; <±1% for suppressed ranges
Linearity......................................... ±1% of fullscale
Response Time ............................. 0 to 90% of fullscale in 20 seconds (±2 seconds)
Drift (Zero and Span)..................... <±1% of fullscale/24 hours, <±2% of fullscale/week at constant
Effect of Temperature.................... <±1% of fullscale over any 10°C interval for rate of change no
Environment .................................. Location - Class B controlled, indoor, non-hazardous
Ambient Temperature.................... 0 to 45°C (32 to 113°F)
Effect of Flow................................. <±1% of range when sample flow rate is changed by 20 ml/min.
Power Requirements..................... 24 VDC ±5%, 50 W max.; ripple and noise: <100 mV peak-to-peak;
b. Sample
1
zero ranges in 1% increments
temperature;
<±2% of fullscale/24 hours, <±4% of fullscale/week of range for 99
to 100% (at constant temperature)
greater than 10°C per hour
line and load regulations: <±1%
Temperature.................................. Non-flammable;: 10 to 66°C (50 to 150°F)
Flow Rate ...................................... 800 to 1400 ml/min.
Exhaust Pressure.......................... -345 to 690 hPa-gauge (-5 to 10 psig)
Particles......................................... filtered to <2 microns
Dewpoint........................................ below 43°C (110°F), no entrained liquid
Materials in Contact with Sample.. Glass, 316 stainless steel, titanium, Paliney No. 7, epoxy resin, Vi-
ton A, platinum, nickel, rhodium and MgF
Sample Humidity ........................... non-condensing at ambient temperatures
c. Physical
Case Classification........................ General purpose for installation in weather-protected areas
Dimensions.................................... See Outline and Mounting Dimensions, Figure 2-6 on page 2-7
Weight ........................................... 8 kg (17.6 lbs.
Mounting........................................ Inside a Platform or custom-installed in a panel
Maximum Length of LON Cable.... 1600 m (1 mile) between Analyzer Module and Platform
1
See the Platform manual for specifications regarding Platform related components.
2
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
Instruction Manual
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Model NGA2000 PMD
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 PMD
A
2-1 UNPACKING
Instruction Manual
760007-A
July 2003
SECTION 2
INSTALLATION
WARNING
If the Paramagnetic Analyzer Module is received as a separate unit, carefully examine
the shipping carton and contents for signs of
damage. Immediately notify the shipping carrier if the carton or contents is damaged. Retain the carton and packing material until all
components associated with the Analyzer
Module are operational.
2-2 ASSEMBLY
If the Analyzer Module requires assembly with
other components (e.g., the Platform and associated I/O Modules), do so at this time. Following the guides on the bottom left and
bottom center of the Platform, carefully slide
the Analyzer Module halfway into place.
HAND INJURY HAZARD
Do not place hands or fingers in the Platform front handles when front panel is
open. Dropping the front panel of the Platform while hand or fingers are inside either
handle can cause serious injury.
Lift the spring-loaded pins on the front of the
Analyzer Module, and carefully slide it the rest
of the distance. Secure the module in position
by releasing the pins, which seat in the available holes in the bottom of the case (see
Figure 2-1 below). If the module and Platform
are difficult to assemble, remove the module,
ensure the top cover of the module is firmly
seated on the hold-down screws, and repeat
the assembly procedure.
Install I/O Module(s) according to guidelines in
the I/O manual. After startup and calibration
have been performed, secure the front panel
with the six screws provided.
Figure 2-1. Analyzer Module Installation Into Instrument Platform
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1
NALYZER MODULE GUIDES
PIN SEATS
DISENGAGED FRONT PANEL
Instruction Manual
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Model NGA2000 PMD
2-3 LOCATION
Install the Analyzer Module in a clean, nonhazardous, weather protected, vibration free
location free from extreme temperature variations. For best results, either install the module near the sample stream to minimize
sample transport time or supply a flow greater
than necessary and route only the appropriate
amount through the Analyzer Module.
Observing these requirements are critical.
Note the following:
• Excessive vibration can cause a noisy
readout. To minimize vibration effects,
the detector/magnet assembly is enveloped in a shock-mounted compartment.
• The user should ensure, when making
any internal electrical connections, that
no cables are placed in contact with the
detector assembly or associated internal
sample inlet and outlet tubing.
An oxygen-free gas, typically nitrogen, is
required for use as the zero standard gas.
Recommendations for span calibration
gases, bases on various operating
ranges, are tabulated in Table 3-4 on
page 3-10. Air (20.93% oxygen) can be
used as span gas regardless of the
ranges used for sampling, although very
low ranges may lose accuracy.
Sample Gas
Sample gas should be non-flammable.
Temperature
Sample temperature at the inlet should be
from 50°F to 150°F (10°C to 66°C). A
maximum entry temperature of 110°F
(43°C) is recommended to prevent cooling of the sample and possible internal
condensation. Such condensation could
damage some components of the Analyzer Module. This recommendation can
be ignored if a thoroughly dry sample is
examined.
• Magnetic susceptibilities and partial
pressures of gases vary with temperature. Permissible ambient temperature
range is 32°F to 113°F (0°C to 45°C).
• The interior of the Detector Assembly is
maintained at approximately 144°F
(62°C) by an electronically controlled
heater. Prior to entering the detector
assembly, the sample is heated in a
coiled tubing to match the detector's
temperature.
2-4 GASES
a. Requirements
Calibration Gases
Analyzer Module calibration requires the
establishment of zero and span calibration points. This requires a zero standard
gas to set the zero point span gas to establish a calibration point at or near the
upper range limit.
Pressure
Sample exhaust pressure limits are -5 to
10 psig (-345 to 690 hPa-gauge). Normal
operation is in the positive range, between 0 and 10 psig (0 and 690 hPagauge). Negative gauge pressures are
not normally recommended, but may be
used in certain special applications.
To prevent over-pressurization, insert a
pressure relief valve into the sample inlet
line. A check valve should also be placed
in the outlet line if the Analyzer Module is
connected to a manifold associated with a
flare or other apparatus that does not operate at atmospheric pressure.
The outlet port is commonly vented to the
atmosphere. Any change in barometric
pressure has a directly proportional effect
on the indicated percent of oxygen, and
should be neutralized through manual or
computer correction of data. Note the following example:
2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 PMD
Instruction Manual
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July 2003
Range = 0% to 5% oxygen
Barometric pressure change after
calibration = 1%
Analyzer Module measurement = 5%
oxygen
Measurement error = 0.01 x 5% oxy-
gen
Fullscale span = 5% oxygen
0.05% oxygen error = 1% of fullscale
The error is more significant for suppressed range 99% to 100%.
An optional barometric pressure
compensation board is available to
automatically perform this correction.
A general rule regarding calibration gas
pressure is that it should be the same as
the expected sample gas pressure during
routine operation.
The above requirement increases the difficulty of operation at negative gauge
pressure. A suction pump can be connected to the outlet port for drawing sample through the Analyzer Module. Such
operation necessitates special precautions to ensure accurate readout, including the following:
The need for equilibrium between sample
and gas calibration pressures.
Any leakage in the sample handling system will decrease readout accuracy.
Flow Rate
Recommended sample flow rate is 800 to
1400 ml/min., ±40 ml/min. Optimum flow
rate is 1100 ml/min.
If flow is held to within tolerance and operating pressure remains constant, zero
and span drift will meet specified limits.
b. Connections
(See Figure 2-3 on page 2-4) Connect
inlet and outlet lines for sample gas to
appropriately labeled fittings on the rear
panel. Both connections are 1/4 inch ferrule-type compression fittings.
Zero and span gases use the same inlet
and outlet as the sample. Figure 2-4 on
page 2-5 shows a typical external sample
handling manifold for gas selection. Particulates must be filtered down to two microns, gases generally require
pressurization, and flow measurement
metering MUST be present.
c. Leak Test
The Analyzer Module is thoroughly tested
at the factory for gas leakage. The user is
responsible for testing for leakage only at
the inlet and outlet fittings on the rear
panel. The user is also responsible for internal leak testing periodically and if any
internal pneumatic components are adjusted or replaced (with a test procedure
selected by the user).
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3
Instruction Manual
(
)
760007-A
July 2003
Note: Reference and purge gas connections are applicable only to certain applications.
Model NGA2000 PMD
Figure 2-2. PMD Front Panel Connections
FAN
SAMPLE
10 PSI MAX
69 kPa MAX
Figure 2-3. PMD Back Panel Connections
NETWORK 1
NETWORK 2
POWER
FUSE
OUT
IN
2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 PMD
Z
Instruction Manual
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July 2003
Sample In
ero
Standard
Gas
Span
Standard
Gas
PMD Analyzer
Needle
Valves
Two Micron
Filter
Flowmeter
Flow Splitter
Figure 2-4. Interconnection of Typical Gas Manifold to PMD Analyzer Module
Module
(≈2:1)
To Vent
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5
Instruction Manual
760007-A
July 2003
Model NGA2000 PMD
2-5 ELECTRICAL CONNECTIONS
NOTE
Electrical connections must be in compliance with National Electrical Code
(ANSI/NFPA 70) and/or any applicable national or electrical codes.
Two electrical connections are required on the
Analyzer Module; POWER and NETWORK.
J5
PRESSURE
COMPENSATION
BOARD
J6
J10
J11
J13
COMPUTER ANALYSIS
J7
J14
J19
W1
FLOW SENSOR CABLE
PREAMP CABLE ASSEMBLY
CASE TEMP SENSOR
FAN
See Figure 2-2 on page 2-4. On the Analyzer
Module, two NETWORK connections are
available, either of which is appropriate for : 1)
interconnection with Backplane of the Platform (see Platform instruction manual) or 2)
"daisy chaining" with other NGA2000 components.
Connect Analyzer Module POWER 24 VDC
power source, either the Platform or external
power source.
BOARD
J4
FLOW
SENSOR
J1
J2
J3
J16
Figure 2-5. PMD Wiring Diagram
MAIN BOARD
J20
SENSOR
ASSEMBLY
J21 J22
LED SOURCE
THERMAL CUTOFF
MAGNET HEATER AND
OPTICAL BENCH
J17
J9
J12
J15
ASSEMBLY
2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 PMD
8.4
[213]
6.7
6.2
[157]
[152]
6.0
8.4
[213]
8.2
[208]
17.41
[442]
[109]
[28]
20.0
[508]
.6
[15]
E. FUSE.
D. POWER CABLE TO NETWORK.
C. NETWORK CABLE CONNECTIONS TO PLATFORM.
B. SAMPLE OUT: 1/4" O.D. TUBE FITTING.
A. SAMPLE IN: 1/4" O.D. TUBE FITTING.
5. MODULE TO BE INSTALLED WITHIN ±15° OF HORIZONTAL.
4. POWER REQUIREMENTS: 24 VDC 3.5 A.
3. ELECTRICAL INSTALLATION MUST BE IN COMPLIANCE WITH NATIONAL ELECTRICAL
CODE (ANSI/NFPA 70) AND/OR ANY APPLICABLE NATIONAL OR LOCAL CODES.
2. MODULE IS NOT WEATHERPROOF.
1. APPROXIMATE WEIGHT: 15 LB (6.8 kg).
[170]
Figure 2-6. PMD Outline and Mounting Dimensions
[15]
10 PSI MAX
2.8
[71]
[13]
1.0
[25]
1.6
[41]
DIMENSIONS
Instruction Manual
760007-A
July 2003
1.6
[40]
INCH
[mm]
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-7
Instruction Manual
760007-A
July 2003
Model NGA2000 PMD
2-8 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 PMD
Instruction Manual
760007-A
July 2003
SECTION 3
OPERATION
3-1 OVERVIEW
Prior to initial startup, the user should perform
the leak test procedure outlined in Section 24c on page 2-3.
For the remainder of this section Analyzer
Module interconnection with a Platform or
some interfacing component will be assumed.
Display and keypad information shall refer to
that which the user can expect to see and do
with regard to the front panel of the Platform.
For a complete description of the Platform
front panel controls and indicators, see the
Platform instruction manual, Displays & Operating Keys.
3-2 DISPLAYS
Three kinds of Display screens are available
to the user:
• Run Mode
• Menu
• Help
a. Run Mode Display
The Run Mode is the normal mode of operation. In this mode, the Display (see
Figure 3-1 on page 3-3) will show current
gas measurement, the component of interest, the current operations of the softkeys, and a graphic bar representing the
displayed concentration as ppm or as a
percent of oxygen.
If more than one Analyzer Module is connected to the system, the Run Mode display will show as many as four gas
measurements on screen. Alarm messages may also appear on the display
(See Table 3-1 on page 3-2).
b. Menu Displays
The menu structure enables the user to
access data and functions, and put information onto the network.
The Main Menu (Figure 3-2 on page 3-3)
is subdivided into three levels of control
based generally on which personnel is
likely to use it: Basic Controls, Expert
Controls and Setup, and Technical Level
Configuration. See Figure 3-3 on page 33, Figure 3-4 on page 3-4, and Figure 3-5
on page 3-4. Many layers of the menu
structure are described at appropriate
places throughout this manual.
From the Run Mode display, press the
MENU softkey to enter the Main Menu
(Figure 3-2 on page 3-3).
c. Help Displays
The Help structure is intended to be an
on-line "tutorial," context sensitive and
topic-interconnected, so that the user can
practically operate NGA2000 without
need of an instruction manual (Figure 3-6
on page 3-4).
Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-1
Instruction Manual
760007-A
July 2003
MESSAGE DISPLAY DESCRIPTION TYPE
barometer System Barometer warning
case temp Case Temperature warning
crude noise Calculated Noise warning
currentrnghi Current, High Range warning
currentrnglo Current, Low Range warning
det tem Detector Temperature warning
Model NGA2000 PMD
fan fet Fan Current warning
heater fet Heater Current warning
led current LED Current warning
lin error Linearizer Error warning
loop current PMD Loop Current warning
n15 volts Power Supply, -15V warning
p15 volts Power Supply, +15V warning
p24 volts Power Supply, +24V warning
P5 volts Power Supply, +5v warning
raw signal Raw Signal warning
Samp Pres Sample Pressure warning
svflow Sample Bypass Flow warning
bicella PMD Photo Sensor failure
bicellb PMD Photo Sensor failure
sw error Software Error failure
Table 3-1. PMD Analyzer Module Alarms
3-2 Operation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 PMD
y
y
y
y
Instruction Manual
760007-A
July 2003
Analyzer PQ 322-14
23.2 ppm HC
0 ppm
Secondar
Secondar
Secondar
Secondar
Variable: XXXX
Variable: XXX
Variable: XXXX
Variable: XXXX
Display Parms. Menu Dual Info
F1 F2 F3 F4 F5
Figure 3-1. Run Mode Display
23.2 ppm HC Analyzer XXXXXXXX
Main Menu
Basic Controls
Expert controls and setup ...
(Operational configuration)
Technical level configuration ...
(Diagnostic and manufacturing/service)
Delete alarm message!
Display Parms. Info
F1 F2 F3 F4 F5
Figure 3-2. Main Menu Display
23.2 ppm HC Analyzer XXXXXXXX
Basic Controls
Measurement range numbers:
Range upper limit: 10 ppm
Range and functional control: Local
Bypass sample flow: 1000 ml/min
Ranges with valid calibration 1&2
Calibration status: Ready
If it won’t calibrate…
Flame condition: On
Light flame…
Home Escape Zero Span Info
F1
F2 F3 F4 F5
Figure 3-3. Basic Controls Menu
50
Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-3
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