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
TABLE OF CONTENTS
Instruction Manual
748332-F
April 2003
PREFACE...........................................................................................................................................P-1
Definitions...........................................................................................................................................P-1
Safety Summary.................................................................................................................................P-2
General Precautions For Handling And Storing High Pressure Gas Cylinders .................................P-4
Documentation....................................................................................................................................P-5
Compliances.......................................................................................................................................P-5
Glossary Of Terms ...........................................................................................................................P-6
1-0 DESCRIPTION AND SPECIFICATIONS .................................................................................................1-1
1-1 Overview................................................................................................................................1-1
1-2 Typical Applications...............................................................................................................1-1
1-3 Theory Of Technology...........................................................................................................1-1
1-4 Sample Requirements...........................................................................................................1-3
1-5 Purge Kits..............................................................................................................................1-3
1-6 Features.................................................................................................................................1-3
1-7 Specifications.........................................................................................................................1-5
a. General ...........................................................................................................................1-5
b. Physical...........................................................................................................................1-5
c. Sample......................................................................................................................... ...1-5
2-0 INSTALLATION........................................................................................................................................2-1
2-1 Unpacking..............................................................................................................................2-1
2-2 Assembly...............................................................................................................................2-1
2-3 Location.................................................................................................................................2-2
2-4 Gas Specifications.................................................................................................................2-2
a. Calibration Gases............................................................................................................2-2
b. Flow Rate........................................................................................................................2-2
c. Sample Pressure/Filtration..............................................................................................2-2
d. Leak Test ........................................................................................................................2-2
2-5 Gas Connections...................................................................................................................2-2
2-6 Electrical Connections...........................................................................................................2-4
3-0 STARTUP AND OPERATION..................................................................................................................3-1
3-1 Overview................................................................................................................................3-1
3-2 Display Screens.....................................................................................................................3-1
a. Run Mode Display...........................................................................................................3-1
b. Menu Displays.................................................................................................................3-1
c. Help Displays ..................................................................................................................3-1
3-3 Startup Procedure .................................................................................................................3-1
3-4 Binding...................................................................................................................................3-2
3-5 Calibration..............................................................................................................................3-4
3-6 Linearization ..........................................................................................................................3-6
3-7 Routine Operation .................................................................................................................3-8
Rosemount Analytical Inc. A Division of Emerson Process Management Contents i
Instruction Manual
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April 2003
4-0 MAINTENANCE AND TROUBLESHOOTING.........................................................................................4-1
4-1 Overview................................................................................................................................4-1
4-2 PCB Replacement.................................................................................................................4-1
4-3 Power Fuse Replacement.....................................................................................................4-2
4-4 Module Fan Replacement .....................................................................................................4-3
4-5 Chopper Motor Replacement ................................................................................................4-4
4-6 Source Replacement.............................................................................................................4-4
4-7 Detector Removal..................................................................................................................4-5
4-8 Flow Sensor Replacement ....................................................................................................4-6
4-9 Case Temperature Sensor Replacement..............................................................................4-6
4-10 Thermal Fuse Replacement..................................................................................................4-6
4-11 Oscillator Tune/Source Balance Shutter Adjustment............................................................4-6
4-12 Cleaning Cells........................................................................................................................4-8
4-13 Cell Desiccant........................................................................................................................4-10
4-14 Modulation Check..................................................................................................................4-11
5-0 REPLACEMENT PARTS..........................................................................................................................5-1
5-1 Matrix.....................................................................................................................................5-1
5-2 Replacement Parts................................................................................................................5-2
Model NGA2000 NDIR
6-0 RETURN OF MATERIAL..........................................................................................................................6-1
6-1 Return Of Material.................................................................................................................6-1
6-2 Customer Service..................................................................................................................6-1
6-3 Training..................................................................................................................................6-1
7-0 APPENDIX A. MENU DISPLAYS ...........................................................................................................7-1
8-0 INDEX 8-1
ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 NDIR
LIST OF ILLUSTRATIONS
Figure 1-1. NDIR Technology .................................................................................................. 1-2
Figure 1-2. NGA2000 NDIR Analyzer Module (Typical - Actual Configuration May Vary)...... 1-4
Figure 2-1. Analyzer Module Installation into Instrument Platform .......................................... 2-1
Figure 2-2. NDIR Back Panel...................................................................................................2-3
Figure 2-3. NDIR Front Panel Electrical Connections.............................................................. 2-4
Figure 2-4. NDIR Wiring Diagram............................................................................................ 2-5
Figure 2-5. Outline and Mounting Dimensions......................................................................... 2-6
Figure 3-1. Run Mode Display ................................................................................................. 3-2
Figure 3-2. Main Menu Display ................................................................................................3-2
Figure 3-3. Basic Controls Menu.............................................................................................. 3-3
Figure 3-4. Expert Controls and Setup Menu........................................................................... 3-3
Figure 3-5. Technical Level Configuration Menu.....................................................................3-3
Figure 3-6. Typical Help Screen............................................................................................... 3-4
Figure 3-7. Typical Linearization Curve, Linearizer OFF......................................................... 3-7
Figure 3-8. Operator-Determined Linearization Curve (Normalized).......................................3-7
Figure 3-9. Display Screens (1 of 5) ........................................................................................ 3-9
Figure 3-10. Display Screens (2 of 5)......................................................................................3-10
Figure 3-11. Display Screens (3 of 5)......................................................................................3-11
Figure 3-12. Display Screens (4 of 5)......................................................................................3-12
Figure 3-13. Display Screens (5 of 5)......................................................................................3-13
Figure 4-1. Printed Circuit Board Fold-Out Panel Views.......................................................... 4-2
Figure 4-2. Power Fuse Location............................................................................................. 4-2
Figure 4-3. Fan Assembly........................................................................................................ 4-3
Figure 4-4. Motor/Source Assembly......................................................................................... 4-4
Figure 4-5. Cell, PCB Assembly – Exploded View................................................................... 4-5
Figure 4-6. Oscillator Tune, Source Balance Shutter Adjustments ......................................... 4-7
Figure 4-7. Detector Block (Exploded View)............................................................................ 4-7
Figure 4-8. Cell Assembly........................................................................................................ 4-9
Instruction Manual
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April 2003
LIST OF TABLES
Table 2-1. Cell Purging Times at Atmospheric Sample Pressure .......................................... 2-3
Table 3-1. NDIR Analyzer Module Alarms.............................................................................. 3-5
Table 4-1. Cell Desiccant...................................................................................................... 4-10
Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii
Instruction Manual
748332-F
April 2003
Model NGA2000 NDIR
iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
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
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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
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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
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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
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
y
y
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
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
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