Emerson Process Management NGA2000 NDIR User Manual

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

Non-Dispersive Infrared Analyzer

http://www.processanalytic.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions

prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Rosemount Analytical representative for clarification.

• Follow all warnings, cautions, and instructions

marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and maintenance of the product.

• Install your equipment as specified in the Installation Instructions of the appropriate Instruction 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.

®

Pyrex Irtran Teflon Ty-Rap

is a registered trademark of Corning Glass Works

®

is a registered trademark of Eastman Kodak Co.

®

and Viton® is a registered trademark of E.I. duPont de Nemours and Co., Inc.

®

is a registered trademark of Thomas & Betts Corp.

Emerson Process Management Rosemount Analytical Inc.

Process Analytic Division

1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.com

http://www.processanalytic.com

Model NGA2000 NDIR

PREFACE

The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the NGA2000 NDIR and the System Accessories of the NGA2000 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, CAUTIO NS and NOTES found throughout this publication.

748332-F

April 2003

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

748332-F April 2003

Model NGA2000 NDIR

SAFETY SUMMARY

If this equipment is used in a manner not specified in these instructions, protective systems may be impaired.

AUTHORIZED PERSONNEL

To avoid explosion, loss of life, personal injury and damage to this equipment and on-site property, all personnel authorized to install, operate and service the this equipment should be thoroughly familiar with and strictly follow the instructions in this manual. SAVE THESE INSTRUCTIONS.

DANGER.

ELECTRICAL SHOCK HAZARD

Do not operate without doors and covers secure. Servicing requires access to live parts which can cause death or serious injury. Refer servicing to qualified personnel. For safety and proper performance this instrument must be connected to a properly grounded three-wire source of power.

WARNING .

POSSIBLE EXPLOSION HAZARD

This equipment is not designed for and should not be used in the analysis of flammable samples. Use of this equipment in this way could result in explosion and death.

Ensure that all gas connectors are made as labeled and are leak free. Improper gas connections could result in explosion or death.

WARNING.

OVER-VOLTAGE SPIKING

If this Analyzer Module is used with a non-Rosemount Analytical po wer supply, adding Rosemo unt 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 GAS

This module requires periodic calibration with a known standard gas. See General Precautions for Handling and Storing High Pressure Gas Cylinders on page P-4.

P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

Model NGA2000 NDIR

CAUTION

HAND INJURY HAZARD

Dropping the front panel of the Platform while hand or fingers are inside either case handle can cause serious injury.

CAUTION

PARTS INTEGRITY

Tampering with or unauthorized substitution of components may adversely affect safety of this product. Use only factory approved components for repair.

CAUTION

OVERBALANCE HAZARD

This Analyzer Module may tip instrument over if it is pulled out too far and the Platform is not properly supported.

748332-F

April 2003

CAUTION

POSSIBLE CELL DAMAGE

Apply leak test liquid to cell or detectors only as a last resort.

NOTICE

Software compatibility is necessary for all NGA2000 components in your system to work together. The version of your Platform's software must be equal to or greater that the version of any other module(s) for successful compatibility. If it is not, contact Rosemount Analytical at 800-433-6076 to order software upgrade kit PN 657150 for the Platform.

You can locate the version of each NGA2000 component as follows: Platform Controller Board

Turn power ON. The display will show "Control Module V2. ...". This is the software version.

Analyzer Module Located on the right side of the Analyzer Module case.

I/O Module Located on the backplane connector of the module. If no label is present, the module is Version

2.0.

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH

PRESSURE GAS CYLINDERS

Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed Gases" published in 1981

Compressed Gas Association 1235 Jefferson Davis Highway Arlington, Virginia 22202

Used by Permission

1. Never drop cylinders or permit them to strike each other violently.

2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when located in areas where extreme temperatures are prevalent.

3. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench, or placed in a cylinder stand, and is ready to be used.

4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a suitable hand-truck.

5. Never tamper with safety devices in valves or cylinders.

6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is attached to a pressurized system.

7. No part of cylinder should be subjected to a temperature higher than 125 never be permitted to come in contact with any part of a compressed gas cylinder.

8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding, precautions must be taken to prevent striking an arc against the cylinder.

°

F (52°C). A flame should

P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

97-C219

Model NGA2000 NDIR

DOCUMENTATION

The following NGA2000 NDIR instruction materials are available. Contact Customer Service Center or the local representative to order.

748332 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.

748332-F

April 2003

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).

This product satisfies all obligations of all relevant standards of the EMC framework in Australia and New Zealand.

NAMUR

N

96

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

GLOSSARY OF TERMS

Analyzer Module

The module that contains all sensor/detector components for development of a Primary Variable signal; includes all signal conditioning and temperature control circuitry.

Backplane

The interconnect circuit board which the Controller Board, Power Supply, Analyzer Module power and network cables, I/O Modules and Expansion Modules plug into.

Control Module

The Operator Interface plus the Controller Board.

Controller Board

The computer board that serves as the Network Manager and operates the Display and Keypad.

Distribution Assembly

The Backplane and the card cages that hold I/O and Expansion Modules.

Expansion Module

A circuit board that plugs into the Backplane from the front of the Platform and performs special features not related to I/O functions.

I/O Module

A circuit board that plugs into the Backplane from the rear of the Platform. Has a connector terminal for communication with external data acquisition devices and provides an input/output function.

Operator Interface

The Display and Keyboard.

Platform

Any workable collection of the following: Controller Board, Power Supply, Distribution Assembly, Enclosure and Operator Interface.

Power Supply

Any of a variety of components that provides conditioned power to other NGA2000 components, from the Power Supply Board that plugs into the front of the Backplane in a stand-alone instrument to several larger ones that can power larger collections of modules and components.

Primary Variable

The measured species concentration value from an Analyzer Module.

Secondary Variable

Data placed on the network by a module regarding current status, e.g., sample flow, source voltage and other diagnostic information.

P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

Model NGA2000 NDIR

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).

748332-F

April 2003

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-7

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

P-8 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

DESCRIPTION AND SPECIFICATIONS

1-1 OVERVIEW

This manual describes the Non-Dispersive Infrared (NDIR) Analyzer Module of Rosemount Analytical's NGA2000 Series of gas analysis components.

Instruction Manual

748332-F

April 2003

SECTION 1

• Methane: Ammonia manufacture

• Acetylene: Manufacture of acetylene,

acrylonitrile, and vinyl chloride

• Sulfur Dioxide: Sulfuric acid stack gas

The NDIR Analyzer Module is designed to continuously determine the concentration of oxygen in a flowing gaseous mixture. The concentration is expressed in one of three fashions:

• parts-per-million

• percent of composition

• percent of fullscale

The user can obtain an output that is linear with concentration by initiating a linearizer, which is based on a fourth-order polynomial. The linearizer is incorporated in the Analyzer Module's electronic circuitry and is adjustable through interconnection with the network.

The entire Analyzer Module is designed as a slide-in module (if configured in stand-alone instrument fashion), removable from the front of the Platform, with gas connections made from the rear. All electronics relative to sample detection and conditioning are included in this module.

Food and Agriculture

• Carbon Dioxide and Water Vapor: Blanketing of perishables, fermentation processes, photosynthesis studies, personnel protection

Aerospace and Oceanography

• Carbon Dioxide, Carbon Monoxide, and Water Vapor: Diving and space chambers

Metals and Ceramics

• Carbon Dioxide: Monitoring of producer gas, steel converting, manufacture of cement, soaking pit, heat treating

• Carbon Monoxide: Inert gas generation, producer gas monitoring, rotary kiln roasting, tin plate annealing, steel converting, aluminum power processing, porcelain kilns, tunnels

• Water Vapor: Heat treating, hydrogen brazing, nickel and chrome plating

• Sulfur Dioxide: Flash smelting

1-2 TYPICAL APPLICATIONS

The NDIR Analyzer Module is designed to cover a wide range of process, stack and automotive applications. Typical measurements include:

Chemical and Petroleum

• Carbon dioxide: Manufacture of ethylene oxide, phthalic anhydride and ammonia; nitrogen generation; and producer gas monitoring

• Carbon Monoxide: Stack monitoring

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1

1-3 THEORY OF TECHNOLOGY

• Ammonia: Ammonia dissociation

Inside of the Analyzer Module, two equal-energy infrared beams are directed through two parallel optical cells, a flow-through sample cell and a reference cell. The reference cell may be sealed or may contain a continuously flowing reference gas. (See Figure 1-1 below.)

The infrared radiation is interrupted by a chopper at a frequency of 5 Hz.

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

During analysis, a portion of the infrared radiation is absorbed by the component of interest in the sample. The quantity of infrared radiation that is absorbed is proportional to the component concentration.

The detector is a "gas microphone" based on the Luft principle. The detector is generally filled with the same gas being analyzed. The infrared energy is therefore absorbed at the same wavelengths in the detector as that in the sample cell, making the detector specific for the analyzed component. The detector converts the difference in energy between sample and reference cells to a capacitance change. This

INFRARED

SOURCE

REFERENCE

CELL

DETECTOR

STATIONARY

PLATE

change, which is proportional to component concentration, is processed and expressed as the primary variable on the network.

Other modules comprising the NGA2000 unit then use this variable for a variety of purposes (e.g., expressing the gas concentration on the Front Panel Display or sending it to external data acquisition devices).

For a general understanding of the electrical interconnections in the NDIR Analyzer Module, see Figure 2-4 on page 2-5.

CHOPPER

SAMPLE IN

SAMPLE CELL

SAMPLE OUT

DIAPHRAGM, DISTENDED

COMPONENT OF INTEREST

DIAPHRAGM, DARK STATE

NON-INTERFERING COMPOUNDS

Figure 1-1. NDIR Technology

1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

1-4 SAMPLE REQUIREMENTS

Maximum allowable sample pressure is 690 hPa-gauge (10 psig) for a standard configuration NDIR that has a flow restrictor which sets the flow at between 0.5 L/min. to 1 L/min. Special high pressure cells (up to 10,350 hPa-gauge, 150 psig) are available. Sample temperature range is 0°C to 55°C, and maximum dewpoint is 40°C. The sample must be filtered to exclude particulates larger than 2 microns in size. Consult factory for special configurations with specifications outside of those listed above.

1-5 PURGE KITS

A purge kit for the motor source or motor source/flowing reference cell accompanies some NDIR modules. The purpose of these kits is to improve performance and accuracy through the reduction of ambient CO

Instruction Manual

748332-F

April 2003

interference. They do not provide protection from explosion hazard. The purge gas vents into the case, which has no outlet fitting for these types of purge gases.

1-6 FEATURES

Among the features available in the NDIR Analyzer Module are:

• Pressure compensation for barometric fluctuations (optional)

• Flow sensing

2

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3

Instruction Manual

)

748332-F April 2003

Model NGA2000 NDIR

REFERENCE OUT

REFERENCE IN

PURGE GAS IN

FAN

SAMPLE OUT (BOTTOM)

SAMPLE IN

CHOPPER MOTOR

POWER SUPPLY BOARD

SOURCE

CASE TEMPERATURE SENSOR

CELLS

PRESSURE COMPENSATION BOARD (OPTION

FLOW SENSOR

DETECTOR

MICRO BOARD

THERMAL FUSE

DETECTOR COVER

DETECTOR TEMPERATURE CONTROL RTD

SIGNAL BOARD

OSCILLATOR BOARD

SHUTTER ADJUST ACCESS HOLES

OSCILLATOR TUNE ADJUST

NETWORK INPUT MODULE

Figure 1-2. NGA2000 NDIR Analyzer Module (Typical - Actual Configuration May Vary)

1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

1-7 SPECIFICATIONS

a. General

Measurement Species:.................. Heteroatomic gases such as ammonia (NH

Ranges:......................................... 10 ppm fullscale to 100% fullscale (application-dependent); 4

Repeatability:................................. ±1% of fullscale (at constant temperature)

Minimum Detectable Level:........... 0.1% CO

Noise: ............................................ <1% of fullscale, peak-to-peak

Linearity:........................................ ±1% of fullscale with 4th order polynomial

Response Time: ............................ .05 to 30 seconds (selectable) for 0 to 90% of fullscale

Drift (Zero and Span):.................... <±1% of fullscale/24 hours at constant temperature (application

Effect of Temperature:................... <±1% of fullscale over any 10°C interval for rate of change no

Environment: ................................. Location - Class B controlled, indoor, non-hazardous

Ambient Temperature:................... 0 to 45°C (32 to 113°F)

Effect of Flow:................................ <1% of range when sample flow rate is changed by ≤250 ml/min.

Power Requirements:....................24 VDC ±5%, 100 W max.; ripple and noise: <100 mV peak-to-

Instruction Manual

April 2003

), carbon dioxide

3

(CO

), carbon monoxide (CO), carbon monoxide + carbon dioxide

2

ethylene (C and sulfur dioxide (SO

fullscale selections, including suppressed zero ranges

dependent);

<±2% of fullscale/week at constant temperature (application dependent)

greater than 10°C per hour (application dependent)

(No effect if flow rate is between 0 and 500 ml/min.)

peak; line and load regulations: <±1%

), hexane (C6H14), methane (CH4), nitric oxide (NO)

2H4

)

2

(at 1 atm. sample pressure; application dependent)

2

748332-F

b. Physical

Case Classification:....................... General purpose for installation in weather-protected areas

Dimensions:................................... See Outline and Mounting Dimensions, Figure 2-5 on page 2-6

Weight: .......................................... Standard: 11 kg (24.2 lbs.); extended: 12.5 kg (27.5 lbs.)

Mounting:....................................... Inside a Platform or custom-installed in a panel

Maximum Length of LON Cable:... 1600 m (1 mile) between Analyzer Module and Platform

c. Sample

Temperature:................................. Non-flammable 0°C to 55°C (32°F to 138°F)

Flow Rate: ..................................... 500 to 1400 ml/min.

Pressure:....................................... Maximum 690 hPa-gauge (10 psig), higher pressure in pressurized

cell applications

Particulates:...................................filtered to <2 microns

Dewpoint:....................................... <40°C (104°F), no entrained liquid

Materials in Contact with Sample:.Gold plated Pyrex, sapphire, quartz, Irtran, FEP Teflon, Viton-A,

316 stainless steel

See the Preface section of the Platform manual for specifications regarding Platform-related components (e.g., case dimensions) and the I/O Module manual for specifications regarding I/O (e.g., relay outputs).

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748332-F

April 2003

SECTION 2

INSTALLATION

WARNING.

Before starting to install this equipment, read the “Essential Instructions” on the inside cover and the Safety Summary beginning on page P-2. Failure to follow the safety instructions could result in serious injury or death.

2-1 UNPACKING

If the NDIR 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 NDIR Analyzer Module requires assembly with other components (e.g., the Platform and associated I/O Modules), do so at this time. Following the guides on the bottom left and bottom center of the Platform, carefully slide the Analyzer Module halfway into place.

ANALYZER M ODULE GUIDES

PIN SEATS

CAUTION.

HAND INJURY HAZARD

Do not place hands or fingers in Platform front handles when the front panel is open. Dropping front panel while hand or fingers are inside either handle can cause serious injury.

Lift the spring-loaded pins on the front of the Analyzer Module, and carefully slide it the rest of the distance. Secure the module in position by releasing the pins, which seat in the available holes in the bottom of the case (see Figure 2-1, below). If the module and Platform are difficult to assemble, remove the module, ensure the top cover of the module is firmly seated on the hold-down screws, and repeat the assembly procedure.

Install I/O Module(s) according to guidelines in the I/O manual. After startup and calibration have been performed, secure the front panel with the six screws provided.

DISENGAGED FRONT PANEL

Figure 2-1. Analyzer Module Installation into Instrument Platform

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1

Instruction Manual

748332-F April 2003

2-3 LOCATION

Install the NDIR Analyzer Module in a clean, non-hazardous, weather protected, vibration free location free from extreme temperature variations. For best results, install the instrument near the sample stream to minimize sample transport time. Operating ambient temperature is 0 Sample dewpoint is 40°C or less.

Unrestricted air flow in the rear of the Analyzer Module is critical to its performance and reliability..

o

C to 45oC (32oF to 113oF).

NOTE

Model NGA2000 NDIR

negated if the same flow rate is used for sample, zero and span gases. But, if flow is high enough to cause elevated pressure, careful control (tighter tolerance) of flow rate is required to avoid errors.

If flow is kept at or below 2 SCFH (1 L/min), sample and instrument temperatures reach equilibrium regardless of stream temperature (within specifications; 0 to 55°C). At extremely high flow rates, this may not be true, although no such effect has been noted up to 18 SCFH (9 L/min).

See Table 2-1 on page 2-3 for cell purging times at atmospheric sample pressure .

2-4 GAS SPECIFICATIONS

a. Calibration Gases

All applications require a zero standard gas to set the zero point on the display and external data acquisition devices. if the factory provided Calibration and Data Sheet (in the rear of the manual) specifies a background gas, use this as a zero gas. If a background gas is not specified, use dry nitrogen.

Span gas should be between 75% and 100% of fullscale span. Flowing reference (if used) should be dry nitrogen.

b. Flow Rate

Recommended sample flow rate is 1 to 2 SCFH (500 TO 1000 cc/min). A lower flow rate will not affect readings but may result in an undesirable time lag. Excessive flow can produce increases cell pressurization and reading error.

At higher cell pressures, the nonlinearity of the calibration curve increases. Therefore, the calibration curve should be redrawn for higher flow rates. Also, the effect of increased cell pressurization can be

c. Sample Pressure/Filtration

Sample should be introduced to the Analyzer Module at a maximum 690 hPagauge (10 psig). Pressurized applications are available, which require pressurized cells and careful control of flow rates, consult factory for these applications. Sample should be filtered for particulates down to two microns.

d. Leak Test

The Analyzer Module is completely tested at the factory for gas leakage. The user is responsible for testing for leakage only at the inlet and outlet fittings on the rear panel. 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).

2-5 GAS CONNECTIONS

(See Figure 2-2 on page 2-3) Connect inlet and outlet lines for sample/zero/span and flowing reference (if applicable) to appropriately labeled fittings on the rear panel. All four connections are 1/4 inch ferrule-type compression fittings.

2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

Model NGA2000 NDIR

CELL LENGTH

mm inch without inlet tube cell with inlet tube at 750 mm Hg

3 0.118 0.85 12 2 sec. 4 0.157 1.14 12 2 sec.

8 0.315 2.28 13 2 sec. 16 0.630 3.56 16 2 sec. 32 1.25 9.12 20 2 sec. 64 2.52 18.24 25 3 sec.

128 4.03 35.48 44 3 sec. 232 9.13 65.12 73 6 sec. 343 13.50 97.76 105 13 sec. 381 15.00 108.60 116 14 sec.

Table 2-1. Cell Purging Times at Atmospheric Sample Pressure

CELL VOLUME

CC

TOTAL VOLUME

CC

TIME FOR 2 VOLUMES

@ 2 SCFH (1L/MIN)

748332-F

April 2003

FAN

OUT

IN

SAMPLE

10 PSI MAX

(69 kPa MAX)

OUT

REFERENCE

IN

10 PSI MAX

(69 kPa MAX)

PURGE IN

15 PSI (103 kPa) MAX

Note: Reference and purge gas connections are applicable only to certain applications.

Figure 2-2. NDIR Back Panel

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3

Instruction Manual

748332-F April 2003

2-6 ELECTRICAL CONNECTIONS

NOTE

Electrical connections must be in compliance with National Electrical Code (ANSI/NFPA 70) and/or any applicable national or electrical codes.

Two electrical connections are required on the Analyzer Module; POWER and NETWORK.

Model NGA2000 NDIR

See Figure 2-3 below. On the Analyzer Module, two NETWORK connections are available, either of which is appropriate for : 1) interconnection with Backplane of the Platform (see Platform instruction manual) or

2) "daisy chaining" with other NGA2000 components.

Connect Analyzer Module POWER 24 VDC power source, either the Platform or external power source.

NETWORK 1

NETWORK 2

POWER

FUSE

Figure 2-3. NDIR Front Panel Electrical Connections

2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

ASSY

SAMPLE J2-1 SOURCE J2-2 REFERENCE J2-3 SOURCE J2-4

FLOW SENSOR

FAN ASSEMBLY

MODULATION CHECK

HEATSINK/SOURCE

MOTOR ASSEMBLY

REF SOURCE

SAMPLE SOURCE

J2

J1

J15

J14

RESISTOR

DRIVER

SOUR CE

J4

POWER SUPPLY BOARD

J6 J10

J9

PRESSURE

COMPENSATION

BOARD

J7

1 2 3 4

J5

1 2

CHASSIS GROUND

J3

J11

J8

FUSE, THERMAL CUTOFF

RTD, TEMP CTRL

J4 J5 J6

J1

COMPUTER BOARD

J2

J3

CASE TEMPERATURE

SENSOR °C

HEAT ER

DETECTOR BASE

SENSOR °C

J7

OSCILLATOR

BOARD

J1

Instruction Manual

748332-F

April 2003

RECORDER

J5

J7

SIGNAL

J4

BOARD

J6

J3 J1

J2

OUTPUT

J5

LON/POWER

BOARD

Figure 2-4. NDIR Wiring Diagram

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5

Instruction Manual

[

]

[28]

748332-F April 2003

Model NGA2000 NDIR

8.4

[213]

[208]

6.2

[157]

4.3

[109]

1.1

[28]

20.0

[508.0]

STAND ARD

24.8

[628.7]

EXTENDED

6.0

[152]

17.41

[142.2]

STANDARD

.6

[15]

1.1

[27]

8.4

213

G. POWER CABLE TO NETWORK. F. NETWORK CABLE CONNECTIONS TO PLATFORM. E. PURGE GAS IN: 1/4" O.D. TUBE FITTING. D. REFERENCE IN: 1/4" O.D. TUBE FITTING. C. REFERENCE OUT: 1/4" O.D. TUBE FITTING. B. SAMPLE OUT: 1/4" O.D. TUBE FITTING. A. SAMPLE IN: 1/4" O.D. TUBE FITTING.

5. MODULE TO BE INSTALLED WITHIN ±15° OF HORIZONTAL.

4. POWER REQUIREMENTS: 24 VDC 3.5 A.

3. ELECTRICAL INSTALLATION MUST BE IN COMPLIANCE WITH NATIONAL ELECTRICAL CODE (ANSI/NFPA 70) AND/OR ANY APPLICABLE NATIONAL OR LOCAL CODES.

2. MODULE IS NOT WEATHERPROOF.

1. APPROXIMATE WEIGHT: 24.2 LB (11.0 kg).

8.2

5.6

[143]

.6

[15]

22.41

[569.2]

EXTENDED

2.8

[71]

1.0

[25]

[13]

.5

1.6

[40]

DIMENSIONS

INCH

[mm]

Figure 2-5. Outline and Mounting Dimensions

2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

STARTUP AND OPERATION

Instruction Manual

748332-F

April 2003

SECTION 3

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 Platform or some interfacing component will be assumed. Display and Keypad information shall refer to that which the user can expect to see and do with regard to the Front Panel of the Platform.

(For a complete description of Platform Front Panel controls and indicators, see Section 1 of the Platform Components instruction manual.)

3-2 DISPLAY SCREENS

Three kinds of Display screens are available to the user (See Figure 3-3 through Figure 3-6.):

• Run Mode

• Menu

• Help

b. Menu Displays

The Menu structure enables the user to access data and functions, and put information onto the network.

The Main Menu (see Figure 3-2 on page 3-2) is subdivided into three levels of control based generally on which personnel is likely to use it: Basic Controls, Expert Controls and Setup, and Technical Controls. (See Figure 3-3 through Figure 3-5.) Many layers of the menu structure are described at appropriate places throughout this manual.

From the Run Mode display, press the MENUS softkey to gain access to the Main Menu. (See Figure 3-2 on page 3-

2.)

c. Help Displays

The Help structure is on-line "tutorial," context-sensitive and topic-interconnected, so that the user can practically operate NGA2000 without need of an instruction manual.

a. Run Mode Display

The Run Mode is the normal mode of operation. In this mode, the Display will show current gas measurement, the component of interest, the current operations of the softkeys, a graphic bar representing the displayed concentration as a percent of fullscale, and up to 4 userselectable secondary variables and associated bargraphs.

If more than one Analyzer Module is connected to the system, the Run Mode display will show as many as four gas measurements on a single screen. Alarm messages may also appear on the display (See Table 3-1 on page 3-5)

Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-1

3-3 STARTUP PROCEDURE

Introduce zero gas into SAMPLE INLET and reference and source purge gas, if applicable, into their respective inlets. Ensure that gas pressures are set to requirements listed on the Specifications page of the Preface section of this manual.

Apply power to the NDIR Analyzer Module. If it is associated with a Platform, do this by plugging in the Platform to a power source. The Platform has no ON/OFF power switch. Once power has been supplied to the Platform, the NDIR Analyzer Module will be energized.

If the user's system contains only one Analyzer Module, all system components, the

Instruction Manual

y

748332-F April 2003

Model NGA2000 NDIR

Controller Board and the network "self-install" (bind together) during initial startup. If the system contains more than one Analyzer Module, the startup procedure will interrogate the network to locate and identify all components on the network. The user will have to bind appropriate combinations of

Diagnostic Service menus. If both settings are within ±5% tolerance of factory setting, go to Section 3-4 below for binding and Section 3-5 on page 3-4 for calibration. If not, refer first to Section 4-11 on page 4-6 for instructions about oscillator tune/source balance shutter adjustments.

components after the startup sequence. After the warm-up period (about one hour for

the NDIR Analyzer Module), all modules are completely functional.

Check the tune and detector signal values against the factory settings listed in the

3-4 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.

Analyzer PQ 322-14

23.2 % CO

Secondar Secondar Secondar Secondar

Display Parms. Menu Dual Info

F1

0 ppm

Variable: XXXX Variable: XXX Variable: XXXX Variable: XXXX

F2 F3 F4 F5

50

Figure 3-1. Run Mode Display

23.2 % CO Analyzer XXXXXXXX Main Menu

Basic Controls

Expert controls and setup ... (Operational configuration)

Technical level configuration ... (Diagnostic and manufacturing/service)

Delete alarm message!

Display Parms. Info

F1

F2 F3 F4 F5

Figure 3-2. Main Menu Display

3-2 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

p

g

23.2 % CO Analyzer XXXXXXXX

Measurement range Numbers:

Range upper limit: 25% Range and functional control: Local Calibration…

Status: Ready

Home Escape Zero Span Info

F1

Figure 3-3. Basic Controls Menu

23.2 % CO Analyzer XXXXXXXX

Expert analyzer controls ...

Auxiliary module controls ... System set up ... Analyzer module set up ... Auxiliary module set up ...

Home Escape Info

F1

Basic Controls

F2 F3 F4 F5

Ex

ert controls and setu

F2 F3 F4 F5

Instruction Manual

748332-F

April 2003

Figure 3-4. Expert Controls and Setup Menu

23.2 % CO Analyzer XXXXXXXX Technical confi

System set up ...

Service menus... Diagnostic menus... Other module diagnostic menus... listing of all modules...

Status: normal

Home Info

F1

F2 F3 F4 F5

uration menu

Figure 3-5. Technical Level Configuration Menu

Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-3

Instruction Manual

p

748332-F April 2003

3-5 CALIBRATION

Calibration can be executed from the Basic Controls menu. Calibration gas data can be entered only through the Expert Controls and Setup menu.

To calibrate the Analyzer Module, introduce zero gas into the SAMPLE INLET, and do the following:

1. If the multi-Analyzer Module, 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 and make the following selections from the Main Menu: Expert Controls and Setup, Analyzer Module Setup, Calibration Gases.

3. Input appropriate data in the Calibration Gas List menu.

4. Press the HOME softkey to return to the Main Menu.

23.2 % CO Analyzer XXXXXXXX

The Main Menu for the analyzer system. Note that this menu refers to the particular analyzer selected from the run screen, when used in a system. The softkey marked “HOME” will always return you to this screen. Help menu system... Help on help... Keyboard controls... Editing controls...

Home Escape Map

F1

Model NGA2000 NDIR

Main Menu Hel

F2 F3 F4 F5

Figure 3-6. Typical Help Screen

6. Press the ZERO softkey to enter the Analyzer Zero menu, press ZERO again and wait.

7. Introduce span gas into the SAMPLE INLET, press SPAN softkey to enter the Analyzer Span menu, press SPAN again and wait.

8. Press HOME to re-enter the Main Menu.

9. 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), a possible 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:

5. Use the ↓ arrow key to select Basic Controls.

3-4 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

1. Select the following from the Main Menu: Expert Controls and Setup,

Model NGA2000 NDIR

Instruction Manual

748332-F

April 2003

Analyzer Module Set Up, and Calibration Parameters.

2. Using the ↓ arrow, select Zero Ranges, press ENTER and, using the up/down arrows, toggle to SEPARATE. Do the same for the Calibrate Ranges selection. Do not press ESCAPE at any time unless retention of prior settings is desired.

3. Return to the Main Menu and make the following selections: Expert Controls and Setup, Expert Controls, CAL DATA softkey, FACTORS softkey, and Range 1 (2, 3, 4) Factors (do Steps 4 and 5 for each range).

4. Select Zero Offset, press ENTER, adjust the value to 500000 with the ↑ and ↓ arrow keys, and press ENTER. Do not press ESCAPE at any time unless retention of prior settings is desired.

DISPLAY MESSAGE DESCRIPTION TYPE

BAROMETER System Barometer WARNING CASE TEMP Case Temperature WARNING CHOP SPEED Chopper Speed WARNING CRUDE NOISE Calculated Noise WARNING DET SIG Detector Signal WARNING DET TEMP Detector Temperature WARNING LIN ERROR Linearizer Error WARNIN G N15 VOLTS Power Supply, -15V WARNING P12 VOLTS Power Supply, +12V WARNING P15 VOLTS Power Supply, +15V WARNING P24 VOLTS Power Supply, +24V WARNING P5 VOLTS Power Supply, +5V WARNING PERCENT MOD Percent Modulation WARNING RAW SIGNAL Raw Signal WARNING SVFLOW Sample Bypass Flow WARNING SW ERROR Software Error FAILURE

Table 3-1. NDIR Analyzer Module Alarms

5. Refer to the Data Sheet in the rear of this manual for Span Factors as originally set at the factory. Select Span Factor, press ENTER, adjust the value to match the values on the Data Sheet with the ↑ and ↓ arrow keys, and press ENTER. If Data Sheet is not available, enter 0.000015 with the ↑ and ↓ arrow keys, and press ENTER. Do not press ESCAPE unless retention of prior settings is desired.

6. Attempt to recalibrate the Analyzer Module according to the procedure outlined at the beginning of Section 35 on page 3-4. If recalibration fails, return to the Range Factors menu, readjust factors and try calibrating again.

Another cause of failure to calibrate is the following: The value for "Maximum range" is lower than the upper limit value for the range in use. See the Range Settings menu for this information.

Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-5

Instruction Manual

748332-F April 2003

3-6 LINEARIZATION

The NDIR Analyzer Module can be operated in linear and non-linear mode. Linearization can be toggled ON/OFF in the Expert Controls menu. In the OFF position, linearization is disabled for all ranges, and the component of interest is measured in percent of fullscale. In the ON position, measurement is in engineering units: Either ppm or percent of concentration.

The NDIR Analyzer Module is linearized with the following fourth-order polynomial:

Y = A

o + A1X + A2X

Where:

X = the normalized non-linear input A

O, A1, A2, A3, A4 = linearization

coefficients Y = the normalized linear output

Linearization coefficients can be developed and stored for each range through the Expert Controls menu. The operating range is selected by entering RANGE = 1, 2, 3 or 4 in the Range Mode section that that menu.

2

+ A3X3 + A4X

Model NGA2000 NDIR

A0 = 0.00000 A1 = 1.00000 A2 = 0.00000 A3 = 0.00000 A4 = 0.00000

To calculate linearization coefficients other than those installed at the factory, take a minimum of 11 data points. (A more accurate curve can be obtained as the user approaches 21 data points. If urgent, a curve can be created with as few as four points, but this is only a temporary fix. A more accurate curve should be created as soon as possible.)

4

These data points can be obtained with an accurate gas divider or other flow mixing device. Before calculating coefficients, the data must be normalized to ranges of 0 to 1 units for both percent and concentration readings. Then, the axis must be reversed as illustrated in Figure 3-7 on page 3-7 and Figure 3-8 on page 3-7. A multiple linear regression is then used to calculate coefficients. (For example: If the range is 0 to 5000 ppm and readings are 0 to 100%, then divide all of the concentrations by 5000 and the readings by 100. Put the normalized concentrations on the Y-axis and the normalized readings on the X-axis.)

Coefficients for each selected range are automatically used when the module is in Linearization Mode. The user instructs the Analyzer Module as to which set of coefficients are to be used for each range. Maximum dynamic range is 3:1.

When ordered, special linearization coefficients for non-standard fullscale ranges are entered in the appropriate range(s) at the factory. If a range is not specified, the set of coefficients will be for Range 4.

The operator may want the module to output measurement in engineering units (ppm). This response is linear over the operating range. The following coefficients will make no correction to the non-linear response, but will cause the NDIR Analyzer Module to output gas measurement in engineering units:

3-6 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

These data points can be entered into any program capable of computing a fourth-order polynomial curve. This curve will be the mirror image of the curve on the Calibration and Data Sheet provided in the rear of this manual; however, the linearization coefficients will be different. Use the coefficients calculated with the curve in the polynomial shown on the previous page.

After taking the data points, the operator may determine coefficients for user-specific gas by either using any program capable of calculating a fourth-order curve fit or calling the factory to have the specific coefficients calculated.

When entering the operator-determined coefficients, note that the microprocessor only recognizes five significant digits to the right of the decimal point (e.g., 0.12345).

Model NGA2000 NDIR

Instruction Manual

748332-F

April 2003

100 %

READING

% FULLSCALE

50 %

0 %

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Display ppm

CONCENTRATION

ppm

Figure 3-7. Typical Linearization Curve, Linearizer OFF

CONCENTRATION

NORMALIZED

1

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1 0

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

READINGS, NORMALIZED

(Axis Reversed)

Figure 3-8. Operator-Determined Linearization Curve (Normalized)

Rosemount Analytical Inc. A Division of Emerson Process Management Startup and Operation 3-7

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

3-7 ROUTINE OPERATION

Set the NDIR Analyzer Module for desired operating range. Zero and span the module, and then supply sample gas to the SAMPLE INLET at the rear of the module. The NDIR Analyzer Module will now automatically and continuously analyze the sample stream.

As a check of instrument performance, the operator should keep a log of zero/span status.

Maximum permissible interval between calibrations depends on the analytical accuracy required. A frequency of once every 24 hours is recommended initially, and that practice should be continued unless experience indicates that some other interval is more appropriate.

Readout accuracy is directly proportional to change in barometric pressure (i.e., a change in cell pressure of 7.6mm of mercury will result in a readout error of about 1% of reading). Therefore, if barometric pressure changes significantly, a recheck of calibration against a span gas is advised. Also, an optional Pressure Compensation Board is available that electronically compensates.

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 Menu, Manufacturing Data, Analyzer Manufacturing Data. Select Maximum Range, and use the arrow keys to scroll the indicated value. The same applies for "minimum range" setting.

3-8 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

4

Basic controls... Expert controls and setup... (Operational configuration) Technical level configuration... (Diagnostic and manufacturing/service)

Enter your security code with softkeys. Security codes are set in the system setup menu in the Technical level menus. Press five characters when Security code says READY. Press six to return to “READY”. Security code: 54321

Measurement range number: 1 Range upper limit: 10 ppm Range and functional control: LOCAL Zero gas concentration: 0 ppm Span gas concentration: 9.89 ppm Ranges with valid calibration: 1&2 Calibration status: Ready If it won’t calibrate... Status: Ready

Are you sure? You must have zero gas flowing through the analyzer. This control does NOT control any autocal. Module bound to this analyzer! If you are sure, press ZERO again now. Press left arrow key when you are done. Calibration status: Ready Error message for last zero: 24-08-94

Main Menu

Basic level security

(expert, technical)

Basic controls

ZERO

Analyzer Zero

PARMS

Are you sure? You must have zero gas flowing through the analyzer. This control does NOT control any autocal. Module bound to this analyzer! If you are sure, press SPAN again now. Press left arrow key when you are done.

Calibration status: Ready Error message for last zero: 24-08-94

Current measurement parameters

Measurement range number: 1

Expert analyzer controls... Auxiliary module controls... System set up... Analyzer module set up... Auxiliary module set up... Local I/O set up...

Range change control: Local Measured Gas: CO2 Linearization mode: ON

Gas Measurement Setup: ON Analyzer operational state: Normal Analyzer alarm state: Normal Alarms report: Failure

Expert controls and setup

SPAN

Analyzer Span

MORE

Technical configuration menu

System set up... Service menus... Diagnostic menus... Other module diagnostic menus... Listing of all modules...

Expert and Technical menus follow in succeeding flow charts.

Check that you are flowing the correct gas, and the gas concentration is what it is supposed to be. Make sure that the reading is stable before starting. If you have changed the range fullscale value or any linearizer coefficients, or enabled or disabled it, or done anything else that would affect how it measures the gas, you may have made it hard for the analyzer to calibrate. If so, manually adjust the coefficients until the readings are close to correct, and try again.

If it won’t calibrate...

Instruction Manual

748332-F

April 2003

Current measurement parameters

Response time: 2.0 Secs

Sample flow: 1000 ml/min.

Sample pressure: 12.3 kPa

Case Temperature: 55.3!C

Figure 3-9. Display Screens (1 of 5)

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 3-9

Instruction Manual

748332-F April 2003

#1

Zero/Span diagnostic data

Date of last zero: 24-08-94 Error message for last zero: 24-08-94 Error percentage for last zero: 5% Raw signal at last zero: 500000 Last zero gas would read: -0.83 ppm Date of last span: 24-08-94 Error message for last span: Great! Error percentage for last span 5% Raw signal at last span: 500000 The last span gas would read: 11.3 ppm

FACTORS

#3

Calibration Factors

Range 1 factors... Range 2 factors... Range 3 factors... Range 4 factors... Zero compensation factor: 1 Span compensation factor: 1

From MAIN MENU ⇒

Measurement range number: 1 Range lower limit: 0 ppm Range upper limit: 10 ppm Linearizer: ON Range and functional control: LOCAL Zero/Span calibration... Ranges with valid calibration: 1&2 Physical measurements...

CAL DATA

Expert controls

CAL

Expert controls and setup

Expert analyzer controls... Auxiliary module controls... System set up... Analyzer Module set up... Auxiliary Module set up... Local I/O set up...

Auxiliary module controls

This screen selects any module with a control screen. This includes any auto calibration or sample module bound to this analyzer. Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag

Dependent on which auxiliary module is present on the network. See I/O Modules manual.

#2

Zero offset: 500000 Span factor: 0.000015 Fullscale range at calibration: 10 ppm Measurement range number: 1 Hardware zero offset: 0.0235 V Raw measurement signal: 0.5250 V

Zero/Span Calibration

Measurement range number: 1 Zero gas concentration: 0 ppm Span gas concentration: 9.89 ppm Sample flow: 1000 ml/min. Raw measurement signal: 0.3256 V Ranges with valid calibration: 1&2 Status: Ready Result... Calibration adjustment limits: Enabled

FACTORS

Range 1 (2,3,4) Factors

Model NGA2000 NDIR

Analyzer module set up... and Auxiliary module set up... Outlined in the next flow chart. Local I/O set up information is included in the I/O Modules manual.

System Set Up

Front panel control... Display resolution... Auxiliary lines...

See Platform manual for a flow chart of these displays.

Physical Measurements

Sample flow: 1000 ml/min Flow lower limit: 150 cc/min. Flow upper limit: 250 cc/min. Barometric pressure: 12.3 kPa Case temperature: 54.3!C

See #1 on this flow chart

Range 1 (2,3,4) Factors

HISTORY

Manufacturer’s settings

Zero offset: 0 Span factor: 1000

Zero offset 500000 Span factor: 500000

Stored settings

Figure 3-10. Display Screens (2 of 5)

3-10 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

)

Instruction Manual

748332-F

April 2003

From MAIN MENU

Expert controls and setup

Expert analyzer controls... Auxiliary module controls... System set up... Analyzer Module set up... Auxiliary Module set up... Local I/O set up...

Analyzer module set up

Calibration gas list... Calibration parameters... Gas measurement parameters... Analyzer parameter list... Physical measurement parameters... Displayed physical parameters... Analyzer tag: IR

Auxiliary module set up

Select an auxiliary module for set up Local I/O set up... Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag

Dependent on which auxiliary module is present on the network. See I/O Modules manual.

⇓

For Expert analyzer

controls, Auxiliary module

controls, and System set

up menus, see preceding

flow chard. Local I/O set up information is included

in the I/O Modules manual.

Calibration gas list

Zero gas - range 1: 0 ppm Span gas - range 1: 9.3 ppm Zero gas - range 2: 0 ppm Span gas - range 2: 19.3 ppm Zero gas - range 3: 0 ppm Span gas - range 3: 101.1 ppm Zero gas - range 4: 0 ppm Span gas - range 4: 247.1 ppm Calibration...

#4

Calibration Parameters

Calibration adjustment limits: enabled Calibration averaging time: 5 Secs Calibration failure alarm: Yes Cal failure error allowed: 5%

Calibration time out: 60 Secs Zero ranges: TOGETHER

Span ranges: SEPARATE

Measurement parameters

Linearization parameters... Response time/delay parameters... Range setting... Units... Linearization functions...

Analyzer Parameter List

Analyzer tag: IR-CO2 First line’s parameter: Flow Second line’s parameter: Flow

Third line’s parameter: Flow Fourth line’s parameter: Flow Linearization parameters...

Zero/Span Calibration

See #2 in Figure 3-10

Linearization parameters

Range 1 linearizer: Enabled if enabled, uses curve no.: 1 Range 2 linearizer: Enabled if enabled, uses curve no.: 2 Range 3 linearizer: Enabled if enabled, uses curve no.: 3 Range 4 linearizer: Enabled if enabled, uses curve no.: 4 Case temperature for coefficients: 45°C Set coefficients…

Response time/delay parameters

Range 1 t90 time: 10 Secs Range 2 t90 time: 1 Secs Range 3 t90 time: 1 Secs Range 4 t90 time: 1 Secs LON update rate: 1 per Sec Output delay time: 0 Secs

Range Settings

Minimum range: 10 ppm Maximum range: 5000 ppm Range 1 lower limit: 0 ppm Range 1 upper limit: 10 ppm Range 2 lower limit: 0 ppm Range 2 upper limit: 100 ppm Range 3 lower limit: 0 ppm Range 3 upper limit: 250 ppm Range 4 lower limit: 0 ppm Range 4 upper limit: 1000 ppm

Gas measurement units: ppm Pressure measurement units: psig Temperature measurement units: F

Variables are still sent as the basic SI unit.

Polynomial set up... Midpoint correction set up... Use the polynomial set up to generate a linearizing polynomial from up to 20 gases.

Linearity coefficients

See #5 above

Units

Linearization functions

Physical Measurements

Barometric pressure: 10.13 hPa Sample flow: 500 cc/min. Case temperature: 45°C Detector temperature: 52°C Pressure limits... Temperature limits...

Displayed Parameters

First line’s parameter: Flow Second line’s parameter: Flow Third line’s parameter: Flow Fourth line’s parameter: Flow May be displayed on the appropriate

Figure 3-11. Display Screens (3 of 5)

line of the single analyzer display screen.

Pressure Limits

Sample pressure upper limit: 15 kPa Sample pressure lower limit: 10 kPa

Temperature Limits

Case upper limit: 60 C Case lower limit: 20 C Detector upper limit: 69 C Detector lower limit: 55 C

#5

Linearity coefficients

Curve 1 (2,3,4) AO coefficient: 1.34523E-4 A1 coefficient: 0.983751 A2 coefficient: 0.115751 A3 coefficient: 1.11575E-6 A4 coefficient: 7.3421E-12

Curve upper limit: 10 ppm Curve over-range: 10% Curve under-range: 5% Status: Enabled

Polynomial set up

Range to be linearized: 1 Current span gas: 9.69 ppm Calculated polynomial order : 4 Gas values shown as: Percent

Gas concentrations...

Analyzer function: Ready

Gas concentrations

Gas value: 0 Raw reading: 0 ppm Linearized values: 0 ppm

Gas value: 10 Raw reading: 11 ppm Linearized values: 10 ppm Point to be measured: Point 1 Analyzer function: Ready

Midpoint correction set up

Correction: Disabled

Point being measured: Pt 1 Point 1 gas concentration: 100 ppm Point 2 gas concentration: 120 ppm Point 3 gas concentration: 150 ppm Point 1 reading: 100 ppm Point 2 reading: 120 ppm Point 3 reading: 150 ppm Span gas value: 100 ppm Analyzer function: Ready

Point 1

Point 2

Range 1 (2,3,4)

Analyzer Parameter List

Primary Variable Parameters Control mode: LOCAL Output delay time: 0 Secs Range 1 upper limit: 10 ppm Range 2 upper limit: 100 ppm Range 3 upper limit: 250 ppm Range 4 upper limit: 1000 ppm

Range 1 lower limit: 0 ppm Range 2 lower limit: 0 ppm Range 3 lower limit: 0 ppm Range 4 lower limit: 0 ppm

Analyzer Parameter List

Primary Variable Parameters Range 1 t90 time: 10 Secs Range 2 t90 time: 1 Secs Range 3 t90 time: 1 Secs Range 4 t90 time: 1 Secs

Linearizer on range 1: Enabled Linearizer on range 2: Enabled Linearizer on range 3: Enabled Linearizer on range 4: Enabled

Analyzer Parameter List

Calibration Parameters Calibration averaging time: 5 Secs Calibration failure alarm: Yes Cal failure error allowed: 5% Calibration time out: 60 Secs Ranges zeroed: TOGETHER Calibrate ranges: SEPARATE Calibration adjustment limits: ENABLED

Analyzer Parameter List

Calibration Gases Zero gas - range 1: 0 ppm Zero gas - range 2: 0 ppm Zero gas - range 3: 0 ppm Zero gas - range 4: 0 ppm

Span gas - range 1: 9.3 ppm Span gas - range 2: 19.3 ppm

Span gas - range 3: 101.1 ppm Span gas - range 4: 247.1 ppm

Figure 3-11. Display Screens (3 of 5

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 3-11

Instruction Manual

748332-F April 2003

From MAIN MENU

Technical configuration menu

System set up... Service menus... Diagnostic menus... Other module diagnostic menus... Listing of all modules...

Main display configuration... Front panel control... Date and time... Module binding... System Reset... Security codes... System tag: Rosemount

Manufacturing data... Service history... In maintenance since: N/A Record security codes...

⇓

For Diagnostic menus, Other module diagnostic menus, and Listing of all

modules, see Figure 3-11.

System Set Up

Service Menus

Model NGA2000 NDIR

Main display configuration, Front panel control, and Date and time displays can be found in the Platform manual.

Module Binding

Analyzer module selected: IR-CO2 Select modules... Proposed bind: View bindings... Bind selections! Unbind everything!

System Reset

Are you sure? Re-initializing will destroy all the binds!!! System reset! Re-initialize network!

Record security codes

Basic level security: Enabled Expert level security: Enabled Technical level security: Enabled Record basic level security code... Record expert level security code... Record technical level security code...

Manufacturing data

Control module data... Analyzer module data... Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag

Service History

Control module data... Analyzer module data... Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag

Record security codes

Basic level security: Enabled Expert level security: Enabled Technical level security: Enabled Record basic level security code... Record expert level security code... Record technical level security code...

See #7 above

Figure 3-12. Display Screens (4 of 5)

Select the modules you wish to bind to the current analyzer. Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag

Analyzer module selected: IR-CO2

Auxiliary module: Auto 1023 Auxiliary module: Acal 2322 Auxiliary module: HART 1092 Auxiliary module: None Auxiliary module None Auxiliary module: None

Proposed new bind:

#7

Record basic level security codes

Press the softkeys in any order to define the code. The actual code is represented by the order in which they are pressed, and shown numerically below. Press the left arrow key when you are done. Actual code number: 54321

Control Unit Manufacturing Data

Control unit serial number: 800002356 Manufacturing date code: 12-08-93 Hardware revision number: 1.00 Software revision number: 1.09 Revision notes... User tag number: PV1c

Analyzer Manufacturing Data

Analyzer module s/n: 900189342 Manufacturing data code: 17-08-93 Bench configuration code: 17 Hardware revision number: 1.13 Software revision number: 1.03 Minimum range: 10 ppm Maximum range: 5000 ppm Measured gas: CO2 User tag number: IR-CO2

STORE

Store historical data

Are you sure? STORE will copy current diagnostic data into the historical ("was") variables, overwriting what is currently there.

Are you sure? RESET will erase ALL configuration and manufacturing data, including serial numbers.

Control Module Service History

Manufacturing date: 12-08-93 In service date: 01-23-94 Last service date: 01-23-94 List notes... Add service date!

Analyzer module Service History

Manufacturing date: 17-08-93 In service date: 21-06-94 Last zero calibration date: 24-08-94 Last span calibration date: 24-08-94 Last service date: 21-06-94 List notes... Add service date!

This function not applicable. Slot position: 1

Select IO modules

Modules Bound

(expert, technical)

RESET

Reset

I/O module

Figure 3-12. Display Screens (4 of 5)

3-12 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

From MAIN MENU

⇓

Technical configuration menu

System set up... Service menus... Diagnostic menus... Other module diagnostic menus... Listing of all modules...

For Service set up and Service menus, see preceding flow charts.

Diagnostic menus

Control module diagnostics... Analyzer module diagnostics... Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag

Other module diagnostics

This screen reserved for other modules if present. Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag

Listing of all modules

Lists all modules detected on the network. Jumps to the module’s diagnostic screen. Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag

Control Unit Diagnostics

See Platform manual.

#8

Power supply voltages... Primary variable parameters... Physical measurements... Temperature control parameters... Miscellaneous control parameters... Barometric pressure parameters... Software diagnostics...

For I/O Module diagnostics,

see I/O Modules manual

See #8 above.

Analyzer Diagnostics

Analyzer diagnostics

Power supply voltages +15V analog is: 14.98V +15V analog was: 14.92V

-15V analog is: -14.85V

-15V analog was: -14.92V +5V digital is: 5.02V +5V digital was: 4.98V +24V power is: 2.38V

+24V power was: 2.42V +12V analog is: 11.88V

+12V analog was: 12.0V

Primary variable parameters

Raw measurement signal: 0.3258 Signal gain setting: 4%

Oscillator tune: 85%

Chopper speed: 5 Hz

Source current: 1.212 A

Modulation check...

Percent modulation: 20%

Calibration time out: 60 Secs Calibration factors... Pk-pk noise: 0 ppm

Physical measurements

See #6 in Figure 3-12

Temperature control

Fan lower setpoint: 60°C Fan upper setpoint : 20°C Minimum fan duty cycle: 30% Case temperature: 45°C Detector setpoint: 62°C Detector P gain: 32.52 Detector I gain: 1.34 Detector bias: 283°C Detector temperature: 62°C

Miscellaneous control parameters

Fan current: 35 mA Fan duty cycle: 50% Heater current: 1.7A Heater duty cycle: 50% Source current pot setting: 50% Actual source current: 1.212A Alarm messages valid for: FAILURE

Barometric pressure parameters

Pressure transducer: Present Barometric pres. Compensation: Enabled Measured pressure: 12.3 kPa Transducer offset: 1013 hPa Transducer slope: 1.0 Transducer PGA gain: 1.0

Software diagnostics

Last message: No error And: No error And: No error And: No error And: No error And: No error And: No error And: No error Edit to reset: Report Software error code (1 = no error): 1

Instruction Manual

748332-F

April 2003

Modulation check

Measurement range number: 1 Detector signal: 7.0 Signal gain setting: 4% Status Ready Instructions: Flow zero

Then: Watt

Percent modulation: 20%

(updated only at the end of this test)

Calibration Factors

See #3 in Figure 3-12

HISTORY

Primary variable parameters

Signal gain settings: 4% Oscillator tune: 85% Source current: 1.212 A Percent modulation: 85%

Figure 3-13. Display Screens (5 of 5)

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Service 3-13

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

3-14 Startup and Operation Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

MAINTENANCE AND TROUBLESHOOTING

DANGER

ELECTRICAL SHOCK HAZARD

Instruction Manual

748332-F

April 2003

SECTION 4

balance adjustments. These are factory-set, and should be adjusted only in the following cases:

Servicing requires access to live parts which can cause death or serious injury. Refer servicing to qualified personnel.

4-1 OVERVIEW

NDIR Analyzer Module components that may require cleaning or replacement include:

• all printed circuit boards

• power fuse

• the module fan

• the chopper motor

• the source

• the detector

• flow sensor

• case temperature sensor

if the operator has changed sources, oscillator board or detector

if the operator disassembles the bench to any degree.

Also available for maintenance adjustment through the Front Panel display and keypad are the source current, preamplifier gain (referred to as Signal Gain on the sub-menu) and the modulation check.

4-2 PCB REPLACEMENT

Refer to Figure 4-1 on page 4-2 for locations of the Signal, Micro, Power Supply, Oscillator and optional Pressure Compensation boards.

All PCBs, except the Oscillator Board and the LON Power Board, are secured to a side of the analyzer module that folds out while interconnect wiring is still in place. Remove the securing screws and fold out the entire panel.

• Analysis cells and optical components

• RTD - detector temp. controller

• thermal fuse

The only components that may require adjustment are the oscillator tune and shutter

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-1

To remove a particular board on the fold-out panel, label and unplug all interconnect wiring, and remove securing hardware. (See to Figure 4-1 on page 4-2.) Do the reverse to install a new board. Use caution when installing connectors by observing correct position (polarity) and alignment of pins.

Instruction Manual

748332-F April 2003

TOP VIEW

POWER SUPPLY BOARD

SIDE VIEW

Model NGA2000 NDIR

PRESSURE COMPENSATION BOARD

Figure 4-1. Printed Circuit Board Fold-Out Panel Views

MICRO BOARD

SIGNAL BOARD

4-3 POWER FUSE REPLACEMENT

Remove power to the Analyzer Module prior to fuse replacement. To replace the Power Fuse, view the front panel of the Analyzer Module, as

shown in Figure 4-2 below, and push and turn the fuseholder cap 1/4 turn counterclockwise. Remove and replace the fuse as required.

FRONT PANEL

FUSE

Figure 4-2. Power Fuse Location

4-2 Maintenance and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

4-4 MODULE FAN REPLACEMENT

The Analyzer Module fan assembly is disassembled as shown in Figure 4-3 below.

AIR FLOW

Instruction Manual

748332-F

April 2003

Before doing so, the entire optical bench must be removed. See Figure 4-5on page 4-5.

Figure 4-3. Fan Assembly

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-3

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

4-5 CHOPPER MOTOR REPLACEMENT

See Figure 4-4 below for a exploded view of the Motor/Source Assembly. The entire optical bench must be removed to perform this replacement.

Housing Assembly

Source Assemblies (see detail below)

Ref - Source Assemblies

Screw

Lock Washer

Insulator

Source Case

Insulator

Source

Ref - Housing Assembly

Motor Plate

Motor

4-6 SOURCE REPLACEMENT

See Figure 4-4 below for a exploded view of the Motor/Source Assembly. The entire optical bench must be removed to perform this replacement.

Dual Cap Assembly

Retaining Ring

Chopper Blade

Screen Filter

Screw

Nylon Washer

O-Ring

Source Buffer

(optional)

Source Gasket

Figure 4-4. Motor/Source Assembly

4-4 Maintenance and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

4-7 DETECTOR REMOVAL

See Figure 4-5 below and Figure 4-8 on page 4-9 for breakdowns of the optical bench. The entire optical bench

Motor/Source Assembly

Detector Assembly

Instruction Manual

748332-F

April 2003

must be removed in order to perform this disassembly.

Oscillator Tune Adjust

Power Transistor/Heatsink

Flow Sensor

Figure 4-5. Cell, PCB Assembly – Exploded View

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-5

Instruction Manual

748332-F April 2003

4-8 FLOW SENSOR REPLACEMENT

See Figure 4-5 on page 4-5 for Flow Sensor location. To replace Flow Sensor, remove all connecting hardware and undo connections to the sample line.

4-9 CASE TEMPERATURE SENSOR

REPLACEMENT

Case Temperature Sensor is attached to the motor source assembly. To replace this sensor, cut the Ty-Rap binder and disconnect the sensor connector. Reverse these instructions by reconnecting the new sensor and attaching with a new Ty-Rap.

Model NGA2000 NDIR

Open Analyzer Module front panel Access the oscillator tune value in the Primary

Variable Parameters menu. Adjust oscillator tune knob to its maximum

setting and then turn it counterclockwise to 80 % of that maximum setting.

Access the detector signal value in the Modulation Check

Flow zero gas (nitrogen) through the sample cell until the display reading stabilizes.

DELICATE COMPONENTS

menu.

CAUTION

4-10 THERMAL FUSE REPLACEMENT

Disassemble and reassemble the Detector block according to Figure 4-7 on page 4-7 to replace the Detector Thermal Fuse.

4-11 OSCILLATOR TUNE/SOURCE BALANCE

SHUTTER ADJUSTMENT

The Analyzer Module is calibrated, tuned and balanced at the factory. If the diagnostic values for oscillator tune and detector signals are within ±5 % of the factory settings in Primary Variable Parameters Check menus), no adjustment is necessary. If not, see Figure 4-5 on page 4-5 and Figure 4-6 on page 4-7 for Oscillator Tune and Source Balance Shutter adjustments, and do the following:

Open Platform front panel, if present.

CAUTION

HAND INJURY HAZARD

and Modulation

The shutter is a delicate component with only a six-degree rotation. Take care when making the required adjustments.

Using an appropriate screwdriver that will fit through the Source Balance Adjustment Screw Holes (see Figure 4-5 on page 4-5), rotate the sample shutter adjust screw until a minimum reading on the display is obtained. (A typical reading is 0.2 through 0.5.)

Add 0.5 V to the value obtained in Step 7 by adjusting the sample shutter adjust screw clockwise. (If this reading exceeds 1.2 V, then a cell cleaning is necessary; see Section 4-12 on page 4-8.)

Rotate the shutter adjust screw clockwise until the display reads the value obtained in Step 8.

Reassemble the Analyzer Module and, if appropriate, the Platform.

Do not place hands or fingers in Platform front handles when the front panel is open. Dropping front panel while hand or fingers are inside either handle can cause serious injury.

4-6 Maintenance and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748332-F

April 2003

DETECTOR ASSEMBLY COVER

(Front View)

Oscillator Tune Adjustment

SHUTTER

Sample

OPEN

CLOSE

Source Balance Shutter Adjustment Screw Hole

Figure 4-6. Oscillator Tune, Source Balance Shutter Adjustments

Detector

Oscillator Board

Resistive Temperature Detector

Thermal Fuse

Detector Heater

Figure 4-7. Detector Block (Exploded View)

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-7

Instruction Manual

748332-F April 2003

4-12 CLEANING CELLS

When zero gas is introduced in the SAMPLE IN inlet and the Detector signal is greater 1.2V, the cells and windows require cleaning. To do this, follow this procedure:

See Figure 4-8 on page 4-9 to identify which detail drawing best matches the configuration in question.

Fold out the PCB panel. Disassemble the optical bench according to

Figure 4-5 on page 4-5 and the cells according to Figure 4-8 on page 4-9.

Model NGA2000 NDIR

Inspect the cell inside by holding it up to a bright light. If particles are seen, repeat Steps 5 and 6 as often as necessary.

After cleaning cell, examine O-rings at the source, detector and end caps. If damaged, replace with new O-rings.

Remove any contaminants from windows with a lint-free cloth soaked in acetone. Do not use alcohol or other solvents. Allow to air dry.

Reverse disassemble instructions to reassemble the unit.

Perform a leak check.

Rinse the cell with acetone. If this does not remove all foreign matter, use a soft brush. Do not use any metallic object inside the cell because it will scratch the gold plating. Loss of gold plating may require cell replacement.

After all matter has been removed, rinse the cell with distilled water and allow to air dry. Do not use towels.

Replace desiccant if required. (See Section 4-13 on page 4-10.)

After cleaning cells, the Analyzer Module must be optically aligned if the diagnostic values for oscillator tune and detector signals are not within ±5% of the factory settings. If they are not within that range, follow Steps 7 through 10 of Section 4-11 on page 4-6.

4-8 Maintenance and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748332-F

April 2003

SHORT PATH CELLS

4mm TO 2.5 INCHES

Detector Assembly

Desiccant Holder

Spacer

Shutter Block Assembly

Desiccant Holders

Sample Cell

Motor/Source Assembly

Detector Assembly

LONG PATH CELLS

Sample Cell

Shutter Block Assembly

Motor/Source Assembly

Figure 4-8. Cell Assembly

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-9

Instruction Manual

748332-F April 2003

4-13 CELL DESICCANT

The reference cell may use a flowing reference. If so, desiccant is required. A desiccant holder is used on the inlet and

GAS DESICCANT PART NUMBER

CO2 Cardoxide 096218 CO Mg (C104)2 096217

H20 Mg (C104)2 096217 SOS Mg (C104)2 096217 CH4 Mg (C104)2 096217 Hexane Mg (C104)2 096217 CO + CO2 Cardoxide + Mg (C104)2 096217/096218

Model NGA2000 NDIR

outlets to keep moisture from entering the reference cell (see Figure 4-7 on page 4-7). The desiccant should be replaced each time the cell is opened, refer to Table 4-1 below. Before inserting desiccant, purge cell with dry inert gas (i.e., N

2).

Table 4-1. Cell Desiccant

4-10 Maintenance and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

4-14 MODULATION CHECK

The modulation check is a measure of the energy absorption capacity of a gas mixture, where total absorbency is 100% modulation and zero absorbency is 0% modulation. The modulation check can be used as a tool for tracking the sensitivity of the Analyzer Module and for discovering potential detector/source problems.

To perform a modulation check, do the following:

Access the Primary Variable Parameters menu.

Select Modulation Check. Follow the Instructions and Then line

commands, which are the following: Flow zero gas, press START softkey and wait.

Instruction Manual

748332-F

April 2003

Flow span gas when prompted, press START softkey and wait.

When the Instructions line again prompts the user to flow zero gas, the modulation check is finished.

Note the value on the Percent Modulation line.

Find the Percent Modulation value on the Data Sheet in the rear of this manual. Some standard Analyzer Modules will not have a value. If a value is present, compare this to the new value.

If 100% span gas was used during the modulation check, the new value should be within ±10% of value on the Data Sheet. If it is out of this range, call the factory for further interpretation. If modulation checks are used for trending, variance from check to check should not exceed ±20% per month.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-11

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

4-12 Maintenance and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

748332-F

Model NGA2000 NDIR

April 2003

SECTION 5

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.

To identify the configuration of an analyzer,

5-1 MATRIX

Each analyzer is configured per the customer sales order. Below is the NDIR sales mat rix which lists the various configurations available.

locate the analyzer name-rating plate. The 12-position sales matrix identifier number appears on the analyzer name-rating plate..

NDIR SINGLE CHANNEL INFRARED MEASUREMENT (ANALYZER MODULE)

01 Current Version Software 02 2.2.4 Version Software 03 3X Version Software - specify version

09, 10, 12, 20, 22, 23, 29, 30, 36, 38 [06], 07, 08, 11, 21, [24], 26, 76, 63 [16], [28], 19, [25], [27], 31, [37], 39, 41, [44] [14], [15], [46], 54, 64, 65, [66], 67, 73 [56], 74, [75], 83, 84, [85], 88 99 SPECIAL

01 Four Standard Ranges R1 One Non-Standard Range R2 Two Non-Standard Ranges R3 Three Non-Standard Ranges R4 Four Non-Standard Ranges 99 Special

Code Software Version

Code

Configuration Identifier [ ] Configurations utilize EXTENDED housings.

Code Linearized Non-Standard Range Selection

01 Standard (No Flow Sensor) 02 400 - 2000 cc/min 99 Special

NDIR 01 10 R1 01 Example

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 5-1

Code Flow Path

Instruction Manual

748332-F April 2003

5-2 REPLACEMENT PARTS

While the following sections list parts which are common to all NDIR Analyzer Modules, the configuration number is required when ordering parts which are specific to an individual application. The configuration number is on the Data Sheet in the rear of this manual.

Model NGA2000 NDIR

623998 Oscillator Board 657466 LON/Power Board 655729 Detector Heater 622917 Temperature Sensor, Detector 898733 Thermal Fuse with Q Pad 902931 Flow Sensor 655943 Case Temperature Sensor 655630 Power Supply Board 655670 Pressure Compensation Board 658350 Computer Analysis Board 655610 Signal Board 655893 Fan 655891 Chopper Motor 655925 Source (Matched Pair)

5-2 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

RETURN OF MATERIAL

6-1 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

equipment 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

Instruction Manual

748332-F

April 2003

SECTION 6

If warranty service is expected, the defective unit will be carefully inspected and tested at the factory. If the failure was due to the conditions 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.

6-2 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

6-3 TRAINING

A comprehensive Factory Training Program of operator and service classes is available. For a copy of the Current Operator and Service Training Schedule contact the Technical Services Department at:

Rosemount Analytical Inc.

Customer Service Center

1-800-433-6076

Rosemount Analytical Inc. A Division of Emerson Process Management Return of Material 6-1

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

6-2 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

A

Analyzer Module

applying power, 3-1 calibration procedure, 3-4 function, 1-1 installation into Platform, 2-1 installation location, 2-2 more that one in system, 3-1 operating temperature, 2-2 unable to calibrate, 3-4

Instruction Manual

748332-F

April 2003

SECTION 7

INDEX

linear mode, 3-6 linearization coefficients

calculating, 3-6 linearizer, 1-1 Luft principle, 1-2

M

Maximum permissible interval between calibrations,

3-8 maximum range

changing, 3-8

B

binding, 3-2

C

Calibration

failure. See calibration gas, 2-2 cells

high pressure, 1-3 connections

electrical, 2-4

inlet/outlet, 2-2

network, 2-4

power, 2-4

D

daisy chaining, 2-4 detector signal, 3-2

F

for non-standard fullscale ranges

linearization coefficients, 3-6

I

I/O Module

installation, 2-1 initial startup, 3-2

N

non-linear mode, 3-6

P

purge kit, 1-3

R

Readout accuracy

barometric pressure, 3-8

Return Authorization, 6-1

S

sample

dewpoint, 1-3, 2-2 excessive flow rate, 2-2 flow rate, 2-2 pressure, 1-3 pressure/filtration, 2-2 temperature, 1-3

shipping damage, 2-1

T

tune signal, 3-2

W

warm-up perio, 3-2

L

leak test, 2-2

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-1

Instruction Manual

748332-F April 2003

Model NGA2000 NDIR

7-2 Index Rosemount Analytical Inc. A Division of Emerson Process Management

WARRANTY

Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods, part(s) or consumables are returned to Seller's designated factory, transportation charges prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, part(s) and consumables are capable of being renewed, repaired or replaced.

The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly or indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from any other cause. All other warranties, expressed or implied are hereby excluded.

IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS, SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Limitations of Remedy.

LAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE. IN NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT ARE NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT. IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TO BUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER.

Force Majeure.

Seller's direct control.

Seller shall not be liable for failure to perform due to labor strikes or acts beyond

SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DE-

Instruction Manual

A

748332-F April 2003

Model NGA2000 NDIR

EMERSON PROCESS MAN

Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com

ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd. 1 Pandan Crescent Singapore 128461 Republic of Singapore T 65-777-8211 F 65-777-0947

http://www.processanalytic.com

GEMENT

EUROPEAN TECHNOLOGY CENTER Fisher-Rosemount GmbH & Co. Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0 F 49-6055-884209

EUROPE, MIDDLE EAST, AFRICA Fisher-Rosemount Ltd. Heath Place Bognor Regis West Sussex PO22 9SH England T 44-1243-863121 F 44-1243-845354

LATIN AMERICA Fisher - Rosemount Av. das Americas 3333 sala 1004 Rio de Janeiro, RJ Brazil 22631-003 T 55-21-2431-1882

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 29 LINRANGE4

Menu: 30 LINRANGE0

Menu: 31 AMPWRI1

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-11

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 32 FLOCHEK1I1

Menu: 33 FILTER

Menu: 34 AM1VI1

7-12 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 35 AMTEMPI1

Menu: 36 AM2VA

Menu: 37 PLIMITSA

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-13

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 38 TLIMITSA

Menu: 39 AMMISCI1

Menu: 40 MODTEST

7-14 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 41 ANALSIMPLE

Menu: 42 FILTERI1

Menu: 43 LINRANGE0I1

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-15

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 44 CALFACTORS

Menu: 45 R1FACTORS

Menu: 46 RN2FACTORS

7-16 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 47 RN3FACTORS

Menu: 48 RN4FACTORS

Menu: 49 AMHELPINDEX

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-17

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 50 LINRANGE1I1

Menu: 51 AMTRENDI1

Menu: 52 CALFACTORSI1

7-18 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 53 APARLST2

Menu: 54 APARLST4

Menu: 55 APARLST5

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-19

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 56 APARLST6

Menu: 57 LISTNOTES

Menu: 58 MPARMS2

7-20 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 59 DISPLAY

Menu: 60 ANALSET2

Menu: 61 ESCAPE_HELP

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-21

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 62 MPARMSI1

Menu: 63 TLIMITSIAI1

Menu: 64 BAROM_PARMS

7-22 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 65 ANALSETI2

Menu: 66 AMHELPINDEX2

Menu: 67 MODTESTI1

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-23

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 68 BAROM_PARMI1

Menu: 69 SW_DIAG

Menu: 70 CALI1

7-24 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 71 AM1VHIST

Menu: 72 LINFUNCT

Menu: 73 POLYSETUP

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-25

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 74 MIDPOINT1

Menu: 75 MIDPOINT2

Menu: 76 MIDPOINT3

7-26 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 77 MIDPOINT4

Menu: 78 POLYGAS1

Menu: 79 POLYGAS2

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-27

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 80 POLYGAS3

Menu: 81 POLYGAS4

Menu: 82 POLYGAS5

7-28 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 83 POLYGAS6

Menu: 84 POLYGAS7

Menu: 85 POLYGAS8

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-29

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 86 POLYGAS9

Menu: 87 POLYGAS0

Menu: 88 EXP_CAL

7-30 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 89 ZEROI2

Menu: 90 EXP_CAL_DAT

Menu: 91 EXP_CAL_DATI

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-31

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 92 UNITS

Menu: 93 UNITSI1

Menu: 94 RESET

7-32 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 95 STORE

Menu: 96 RFHIST1A

Menu: 97 RFACTORSIA

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-33

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 98 RFHIST2A

Menu: 99 RFHIST3A

Menu: 100 RFHIST4A

7-34 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 101 TWEAKI1

Menu: 102 INIT

Menu: 103 SW_DIAGI1

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-35

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 104 STOREDPVA

Menu: 105 ZERO_NOW2

Menu: 106 SPAN_NOW2

7-36 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 107 POLYSETI1

Menu: 108 POLYSETI2

Menu: 109 POLYSETI3

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-37

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 110 ANALSETI3

Menu: 111 MPARMS

Menu: 112 FLOWLIMITS

7-38 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

Instruction Manual

748417-B

April 2003

Menu: 113 PLIMITSAI1

Menu: 114 ABOUT

Menu: 115 ABOUT1

Rosemount Analytical Inc. A Division of Emerson Process Management Index 7-39

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

Menu: 116 ALARM1

7-40 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 NDIR

A

Analyzer Module

applying power, 3-1

calibration procedure, 3-4

function, 1-1

installation into Platform, 2-1

installation location, 2-2

more that one in system, 3-1

operating temperature, 2-2

unable to calibrate, 3-4

Instruction Manual

748417-B

April 2003

SECTION 8

INDEX

linear mode, 3-6 linearization coefficients

calculating, 3-6 linearizer, 1-1 Luft principle, 1-2

M

Maximum permissible interval between calibrations,

3-8 maximum range

changing, 3-8

B

binding, 3-2

C

Calibration

failure. See calibration gas, 2-2 cells

high pressure, 1-3 connections

electrical, 2-4

inlet/outlet, 2-2

network, 2-4

power, 2-4

D

daisy chaining, 2-4 detector signal, 3-2

F

for non-standard fullscale ranges

linearization coefficients, 3-6

I

I/O Module

installation, 2-1 initial startup, 3-2

N

non-linear mode, 3-6

P

purge kit, 1-3

R

Readout accuracy

barometric pressure, 3-8

Return Authorization, 6-1

S

sample

dewpoint, 1-3, 2-2 excessive flow rate, 2-2 flow rate, 2-2 pressure, 1-3 pressure/filtration, 2-2 temperature, 1-3

shipping damage, 2-1

T

tune signal, 3-2

W

warm-up perio, 3-2

L

leak test, 2-2

Rosemount Analytical Inc. A Division of Emerson Process Management Index 8-1

Instruction Manual

748417-B April 2003

Model NGA2000 NDIR

8-2 Index Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 PMD, NDIR

VAISALA BAROMETRIC PRESSURE TRANSDUCER

Addendum

748461-B

April 2003

This addendum serves as an amendment to the Model NGA 2000 PMD and NDIR instruction manuals. The following information should be considered part of the manual, if your instrument has a Vaisala Barometric Pressure Transducer installed in it, or if you are retrofitting a PMD or NDIR with a Vaisala transducer kit.

The Vaisala PTB100 series Analog Barometer is a N.I.S.T. traceable precision silicon capacitive atmospheric pressure transducer. The sensor delivers an analog voltage output that is inversely proportional to its inlet pressure. It has an operational ambient pressure range of 800 to 1060 hPa.

The original PMD and NDIR instruments were designed for use with a resistance bridge type of pressure transducer requiring an external gain amplifier with an offset trim The Vaisala transducer contains an integral gain amplifier that is scaled for a 0 to +5 Vdc output. The 661380 “Interface Board” contains the circuitry to convert the Vaisala single ended 0 to +5 V dc output into the referenced bridge 0 to +0.625 V dc output configuration that is required by the Analyzer module’s Computer Analysis Board. The Vaisala transducer kit is backward compatible with the original Rosemount pressure transducer.

Vaisala Interface Board Circuit Function:

The Vaisala Interface Circuit board adapts the single ended analog output of the Vaisala sensor into a Precision Voltage referenced, balanced bridge (at 1 atmosphere) input configuration. A “Bridge Balance” pot on the Vaisala Interface Circuit board provides the fine trim “Bridge Balancing” calibration adjustment that is required to set up each indi-

vidual transducer at a known ambient air pressure. Test points are provided on the circuit board for this adjustment.

The Vaisala transducer output range is 0 to +5 Vdc.

The Vaisala analog output voltage is inverted and fed into a balanced summing node that is referenced by a precision regulator. The summing node voltage is 0.000 Vdc at 1013 hPa (1 atmosphere ambient air pressure). The summing node voltage is then buffered, inverted, and gain reduced by a factor of 8 to produce the Pressure Compensation Output voltage at J12-1 for the Computer Analysis board.

Low noise, Low input current offset Op-Amps, and common substrate resistors are used to reduce gain tracking errors and null thermal coefficient effects.

1-1 INSTALLATION & RETROFIT

INSTRUCTIONS

1. Remove the original Rosemount transducer circuit board assembly, located on the motherboard at J12 and J13 (if present).

2. Install the transducer with the pressure inlet facing the rear of the instrument using the mounting studs provided on lefthand side of the detector housing.

3. Install the Interface board into it’s mating sockets (J12 and J13) on the motherboard.

4. Connect the 4-pin cable (P1) from the interface board (noting pin polarity) to the Vaisala Pressure Transducer.

http://www.processanalytic.com

Addendum

748461-B April 2003

5. Connect the instrument sample inlet tubing to the Vaisala Pressure Inlet port.

Model NGA2000 PMD, NDIR

Barometric Pressure menu reads the correct ambient air pressure.

6. Enable the Barometric Pressure Compensation and the Use Local Reading options via the Expert Controls – Analyzer Module Diagnostics – Barometric Pressure Compensation menus of the instrument. The instrument will automatically detect and report the ‘Presence’ of the Pressure Compensation Option.

1-2 ADJUSTMENT PROCEDURE

Circuit adjustment can be made using Barometric Pressure menu display, or an external Digital voltmeter.

Display Method

With no sample inlet lines connected and the instrument exhaust ported to atmosphere, adjust R1 on the 661380 Interface board until the Barometric Pressure reading on the

DMM Method

Connect the DMM (+) to TP1 on the 661380 Interface board, (-) to TP2. Set the DMM to measure mVDC. With no sample inlet lines connected and the instrument exhaust ported to atmosphere, adjust R1 on the Interface board until the DMM reads 0.000 Vdc ± 0.001 V. The instrument is now calibrated at 1 ATM.

1-3 HIGH ALTITUDE VERSION OPTION

For applications where the instrument is to be used above 5400 Feet (MSL) an alternate transducer option is available from the factory. This version consists of a Vaisala model PTB100B transducer (900-1100 hPa range). Please contact the factory if you require this option.

2 of 2

Addendum – Vaisala Transducer Rosemount Analytical Inc. A Division of Emerson Process Management

WARRANTY

Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods, part(s) or consumables are returned to Seller's designated factory, transportation charges prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, part(s) and consumables are capable of being renewed, repaired or replaced.

The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly or indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from any other cause. All other warranties, expressed or implied are hereby excluded.

IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS, SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Limitations of Remedy.

LAY IN PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE. IN NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT ARE NOT LIMITED TO, LOSS OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT. IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND/OR INDEMNITY COVERAGE PROVIDED TO BUYER, ITS ASSIGNS, AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER.

Force Majeure.

Seller's direct control.

Seller shall not be liable for failure to perform due to labor strikes or acts beyond

SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DE-

Instruction Manual

A

748417-B April 2003

Model NGA2000 NDIR

EMERSON PROCESS MAN

Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com

ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd. 1 Pandan Crescent Singapore 128461 Republic of Singapore T 65-777-8211 F 65-777-0947

http://www.processanalytic.com

GEMENT

EUROPEAN TECHNOLOGY CENTER Fisher-Rosemount GmbH & Co. Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0 F 49-6055-884209

EUROPE, MIDDLE EAST, AFRICA Fisher-Rosemount Ltd. Heath Place Bognor Regis West Sussex PO22 9SH England T 44-1243-863121 F 44-1243-845354

LATIN AMERICA Fisher - Rosemount Av. das Americas 3333 sala 1004 Rio de Janeiro, RJ Brazil 22631-003 T 55-21-2431-1882

Emerson Process Management NGA2000 NDIR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ESSENTIAL INSTRUCTIONS

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

LIST OF TABLES

PREFACE

DEFINITIONS

SAFETY SUMMARY

AUTHORIZED PERSONNEL

DOCUMENTATION

COMPLIANCES

GLOSSARY OF TERMS

DESCRIPTION AND SPECIFICATIONS

1-1 OVERVIEW

1-2 TYPICAL APPLICATIONS

1-3 THEORY OF TECHNOLOGY

Figure 1-1. NDIR Technology

1-4 SAMPLE REQUIREMENTS

1-5 PURGE KITS

1-6 FEATURES

Figure 1-2. NGA2000 NDIR Analyzer Module (Typical - Actual Configuration May Vary)

1-7 SPECIFICATIONS

a. General

b. Physical

c. Sample

INSTALLATION

2-1 UNPACKING

2-2 ASSEMBLY

Figure 2-1. Analyzer Module Installation into Instrument Platform

2-3 LOCATION

2-4 GAS SPECIFICATIONS

a. Calibration Gases

b. Flow Rate

c. Sample Pressure/Filtration

d. Leak Test

2-5 GAS CONNECTIONS

Table 2-1. Cell Purging Times at Atmospheric Sample Pressure

Figure 2-2. NDIR Back Panel

2-6 ELECTRICAL CONNECTIONS

Figure 2-3. NDIR Front Panel Electrical Connections

Figure 2-4. NDIR Wiring Diagram

Figure 2-5. Outline and Mounting Dimensions

STARTUP AND OPERATION

3-1 OVERVIEW

3-2 DISPLAY SCREENS

b. Menu Displays

c. Help Displays

a. Run Mode Display

3-3 STARTUP PROCEDURE

3-4 BINDING

Figure 3-1. Run Mode Display

Figure 3-2. Main Menu Display

Figure 3-3. Basic Controls Menu

Figure 3-4. Expert Controls and Setup Menu

Figure 3-5. Technical Level Configuration Menu

3-5 CALIBRATION

Figure 3-6. Typical Help Screen

Table 3-1. NDIR Analyzer Module Alarms

3-6 LINEARIZATION

Figure 3-7. Typical Linearization Curve, Linearizer OFF

Figure 3-8. Operator-Determined Linearization Curve (Normalized)

3-7 ROUTINE OPERATION

Figure 3-9. Display Screens (1 of 5)

Figure 3-10. Display Screens (2 of 5)

Figure 3-11. Display Screens (3 of 5)

Figure 3-12. Display Screens (4 of 5)

Figure 3-13. Display Screens (5 of 5)

MAINTENANCE AND TROUBLESHOOTING

4-1 OVERVIEW

4-2 PCB REPLACEMENT

Figure 4-1. Printed Circuit Board Fold-Out Panel Views

4-3 POWER FUSE REPLACEMENT

Figure 4-2. Power Fuse Location

4-4 MODULE FAN REPLACEMENT

Figure 4-3. Fan Assembly

4-5 CHOPPER MOTOR REPLACEMENT

4-6 SOURCE REPLACEMENT