Emerson Rosemount Analytical NGA2000 CLD Instruction Manual
Instruction Manual
760000-C
November 2002
Model NGA2000 CLD
Chemiluminescence 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
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.
to ensure they continue to operate within their
• 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 replacement parts specified by
Rosemount. Unauthorized parts and procedures can affect the product’s performance, place the safe
operation of your process at risk, and VOID YOUR WARRANTY
. Look-alike substitutions may result
in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except when
maintenance is being performed by qualified persons, to prevent electrical shock and personal
injury.
The information contained in this document is subject to change without notice.
Teflon is a Registered Trademark of E.I. duPont de Nemours and Co., Inc.
Kynar is a Registered Trademark of Atochem North America, Inc.
SNOOP is a registered trademark of NUPRO Co.
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com
Model NGA2000 CLD
TABLE OF CONTENTS
PREFACE...........................................................................................................................................P-1
Definitions ...........................................................................................................................................P-1
Safety Summary .................................................................................................................................P-2
General Precautions For Handling And Storing High Pressure Gas Cylinders .................................P-6
Documentation....................................................................................................................................P-7
Compliances .......................................................................................................................................P-7
Glossary Of Terms ...........................................................................................................................P-8
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.................................................................................................................................1-1
1-5 Specifications.........................................................................................................................1-4
a. General ...........................................................................................................................1-4
b. Physical...........................................................................................................................1-4
c. Sample ............................................................................................................................1-4
d. Gas Connections.............................................................................................................1-5
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November 2002
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. Overview .........................................................................................................................2-2
b. Connections ....................................................................................................................2-2
c. Specifications ..................................................................................................................2-3
2-5 Electrical Connections ...........................................................................................................2-4
3-0 OPERATION .........................................................................................................................3-1
3-1 Overview................................................................................................................................3-1
3-2 Displays & Operating Keys....................................................................................................3-1
a. Menu Lines & Softkey Functionality................................................................................3-1
b. Common Function Keys..................................................................................................3-2
c. Entering & Changing Variables.......................................................................................3-3
d. Starting a Function..........................................................................................................3-3
e. Measure Mode Display ...................................................................................................3-4
f. Main Menu ......................................................................................................................3-4
3-3 Startup & Initialization............................................................................................................3-7
a. Routine Operation ...........................................................................................................3-7
3-4 Basic Controls and Status .....................................................................................................3-8
a. Analyzer Channel Status ................................................................................................3-8
b. Single Component Display..............................................................................................3-8
c. Multi Component Display................................................................................................3-9
3-5 Basic Controls........................................................................................................................3-10
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3-6 Display Controls ....................................................................................................................3-11
3-7 Analyzer And I/O, Expert Controls And Setup.......................................................................3-12
a. Range Settings................................................................................................................3-12
b. Physical Measurements ..................................................................................................3-13
c. Concentration Alarms .....................................................................................................3-13
d. Linearization Parameters ................................................................................................3-14
e. Linearization Functions ...................................................................................................3-15
f. Response Time ...............................................................................................................3-17
g. Automatic Range Change...............................................................................................3-17
h. Display Units ...................................................................................................................3-18
i. Physical Measurements & Pressure Limits ....................................................................3-18
j. Single Component Display Parameters..........................................................................3-19
3-8 Calibration Procedure............................................................................................................3-21
a. Calibration Setup.............................................................................................................3-21
b. Basic Controls Calibration...............................................................................................3-22
c. Expert Controls Calibration.............................................................................................3-23
d. Unable to Calibrate .........................................................................................................3-25
3-9 System & Network I/O Module Controls (Setup) – System SIO...........................................3-26
a. Analog Output Setup.......................................................................................................3-26
b. Serial Interface Setup .....................................................................................................3-29
c. Relay Outputs Setup.......................................................................................................3-29
3-10 System & Network I/O Module Controls (Setup) – System DIO ..........................................3-31
3-11 System Configuration and Diagnostics .................................................................................3-32
a. Diagnostic Menus............................................................................................................3-32
b. Load/Save Module Configuration....................................................................................3-34
c. Date and Time.................................................................................................................3-35
d. Security Codes................................................................................................................3-35
e. System Reset..................................................................................................................3-36
3-12 Converter Temperature Adjustment ......................................................................................3-37
3-13 Measurement of Converter Efficiency ...................................................................................3-38
a. Test Setup for Measurement of Conversion Efficiency...................................................3-38
b. Test Procedure................................................................................................................3-38
c. Subnormal Conversion Efficiency...................................................................................3-39
d. Replacement of Converter ..............................................................................................3-40
e. Capillaries .......................................................................................................................3-40
f. TEA Scrubber..................................................................................................................3-40
Model NGA2000 CLD
4-0 MAINTENANCE AND SERVICE ..........................................................................................4-1
4-1 Overview................................................................................................................................4-1
4-2 Fuses .....................................................................................................................................4-1
4-3 Fans.......................................................................................................................................4-1
4-4 Converter ...............................................................................................................................4-1
4-5 Ozonator ................................................................................................................................4-1
4-6 Printed Circuit Boards............................................................................................................4-1
4-7 Detector Disassembly............................................................................................................4-3
a. Reaction Chamber Removal...........................................................................................4-3
b. Reaction Chamber Installation........................................................................................4-3
c. Photodiode Removal.......................................................................................................4-4
d. Photodiode Installation....................................................................................................4-4
5-0 TROUBLESHOOTING ..........................................................................................................5-1
5-1 Leaks .....................................................................................................................................5-1
ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 CLD
6-0 REPLACEMENT PARTS ......................................................................................................6-1
6-1 Matrix .....................................................................................................................................6-1
6-2 Replacement Parts ................................................................................................................6-1
7-0 RETURN OF MATERIAL......................................................................................................7-1
7-1 Return Of Material .................................................................................................................7-1
7-2 Customer Service ..................................................................................................................7-1
7-3 Training..................................................................................................................................7-1
8-0 INDEX....................................................................................................................................8-1
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Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii
Instruction Manual
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November 2002
Figure 1-1. Flow Diagram - CLD Analyzer Module With Bypass Flow Sensor .................................1-2
Figure 1-2. Flow Diagram - CLD Analyzer Module Without Bypass Flow Sensor ...........................1-2
Figure 1-3. CLD Analyzer Module - Top View..................................................................................1-3
Figure 2-1. Analyzer Module Installation into Instrument Platform....................................................2-1
Figure 2-2. CLD Rear Panel Connections.........................................................................................2-3
Figure 2-3. Front Panel Controls and Electrical Connections ...........................................................2-4
Figure 2-4. CLD Wiring Diagram .......................................................................................................2-5
Figure 2-5. Outline and Mounting Dimensions..................................................................................2-6
Figure 3-1. Measure Mode Display ...................................................................................................3-1
Figure 3-2. The Display Screen.........................................................................................................3-3
Figure 3-3. Changing Variables.........................................................................................................3-3
Figure 3-4. Function Confirmation Display ........................................................................................3-3
Figure 3-5. Main Menu Display..........................................................................................................3-4
Figure 3-6. Module Manufacturing Data Displays .............................................................................3-5
Figure 3-7. Main Menu Sub Menus ...................................................................................................3-6
Figure 3-8. Startup Display................................................................................................................3-7
Figure 3-9. Basic Controls Menu .......................................................................................................3-10
Figure 3-10. Display Controls Menu ..................................................................................................3-11
Figure 3-11. Analyzer and I/O Expert Controls and Setup Menu......................................................3-12
Figure 3-12. Expert Controls Menu ...................................................................................................3-12
Figure 3-13. Range Settings Menu....................................................................................................3-12
Figure 3-14. Physical Measurements Menu......................................................................................3-13
Figure 3-15. Concentration Alarm Setup Menu.................................................................................3-13
Figure 3-16. Gas Measurement Parameters Menu...........................................................................3-14
Figure 3-17. Linearization Parameters Menu ....................................................................................3-14
Figure 3-18. Linearity Coefficients Menu...........................................................................................3-14
Figure 3-19. Linearization Functions Menu .......................................................................................3-15
Figure 3-20. Polynomial Setup Menu ................................................................................................3-15
Figure 3-21. Gas Concentrations Menu ............................................................................................3-15
Figure 3-22. Midpoint Correction Setup Menu ..................................................................................3-16
Figure 3-23. Response time/delay Parameters................................................................................3-17
Figure 3-24. Automatic Range Control Menu....................................................................................3-17
Figure 3-25. Actual Switch Levels Menu ...........................................................................................3-18
Figure 3-26. Display Units Menu .......................................................................................................3-18
Figure 3-27. Pressure Limits Menu ...................................................................................................3-19
Figure 3-28. Temperature Limits Menu .............................................................................................3-19
Figure 3-29. Physical Measurements – Manufacturer’s settings Display..........................................3-19
Figure 3-30. Displayed Parameters Menu.........................................................................................3-19
Figure 3-31. Calibration Gas List Menu.............................................................................................3-21
Figure 3-32. Calibration Parameters Display ....................................................................................3-22
Figure 3-33. Zero/Span Calibration Menu .........................................................................................3-23
Figure 3-34. Analyzer Zero Display...................................................................................................3-23
Figure 3-35. Zero/Span Diagnostic Data Menu.................................................................................3-24
Figure 3-36. Calibration Factors Menu..............................................................................................3-24
Figure 3-37. Range Factors Menu.....................................................................................................3-24
Figure 3-38. Range Factors -Manufacturer’s/Stored Settings Display..............................................3-25
Figure 3-39. System & Network I/O Module Controls Menu .............................................................3-26
Figure 3-40. System SIO Module Menu ............................................................................................3-26
Figure 3-41. Analyzer Modules Menu ...............................................................................................3-26
Model NGA2000 CLD
LIST OF ILLUSTRATIONS
iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 CLD
Figure 3-42. Analog Output Setup Menu...........................................................................................3-27
Figure 3-43. Signals Menu ...............................................................................................................3-27
Figure 3-44. Output Signal If Assigned Module Fails Menu..............................................................3-28
Figure 3-45. Special Scaling for Concentration Signal Menu............................................................3-28
Figure 3-46. Analog Output Updates per Second Menu ...................................................................3-29
Figure 3-47. Serial Interface Setup Menu .........................................................................................3-29
Figure 3-48. AK Protocol Definitions Menu .......................................................................................3-29
Figure 3-49. Relay Outputs Setup Menu...........................................................................................3-30
Figure 3-50. Choose Source Module Menu ......................................................................................3-30
Figure 3-51. Choose Signal Menu.....................................................................................................3-30
Figure 3-52. System DIO Module Menu............................................................................................3-31
Figure 3-53. System Configuration and Diagnostics Menu...............................................................3-32
Figure 3-54. Diagnostic Menu ...........................................................................................................3-32
Figure 3-55. Analyzer Diagnostics Menu ..........................................................................................3-32
Figure 3-56. Power Supply Voltages Menu.......................................................................................3-33
Figure 3-57. Primary Variable Parameters Menu..............................................................................3-33
Figure 3-58. Temperature Control Menu (Screen 1) .........................................................................3-33
Figure 3-59. Temperature Control Menu (Screen 2) .........................................................................3-33
Figure 3-60. NO/NOx Flow Balance Menu........................................................................................3-34
Figure 3-61. Calculate Factor Using Pressure Ratio Menu...............................................................3-34
Figure 3-62. Load/Save Configuration (CM/MCA) Menu ..................................................................3-34
Figure 3-63. Date and Time Menu.....................................................................................................3-35
Figure 3-64. Security Codes Menu....................................................................................................3-35
Figure 3-65. Define Basic Level Security PIN Menu .........................................................................3-35
Figure 3-66. System Reset Menu......................................................................................................3-36
Figure 3-67. Measuring Efficiency of NO
Figure 3-68. Conversion Efficiency as a Function of Converter Temperature ..................................3-42
Figure 4-1. CLD Module Assembly....................................................................................................4-2
Figure 4-2. Converter Assembly........................................................................................................4-3
Figure 4-3. Detector Assembly ..........................................................................................................4-5
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to NO Converter.............................................................3-41
2
LIST OF TABLES
Table 2-1. Gas Specifications...................................................................................................... 2-2
Rosemount Analytical Inc. A Division of Emerson Process Management Contents v
Instruction Manual
760000-C
November 2002
Model NGA2000 CLD
vi Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA2000 CLD
November 2002
PREFACE
The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of the NGA 2000 CLD and the System Accessories
of the NGA 2000 System.
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.
DEFINITIONS
The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout
this publication.
760000-C
DANGER .
Highlights the presence of a hazard which will cause severe personal injury, death, or substantial
property damage if the warning is ignored.
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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November 2002
Model NGA2000 CLD
SAFETY SUMMARY
If this equipment is used in a manner not specified in these instructions, protective systems may be
impaired.
AUTHORIZED PERSONNEL
To avoid explosion, loss of life, personal injury and damage to this equipment and on-site
property, all personnel authorized to install, operate and service the this equipment should be
thoroughly familiar with and strictly follow the instructions in this manual. SAVE THESE INSTRUCTIONS.
DANGER.
ELECTRICAL SHOCK HAZARD
Do not operate without doors and covers secure. Servicing requires access to live parts which can
cause death or serious injury. Refer servicing to qualified personnel. For safety and proper performance this instrument must be connected to a properly grounded three-wire source of power.
WARNING .
TOXIC AND OXIDIZING GAS
This module generates ozone which is toxic by inhalation and is a strong irritant to throat and
lungs. Ozone is also a strong oxidizing agent. Its presence is detected by a characteristic pungent
odor.
The module's exhaust contains both ozone and nitrogen dioxide, both toxic by inhalation, and may
contain other constituents of the sample gas which may be toxic. Such gases include various oxides of nitrogen, unburned hydrocarbons, carbon monoxide and other products of combustion reactions. Carbon monoxide is highly toxic and can cause headache, nausea, loss of consciousness,
and death.
Avoid inhalation of the ozone produced within the module, and avoid inhalation of the sample and
exhaust products transported within the module. Avoid inhalation of the combined exhaust products at the exhaust fitting.
Keep all tube fittings tight to avoid leaks The user is responsible for testing for leakage only at the
inlet and outlet fittings on the rear panel. Periodically, the user should do an internal leak test (with
a test procedure chosen by the user).
Connect rear exhaust outlet to outside vent with stainless steel or Teflon line. Check vent line and
connections for leakage.
P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA2000 CLD
WARNING.
PARTS INTEGRITY
Tampering or unauthorized substitution of components may adversely affect safety of this product.
Use only factory documented components for repair.
WARNING.
OVERBALANCE HAZARD
This analyzer module may tip instrument over if it is pulled out too far and the Platform is not properly supported.
WARNING.
INTERNAL ULTRAVIOLET LIGHT
Ultraviolet light from the ozone generator can cause permanent eye damage. Do not look directly at
the ultraviolet source. Use of ultraviolet filtering glasses is recommended.
November 2002
760000-C
WARNING.
TOXIC CHEMICAL HAZARD
The ozone generator lamp contains mercury. Lamp breakage could result in mercury exposure.
Mercury is highly toxic if absorbed through the skin or ingested, or if vapors are inhaled.
Handle lamp assembly with extreme care. If the lamp is broken, avoid skin contact and inhalation
in the area of the lamp or the mercury spill.
Immediately clean up and dispose of the mercury spill and lamp residue as follows:
• Wearing rubber gloves and goggles, collect all droplets of mercury by means of a suction pump
and aspirator bottle with a long capillary tube. (Alternately, a commercially available mercury
spill clean-up kit, such as J.T. Baker product No. 4439-01, is recommended.)
• Carefully sweep any remaining mercury and lamp debris into a dust pan. Carefully transfer all
mercury, lamp residue and debris into a plastic bottle which cab be tightly capped.
• Label and return to hazardous material reclamation center. Do not place in the trash, incinerate
or flush down the sewer.
• Cover any fine droplets of mercury in non-accessible crevices with calcium polysulfide and sul-
fur dust
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3
Instruction Manual
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WARNING.
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.
WARNING.
POSSIBLE EXPLOSION HAZARD
Ensure that all gas connections are made as labeled and are leak free. Improper gas connections
could result in explosion or death.
Model NGA2000 CLD
WARNING.
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 or death.
CAUTION
PRESSURIZED GAS
This module requires periodic use of pressurized gas. See General Precautions for Handling and
Storing High Pressure Gas Cylinders, page P-6
CAUTION
EXTERNALLY RESTRICT SAMPLE FLOW TO LESS THAN 2200 CC/MIN.
No restrictor is provided in the sample inlet of this module. For those users who cannot externally
limit sample flow, accessory restrictor PN 657300 is available from Rosemount Analytical.
To obtain this accessory, call 800-433-6076.
CAUTION
OVER-VOLTAGE SPIKING
If this analyzer module is used with a non-Rosemount Analytical power supply, adding Rosemount
Analytical PN 903341 Current Protector in series with the 24V positive power line will prevent overvoltage spiking and resultant fuse blowing when powering up the instrument.
P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA2000 CLD
NOTICE
Software compatibility is necessary for all NGA 2000 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 NGA 2000 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.
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November 2002
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5
Instruction Manual
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November 2002
Model NGA2000 CLD
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
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 never be
P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
9
6
Model NGA2000 CLD
November 2002
DOCUMENTATION
The following NGA 2000 CLD instruction materials are available. Contact Customer Service Center or the
local representative to order.
760000 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.
760000-C
Rosemount Analytical Inc. has satisfied all obligations from the European Legislation to harmonize the
product requirements in Europe.
This product complies 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.
FM
APPROVED
NAMUR
NRTL /C
®
97-C219
N
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Model NGA2000 CLD
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 NGA 2000 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-8 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA2000 CLD
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).
November 2002
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Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-9
Instruction Manual
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Model NGA2000 CLD
P-10 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 CLD
DESCRIPTION AND SPECIFICATIONS
1-1 OVERVIEW
This manual describes the Chemiluminescence
(CLD) Analyzer Module of Rosemount Analytical's NGA 2000 Series of gas analysis components (See Figure 1-1, Figure 1-2 page 1-2 and
Figure 1-3, page 1-3).
SECTION 1
NO
tronically excited state (NO
the excitation)). These revert immediately to the
ground state, with emission of photons (essentially, red light). The reactions involved are:
Instruction Manual
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November 2002
molecules thus produced are in an elec-
2
* - the "*" refers to
2
NO + O
→ NO2* + O2
3
The CLD Analyzer Module is designed to continuously determine the concentration of nitric
oxide and oxides of nitrogen (NO plus nitrogen
dioxide [NO
]) in a flowing gaseous mixture. The
2
concentration is expressed in parts-per-million.
The CLD 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
The CLD Analyzer Module has specific applications in the following areas:
• Oxides of nitrogen emissions from the
combustion of fossil fuels in:
Vehicle engine exhaust
Incinerators
Boilers
Gas appliances
Turbine exhaust
• Nitric acid plant emissions
NO
* → NO2 + red light
2
As NO and O
mix in the reaction chamber, the
3
intensity of the emitted red light is measured by
a photodiode and is proportional to the concentration of NO in the original gas sample.
To measure NOx (NO + NO
), any NO2 in the
2
sample is reduced to NO (at <95% efficiency)
by being continuously passed through a heated
bed of vitreous carbon (this occurs before the
sample gas is presented to the ozone). Any NO
initially present in the sample passes through
this converter stage unchanged before being
routed to the reaction chamber.
The photodiode generates a DC current, which
is then amplified, conditioned and expressed on
the network as the Primary Variable.
1-4 FEATURES
Among the features included in the CLD Analyzer Module are: 1) ozonator air loss shutoff
and 2) NO/NOx mode capability.
• De-NO
control system
X
• Nitric oxide emissions from decaying or-
ganic material (e.g., landfills).
1-3 THEORY OF TECHNOLOGY
The CLD Analyzer Module uses the chemiluminescence method of detection. This technology
is based on the reaction of NO with ozone (O
to produce NO
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
and oxygen (O
2
). Some of the
2
)
3
Instruction Manual
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Model NGA2000 CLD
BULKHEAD REDUCER
1/4T - 1/8T BRS
OZONE AIR
SAMPLE
BULKHEAD REDUCER
1/4T - 1/8T SS
EXHAUST
BULKHEAD
1/4T SS
BULKHEAD REDUCER
CONNECTOR
1/4T SS
1/4T - 1/8T BRS
OZONE AIR
SAMPLE
BULKHEAD REDUCER
1/4T - 1/8T SS
OZONE GENERATOR
659494
CONNECTOR,GLASS
BLUE
VENT CAPILLARY
70cc/min 4 PSIG
634398
PUMP CAPILLARY
1/8 OD TEFLON
657473
SAMPLE PRESSURE
SENSOR 15 PSIG 655253
KYNAR
ELBOW 1/8T
SS
1/8 OD SS
TEE
1/8T
ELBOW 1/8T
SS
1/8 OD SS
2 70 cc/min. 5 psig CAPILLARY: PN 659657
200 cc/min. 2 psig CAPILLARY: PN 659658
CROSS
1/8T BRS
MALE CONNECTOR
1/8T-3/8NPT B RS
FLOW
BALANCE
VALVE
903207
TEE ASSEMBLY
1/8T-1/4MPT
1/4T - 1/8FP T SS
TEE
CONNECTOR
1/8T-1/8NPT BRS
MALE CONNECTOR
1/8T-3/8NPT BR S
PRESSURE SENSOR
30 PSIG AIR
655254
ELBOW
1/8T-1/8MPT KYNAR
1
BACK
PRESSURE
REGULATOR
REDUCER
1/4T - 1/8T SS
ELBOW
1/8T - 1/8MPT
SS
.116 ID VITON BLK
PRESSURE SWITCH
662298
BYPASS
FLOW
SENSOR
902931
ELBOW
1/8T-1/4MPT
SS
AIR RESTRICTOR
430cc/min @ 12 PSIG
658157
CONNECTOR,
GLASS BLUE
SOLENOID
VALVE
NO/NOx
655263
ELBOW
1/8T-1/8MPT
KYNAR
TEE 1/8T
KYNAR
NOx TO NO
CONVERTER
655250
TOP
NC NO
C
TEE 1/8T
KYNAR
CROSS
1/8T SS
CONNECTOR, MALE
1/8T-3/8MPT SS
1 BRASS/NEOPRENE 655269
STAINLESS STEEL/VITON 659063
Figure 1-1. Flow Diagram - CLD Analyzer Module With Bypass Flow Sensor
OZONE GENERATOR
659494
CONNECTOR,GLASS
BLUE
VENT CAPILLARY
70cc/min 4 PSIG
634398
PUMP CAPILLARY
2 PSIG
SAMPLE PRESSURE
SENSOR 15 PSIG 655253
TEE
1/8T
KYNAR
TEE 1/8T
KYNAR
UNION 1/8T S S
UNION 1/4T- 1/8T SS
REDUCING UNION
1/8T - 1/16T S S
CROSS
1/8T BRS
MALE CONNECTOR
1/8T-3/8NPT B RS
FLOW
BALANCE
VALVE
903207
TEE ASSEMBLY
1/8T-1/4MPT
CONNECTOR
1/8T-1/8NPT BRS
MALE CONNE CTOR
1/8T-3/8NPT BRS
PRESSURE SWITCH
662298
PRESSURE SENSOR
30 PSIG AIR
655254
BACK
PRESSURE
REGULATOR
EXHAUST
BULKHEAD
1/4T SS
.116 ID VITON BLK
ELBOW
1/8T-1/4MP T
SS
AIR RESTRICTOR
430cc/mi n @ 12 PSIG
658157
CONNECTOR,
GLASS BLUE
NO/NOx
SOLENOID
VALVE
655263
TEE 1/8T
SS
NOx TO NO
CONVERTER
TOP
NC NO
C
655250
TEE 1/8T
KYNAR
CROSS
1/8T SS
CONNECTOR, MALE
1/8T-3/8MPT SS
Figure 1-2. Flow Diagram - CLD Analyzer Module Without Bypass Flow Sensor
REACTION
CHAMBER
2
REDUCING UNION
1/8T - 1/16T SS
1/8 OD SS
1/8 OD SS
SAMPLE CAPILLARY
OZONE
EXHAUST
SAMPLE
DETECTOR
REACTION
CHAMBER
OZONE
EXHAUST
SAMPLE
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 CLD
Instruction Manual
760000-C
November 2002
COMPUTER
BOARD
DRIVER BOARD
OZONE
GENERATOR
SIGNAL
BOARD
INLET/OUTLET
FITTINGS
FANS
NO2 TO NO
CONVERTER
3-WAY
SOLENOID VALVE
DETECTOR
SAMPLE
CAPILLARY
FLOW SENSOR
POWER SUPPLY
BOARD
FUSE
FLOW BALANCE
NEEDLE VALVE
NETWORK/POWER
CONNECTOR
SAMPLE BACKPRESSURE REGULATOR
Figure 1-3. CLD Analyzer Module - Top View
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
Instruction Manual
760000-C
November 2002
1-5 SPECIFICATIONS
a. General
Measurement Species:.................. NO, NOx
Ranges: ......................................... 0 to 10 ppm through 0 to 10,000 ppm NO, NOx
Repeatability:................................. ±0.5% of fullscale (at constant temperature)
Min. Detectable Level:................... 0.1 ppm
Noise: ............................................ <1% of fullscale, peak to peak
Linearity: ........................................ ±1% of fullscale
Response Time: ............................ <1 sec. for 90% of fullscale for ranges of 25 ppm or greater
....................................................... <3 sec. for 90% of fullscale for ranges of less than 25 ppm
t90 Response ................................ 1-2 sec.
Zero Drift: (at constant temperature) <±1% of fullscale/24 hours, <±2% of fullscale/week
Span Drift: (at constant temperature) <±1% of fullscale/24 hours, <±3% of fullscale/week
Effect of Temperature:................... <2% of fullscale (over any 10°C ambient temperature variation
Ambient Temperature:................... 0°C to 45°C (32°F to 113°F)
Power Requirements:.................... 24V DC 120W
Model NGA2000 CLD
interval for a rate of change no greater than 10°C/hour)
b. Physical
Case Classification:....................... General purpose for installation in weather-protected area
Dimensions:................................... See Figure 2-5. Outline and Mounting Dimensions p2-6
Weight: .......................................... 8.1 kg (18 lbs.)
Mounting:....................................... Inside a Platform or custom-installed in a panel
Max. Length of LON Cable:........... 1600m (1 mile) between Analyzer Module and Platform
c. Sample
Temperature: ................................ 0°C to 45°C (32°F to 131°F)
Total Flow Rate: .......................... (Externally measured) 900 to 2200 cc/min. with backpressure
regulator pressure adjusted to 344 hPa (5 psig)
Particles: ...................................... Filtered to <2 microns
Dewpoint: ..................................... 5.5°C below ambient temperature, no entrained liquid
Materials in contact with Sample:.. Stainless steel, Teflon, glass, brass and neoprene
Optional: ..................... Stainless steel, Teflon, glass and Kynar
Ozonator Gas: ............................... Clean, dry air or oxygen; flow rate: 1 L/min. maximum; pressure:
689 hPa to 1034 hPa-gauge (10 to 15 psig); maintain a constant
pressure ±34 hPa (±0.5 psig)
d. Gas Connections
Ozone Air:...................................... 1/4” O.D. tube fitting, brass
Exhaust:......................................... 1/4” O.D. tube fitting, stainless steel
Sample In: ..................................... 1/4” O.D. tube fitting, stainless steel
See the Preface section of the Platform manual for specifications regarding Platform-related components
(e.g., case dimensions) and the I/O Module manual for specifications regarding I/O (e.g., relay outputs).
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 CLD
A
Instruction Manual
760000-C
November 2002
SECTION 2
INSTALLATION
WARNING.
Before starting to install this equipment,
read the “Essential Instructions” on the inside cover and the Safety Summary beginning on page P-2. Failure to follow the safety
instructions could result in serious injury or
death.
2-1 UNPACKING
If the Chemiluminescence (CLD) 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 CLD
Analyzer Module are operational.
2-2 ASSEMBLY
If the CLD 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.
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.
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.
Refer to Section 2-5, page 2-4 for electrical
connections.
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.
NALYZER MODULE GUIDES
PIN SEATS
DISENGAGED FRO NT PANEL
Figure 2-1. Analyzer Module Installation into Instrument Platform
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1
Instruction Manual
760000-C
November 2002
Model NGA2000 CLD
2-3 LOCATION
Install the CLD Analyzer Module in a clean,
weather-protected, vibration-free location free
from extreme temperature variations and moisture. For best results, install the instrument near
the sample stream to minimize sample transport
time.
The analyzer should be installed within ±15° of
horizontal.
NOTE
Unrestricted air flow to the rear of the Analyzer Module is critical to its performance
and reliability.
Operating ambient temperature is 0
o
(32
F to 113oF). Temperature change should
not exceed 10
o
C (18oF) per hour. The same
temperature range restrictions apply to the location of the air and span gas cylinders.
o
C to 45oC
2-4 GASES
a. Overview
See Table 2-1, page 2-2. The CLD Analyzer
Module requires two cylinder gases: 1)
breathing grade air or oxygen and 2) a
standard of accurately known composition
for use as a span gas.
Each gas should be supplied from a cylinder equipped with a clean, non-corrosive,
two-stage regulator. A shutoff valve is recommended.
b. Connections
(See Figure 2-2, page 2-3) Connect inlet
and outlet lines for sample, air, and exhaust
to appropriately labeled fittings on the rear
panel, each of which is a 1/4-inch ferrule-type compression fitting.
Stainless steel or Teflon tubing is recommended for the sample line. Exhaust tubing
should be 1/4 inch (6.3 mm) or larger, and
made of stainless steel or Teflon.
MAXIMUM NOx
LEVEL IN PARTS
PER MILLION
GAS SUPPLIED
TO REAR PANEL
AIR INLET
800 Air
2,500 Air
10,000 Oxygen
SETTING ON OZONE
PRESSURE GAUGE
(pressure values:
gauge)
690 hPa (10 psig); provides flow of approximately 500 cc/min. to
ozone generator
690 hPa (10 psig); provides flow of approximately 1000 cc/min. to
ozone generator.
1035 hPa (15 psig); provides flow of approximately 1000 cc/min to
ozone generator.
SETTING ON SAMPLE
PRESSURE GAUGE
(pressure values:
gauge)
344 hPa (5 psig); provides flow of approximately 200 cc/min. to
reaction chamber
344 hPa (5 psig); provides flow of approximately 70 cc/min to
reaction chamber.
103 hPa (1.5 psig); provides flow of approximately 20 cc/min. to
reaction chamber.
CAUTION.
Externally Limit Sample Flow Rate To Less Than 2200 Cc/Min.
Table 2-1. Gas Specifications
2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 CLD
Instruction Manual
760000-C
November 2002
c. Specifications
Calibration Gases
Either U.S.P. breathing grade air or nitrogen
is recommended for use as zero gas. A mixture of NO or NO
gen is recommended as span gas. For
maximum accuracy, the concentration of
NO in the span gas should be about the
same as that in the expected sample
stream.
Ozonator Source Gas
For analyzers with ranges less than
0 to 2,500 ppm, U.S.P. breathing grade air
should be used for generation of the ozone
required for the chemiluminescence reaction. For ranges greater than 0 to 2,500
ppm, breathing grade oxygen is required.
EXHAUST
EXHAUST FAN SAMPLE IN INTAKE FAN
OZONATOR AIR
Figure 2-2. CLD Rear Panel Connections
At no time should sample flow exceed
2200 cc/min. Damage to internal compo-
in a background of nitro-
2
nents may occur if this flow level is exceeded.
EXTERNALLY RESTRICT SAMPLE FLOW
TO LESS THAN 2200 CC/MIN.
No restrictor is provided in the sample
inlet of this module. For those users
who cannot externally limit sample flow,
accessory restrictor PN 657300 is available from Rosemount Analytical. To obtain this accessory, call 800-433-6076.
WARNING
CAUTION .
Sample
The sample must be clean and dry before
entering the Analyzer Module. Sample
should be filtered for particulates down to
two microns, and should have a dew point
o
5
C (13oF) below coldest ambient tempera-
ture.
Pressure
Between 690 and 1035 hPa-gauge (10 and
15 psig) of ozonator air (or oxygen, if appropriate) should be present at the rear
panel of the module. Bypass sample gas
flow rate should be between 700 and 2000
cc/min. with backpressure regulator pressure (see Capillary Pressure in “Current
Measurement Parameters” menu, which
can be viewed by selecting the PARMS
softkey in “Main Menu”) adjusted to 344
hPa (5 psig).
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3
Instruction Manual
760000-C
November 2002
Model NGA2000 CLD
Zero/span gases should be introduced at
the SAMPLE IN fitting at normal sample inlet flow rate.
WARNING
At no time should ozonator gas pressure
exceed 2070 hPa-gauge (30 psig). Damage to internal components may occur if
this pressure level is exceeded.
Leak Test
The CLD Analyzer Module is completely
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. Periodically, the user should do
an internal leak test (with a test procedure
chosen by the user).
Contaminants
White crystal deposits on the windows of
the reaction chamber, and the clogging of
capillaries and vent are usually due to sample contaminates such as ammonia reacting
with the high ozone levels and NO components.
To eliminate the contaminates, the sampling
system should be reworked or a preventive
maintenance program developed (if dropout
is not excessive). Another source of crystalline formation is contaminated air.
2-5 ELECTRICAL CONNECTIONS
NOTE
Electrical installation must be in compliance
with National Electrical Code (ANSI/NFPA
70) and/or any applicable national or local
codes.
Refer to Figure 2-3, page 2-4. Two electrical
connections are required on the Analyzer Module: POWER and NETWORK. On the Analyzer
Module, two NETWORK connectors are available, either of which is appropriate for:
1. Interconnection with the Backplane of the
Platform. (See instruction manual for the
NGA 2000 Platform).
2. "Daisy-chaining" with other NGA 2000 components.
Connect Analyzer Module POWER to 24 VDC,
120 Watt power source, either the Platform or
external power source.
Metering Valve
Regulator Adjus t
Slot
Flow
Sample
Balance
Regulator
24V
250 V
CLD
LON
1
LON
2
1 +
2 3 GND
T 6A
Network1 Connect ion
Network2 Connect ion
Power Connection
Fuse
Figure 2-3. Front Panel Controls and Electrical Connections
2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 CLD
5
3
5
4
4
4
Instruction Manual
760000-C
November 2002
POWER SUPPLY BOARD-LON/POWER
MODULE ASSEMBLY 657510
J2
J1
LON/PWR MODULE
656761
J5
3 2 1
RED
CABLE, CONTR OLLER PWR 903034
NC
J6
1 2
1
2
POWER SUPPLY
BOARD 657520
J13
8 7
1
2
J1
10
9
3
12
7
HEATERS
J11
1
10
J3
6
1
12
RED
DETECTOR
658160
CONVERTER HEATER JACKET 655228
J3
E3
E2
E1
GRN
ORN
BLK
GRN
BLK
1
GRN
J2
2
ORN
3
WHT
WHT
THERMISTOR 655216
THERMOSTAT
657298
THERMOSTAT
CONVERTER TEMPERATURE
SENSOR 65528 2
CONVERTER
655250
NC
1
J1
J4
1
J2
COMPUTER ANALYSIS BOARD 655520
1
J3
J5 J6
CABLE, INTERNAL NETWOR K 903035
HARNESS, SIGNAL POWER 655252
CABLE, FLOW SENSOR 655384
PRESSURE
SWITC H (NO)
RED
WHT
BLK
FLOW
SENSOR
902931
4-15 PSIG
662298
BRN (NO)
1
HARNESS, DRIVER POWER 655243
HEATER/THERMOSTAT ASSEMBLY 655235
PHOTODIODE SOCKET ASSEMBLY 655218
NO/NOx
SOLENOID
655263
WHT
WHT
SHLD
GRN
JUMPER
657162
OZONATOR
POWER
SUPPLY
657716
SHIELD
HARNESS, EXPANSION I/O 655249
111
1
J7
2
SAMPLE
PRESSURE
SENSOR
655253
YEL (COM)
OZONATOR
659494
TRANSISTOR
E
2SD1308
C
655264
B
B = YEL
C = RED
E = BLU
RED
SAMPLE
PRESSURE
SENSOR
655254
RED
WHT
BLU
RED
YEL
BLK
ORN
ORN
BRN
WHT
BLK
RED
BLK
RED
WHT
WHT
BRN
BRN
YEL
J6
4
3
J8
2
1
J9
J1
J13
BRN
1 4 5 6
GRN
WHT
RED
3
J2
2
1
3
J1
2
1
J4 2
1
2
1
3
J9
2
1
1
2
3
4
J8
5
6
7
8
4
3
J5
2
1
4
3
J12
2
1
12
10
J5
J3
SIGNAL BOARD 655580
1 2 3 4 5 6 7 8 9
SHLD*
ORN
GRN
WIRE*
YEL
WHT
BLU
BLK
*COAX CABLE
RED
J11
1 2 3 6
J2
GRN
WHT
BLK
RED
BLK
WHT
RED
RED
4 3 1
J10
J3
DRIVER BOARD
655620
3
J11
1
J2 J6
10
2
1
2
CABLE, ANALO G I/O 903033
BLK
WHT
BLK
7 6
1
8
CABLE, DIGIT AL I/O 655246
CABLE, DIAGNOSTICS 903032
24
1 Optional in Bypass Flow
Sensor Configuration.
FAN 655245
FAN 655245
Figure 2-4. CLD Wiring Diagram
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5
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