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 repre-
sentative 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 mainte-
nance of the product.
• Install your equipment as specified in the Installation Instructions of the appropriate In-
struction Manual and per applicable local and national codes. Connect all products to the
proper electrical 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
Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA 2000 HFID
PREFACE
The purpose of this manual is to provide information concerning the components, functions,
installation and maintenance of the NGA 2000 HFID 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.
760004-A
February 2002
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
760004-A
February 2002
Model NGA 2000 HFID
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
Operate this equipment only when covers are secured. Servicing requires access to live parts
which can cause death or serious injury. Refer servicing to qualified personnel. For safety
and proper performance, this module must be connected to a properly grounded three-wire
source of electrical power.
WARNING .
POSSIBLE EXPLOSION HAZARD
This equipment is used in the analysis of sample gases which may be flammable, and the
burner fuel used in the ionization process is flammable. A continuous dilution purge system
is factory-installed (in accordance with Standard ANSI/NFPA 496-1993, Chapter 6, and it must
be functional at all times during operation. Do not disable this purge system.
WARNING.
FLAMMABLE SAMPLES
The internal compartment of the oven is vented to the main enclosure by the top and bottom
vents. DO NOT RESTRICT THOSE VENTS.
Consult the factory if flammable samples will be measured.
P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA 2000 HFID
WARNING.
HIGH TEMPERATURE
This equipment is used in the analysis of sample gases at temperatures of up to 250C. All components and material in contact with the sample, the oven and the burner can reach this temperature
level.
Operate this equipment only when covers are secured. Servicing requires access to "hot" parts
which can cause serious injury. Refer servicing to qualified personnel.
NOTE
This Analyzer Module is completely leak-tested at the factory for gas leakage. The user is responsible for testing for leakage at the inlet and outlet fittings on the rear panel (with a test procedure chosen by the user). The user is also responsible for leak-testing periodically and if any internal
pneumatic components are adjusted or replaced. See leak test instructions in Section 2-5.
WARNING.
760004-A
February 2002
PARTS INTEGRITY
Tampering with or unauthorized substitution of components may adversely affect safety of this
product. Use only factory-approved components for repair.
CAUTION.
PURGE AIR REQUIREMENT
This Analyzer Module must be used in conjunction with a device (Control Module or PC Interface)
that can actively monitor network variables related to pressure or flow of the continuous dilution
purge, or the front panel LEDs of the Analyzer Module, as installed, must be visible. The purpose of
this requirement is to maintain adherence to ANSI/NFPA 496 standard which assures the continued
viability of the purge system. Under no circumstances should any pressure or flow indicator be
connected to the PURGE AIR OUT outlet of the Analyzer Module because this may affect the sealing
performance of the module.
CAUTION.
PRESSURIZED GAS
This module requires calibration with a known standard gas. See General Precautions for Handling
and Storing High Pressure Gas Cylinders, page P-5.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3
Instruction Manual
760004-A
February 2002
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.
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.
CAUTION .
PRESSURIZED ENCLOSURE
Model NGA 2000 HFID
This enclosure shall not be opened unless the area is known to be free of flammable materials or
unless all devices within have been de-energized.
Area classification for the protected enclosure:
Nonclassified.
Pressurization: Type Z
Temperature Identification Number: T4A
Power shall not be restored after enclosure has been opened (or loss of purge) until enclosure has
been purged for a minimum of 6 (six) minutes at the minimum pressure of 689 hPa (10 psig).
P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA 2000 HFID
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.
760004-A
February 2002
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
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5
Instruction Manual
9
6
760004-A
February 2002
Model NGA 2000 HFID
DOCUMENTATION
The following NGA 2000 HFID instruction materials are available. Contact Customer Service Center or
the local representative to order.
748414 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.
FM
APPROVED
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).
NRTL /C
®
97-C219
NAMUR
This product satisfies all obligations of all relevant standards of the EMC framework in Australia and New
Zealand.
N
P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA 2000 HFID
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
760004-A
February 2002
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.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-7
Instruction Manual
760004-A
February 2002
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).
Model NGA 2000 HFID
P-8 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
DESCRIPTION AND SPECIFICATIONS
Instruction Manual
760004-A
February 2002
SECTION 1
1-1 OVERVIEW
This manual describes the Heated Flame Ionization Detector (HFID) Analyzer Module of
Rosemount Analytical's NGA 2000 Series of
gas analysis components. See Figure 1-1 and
Figure 1-2.
The HFID Analyzer Module is designed to continuously determine the concentration of hydrocarbons in a flowing gaseous mixture at a
user-selectable temperature setpoint between
93°C and 204°C (200°F and 400°F). The concentration is expressed in ppm or percent of
volume.
The entire HFID Analyzer Module is designed
as a stand-alone module, 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 monitoring of atmospheric air for low-level
hydrocarbon contaminants and determining the
hydrocarbon content of exhaust emissions from
internal combustion engines are examples of
typical applications for the HFID Analyzer Module.
1-3 SAFETY GAS FEATURES
The HFID Analyzer Module is designed with a
factory-installed continuous dilution purge system in accordance with standard ANSI/NFPA
496 - 1993, Chapter 6. Front-panel LEDs indicate that the burner flame is lit and that the
purge system is enabled. In addition, fuel gas is
automatically shut off when a flame-out condition occurs or the safety system is disabled.
The purge system is enabled only if there is
proper purge gas flow in, purge gas pressure,
and internal case pressure, and after five times
the case volume has been exchanged.
All tubing ahead of the burner is rigid metallic tubing assembled with ferrule/nut type
compression fittings. However, should an
internal fuel leak occur, a worst-case leak
would be dissipated below 25% of the LEL
of hydrogen through the combination of an
inlet fuel flow restrictor and purge gas flow.
This module is designed to use 40%
H
2
/60% He fuel at a maximum inlet pres-
sure of 3446 hPa-gauge (50 psig).
A standard HFID Analyzer Module is only
equipped to analyze a non-flammable sample, below 100% of the LEL.
WARNING
POSSIBLE EXPLOSION HAZARD
Protection against explosion depends
upon a special fuel flow restrictor in the
fuel inlet fitting. Do not remove fuel inlet
restrictor. Do not use 100% hydrogen
fuel. Replace only with a factory supplied fitting.
1-4 THEORY OF TECHNOLOGY
This Analyzer Module uses the flame ionization method of detection. The sensor is a
burner in which a regulated flow of sample
gas passes through a flame sustained by
regulated flows of a fuel gas (a hydrogen/diluent mixture) and air.
Within the flame, the hydrocarbon components of the sample stream undergo a complex ionization that produces electrons and
positive ions. Polarized electrodes collect
these ions, causing current to flow through
an electronic measuring circuit.
The ionization current is proportional to the
rate at which carbon atoms enter the
burner, and is therefore a measure of the
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Instruction Manual
g
760004-A
February 2002
Model NGA 2000 HFID
concentration of hydrocarbons in the sample.
This measure of concentration is placed on the
+90V
network, where it can be shown on a data
acquisition device.
Negative Ion
Collection Plate
Signal Conditionin
Positive
Carbon
Ions
Sample
Figure 1-1. Flame Ionization Detection Technology
C
Air
Fuel
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Burner Exhaust, Bypass Out and Purge Air Out to be vented to atmospheric pressure and to
non-classified location in accordance with ANSI/NFPA-496 guidelines.
No connection shall be made to this fitting. If this caution is ignored, damage to the case seals
could occur, and the instrument will not operate properly.
WARNING
HIGH TEMPERATURE
The Sample In, Bypass Out, and Burner Exhaust Out connections can reach temperatures of up to
250°C (480°F). Severe burns could result from touching these connections.
See the Preface section of the Platform Components manual for specifications regarding Platform-related
components and the Preface of the I/O Module manual for specifications regarding I/O (e.g., relay outputs).
1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
SECTION 2
INSTALLATION
2-1 UNPACKING
If the HFID 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, do so at this time.
Connect the network cable to either the NETWORK 1 or NETWORK 2 connection on the
Analyzer Module. Connect the power cable to
the Analyzer Module front panel and an electrical +24VDC power supply.
2-3 LOCATION
Install the Analyzer Module in a clean,
weather-proofed, non-hazardous, vibration-free
location free from extreme temperature variations. For best results, install the Analyzer Module near the sample stream to minimize sample
transport time.
The cylinders of fuel, air, and calibration
gas(es) and the source of purge and regulated air should be located in an area of
relatively constant ambient temperature.
2-4 GASES
a. Overview
During normal operation, the Analyzer
Module requires fuel and air to maintain the
burner flame as well as suitable standard
gases for calibration and instrument air for
purge requirements. In addition, instrument
air for regulated air in is required to control
the sample pressure at the sample capillary.
Criteria for selection of these gases follow in
Section 2-4c.
After initial startup or after startup following
a prolonged shutdown, the analyzer may
display baseline drift for a considerable period of time, particularly on the most sensitive range. Commonly, the drift is caused by
small amounts of hydrocarbons in the inner
walls of the tubing in both the internal flow
system and the external gas supply system.
Drift results from any factor influencing the
equilibrium of these absorbed hydrocarbons, such as temperature or pressure.
WARNING
INSTALLATION RESTRICTIONS
For safety, the Analyzer Module should be
installed in a non-confined, ventilated space.
Do not block any of the rear panel outlets as
they are part of the safety system.
Operating ambient temperature is 15°C to
35°C, limited to temperature changes of less
than 10°C/hr. Acceptable dew point range is
less than 95% relative humidity, but not in excess of 45°C wet bulb temperature.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 2-1
Note that this type of drift occurs only when
the flame is burning. If drift occurs when the
flame is extinguished, the electronic circuitry
is at fault. To minimize drift, use clean fuel
and air, keep the analyzer clean, and locate
the gas cylinders in an area of relatively
constant ambient temperature.
The cylinders supplying all gases each
should be equipped with a clean, hydrocarbon-free, two-stage regulator and a shutoff
valve.
All new external gas tubing (except for
PURGE IN/OUT and SAMPLE BYPASS) is
strongly recommended, preferably precleaned, stainless steel, gas chromato-
Instruction Manual
G
760004-A
February 2002
Model NGA 2000 HFID
graph-grade tubing. Thoroughly clean before
use (if a hydrocarbon-based cleaning solvent
such as acetone is used, purge tubing with dry
nitrogen or helium for several minutes before
using.)
Gas line connections are compression fittings.
Do not use pipe thread tape.
Since the oxidation of hydrogen is accompanied
by the formation of water vapor, the Exhaust
tubing always should be slanted downward at
least 6 degrees from horizontal. Otherwise,
water may accumulate in the line, causing back
pressure and noisy readings, or may back up in
the line and flood the burner. Depending on
the percent of water vapor in the sample,
the sample bypass out connection may
have condensation. Proper drainage may
be required.
If the sample is toxic or noxious, or is to be
reclaimed, connect the Bypass outlet to a
suitable disposal system. Do not use any
device that may cause back pressure in the
line.
Purge air and burner air should be supplied
from separate sources.
PURGE
AIR OUT
REGULATE
D
WARNIN
BURNER
AIR IN
PURGE
ATTENTION
Possible electric shock, explosion or toxic gas hazard. See front of module
BURNER
EXHAUST
VENT TO SAFE AREA
SLOPE DOWNWARD 6
MINIMUM
HOT !
ATTENTION
CHAUD !
HEATED
SAMPLE IN
HEATED
SAMPLE
BYPASS OUT
Danger d'electrocution, d'explosion ou d'emanation de gaz
toxique. Se refere aux details inscrits surla face du module.
2-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
b. Pneumatic Connections
WARNING
HIGH TEMPERATURES
The Sample In, Sample Bypass Out, and
Burner Exhaust Out gases and fittings can
reach temperatures of up to 250°C. Make
connections to these fittings when the oven
heater is disabled or the module is powered
down.
(See Figure 2-1) Connect inlet and outlet
lines for sample, burner fuel and air, exhaust, bypass, regulated air, and purge to
appropriately labeled fittings on the rear
panel. All connections are 1/4-inch ferrule-type compression fittings except the
PURGE AIR IN and OUT connections,
which are 3/8-inch compression fittings. The
Burner Exhaust is a 3/8-inch connection.
It is recommended that no connection be
made to the PURGE AIR OUT port. If, however, the analyzer's location requires interconnection with a venting system, the 3/8"
O.D. line should be kept as short as possible, and no longer than four feet.
CAUTION
POSSIBLE INSTRUMENT DAMAGE
c. Specifications
Fuel Gas
Standard analysis usually requires
mixed fuel, i.e., 40% ±2%) hydrogen
2/
and 60% helium. H
recommended over H
of better linearity in concentration output. Such blends are supplied by many
gas vendors specifically for this use,
with a guaranteed maximum total hydrocarbon content of 0.5 ppm, measured as methane. This specification
should be used when obtaining these
mixtures.
The fuel restrictor is marked with a
red dot, and the sample capillary is
marked with a red or green dot for
mixed fuel applications.
Burner Air
In order to ensure a low background
signal, burner air should contain less
than 1 ppm maximum total hydrocarbon
content. An alternate source for burner
air and zero gas (see CALIBRATION
GASES below) is a combination diaphragm pump and heated palladium
catalyst. This process continuously removes moderate amounts of hydrocarbons and carbon monoxide from
ambient air.
He mixed fuel is
2/N2
fuel because
NOTE
No connection should be made to the
PRESSURE RELIEF VALVE fitting. Doing so
may cause damage to the instrument.
CAUTION
PURGE AIR REQUIREMENTS
The front panel LEDs of the Analyzer Module, as installed, are not visible, the user
should provide an indicator for the safety
system as per ANSI/NFPA 496 standards.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 2-3
Purge Air
Instrument quality air or nitrogen is required for the safety purge system.
Regulated Air
Instrument quality air or nitrogen is required. The air should contain less than
2 ppm maximum total hydrocarbon
content.
Calibration Gases
Calibration method and gases depend
on the operating range, and the desired
measurement accuracy. In all methods,
zero and span gases are used, and are
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
introduced through the sample inlet at the
rear of the module.
Zero Gas - Analysis is affected by the
background gas of the sample. Therefore, it
is recommended to use zero gas with as
close to the background composition of the
sample as possible. Normally less than 0.5
4
THC as CH
Span Gas - Span gas consists of a specified concentration of methane or other hydrocarbon in a background gas such as
nitrogen. Analysis is affected by the background gas of the sample. Therefore, span
gas containing the same background gas as
the sample is recommended. Then, the
background effect is canceled out.
Sample Gas
Sample gas should be nonflammable (below 100% of the sample's LEL). For high
sensitivity applications requiring background
gas compensation, contact the factory.
is sufficient.
Burner Air Pressure should be : 1725
to 3450 hPa-gauge (25 to 50 psig) for
cylinder regulator, 1035 hPa-gauge (15
psig) nominal for internal pressure.
Regulated Air Pressure should be 689
to 1725 hPa-gauge (10 to 25 psig) for
cylinder regulator.
Purge Air Pressure should be 689 to
1380 hPa-gauge (10 to 20 psig).
Nominal Internal Case Pressure is
about 0.5 to 1.0 inch of water, and the
pressure relief valve is set at 1/3 psig
(nominal).
CAUTION
OVER PRESSURE DAMAGE
Noncompliance with these specifications, particularly those concerning
purge air, could cause over-pressure
damage to the module.
Flow Rate
Required sample flow rate is 1.0 L/min. to
2.5 L/min. for a supply pressure between 5
and 9 psig. Flow rate for purge gas should
be 16 to 18 L/min. Flow rate for regulated
air should be 2 to 4 L/min.
Pressure/Filtration
Sample Pressure at the SAMPLE inlet
should be within the range of 345 to 620
hPa-gauge (5 to 9 psig, 7.0 psig nominal),
and internally, should be between 206.7
and 275.6 hPa-gauge (3.0 and 4.0 psig).
Burner Fuel Pressure should be: 3101 to
3450 hPa-gauge (45 to 50 psig) for cylinder
regulator, 1723 hPa-gauge (25 psig) nominal for internal pressure.
NOTE
The sample gas and regulated air
should be filtered for particulates
down to 2 microns to prevent the
plugging of pneumatic components.
2-5 LEAK TEST
The analyzer module is completely leak
tested at the factory. The user is responsible for testing for leakage 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 chosen by the user).
2-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
A
Instruction Manual
760004-A
February 2002
REGULATOR,
PURGE AIR
PLUG
1/4NPT
SWITCH,
PURGE
FLOW
DIFFUSER
PURGE
PRESSURE
SENSOR
BULKHEAD
3/8T BRASS
REDUCER
3/8T - 1/4T
BRASS
B
PURGE
AIR IN
PLUG
1/8NPT
ADAPTER
1/4T - 1/8NPT
BRASS
ELBOW
PURGE AIR
RESTRICTOR
BRASS
TUBING 1/4 OD
VITON
TUBING 1/4 OD
COPPER
ELBOW
1/4T - 1/4MPT
BRASS
REGULATED
CHECK
VALVE
1/3 PSIG
ELBOW
1/4T - 1/4FPT
BRASS
ELBOW
1/4T - 1/4NPT
BRASS
IN
FIXED FLOW
CONTROLLER,
REGULATED AIR
BULKHEAD
RESTRICTOR
1/4T - 1/4T
AIR IN
SS
BULKHEAD
1/4T - 1/4T
BRASS
MANIFOLD,
SAMPLE
UNION
1/4T BRASS
PRESSURE SENSOR,
REGULATED AIR
0 - 15 PSIG
HEATED
SAMPLE
IN
OUT
RUN TEE
1/4T - 1/4MPT
BRASS
SAMPLE
BYPASS
OUT
BURNER
DETECTOR
FUEL RESTRICTOR
1/8T - 1/8T
TUBING 1/8 OD
COPPER
TUBING 1/4 OD
COPPER
AIR IGNITE
RESTRICTOR
BURNER
EXHAUST
BULKHEAD
1/4T - 1/8T
SS
RESTRICTOR,
BYPASS
SENSOR,
SAMPLE
TEMPERATURE
SAMPLE
CAPILLARY
CONNECTOR
1/16T - 1/8NPT
SS
ELBOW
1/8T - 1/8T
BRASS
PRESSURE
RELIEF
VALVE
BULKHEAD
REDUCER
1/4T - 1/8T
BRASS
TUBING 1/8 OD
COPPER
RUN TEE
1/8T - 1/8MPT
BRASS
AIR
RESTRICTOR
ELBOW
1/8T - 1/8MPT
BRASS
BURNER
AIR IN
SENSOR,
BURNER AIR
PRESSURE
-
TUBING 1/8 OD
COPPER
OUT
PURGE
AIR OUT
FILTER
RUN TEE
1/4T - 1/4FPT
BRASS
PORT CONNECTO R
1/4
TUBING 1/8 OD
COPPER
TUBING 1/8 OD
SS
GA
BULKHEAD
3/8T - 1/4MPT
BRASS
TUBING 1/4 OD
VITON
OUT
IN
PRESSURE
REGULATOR,
BURNER AIR
0 - 60 PSIG
BULKHEAD
CONNECTOR
1/4T - 1/8NPT
SS
PRESSURE
SWITCH
SENSOR,
FUEL
PRESSURE
-
GA
IN
REGULATOR,
FUEL
PRESSURE
0 - 30 PSIG
FUEL
IN
SOLENOID
VALVE
TUBING 1/8 OD
SS
FUEL
RESTRICTOR
MALE
CONNECTOR
1/8T - 1/8NPT
SS
Figure 2-2. Flow Diagram
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 2-5
Two electrical connections are required on the
Analyzer Module: POWER and NETWORK
(See Figure 2-3 and Figure 2-4). On the Analyzer Module, two NETWORK connectors are
available, either of which is appropriate for: 1)
interconnection with the control module or 2)
"daisy-chaining" with other NGA 2000 components. Connect Analyzer Module POWER to an
external +24 VDC power source with a voltage
tolerance of ±5% and a minimum power rating
of 120 watts.
Do not operate flammable
sample without following
instructions in the Manual.
An explosion resulting in
severe personal injury or
death could occur.
DANGER
Ne pas utiliser l′echantillon
inflammable avant d′avoir pris
connaissance des inst ructions
contenues dans le manuel . Le
non respect de ces in structions
peut entrainer une ex plosion
provoquant des blessure graves
ou mortelles.
BURNER
AIR
FUEL
POSSIBLE
EXPLOSION HAZARD
Hydrogen fuel gas is use d in this instrument.
Do not remove fuel res trictor or operate at
greater than 50 psig. An explosion resulting
DANGER D′EXPLOSION
Cet instrument contient du gaz hydrogene. Ne
retirez pas le limitateur d′de
combustible, et n′operez pas au plus de 50
psig
Ces conditions peuvent provoquer une explosion
POWER
OVEN
HEAT
FLAME
ON
PURGE
AIR
FUEL
OVERRIDE
IGNITE
24V
LON
1
LON
2
1 +
2 3 GND
T 6A
250 V
Figure 2-4. Front Panel Connections, Controls and Indicators
2-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
[
]
[75]
[83]
[81]
[35].9[23]
FRONT VIEW
1.1
8.2
[208]
6.8
[174]
[18]
Instruction Manual
760004-A
February 2002
3.6
[91]
1.9
.7
[48]
.6
[15]
SIDE VIEW
.3
[7]
.7
[17]
.2
[6]
REAR VIEW
.25
[6]
DIA
4.3
110
2.0
[51]
1.1
[27]
2.0
[52]
4.2
[107]
4.0
[103]
5.4
[137]
[152]
22.5
[571]
7.2
[183]
6.0
1.1
[28]
2.8
[71]
1.4
[34]
1.0
[25]
2.4
[60]
3.0
3.1
[78]
3.3
1.4
3.2
Dimensions:
INCHES
[MM]
Figure 2-5. HFID Outline and Mounting Dimensions
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 2-7
Instruction Manual
,
J4
P4J5P5
J1
P1
,
AIR
HEAT
FLAMEON
HARNESS
P2
12345678
,
J5 +10VREF
SHIELD
R38
GRY
PUR
760004-A
February 2002
P6
J6
J1
P1
FLAT 24 COND
P4J4P5
CABLE ASSEMBLY
CABLE ASSEMBLY, FLAT 20 COND
FLAT 3 COND
CABLE ASSEMBLY
CABLE ASSEMBLY,
FLAT 16 COND
P4
J4
CABLE ASSEMBLY,
FLAT 30 COND
J6
P6
POWER
SUPPLY
BOARD
J3
P3
J1
P1
J5
SAFETY
BOARD
COMPUTER
ANALYSIS
BOARD
J2
P2
CABLE ASSEMBLY,
FLAT 3 COND
P9
P3
J3
J9
FUEL SOL.
OVEN HEATER
-
+-+-+
P10
YEL
BLU
GRN
BRN
RED
ORN
P15
P16
J2
P7
J7
J3
P3
J15
J16
MTG
STUD
J7
3-WAY SOLENOID
CABLE ASSY,
PRESSURE
POWER
Model NGA 2000 HFID
POWER
OVEN
LON/POWER
MODULE
J5
P5
J2
P2
J8
P8
J11
P11
P7
BLK
BLK
RED
RED
AIR
FUEL IN
SENSOR,
CASE
PRESS
SWITCH
FLOW
SW
FLOW
SW
SWITCH
GND
STRAP
CASE TEMP
POL
VOL
2-WAY SOLENOID
SWITCH
FLOW
E2 24VOLT
E1 RTN
E3
CABLE ASSEMBLY,
HARNESS,
CHASSIS
CHASSIS
GND
R37
P18
P17
FLAT 10 COND
THERMOSTAT
HEATER
P10
J10
CABLE ASSEMBLY,
SENSOR BD TO HARNESS
J18
J17
CABLE ASSEMBLY, ANODE
CABLE ASSEMBLY, CATHODE
BLK
RED
GRN
J14
P14
GLOW PLUG
HARNESS
P1
J1
SHIELD
PREAMP
BOARD
E3
E2
FAN ASSEMBLY
SENSOR,
AIR
PRESSURE
OVEN
CABLE ASSEMBLY, THERMAL FUSE
J6
P1 J1
JP1
RTN
J3
P3
SENSOR,
SENSOR,
FUEL
SAMPLE
PRESSURE
PRESSURE
J11 P11
J10 P10
J9 P9
J10 P10
J11
P11
SENSOR
BOARD
J13
P13
J16
P16
J15
P15
P4 J4
P5 J5
SAMPLE RTD
SENSOR ASSEMBLY,
CABLE
ASSEMBLY,
IGNITOR
J1 P1
PURGE AIR
SWITCH
ASSEMBLY,
MANUAL
IGNITE
LED INDICATOR
ASSEMBLY
P2 J2
PWR
MOD
J1
J8 P8
OVEN HEATER
J6
J1
SENSOR ASSEMBLY,
REF TEMP
OVEN
ANODE
HEATER
J2
POWER
MODULE
ASSEMBLY
J4
J12 P12
NC
J12 P12
J7 P7
NC
J14
P3 J3
CABLE ASSEMBLY,
FLAME OUT
CATHODE
DETECTOR
BLOCK
ASSEMBLY
THERMAL OVEN SAMPLE
SWITCH RTD RTD
Figure 2-6. HFID Wiring Diagram
2-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
2-7 INSTALLATION CONSIDERATIONS CHECK-
LIST
Verify the following:
• The Analyzer’s location should
be:
Clean
A well ventilated area
weatherproofed
Non-hazardous
Vibration-free
Have stable ambient temperature
• The gas cylinders should be
equipped with a clean, hydrocarbon free two stage regulator and
shut off valve.
• All external tubing, regulators,
valves, pumps, fittings, etc. are
clean.
• The bypass line connection must
be slanted down a minimum of 6
degrees from horizontal for
drainage of water condensation.
• If required, thermal insulation
around the bypass fitting to prevent condensation in the bypass
restrictor.
• If required, thermal insulation for
the sample inlet connection to
minimize the cold spot.
• The heated line is at the correct
temperature.
• The sample, zero, and span
gases are at the correct temperature.
• The heated line to have over
temperature protection.
• The sample, bypass, and burner
exhaust tubing material must
handle high temperature and
have thermal insulation to protect
from burns.
• The correct fuel type is being
used.
• The THC content of the supply
gases are compatible with the
analysis range.
• The calibration background
gases are similar to the sample.
• The purge air out, burner exhaust, and bypass are vented to
atmospheric pressure. The pressure should be constant.
• The burner exhaust tube must be
slanted down a minimum of 6
degrees from horizontal.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 2-9
• The purge air out tubing to be
3/8 inch and less than 4 feet in
length.
• All external gas connections
have been leak checked.
• The dead volume for external
sample and fuel lines have been
minimized.
• The stainless steel tubing used
for the fuel and sample lines is
clean.
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
2-10 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
SECTION 3
OPERATION
3-1 OVERVIEW
Prior to initial startup, the user should leak test
the module as outlined in Section 2.
For the remainder of this section, Analyzer
Module interconnection with a control module
or some interfacing component will be assumed operational.
3-2 STARTUP PROCEDURE
WARNING
PRESSURIZED ENCLOSURE
This enclosure shall not be opened unless
the area is known to be free of flammable
materials or unless all devices within have
been de-energized.
Area classification for the protected enclosure:
Non-Classified.
Pressurization: Type Z
3. Connect the LON cable(s) and the
+24VDC power cable.
4. Turn power ON.
5. Check the 4 LEDs. The power green LED
should be illuminated. The Oven amber
LED should be blinking or on. The other
LEDs should be OFF.
6. Allow the network to initialize.
7. If the user's system contains only one
Analyzer Module, all system components,
the Controller Board and the network
"self-install" (bind together) during initial
startup. If the system contains more than
one Analyzer Module, the startup sequence will interrogate the network to locate and identify all components on the
network. The user will have to bind appropriate combinations of components
after the startup sequence. (See Section
3-3.)
8. Check the general health of the analyzer
by reviewing the status of the Self Tests.
All “Pass” conditions should be obtained.
Temperature Identification Number: T4A
Power shall not be restored after enclosure has been opened (or loss of purge)
until enclosure has been purged for a
minimum of 6 minutes at the minimum
pressure of 689 hPa (10 psig). For safety,
the Analyzer Module should be installed in
a non-confined, ventilated space. Do not
block any of the rear panel outlets as they
are part of the safety system.
1. Connect supply gases and outlets to/from
module.
2. Turn ON the purge gas only. Perform a
leak check. Wait a minimum of 6 minutes.
Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-1
These test results can be found by selecting the following from the Main Menu:
Technical Level Configuration, Diagnostic
Menus, Analyzer Module Diagnostics,
Self Test. All tested parameters should
indicate "Pass."
Descriptions of the tests performed follow:
•EEPROM test - Checks the EEPROM
on the Analysis Computer PCB.
•EPROM test - Checks the EPROM
on the Analysis Computer PCB.
•RAM test - Checks the RAM on the
Analysis Computer PCB.
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
•Power supply test - Verifies that all
internal DC voltages are within the
required tolerances.
•Network test - Checks the internal
network interface.
•20 bit ADC test - Checks the 20-bit
ADC on the Analysis Computer PCB
by sending a DC signal through the
Preamp PCB and reading the signal
back with the 20-bit ADC.
•12 bit ADC test - Checks the 12-bit
ADC on the Analysis Computer PCB
by sending a DC signal and reading
the signal back with the 12-bit ADC.
•Power Supply PCB test - Checks
the presence of the Power Supply
PCB by activating the 3-way air solenoid.
•Safety PCB test - Checks the pres-
ence of the Safety PCB by sending a
command and reading it back.
9. Set the desired oven setpoint in the range
of 93°C to 204°C (200°F to 400°F).
10. Wait for the Purge Air green LED to illuminate.
11. Introduce the remaining supply gases.
Perform leak check. (See Section 1-5
Specifications)
12. Set and verify the internal gas pressures.
Internal
Pressure
Regulator
Burner Air
Fuel
Sample
(non-adjustable)
Purge air of the following specifications
must be present:
Typical Operating
Pressures
965 to 1103 hPa-gauge
(14 to 16 psig)
1516 to 1723 hPa-gauge
(22 to 25 psig)
206 to 290 hPa-gauge
(3.0 to 4.0 psig)
•Case temperature test - Compares
the temperature read between the
Preamp temperature sensor and the
case temperature sensor. They must
be within 10°C of each other. This test
sometimes fails if the case is opened.
The sensor in the Preamp will take
longer to cool off since it is in an enclosure. Re-running the self-test after
thermal equilibrium will produce a
positive result if the sensors are
working properly.
•Oven/Sample Temperature test Compares the temperature read between the sample temperature sensor
and the oven temperature sensor.
They must be within 50°C of each
other.
The self-test can be repeated at any time
by activating the TEST softkey in the Self
Test Results menu.
Flow: 16 to 18 L/min.
Supply Pressure: 689 to 1378 hPa-gauge
(10 to 20 psig)
Noncompliance could cause damage to
the module. At the very least, the module's safety system, which requires a
certain volume of purge air flowing
through the case before allowing burner
ignition, will not allow the instrument to
operate. The lowest purge air
flow/pressure setting possible during
burner operation is preferable. Thus, the
user should set the external purge air
pressure initially at 689 hPa-gauge (10
psig). Check the Miscellaneous Control
Parameters screen under Technical Diagnostics, and note whether the Purge
Gas (switch) variable is "ON." If it is
"OFF," increase purge air supply by
69 hPa-gauge (1 psig), and recheck the
Purge Gas variable until it reads "ON."
DO NOT EXCEED 1378 hPa-GAUGE (20
PSIG). If the maximum setting is reached,
3-2 Operation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
and the Purge Gas variable does not read
"ON," contact factory. If the safety system
is initiated successfully (Purge Gas variable is "ON"), continue with the remainder
of the startup procedure.
NOTE
Do not restrict the PURGE OUT port
and the pressure relief valve. They
must be vented to atmospheric pressure.
13. Manual or Auto-ignite the flame. The
Flame-On green LED should be illuminated.
Two methods of burner ignition are possible: auto-ignition and manual ignition.
(Note: The burner is easier to ignite when
the oven has reached the desired setpoint
temperature.)
Auto-ignition provides fuel override and
three attempted ignitions (default setting),
if necessary.
Before ignition and operation, Fuel Flow
must be set to ON in "Light Flame" display
screen under Basic Controls and oven
temperature must be at least 85°C.
The manual ignition switch on the Analyzer Module front panel must be manipulated in the following ways:
After igniting flame, release
switch for 2 seconds
Press switch down for
2 seconds
Repeat release switch and
press down steps as
necessary.
14. Allow the case and oven to warm up, approximately 1 to 2 hours.
15. Verify that all 4 LEDs are illuminated.
16. Note the four LEDs on the front panel of
the Analyzer Module. They provide necessary information for either ignition procedure. The LEDs, when illuminated,
denote the following information:
• Green - unit powered on
• Amber - continuous illumination im-
plies oven has reached operating
temp. Within ±6°C of setpoint
• Green - Flame on
• Green - purge air system intact (it has
filled five volumes of the module interior)
•Press up and hold for one minute.
This opens burner fuel and air solenoids.
•Press down to ignite burner glow plug
for up to 10 seconds.
•Repeat as necessary (if fuel and air
sources are farther away than 10 feet,
several more attempts may be necessary).
•If the flame has been lit, but the flame
temperature increases slowly, perform the following steps:
Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-3
17. Check and re-adjust the internal pressures if required.
The unit is ready for operation.
3-3 BINDING
To achieve full coordination between Analyzer
Modules and associated I/O Modules, the
user must bind those components together in
the System Set Up portion of the Technical
Configuration Menu in software.
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
3-4 CALIBRATION
Calibration gas setup is as follows:
1. Set oven temperature setpoint.
2. Apply regulated air at a pressure between
10 and 25 psig.
3. Allow case, oven, and sample temperatures to stabilize.
4. Supply heated zero gas to sample inlet.
Adjust external flow controller or throttle
valve so that the sample inlet pressure is
between 5 and 9 psig., 7 nominal.
5. Supply heated span gas to sample input.
Repeat adjustment described in step 3.
The reading of the sample pressure,
oven, and sample temperatures should be
the same as that used during the adjustment of the zero gas.
See Section 2-4c for a description of the
method for choosing calibration zero and span
gases.
To calibrate the Analyzer Module, introduce
zero gas into the SAMPLE INLET, and do the
following:
1. If more than one Analyzer Module is functional and the split Run Mode display is
shown, press the DISPLAY softkey until
the desired Analyzer's Run Mode display
is acquired.
2. Press the MENUS softkey to enter the
Main Menu.
3. Verify the fuel type in the Miscellaneous
Control Parameters menu (under the
Technical Configuration menu structure,
select the following from the Main Menu:
Diagnostic menus, Analyzer Module Diagnostics and then Miscellaneous Control
Parameters).
4. Verify the capillary type in the Analyzer
Manufacturing Data menu (under the
Technical Configuration menu structure,
select the following from the Main Menu:
Technical Level Configuration, Service
Menus, Manufacturing Data, Analyzer
Module Data).
5. In the Calibration Gas List menu (from the
Main Menu, select Expert Controls and
Setup, Analyzer Module Setup, then Calibration Gas List), enter necessary data,
including the Operational Sample Pressure and the Calibration Gas HC Response Factor. Common HC factors are:
methane (CH
propane (C
not used to compensate the reading, but
are used to select the proper preamp
sense resistor.
6. Press HOME to re-enter the Main Menu,
enter the Basic Controls menu, select desired range, introduce zero gas and allow
its response to stabilize, press the ZERO
softkey to enter the Analyzer Zero menu,
press ZERO again and wait.
7. Press the SPAN softkey to enter the
Analyzer Span menu, introduce span gas
and allow its response to stabilize, press
SPAN again and wait.
8. Repeat steps 6 and 7.
9. Press the HOME softkey to re-enter the
Main Menu.
10. Press DISPLAY softkey for the Run Mode
display.
If the user is unable to calibrate the Analyzer
Module (i.e., when ZERO or SPAN is initiated,
nothing happens), several possible solutions
present themselves. One solution relates to
the use of an incorrect gas for zeroing or
spanning (e.g., using a high concentration gas
to zero or a zero gas to span the Analyzer
Module). Simply recalibrating with the appropriate gas(es) will not correct the problem because the ZERO OFFSET or SPAN FACTOR
has been set to an extreme value in the process.
To remedy the problem, do the following:
4
), 1.0, ethane (C2H6), 1.90,
3H8
), 3.00. These factors are
3-4 Operation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
1. Verify that correct zero and span calibration gases are being used properly. If so,
attempt to recalibrate according to instructions at the beginning of Section 3-4,
ensuring that the oven, sample and case
temperatures and displayed measurement reading are stable before initiating
the calibration routine. If incorrect gases
were used in the initial, failed calibration,
skip to Step 2.
2. Make the following selections from the
Main Menu: Expert Controls and Setup,
Analyzer Module Setup, then Calibration
Parameters. Disable Calibration Adjustment Limits.
3. Recalibrate the analyzer module according to instructions at the beginning of section 3.4, ensuring that oven, sample, and
case temperatures and displayed measurement reading are stable before initiating the calibration routine.
4. Enable Calibration Adjustment Limits in
the Calibration Parameters menu.
NOTE
eration depend on the concentration of total
hydrocarbons in the sample.
If maximum sensitivity is required from the
HFID Analyzer Module, use an optimum combination of settings on the FUEL, and AIR
pressure regulators. Settings must be determined experimentally, but the curves in Figures 3-1 and 3-2 may be used as guides.
The Analyzer Module will not allow the user to
increase the upper limit of a range beyond the
"maximum range" software setting. To change
the "maximum range" value, select the following from the Main Menu: Technical Configuration Menu, Service Menus,
Manufacturing Data, and Analyzer Module
Data. Select Maximum Range, and use the
arrow keys to scroll the indicated value. The
same applies for Minimum Range settings.
During shutdown, always turn off fuel gas first,
then the air and sample gases. The flame can
also be turned off by setting Ignition System
Enable to "Off" in the Light Flame menu (under Basic Controls). Subsequently, remember
to set Ignition System Enable to "On" before
attempting to ignite the flame.
If the range selections straddle 725 ppm,
4
CH
, the zero and span calibration for each
range must be done separately.
3-5 ROUTINE OPERATION
After case, oven, and sample temperature
stabilization, calibration, and binding, proceed
as follows:
Supply heated sample gas to SAMPLE INLET. Adjust external flow controller or throttle
valve so that the sample inlet pressure is between 5 and 9 psig, 7 psig nominal. The
reading on the SAMPLE pressure gauge and
sample and oven temperatures should be the
same as that used during adjustment of the
zero and span calibration gas control.
Adjust the Range Number setting. The Analyzer Module will now automatically and continuously output the measured hydrocarbon
content of the sample. Output is in terms of
the particular hydrocarbon present in the span
gas. Note that readings obtained during op-
After initial startup, or startup following a prolonged shutdown, the Analyzer Module requires about one day's continuous operation
to stabilize. For several days afterwards, calibrate daily. The frequency of subsequent calibrations can be reduced as experience
dictates, consistent with the accuracy requirements of the particular application.
3-6 SAFETY SYSTEM
The HFID Analyzer Module safety system will
not allow ignition or continuous burner function unless the following conditions are present:
•The internal purge gas pressure is at least
380 hPa - gauge (5.5 psig). (Monitor display message, Purge Gas Pressure in
Physical Measurements menu, for proper
setting.)
•Flow rate for purge air in is at least
16 L/min. and case pressure is greater
Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-5
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
than 0.5 inches of water. (Monitor display
message, Purge Gas (ON) in Miscellaneous Control Parameters menu for correct
state. Proper sealing hardware must be
used in order to obtain the required purge
air in flow rate and case pressure).
•Five case volumes of purge air have been
achieved and the three above conditions
are present. The time duration to achieve
a safe system is a minimum of 6 min. The
elapsed time can be monitored in the
Technical Startup Analyzer menu. (Monitor the Purge Air Green LED (ON), Purge
Control Status (ON), or Purge Air Alarm
for indication of the state of the safety
system.)
As stated above, proper sealing hardware is
crucial to the successful operation of the
safety system. Therefore, a specific torque
sequence (shown in Figure 3-3) must be followed when the front panel of the module is
being reinstalled after removal. All front and
rear panel screws must be installed.
NOTE
Do not over-torque rear panel screws.
3-6 Operation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
A
)
1.0
0.8
Instruction Manual
760004-A
February 2002
RESPONSE
(100 ppm CH
fullscale)
4
0.6
0.4
0.2
SAMPLE: 100 ppm CH4 in N
at 3.5 psig (241 hPa)
0
0
5
344
10
688
15
1032
20
1376
IR: 30 psig (2064 hPa
AIR: 20 psig (1376 hPa)
AIR: 10 psig (688 hPa)
2
25
1726
30
2064
psig
FUEL PRESSURE
hPa
Figure 3-1. Typical Curves of Module Response vs. Pressure Setting on Fuel Pressure Regulator
1.0
FUEL: 30 psig (2064 hPa) H
0.8
FUEL: 25 psig (1726 hPa) H
2
2
0.6
FUEL: 20 psig (1376 hPa) H
2
RESPONSE
(100 ppm CH
fullscale)
4
0.4
0.2
25
1726
2
30
2064
SAMPLE: 100 ppm CH4 in N
at 3.5 psig (241 hPa)
0
0
5
344
10
688
15
1032
20
1376
psig
AIR PRESSURE
hPa
Figure 3-2. Typical Curves of Module Response vs. Pressure Setting on Air Pressure Regulator
Rosemount Analytical Inc. A Division of Emerson Process Management Operation 3-7
Instruction Manual
760004-A
February 2002
DISPLAY MESSAGEDESCRIPTIONTYPE
AIR FET
AIR PRESS
BAIR FLOW
BAROMETER
BFUEL FLOW
BLOCK FET
CASE TEMP
CRUDE NOISE
CURRENTRNGHI
CURRENTRNGLO
CURRENTSFAC
FLAME TEMP
FUEL PRES
LIN ERROR
N15 VOLTS
P10 VOLTS
P15 VOLTS
POL VOLTS
SAMP PRES
CALRESULT
PURGE AIR
SW ERROR
Model NGA 2000 HFID
FID Air FET currentWARNING
FID Air PressureWARNING
Burner Air FlowWARNING
System BarometerWARNING
Burner Fuel FlowWARNING
Heater currentWARNING
Case TemperatureWARNING
Calculated NoiseWARNING
Current, High RangeWARNING
Current, Low RangeWARNING
Current RangeWARNING
Flame TemperatureWARNING
Fuel PressureWARNING
Linearizer ErrorWARNING
Power Supply -15VWARNING
Power Supply +10V REFWARNING
Power Supply +15VWARNING
Polarizing VoltsWARNING
Sample PressureWARNING
Calibration ErrorFAILURE
FID Purge AirFAILURE
Software ErrorFAILURE
Table 3-1. HFID Analyzer Module Alarms
Torque Sequence:
Screw #1, 4 to 5 turns
Screw #2, 4 to 5 turns
Screw #3, 4 to 5 turns
Screw #4, 4 to 5 turns
Screw #5, 4 to 5 turns
Screw #6, 4 to 5 turns
614
235
Repeat torque sequence until
all screws are tight.
The gasket must fill in between
the front panel plate and the enclosure.
Figure 3-3. Front Panel Torque Sequence
3-8 Operation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MAINTENANCE AND SERVICE
WARNING
QUALIFIED PERSONNEL
This equipment should not be adjusted or
repaired by anyone except properly qualified service personnel.
4-1 OVERVIEW
This section contains instructions and procedures for troubleshooting and maintaining the
HFID analyzer module. To access the internal components of the analyzer module, perform the following:
Instruction Manual
760004-A
February 2002
SECTION 4
1. Remove power to the unit; shut off gases
and disconnect lines. Allow module to
cool.
2. Refer to Figure 4-1. Remove the six
screws securing the front panel, then the
six screws securing the cover to the rear
panel. Slide cover towards rear panel to
remove. Loosen four screws securing inner insulation shield to base, lift up to remove.
Figure 4-2 illustrates the locations of major
components of the HFID.
PURGE
AIR OUT
REGULATED
AIR IN
BURNER
PURGE
AIR IN
AIR IN
WARNING
ATTENTION
HEATED
SAMPLE
BYPASS
WARNING
ATTENTION
BURNER
EXHAUST
OUT
HEATED
SAMPLE IN
Cover
FUEL
IN
PRESSURE
RELIEF
VALVE
Cover/Rear Panel Securing Screws (6)
Securing
Screw (4)
Figure 4-1. Removal of Cover and Insulation Shield
Insulation Shield
Front Panel Securing
Screws (6)
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-1
Instruction Manual
760004-A
February 2002
Rear Panel Assembly
656954
Oven Assembly
659551
Model NGA 2000 HFID
Electronics Assembly
656943
DC Power Supply Module Assembly
657413
Fan Assembly
657414
Fixed Flow Controller Assembly
657434
Figure 4-2. Locations of Major Assemblies of the HFID
Front Panel Assembly
656949
4-2 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
4-2 OVEN
Though the oven can be replaced as a complete unit, all internal components are field replaceable.
a. Removal
Refer to Figure 4-3, disconnect the oven's
three gas lines and seven electrical cables, noting location of mating connectors
for re-installation.
NOTE
DO NOT remove the fittings from the
gas lines on the detector.
Remove the two hex nuts securing the
oven to the chassis and the two
screws securing oven to the rear
panel. Lift oven assembly from analyzer.
Oven Assembly
659551
Figure 4-3. Removal of Oven from Chassis
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-3
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
b. Disassembly
1. Refer to Figure 4-4A. Remove the
four retaining screws on the oven
cover, remove cover.
2. Remove the two screws and one nut
securing the outer oven front panel
to the outer oven, remove front
panel.
3. Remove the nuts and ferrules from
sample in and sample bypass out.
CAUTION
PREAMP CONNECTORS
The electrical preamp connectors are fragile, handle with care to avoid breaking solder connection.
4. Refer to Figure 4-4B. Remove the
two nuts and washers from the electrical preamp connectors on the inner
oven front panel. Do not unsolderthese connections.
5. Unscrew the three screws from inner
front panel and remove it.
6. Refer to Figure 4-4C. Remove the
two hex nuts securing the burner to
the bottom of the inner oven.
7. Disconnect the sample input and
output bypass fittings.
8. Lift the burner/thermal block up and
out, while disconnecting exhaust.
Reverse procedure for installation.
4-4 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
C
Instruction Manual
760004-A
February 2002
Nuts and Ferrules (2 ea.)
Outer Oven
A
Outer Oven Front Panel
657356
B
Oven Cover 657105 (with
insulation 657346)
Exhaust
Inner Oven Retaining Screw (2) and
Washer (2)
Inner Oven
Inner Oven Front
Panel 657352
Preamp connector
nut, washer (typ 2)
Spring, Heated
Bridge 904294
Heated Bridge
659555
Heater/Cable
Assembly 659643
Jam Nuts
659550
For clarity, outer oven not shown in Figures B and C.
Figure 4-4. Oven Assembly
Burner
657359
Insulating Washers
073737
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-5
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
4-3 BURNER
This section covers burner components which
can be replaced without removal of oven from
the chassis.
a. Temperature Sensor
1. Refer to Figure 4-4A. Remove the
four screws on the oven cover, remove cover.
2. Refer to Figure 4-5. Remove the
burner cap retainer.
3. Disconnect the temperature sensor
wiring connector, note location.
4. Remove the temperature sensor.
5. Insert replacement sensor.
NOTE
The leads of the temperature sensor
must be leading away and down from
the sensor to enable proper fit of
burner cap retainer.
5. Insert replacement RTD detector into
hole, snug down set screw.
6. Re-attach wiring connector.
7. Install oven cover.
c. Igniter
1. Refer to Figure 4-4A. Remove the
four screws on the oven cover, remove cover.
2. Refer to Figure 4-5. Disconnect the
igniter wiring connector, note location.
3. Using an open-end wrench, unscrew
the igniter assembly from the burner.
Verify that o-ring is also removed.
4. Install replacement igniter and new oring. Using open-end wrench, snug
down. Do not over-tighten!
5. Re-attach wiring connector.
6. Install oven cover
6. Install the burner cap retainer. U-slot
must be located above temperature
sensor.
7. Re-attach wiring connector.
8. Install oven cover.
b. RTD Detector
1. Refer to Figure 4-4A. Remove the
four screws on the oven cover, remove cover.
2. Refer to Figure 4-5. Loosen the set
screw securing RTD detector.
4. Gently grasp RTD detector wires and
pull out of hole.
d. Flameout Sensor
1. Refer to Figure 4-4A. Remove the
four screws on the oven cover, remove cover.
2. Refer to Figure 4-5. Disconnect the
flameout detector wiring connector,
note location.
3. Lift up the burner cap until flameout
sensor is accessible. Using an openend wrench, unscrew the flameout
detector from the burner. Verify that
o-ring is also removed.
4. Install replacement flameout detector
and new o-ring. Using open-end
wrench, snug down. Do not over-
tighten!
5. Re-attach wiring connector.
6. Install oven cover.
4-6 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Burner Cap
O-Ring
903736
Igniter Assembly
657205
Instruction Manual
760004-A
February 2002
Retainer, Burner Cap
Temperature Sensor
657468
O-Ring
903737
Flameout Sensor
657199
RTD Detector
657063
Set Screw
M3X0.5 x 10mm
903125
The components shown can be replaced without removing burner/thermal block from oven.
Oven not shown for clarity.
Thermal block shown in phantom for clarity.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-7
Instruction Manual
y
760004-A
February 2002
Model NGA 2000 HFID
4-4 BURNER INTERNAL COMPONENTS
WARNING
BURNER CONTAMINATION
Do not handle internal parts of the burner
with bare hands. All tools used for maintenance must be free of contaminates.
a. Disassembly of Burner/Thermal Block
1. Remove oven from analyzer module
per Section 4-2a.
2. Remove burner/thermal block from
oven per Section 4-2b.
3. Refer to Figure 4-6. Disconnect sample capillary nut at base of burner.
4. Remove screw securing thermal block
to burner.
5. Carefully pull burner away from thermal block.
Burner
Thermal Block
Sample capillary
input
Sample capillar
Figure 4-6. Burner/Thermal Block Disassembly
4-8 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
b. Replacing Burner Jets
Disassemble the burner only if contaminants are evident. Combustion products
or other contaminates which accumulate
inside the burner may form electrical
leakage paths between the collector and
the burner contact, resulting in noisy
readings.
If the analyzer module is to be operated at
the highest sensitivity, traces of such
contaminates can cause erroneous readings. For best performance, replace the
burner jet follows:
WARNING
BURNER CONTAMINATION
Do not handle internal parts of the burner
with bare hands. All tools used for maintenance must be free of contaminates.
1. Remove oven from analyzer module
per Section 4-2a.
2. Remove burner/thermal block from
oven per Section 4-2b.
3. Remove thermal block from burner
per Section 4-4a.
4. Refer to Figure 4-7A. Remove
screws (2) holding burner cap retainer, remove retainer.
5. Holding burner base, lift burner cap
off of assembly, set aside, remove
gasket.
6. Refer to Figure 4-7B. Holding burner
base, lift combustion chamber off, set
aside.
A
Gasket
656931
Burner Cap
Retainer
Burner Cap
Burner Base
Figure 4-7. Burner Disassembly
B
Combustion
Chamber
O-Ring
904373
Burner Base
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-9
Instruction Manual
g
760004-A
February 2002
Model NGA 2000 HFID
7. Refer to Figure 4-8. Lift air baffle out
of burner base.
8. Remove the sample jet and gasket
from the bottom of the burner base.
9. Remove the jet nut. Grasp jet assembly and lift out (along with upper
gasket) of burner base. Remove
bottom gasket.
Air Baffle (Ref)
102260
See Below
Nut, Jet
657016
Gasket
102273
Jet Assembly
657012
Sample Jet
657005
Gasket
102256
Figure 4-8. Burner Jets
Air Baffle
End bent to raise it above the tab a
distance equal to the hei
≈ .06
ht of the tab.
Position with tab over
the air hole
(approximately 1/16” to
the right).
4-10 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
c. Burner Jet Installation
WARNING
BURNER CONTAMINATION
Do not handle internal parts of the burner
with bare hands. All tools used for maintenance must be free of contaminates.
1. Install new lower gasket, jet assembly
and upper gasket into burner base,
finger-tight jet nut.
2. Install new sample jet (with gasket)
and tighten.
3. Tighten jet nut.
4. Install air baffle per Figure 4-8.
NOTE
Incorrect installation of air baffle will
cause ignition failure.
5. See Figure 4-7B. Insert new o-ring
into burner base.
6. Set combustion chamber into burner
base being careful not to move airbaffle.
7. See Figure 4-7A. Insert new gasket
on combustion chamber, install
burner cap and burner cap retainer,
torque screws to 6 inch lbs.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-11
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
4-5 THERMAL BLOCK
The sample RTD can be replaced with the
thermal block attached to burner and mounted
in oven. The cartridge heater and thermostat
are also replaceable with thermal block secured to burner, but must be removed from
the oven.
a. Sample RTD
1. Refer to Figure 4-4A. Remove the
four screws securing the oven cover,
remove cover.
2. Disconnect the sample RTD wiring
connector, note location.
3. Refer to Figure 4-9. Remove the two
screws securing the sample RTD, pull
sample RTD out.
4. Install replacement sample RTD, secure with screws.
4-12 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
b. Cartridge Heater
1. Remove oven from analyzer module
per Section 4-2a.
2. Remove burner/thermal block from
oven per Section 4-2b.
3. Refer to Figure 4-9. Loosen retaining
set screw, pull out cartridge heater.
4. Install replacement cartridge heater,
snug down set screw.
5. Install burner/thermal block into oven.
6. Install oven into analyzer module.
c. Thermostat
1. Remove oven from analyzer module
per Section 4-2a
2. Remove burner/thermal block from
oven per Section 4-2b.
3. Refer to Figure 4-9. Remove the two
retaining screws, pull thermostat out.
4. Install replacement thermostat, attach
with the two retaining screws.
5. Install burner/thermal block into oven.
6. Install oven into analyzer module.
d. Sample Capillary
1. Remove oven from analyzer module
per Section 4-2a
2. Remove burner/thermal block from
oven per Section 4-2b.
3. Remove burner from thermal block
per Section 4-4a
4. Refer to Figure 4-10. Remove the
two screws securing the capillary
cover to thermal block, remove cover.
5. Remove capillary nut, remove capillary.
6. Install replacement capillary.
7. Insert capillary into thermal block.
The capillary may require bending to
fit.
8. Install cover.
Capillary
Cover
Figure 4-10. Thermal Block Assembly
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-13
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
4-6 ELECTRONICS ASSEMBLY
The electronics assembly must be removed
from the chassis if replacement of any of the
following components is necessary:
Power Supply Board
Safety Board
Computer Analysis Board
Preamp Assembly
Sensor Board
Case Temperature Sensor
Case Pressure Switch
1. Remove the hex nut and screw as
shown in Figure 4-11.
2. Lay electronics assembly on bench,
do not disconnect cables or tubing.
Electronics Assembly
656943
Screw
Hex Nut
Figure 4-11. Removing Electronics Assembly from Chassis
4-14 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Preamp Assembly
656945
Case Pressure Purge
Switch 903690
Computer Analysis Board
659149
Instruction Manual
760004-A
February 2002
Sensor Board
657060
Case Temperature Sensor
656026
Figure 4-12. Electronics Assembly – Exploded View
a. Printed Circuit Boards
When replacing a circuit board, the following procedure is recommended:
Per Section 4-6, remove securing hardware from electronics assembly and lay
on bench.
Safety Board
657499
Power Supply Board
655764
Remove securing hardware from printed
circuit board to be replaced, do not disconnect cable(s).
One at a time, remove the wiring connectors and attach to replacement board.
Mount replacement board to electronics
assembly.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-15
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
b. Case Temperature Sensor
1. Per Section 4-6, remove securing
hardware from electronics assembly
and lay on bench.
2. Disconnect case temperature sensor
cable.
3. Remove screw securing cable clamp
holder to signal board.
4. Remove case temperature sensor
from cable clamp holder.
5. Per Figure 4-13 insert replacement
case temperature sensor into cable
clamp holder.
6. Re-assemble to signal board mounting screw.
Center sen-
sor in cable
clamp
Figure 4-13. Case Sensor Installation
4-16 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
c. Case Pressure Purge Switch
1. Per Section 4-6, remove securing
hardware from electronics assembly
and lay on bench.
2. Disconnect the two electrical terminals, note location.
3. Disconnect tube at pressure switch.
4. Remove mounting screws (2) and
washers (2).
5. Reverse procedure for installation of
replacement switch.
Case Pressure Purge
Switch 903690
The bracket does not have to be removed from the electronics assembly for this
procedure.
Figure 4-14. Case Pressure Purge Switch Installation
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-17
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
d. Preamp Assembly
1. Per Section 4-6, remove securing
hardware from electronics assembly
and lay on bench.
2. Disconnect and note location of cables.
3. Remove the two screws and washers
from the top bracket and slide the
preamp assembly out.
Top Bracket
4. Remove the lower bracket from the
preamp assembly and install on replacement preamp assembly.
5. Slide replacement preamp assembly
into top bracket and secure with
mounting hardware.
6. Re-connect cables.
Preamp Assembly
656945
Bottom Bracket
Figure 4-15. Preamp Assembly Installation
4-18 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
4-7 FAN ASSEMBLY
1. Disconnect and note location of cables.
2. Remove the two hex nuts securing the fan
to the chassis, lift fan assembly out.
Instruction Manual
760004-A
February 2002
Fan Assembly
657414
Figure 4-16. Fan Assembly Installation
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-19
Instruction Manual
760004-A
February 2002
4-8 FLOW CONTROLLER
1. Disconnect the all tubing and wiring connectors, note locations.
2. Remove the four hex nuts securing the
flow controller assembly to the analyzer
module chassis.
Model NGA 2000 HFID
Flow Controller Assembly
657434
Figure 4-17. Flow Controller Replacement
4-20 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Regulated Air In
Instruction Manual
760004-A
February 2002
Regulator 250 psi
023382
Remove red cap
after installation
Remove and discard bracket supplied with regulator, assembly as shown.
Figure 4-18. Flow Controller Assembly
FLOW
Regulated Air Out
Sample Sensor
656418
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-21
Instruction Manual
760004-A
February 2002
4-9 DC POWER SUPPLY MODULE
Disconnect and note location of all wiring to
DC power supply module.
Remove the two hex nuts securing module to
chassis, remove module.
Model NGA 2000 HFID
DC Power Supply Module
Figure 4-19. DC Power Supply Module Replacement
4-22 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
4-10 FRONT PANEL COMPONENTS
The following components are mounted to the
front panel:
•
LON/Power Module
•
Manual Ignite Toggle Switch
Connector
fitting
Burner Air Solenoid Valve
656219
Instruction Manual
•
LED Indicator Assembly
•
Purge Air Regulator
•
Purge Air Flow Switch
•
Burner Air Solenoid Valve
•
Burner Air Regulator
•
Fuel Regulator
•
Burner Air Sensor
•
Fuel Sensor
•
Air Ignite Restrictor
•
Air Measurement Restrictor
760004-A
February 2002
Air Measurement Restrictor 656888
Air Ignite Restrictor
655794
Burner Air Sensor
656443
Fuel Sensor
656444
Sensor Fittings
657412
Male Adapter
Fitting
Burner Air Regulator
902832
Diffuser
657548
Purge Air Flow
Switch 656533
Purge Air Regulator
871672
Regulator Mounting Nut
Plugs
Manual Ignite
Toggle Switch
657053
Regulator Mounting Bracket
LON/Power Module
656560
O-Ring
010177
LED Indicator Assembly
657029
O-Ring
011167
Fuel Regulator
902832
O-Rings
008025
Toggle Switch Seal
898980
Figure 4-20. Front Panel – Exploded View
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-23
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
Replacing Front Panel Components
1. To access components, remove the
four front panel mounting screws (two
on front, one on each side).
2. Remove the burner air regulator and
fuel regulator mounting nuts.
3. Remove the purge air regulator
mounting bracket screws.
The front panel can now be pulled away
from the chassis.
NOTE
The wiring from front panel components is still connected. Do not disconnect unless replacing that
component.
Front panel mounting screw
(opposite side also)
Front panel
mounting screws
Figure 4-21. Accessing Front Panel Components
4-24 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
a. LON/Power Module
1. Disconnect wiring connectors, note
locations.
2. Refer to Figure 4-20. From the out-
side of the front panel, remove the
two mounting screws.
3. Install replacement module in reverse
order.
b. LED Indicator Assembly
1. Disconnect wiring connector, note lo-
cation.
2. Refer to Figure 4-20. From the inside
of the front panel, remove the two hex
nuts securing LED indicator assembly
to front panel. Remove indicator assembly and o-rings (four).
3. Inspect o-rings for damage, replace if
necessary. Install o-rings on replacement indicator assembly, mount
assembly on mounting studs with hex
nuts.
4. Re-connect wiring connector.
c. Manual Ignite Toggle Switch
1. Disconnect wiring connector, note lo-
cation.
d. Burner Air Sensor
1. Disconnect wiring connector, note location.
2. Using an open-end wrench to hold the
sensor fitting while using another
open-end wrench to remove the sensor.
3. Replace the Teflon pipe thread tape
on the treads of the sensor fitting.
4. Install sensor onto sensor fitting.
5. Re-connect wiring connector.
e. Fuel Sensor
1. Disconnect wiring connector, note location.
2. Using an open-end wrench to hold the
sensor fitting while using another
open-end wrench to remove the sensor.
3. Replace the Teflon pipe thread tape
on the treads of the sensor fitting.
4. Install sensor onto sensor fitting.
5. Re-connect wiring connector.
f. Burner Air and Fuel Regulators
2. Refer to Figure 4-20. From the outside of the front panel, remove the
toggle switch seal.
3. Pull the switch and o-ring out from inside the front panel.
4. Inspect o-ring for damage, replace if
necessary. Install o-ring on replacement switch, insert through front
panel from the inside.
5. Install switch seal.
6. Re-connect wiring connector.
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-25
1. Disconnect the two tubes and the
sensor fitting on the rear of the regulator, note locations.
2. Replace the Teflon pipe thread tape
on the threads of the sensor fitting.
3. Remove the regulator and o-ring.
4. The replacement regulator comes
with two panel mounting nuts, remove
both and discard one of them.
Instruction Manual
760004-A
February 2002
Model NGA 2000 HFID
5. Inspect o-ring for damage, replace if
necessary. Install o-ring onto regulator threaded shaft.
6. Insert regulator into front panel, secure with mounting nut.
7. Re-attach the three tubes.
g. Purge Air Regulator
1. Remove the regulator mounting nut,
remove mounting bracket.
2. Loosen nut on tee fitting attached to
purge air flow switch.
3. Disconnect tube at elbow, remove
regulator.
4. Remove the two plugs, elbow and
male adapter fittings from the regulator.
5. Replace the Teflon pipe thread tape
on the two plugs, the elbow and the
male adapter and install into replacement regulator.
6. Connect tube to elbow, insert male
adapter into tee fitting.
7. Install mounting bracket onto regulator, hand snug mounting nut.
i. Burner Air Solenoid Valve
1. Disconnect the tube at the top elbow
fitting.
2. Disconnect the tube at the tee fitting,
remove valve analyzer module.
3. Holding the air ignite restrictor, unscrew the solenoid valve.
4. On the solenoid valve, remove the
connector fitting.
5. Replace the Teflon pipe thread tape
on the elbow, connector and restrictor.
6. Verify replacement solenoid valve
wires (flat side of body) are exiting on
the same side as the COM port as
shown in Figure 4-20. If not, use an
open-end wrench to hold the N.O. hex
port while rotating body.
7. Install air ignite restrictor into N.C.
port.
8. Install elbow into COM port and connector fitting into N.O. port.
9. Re-connect tubes.
j. Air Ignite Restrictor
8. Attach mounting bracket to front
panel, tighten regulator mounting nut.
h. Purge Air Flow Switch and Diffuser
1. Unscrew flow switch from tee fitting.
2. Replace Teflon pipe thread tape on
tee fitting.
3. Remove diffuser from flow switch and
install into replacement flow switch.
4. Install replacement flow switch.
5. Install purge switch onto tee fitting.
6. Re-connect tubes.
4-26 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
1. On the burner air solenoid valve:
a. Disconnect the tube at the top el-
bow fitting.
b. Disconnect tube at tee fitting.
c. Lift solenoid valve from analyzer
module.
d. Disconnect tube going to air ignite
restrictor.
e. Remove restrictor from solenoid
valve.
2. Add Teflon pipe thread tape to replacement restrictor, install into
solenoid.
3. Re-connect tubes to restrictor, elbow
and tee fitting.
Model NGA 2000 HFID
Instruction Manual
760004-A
February 2002
4-11 REAR PANEL COMPONENTS
The following components are mounted to the
rear panel:
•
Fuel In 2-Way Solenoid Valve
VIEW FROM INSIDE ANALYZER MODULE
• Regulated Air In Check Valve
•
Burner Air In Filter
•
Heated Sample Bypass Out Restrictor
•
Heated Sample In Restrictor
Check Valve, Regulated Air In
903728
VIEW FROM OUTSIDE ANALYZER MODULE
Filter, Burner Air In
017154
Restrictor, Heated Sample
Bypass Out – 10 Micron
619615
Figure 4-22. Rear Panel Components
Solenoid Valve, Fuel In
656218
Restrictor, Heated
Sample In – 40 Micron
619616
Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 4-27
2. Inside the analyzer module, disconnect the tube going to the connector
on the “out” port of the solenoid valve.
3. On the rear of the analyzer module at
the fuel in port:
a. Disconnect the fuel in tube.
b. Remove nuts and washers.
c. Remove solenoid valve from
analyzer module
4. Remove the fittings from the solenoid
valve and replace the Teflon pipe
thread tape.
5. Verify that body of replacement solenoid valve is oriented as shown in
Figure 4-22. If not, rotate till wires are
in-line with “out” port.
into the bulkhead fitting to force out
the filter disc.
3. Install the replacement filter in the
same manner, through the rear of the
bulkhead fitting.
4. Re-connect tubes.
c. Heated Bypass Sample Out and Heated
Sample In Restrictors
1. On the outside of the rear panel, disconnect tube and remove nut.
2. Insert a small spade screwdriver into
the bulkhead and remove the restrictor.
3. Install in reverse order.
d. Regulated Air In Check Valve
1. Disconnect tube at elbow.
2. Remove check valve from female
connector.
6. Install fittings into replacement solenoid valve, re-install in analyzer module.
b. Burner Air In Filter
1. Leaving the bulkhead fitting secured
to the rear panel, remove the tubes,
nuts and ferrules from the fitting.
2. Insert a clean, rigid piece of tube or
rod (smaller than .25 inch diameter)
3. Remove elbow from check valve.
4. Add Teflon pipe thread tape to check
valve threads.
5. Install elbow onto check valve.
6. Install check valve into female connector, verifying orientation of elbow
fitting as shown in Figure 4-22.
4-28 Maintenance and Service Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
TROUBLESHOOTING
Instruction Manual
760004-A
February 2002
SECTION 5
5-1 TROUBLESHOOTING CHECKLIST
a. Safety System
1. Verify purge supply pressure at bulkhead is between 10 and 20 psig.
2. Check case for leaks.
3. Check burner for leaks.
4. Verify purge pressure sensor tube
connection.
5. Verify purge out port is vented to atmospheric pressure.
6. Verify Safety PCB connector J2 is
attached.
7. Check for a +24V power glitch.
8. Verify that there is no large vibration
shock.
b. Ignition
1. Verify that the fuel pressure/flow is
correct.
2. Verify that the burner air pressure/flow is correct.
3. Verify that the igniter is generating
enough heat.
4. Verify the burner exhaust is vented to
atmosphere.
5. Verify safety system has been activated.
6. Verify the manual switch is operating
correctly.
7. Verify auto-ignite parameters are
properly set.
8. Verify burner is properly sealed.
9. Check for external leak in purge line.
10. Verify case pressure is greater than
0.5” of water.
11. Check case for over-pressurization.
12. Verify the purge flow/pressure switch
harness is routed away from the solenoid valves.
13. Verify the purge timer is counting.
14. Verify purge timer jumper is correctly
installed.
15. Verify Internal purge pressure is
greater than 5.5 psig.
16. Verify the purge gas switch has been
activated.
9. Verify quality of air supply is good.
10. Verify quality of fuel supply is good.
11. Check burner tip for damage.
12. Check air and fuel restrictor for correct flow.
13. Check burner tip alignment.
14. Verify burner cone is tight.
15. Check burner air and fuel lines for
leaks.
16. Verify oven temperature is greater
than 85°C.
17. Verify the reference thermistor is
100K ohm ±15% at 25°C.
Rosemount Analytical Inc. A Division of Emerson Process Management Troubleshooting 5-1
Instruction Manual
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February 2002
Model NGA 2000 HFID
18. Verify that there is +10VDC to the
reference thermistor.
c. Drift
1. Verify that the sample, burner air, and
fuel supply pressures are constant.
2. Check that the tubing, regulators,
pumps, fittings, and valves are clean
of hydrocarbons.
3. Verify that the oxygen level in the
burner air and sample are constant.
4. Verify the THC level is correct for the
burner air and fuel supply.
5. Check that the ambient temperature
is changing <10°C per hour.
6. Verify the burner is clean.
7. Verify temperature of the sample gas,
case, burner, and oven has stabilized.
8. Verify the Preamp PCB is clean.
d. Noise
1. Check that the burner exhaust is free
from water condensation.
2. Verify connection to the collector is
correct.
3. Verify connection to the polarizing
voltage is correct.
4. Check the ambient temperature is
changing <10°C per hour.
5. Verify the +24VDC is clean and
grounded properly.
6. Verify there are no strong magnetic
fields near.
7. Check for excessive vibration.
8. Verify burner exhaust is vented to a
constant atmospheric pressure.
9. Verify bypass line is vented to a constant atmospheric pressure.
9. Verify atmospheric pressure at burner
exhaust is constant.
10. Verify purge gas pressure is constant.
11. Verify burner has been on and stabilized.
12. Check for gas leaks.
10. Verify purge out port vented to a constant atmospheric pressure.
11. Verify the collector wires are routed
away from the heater.
12. Verify the collector wires are clean
and not damaged.
5-2 Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
760004-A
Model NGA 2000 HFID
February 2002
SECTION 6
REPLACEMENT PARTS
WARNING
PARTS INTEGRITY
Tampering with or unauthorized substitution of components may adversely affect safety of this product.
Use only factory-approved components for repair.
6-1 MATRIX
Each analyzer is configured per the customer sales order. Below is the HFID sales matrix which lists the
various configurations available.
To identify the configuration of an analyzer, locate the analyzer name-rating plate. The 12-position sales
matrix identifier number appears on the analyzer name-rating plate.
659619Heated Sample In Restrictor Assembly – 40 Microns
657065Thermostat 450°F
659643Cartridge Heater
Instruction Manual
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February 2002
659615Restrictor, Heated Bypass Sample Out – 10 Microns
659616Restrictor, Heated Sample In – 40 Microns
Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 6-3
Instruction Manual
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February 2002
Model NGA 2000 HFID
6-4 Replacement PartsRosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
RETURN OF MATERIAL
Instruction Manual
760004-A
February 2002
SECTION 7
7-1 RETURN OF MATERIAL
If factory repair of defective equipment is required, proceed as follows:
1. Secure a return authorization from a
Rosemount Analytical Inc. Sales Office or
Representative before returning the
equipment. Equipment must be returned
with complete identification in accordance
with Rosemount instructions or it will not
be accepted.
Rosemount CSC will provide the shipping
address for your instrument.
In no event will Rosemount be responsible for equipment returned without proper
authorization and identification.
2. Carefully pack the defective unit in a
sturdy box with sufficient shock absorbing
material to ensure no additional damage
occurs during shipping.
3. In a cover letter, describe completely:
•The symptoms that determined the
equipment is faulty.
•The environment in which the equip-
ment was operating (housing,
weather, vibration, dust, etc.).
•Site from where the equipment was
removed.
•Whether warranty or non-warranty
service is expected.
•Complete shipping instructions for the
return of the equipment.
4. Enclose a cover letter and purchase order
and ship the defective equipment according to instructions provided in the
Rosemount Return Authorization, prepaid,
to the address provided by Rosemount
CSC.
Rosemount Analytical Inc.
Process Analytical Division
Customer Service Center
1-800-433-6076
tions listed in the standard Rosemount warranty, the defective unit will be repaired or
replaced at Rosemount’s option, and an operating unit will be returned to the customer in
accordance with the shipping instructions furnished in the cover letter.
For equipment no longer under warranty, the
equipment will be repaired at the factory and
returned as directed by the purchase order
and shipping instructions.
7-2 CUSTOMER SERVICE
For order administration, replacement Parts,
application assistance, on-site or factory repair, service or maintenance contract information, contact:
Rosemount Analytical Inc.
Process Analytical Division
Customer Service Center
1-800-433-6076
7-3 TRAINING
A comprehensive Factory Training Program of
operator and service classes is available. For
a copy of the Current Operator and ServiceTraining Schedule contact the Technical
Services Department at:
Rosemount Analytical Inc.
Phone: 1-714-986-7600
FAX: 1-714-577-8006
If warranty service is expected, the defective
unit will be carefully inspected and tested at
the factory. If the failure was due to the condi-
Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 7-1
Instruction Manual
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February 2002
Model NGA 2000 HFID
7-2 Return of MaterialRosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
APPENDIX A - MENU DISPLAYS
Menu: 0 ANALOP
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February 2002
SECTION 8
Menu: 1 ANALSET
MENU: 2 FLOCHEK
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-1
Instruction Manual
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MENU: 3 FLOCHEKI1
MENU: 4 ACALSET
Model NGA 2000 HFID
MENU: 5 APARLST
8-2 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 6 ANALSETI1
MENU: 7 CALLIST
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February 2002
MENU: 8 CALLISTI1
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-3
Instruction Manual
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February 2002
MENU: 9 ACALSETI1
MENU: 10 APARLSTI1
Model NGA 2000 HFID
MENU: 11 AMMAN
8-4 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 12 AMMANI1
MENU: 13 AMSVC
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February 2002
MENU: 14 AMSVCI1
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-5
Instruction Manual
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February 2002
MENU: 15 ADIAG
MENU: 16 AMPWR
Model NGA 2000 HFID
MENU: 17 AM1V
8-6 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 18 AMTEMP
MENU: 19 AMMISC
Instruction Manual
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February 2002
MENU: 20 AMTREND
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-7
Instruction Manual
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February 2002
MENU: 21 ADIAGI1
MENU: 22 RANGESETAM
Model NGA 2000 HFID
MENU: 23 RANGESSETI1
8-8 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 24 LINRANGE1
MENU: 25 LINRANGE2
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February 2002
MENU: 26 LINRANGE3
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-9
Instruction Manual
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February 2002
MENU: 27 LINRANGE4
MENU: 28 LINRANGE0
Model NGA 2000 HFID
MENU: 29 AMPWRI1
8-10 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 30 FLOCHEK1I1
MENU: 31 FILTER
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February 2002
MENU: 32 AM1VI1
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-11
Instruction Manual
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February 2002
MENU: 33 AMTEMPI1
MENU: 34 AM2VA
Model NGA 2000 HFID
MENU: 35 PLIMITSA
8-12 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 36 TLIMITSA
MENU: 37 AMMISCI1
Instruction Manual
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February 2002
MENU: 38 ANALSIMPLE
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-13
Instruction Manual
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February 2002
MENU: 39 FILTERI1
MENU: 40 LINRANGE0I1
Model NGA 2000 HFID
MENU: 41 PLIMITSAI1
8-14 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 42 CALFACTORS
MENU: 43 R1FACTORS
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February 2002
MENU: 44 RN2FACTORS
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-15
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February 2002
MENU: 45 RN3FACTORS
MENU: 46 RN4FACTORS
Model NGA 2000 HFID
MENU: 47 AMHELPINDEX
8-16 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 48 LINRANGE1I1
MENU: 49 CALFACTORSI1
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February 2002
MENU: 50 APARLST2
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-17
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February 2002
MENU: 51 APARLST4
MENU: 52 APARLST5
Model NGA 2000 HFID
MENU: 53 APARLST6
8-18 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 54 IGNITION
MENU: 55 LISTNOTES
Instruction Manual
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February 2002
MENU: 56 LIGHTFLAMEI1
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Instruction Manual
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February 2002
MENU: 57 AUTOFLAMEI1
MENU: 58 DISPLAY
Model NGA 2000 HFID
MENU: 59 MPARMS
8-20 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 60 AMTOPINFO
MENU: 61 ANALSET2
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February 2002
MENU: 62 MPARMSI1
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-21
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February 2002
MENU: 63 TLIMITSAI1
MENU: 64 IGNITIONI1
Model NGA 2000 HFID
MENU: 65 SELFTEST
8-22 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 66 AMHELPINDEX2
MENU: 67 SOFT_DIAG
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MENU: 68 CALI1
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-23
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MENU: 69 AM2VC
MENU: 70 AM2VD
Model NGA 2000 HFID
MENU: 71 OVENTEMP
8-24 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA 2000 HFID
MENU: 72 LINFUNCT
MENU: 73 POLYSETUP
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February 2002
MENU: 74 MIDPOINT1
Rosemount Analytical Inc. A Division of Emerson Process Management Appendix A – Menu Displays 8-25
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MENU: 75 POLYGAS1
MENU: 76 POLYSETI1
Model NGA 2000 HFID
MENU: 77 POLYGAS2
8-26 Appendix A - Menu Displays Rosemount Analytical Inc. A Division of Emerson Process Management
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