Emerson Process Management ROSEMOUNT NGA2000 HFID User Manual
Instruction Manual
748297-E
June 2003
Model NGA2000 HFID
Heated Flame Ionization Detector Analyzer Module
http://www.processanalytic.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and
international standards. Because these instruments are sophisticated technical products, you
MUST properly install, use, and maintain them
normal specifications. The following instructions MUST be adhered to and integrated into your
safety program when installing, using, and maintaining Rosemount Analytical products. Failure to
follow the proper instructions may cause any one of the following situations to occur: Loss of life;
personal injury; property damage; damage to this instrument; and warranty invalidation.
to ensure they continue to operate within their
• Read all instructions
prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Rosemount Analytical
representative for clarification.
• Follow all warnings, cautions, and instructions
marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and
maintenance of the product.
• Install your equipment as specified in the Installation Instructions of the appropriate
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 replace ment parts
specified by Rosemount. Unauthorized parts and procedures can affect the product’ s
performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY
Look-alike substitutions may result in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except
when maintenance is being performed by qualified persons, to prevent electrical shock
and personal injury.
.
The information contained in this document is subject to change without notice.
®
Teflon
is a registered trademark of E.I. duPont de Nemours and Co., Inc.
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 HFID
TABLE OF CONTENTS
Instruction Manual
748297-E
June 2003
PREFACE...........................................................................................................................................P-1
Definitions...........................................................................................................................................P-1
Safety Summary.................................................................................................................................P-2
General Precautions For Handling And Storing High Pressure Gas Cylinders .................................P-5
Documentation....................................................................................................................................P-6
Compliances.......................................................................................................................................P-6
Glossary..............................................................................................................................................P-7
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 Gas Safety Features..............................................................................................................1-2
1-5 Specifications.........................................................................................................................1-4
a. General ...........................................................................................................................1-4
b Gas Requirements............................................................................................................1-5
c. Physical............................................................................................................................1-5
d. Gas Connections.............................................................................................................1-6
2-0 INSTALLATION ....................................................................................................................2-1
2-1 Unpacking..............................................................................................................................2-1
2-2 Assembly...............................................................................................................................2-1
2-3 Location.................................................................................................................................2-1
2-4 Gases ....................................................................................................................................2-1
a. Overview.........................................................................................................................2-1
b. Pneumatic Connections..................................................................................................2-3
c. Fuel Gas Specification....................................................................................................2-3
d. Burner Air Specification ..................................................................................................2-3
e. Purge Air Specification....................................................................................................2-3
f. Regulated Air Specification.............................................................................................2-3
g. Calibration Gases Specification......................................................................................2-3
h. Sample Gas Specification...............................................................................................2-4
i. Flow Rate Specification ..................................................................................................2-4
j. Pressure/Filtration Specification .....................................................................................2-4
k. Leak Test ........................................................................................................................2-4
2-5 Electrical Connections...........................................................................................................2-6
2-6 Installation Considerations Checklist.....................................................................................2-9
3-0 STARTUP AND OPERATION ..............................................................................................3-1
3-1 overview.................................................................................................................................3-1
3-2 Startup Procedure .................................................................................................................3-1
3-3 Binding...................................................................................................................................3-4
3-4 Calibration..............................................................................................................................3-4
3-5 Routine Operation .................................................................................................................3-5
3-6 Safety System .......................................................................................................................3-6
Rosemount Analytical Inc. A Division of Emerson Process Management Contents i
Instruction Manual
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June 2003
4-0 MAINTENANCE AND TROUBLESHOOTING .....................................................................4-1
4-1 Overview................................................................................................................................4-1
4-2 Component Replacement......................................................................................................4-3
a. Oven................................................................................................................................4-3
b. Burner Sensor, Detectors and Ignitor.............................................................................4-4
c. Burner Internal Components...........................................................................................4-7
d. Thermal Block.................................................................................................................4-11
e. Electronics Assembly......................................................................................................4-13
f. Fan Assembly .................................................................................................................4-18
g. Flow Controller................................................................................................................4-19
h. DC Power Supply Module...............................................................................................4-21
i. Front Panel Components................................................................................................4-22
j. Rear Panel Components.................................................................................................4-27
4-3 Troubleshooting Checklist.....................................................................................................4-29
a. Safety System.................................................................................................................4-29
b. Ignition.............................................................................................................................4-29
c. Drift..................................................................................................................................4-30
d. Noise...............................................................................................................................4-30
5-0 REPLACEMENT PARTS......................................................................................................5-1
5-1 Matrix.....................................................................................................................................5-1
5-2 Replacement Parts................................................................................................................5-2
a. General ...........................................................................................................................5-2
b. Pneumatics.....................................................................................................................5-2
c. Oven Components..........................................................................................................5-3
Model NGA2000 HFID
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
ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 HFID
LIST OF ILLUSTRATIONS
Figure 1-1.
Figure 1-2. Heated Flame Ionization Detector Analyzer Module – Top View.......................... 1-3
Figure 2-1. Back Panel Connections........................................................................................ 2-2
Figure 2-2. Flow Diagram......................................................................................................... 2-5
Figure 2-3. Front Panel Electrical Connections ....................................................................... 2-6
Figure 2-4. Front Panel Connections, Controls and Indicators................................................2-6
Figure 2-5. HFID Outline and Mounting Dimensions............................................................... 2-7
Figure 2-6. HFID Wiring Diagram............................................................................................. 2-8
Figure 3-1. Typical Curves of Module Response vs. Pressure Setting on Fuel Pressure
Figure 3-2. Typical Curves of Module Response vs. Pressure Setting on Air Pressure
Figure 3-3. Front Panel Torquing Sequence............................................................................ 3-8
Figure 4-1. Removal of Cover and Insulation Shield ............................................................... 4-1
Figure 4-2. Locations of Major Assemblies of the HFID .......................................................... 4-2
Figure 4-3. Removal of Oven from Chassis............................................................................. 4-3
Figure 4-4. Oven Assembly...................................................................................................... 4-5
Figure 4-5. Burner - Sensor, Flameout Detector, RTD Detector and Ignitor ........................... 4-6
Figure 4-6. Burner/Thermal Block Disassembly....................................................................... 4-7
Figure 4-7. Burner Disassembly............................................................................................... 4-8
Figure 4-8. Burner Jets............................................................................................................. 4-9
Figure 4-9. Thermal Block – Sample RTD, Cartridge Heater and Thermostat...................... 4-11
Figure 4-10. Thermal Block Assembly..................................................................................... 4-12
Figure 4-11. Removing Electronics Assembly from Chassis...................................................4-13
Figure 4-12. Electronics Assembly – Exploded View............................................................... 4-14
Figure 4-13. Case Sensor Installation......................................................................................4-15
Figure 4-14. Case Pressure Purge Switch Installation ............................................................ 4-16
Figure 4-15. Preamp Assembly Installation ............................................................................. 4-17
Figure 4-16. Fan Assembly Installation....................................................................................4-18
Figure 4-17. Flow Controller Replacement .............................................................................. 4-19
Figure 4-18. Flow Controller Assembly – Exploded View........................................................ 4-20
Figure 4-19. DC Power Supply Module Replacement............................................................. 4-21
Figure 4-20. Front Panel – Exploded View .............................................................................. 4-22
Figure 4-21. Accessing Front Panel Components...................................................................4-23
Figure 4-22. Rear Panel Components ..................................................................................... 4-27
Flame Ionization Detection Technology ................................................................ 1-1
Regulator ............................................................................................................... 3-7
Regulator ............................................................................................................... 3-7
Instruction Manual
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June 2003
LIST OF TABLES
Table 3-1. HFID Analyzer Module Alarms .............................................................................. 3-8
Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii
Instruction Manual
748297-E
June 2003
Model NGA2000 HFID
iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
Model NGA2000 HFID
PREFACE
The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of the NGA2000 HFID Analyzer.
Some sections may describe equipment not used in your configuration. The user should
become thoroughly familiar with the operation of this module before operating it. Read
this instruction manual completely.
DEFINITIONS
The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout
this publication.
DANGER .
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June 2003
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
748297-E
June 2003
Model NGA2000 HFID
SAFETY SUMMARY
If this equipment is used in a manner not specified in these instructions, protective systems
may be impaired.
AUTHORIZED PERSONNEL
To avoid explosion, loss of life, personal injury and damage to this equipment and on-site
property, all personnel authorized to install, operate and service the this equipment should be
thoroughly familiar with and strictly follow the instructions in this manual. SAVE THESE INSTRUCTIONS.
DANGER.
ELECTRICAL SHOCK HAZARD
Operate this equipment only when covers are secured. Servicing requires access to live parts
which can cause death or serious injury. Refer servicing to qualified personnel. For safety and
proper performance, this module must be connected to a properly grounded three-wire source of
electrical power.
WARNING
POSSIBLE EXPLOSION HAZARD
This equipment is used in the analysis of sample gases which may be flammable, and the burner
fuel used in the ionization process is flammable. A continuous dilution purge system is factory-installed (in accordance with Standard ANSI/NFPA 496-1993, Chapter 6, and it must be functional at all times during operation. Do not disable this purge system.
The internal compartment of the oven is vented to the main enclosure by the top and bottom vents.
DO NOT RESTRICT THOSE VENTS..
WARNING .
FLAMMABLE SAMPLES
Consult the factory if flammable samples will be measured.
Preface Rosemount Analytical Inc. A Division of Emerson Process Management
P-2
Instruction Manual
Model NGA2000 HFID
WARNING.
HIGH TEMPERATURE
This equipment is used in the analysis of sample gases at temperatures of up to 250 °C. All components and material in contact with the sample, the oven and the burner can reach this temperature
level.
Operate this equipment only when covers are secured. Servicing requires access to "hot" parts
which can cause serious injury. Refer servicing to qualified personnel.
NOTE
This Analyzer Module is completely leak-tested at the factory for gas leakage. The user is responsible for testing for leakage at the inlet and outlet fittings on the rear panel (with a test procedure
chosen by the user). The user is also responsible for leak-testing periodically and if any internal
pneumatic components are adjusted or replaced. See leak test instructions in Section 2-4k on page
2-4.
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June 2003
WARNING
PARTS INTEGRITY
Tampering with or unauthorized substitution of components may adversely affect safety of this
product. Use only factory-approved components for repair.
CAUTION
PURGE AIR REQUIREMENTS
This Analyzer Module must be used in conjunction with a device (Control Module or PC Interface)
that can actively monitor network variables related to pressure or flow of the continuous dilution
purge, or the front panel LEDs of the Analyzer Module, as installed, must be visible. The purpose of
this requirement is to maintain adherence to ANSI/NFPA 496 standard which assures the continued
viability of the purge system. Under no circumstances should any pressure or flow indicator be
connected to the PURGE AIR OUT outlet of the Analyzer Module because this may affect the sealing
performance of the module.
CAUTION
PRESSURIZED GAS
This module requires calibration with a known standard gas. See General Precautions for Handling
and Storing High Pressure Gas Cylinders on page P-5.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface -
P-3
Instruction Manual
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June 2003
WARNING
POSSIBLE EXPLOSION HAZARD
Ensure that all gas connections are made as labeled and are leak free. Improper gas connections
could result in explosion or death.
CAUTION
OVER-VOLTAGE SPIKING
If this Analyzer Module is used with a non-Rosemount Analytical po wer supply, adding Rosemount
P/N 903341 Current Protector in series with the 24 V positive power line will prevent over-voltage
spiking and resultant fuse blowing when powering up the instrument.
WARNING
PRESSURIZED ENCLOSURE
Model NGA2000 HFID
HOT INTERNAL PARTS
This enclosure shall not be opened unless the area is known to be free of flammable materials or
unless all devices within have been de-energized.
Area classification for the protected enclosure:
Nonclassified.
Pressurization: Type Z
Temperature Identification Number: T4A
Power shall not be restored after enclosure has been opened (or loss of purge) until enclosure has
been purged for a minimum of 6 (six) minutes at the minimum pressure of 689 hPa (10 psig)
Preface Rosemount Analytical Inc. A Division of Emerson Process Management
P-4
Instruction Manual
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Model NGA2000 HFID
June 2003
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 extreme s 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 whe n an empty cylinder is
attached to a pressurized system.
7. No part of cylinder should be subjected to a temperature higher than 125°F (52°C). A flame should
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 wel ding,
precautions must be taken to prevent striking an arc against the cylinder.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface -
P-5
Instruction Manual
9
6
748297-E
June 2003
Model NGA2000 HFID
DOCUMENTATION
The following NGA2000 HFID instruction materials are available. Contact Customer Service Center or the
local representative to order.
748297 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.
Rosemount Analytical Inc. has satisfied all obligations from the European Legislation to harmonize the
product requirements in Europe.
FM
APPROVED
®
97-C219
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
Preface Rosemount Analytical Inc. A Division of Emerson Process Management
P-6
Instruction Manual
Model NGA2000 HFID
GLOSSARY
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
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June 2003
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.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface -
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Instruction Manual
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June 2003
Softkeys
The five function keys located below the front panel display; they assume the function displayed directly
above each on the display, a function dictated by software.
System
Any collection of Analyzer Module(s), Platform(s), I/O Module(s) and Expansion Module(s).
Model NGA2000 HFID
Preface Rosemount Analytical Inc. A Division of Emerson Process Management
P-8
Model NGA2000 HFID
SECTION 1
DESCRIPTION AND SPECIFICATIONS
from internal combustion engines are exam-
1-1 OVERVIEW
This manual describes the Heated Flame
Ionization Detector (HFID) Analyzer Module of
Rosemount Analytical's NGA2000 Series of
gas analysis components. See Figure 1-1
below and Figure 1-2 on page 3.
The HFID Analyzer Module is designed to
continuously determine the concentration of
hydrocarbons in a flowing gaseous mixture at
a user-selectable temperature setpoint between 93°C and 204°C (200°F and 400°F).
The concentration is expressed in ppm or
percent of volume.
The entire HFID Analyzer Module is designed
as a stand-alone module, with gas connections made from the rear. All electronics relative to sample detection and conditioning are
included in this module.
1-2 TYPICAL APPLICATIONS
The monitoring of atmospheric air for low-level
hydrocarbon contaminants and determining
the hydrocarbon content of exhaust emissions
+90V
Sample
ples of typical applications for the HFID Analyzer Module.
1-3 THEORY OF TECHNOLOGY
This Analyzer Module uses the flame ionization method of detection. The sensor is a
burner in which a regulated flow of sample
gas passes through a flame sustained by
regulated flows of a fuel gas (a hydrogen/diluent mixture) and air.
Within the flame, the hydrocarbon components of the sample stream undergo a complex ionization that produces electrons and
positive ions. Polarized electrodes collect
these ions, causing current to flow through an
electronic measuring circuit.
The ionization current is proportional to the
rate at which carbon atoms enter the burner,
and is therefore a measure of the concentration of hydrocarbons in the sample. This
measure of concentration is placed on the
network, where it can be shown on a data acquisition device.
Negative Ion
Collection Plate
Signal Conditioning
Positive
Carbon
Ions
Air
Fuel
Instruction Manual
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June 2003
Figure 1-1. Flame Ionization Detection Technology
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Instruction Manual
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1-4 GAS SAFETY FEATURES
The HFID Analyzer Module is designed with a
factory-installed continuous dilution purge system in accordance with standard ANSI/NFPA
496 - 1993, Chapter 6. Front-panel LEDs indicate that the burner flame is lit and that the
purge system is enabled. In addition, fuel gas
is automatically shut off when a flame-out
condition occurs or the safety system is disabled.
Model NGA2000 HFID
dissipated below 25% of the LEL of hydrogen
through the combination of an inlet fuel flow
restrictor and purge gas flow.
This module is designed to use 40% H
He fuel at a maximum inlet pressure of 3446
hPa-gauge (50 psig).
A standard HFID Analyzer Module is only
equipped to analyze a non-flammable sample,
below 100% of the LEL..
/60%
2
The purge system is enabled only if there is
proper purge gas flow in, purge gas pressure,
and internal case pressure, and after five
times the case volume has been exchanged.
All tubing ahead of the burner is rigid metallic
tubing assembled with ferrule/nut type compression fittings. However, should an internal
fuel leak occur, a worst-case leak would be
WARNING
POSSIBLE EXPLOSION HAZARD
Protection against explosion depends
upon a special fuel flow restrictor in the
fuel inlet fitting. Do not remove fuel inlet
restrictor. Do not use 100% hydrogen fuel.
Replace only with a factory supplied fitting.
Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
1-2
Model NGA2000 HFID
A
Gas Lines
Burner Air & Fuel Regulators
(Stacked Vertically)
(See Figure 2-2)
Fuel Shutoff
Solenoid Valve
Oven
ir Circulation Fan
Case Heater
Sample Flow
Controller
Purge Air
Flow Switch
Burner Air
Solenoid Valve
Instruction Manual
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Purge Air Outlet
Detector
(Burner)
Preamp Board
(In Shield)
Case Pressure Switch
Computer Board
Sensor Board
Safety Board
DC-DC Module
Power Supply Board
Purge Air
Regulator
Network & Power Module
Figure 1-2. Heated Flame Ionization Detector Analyzer Module – Top View
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications
1-3
Instruction Manual
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June 2003
1-5 SPECIFICATIONS
a. General
Measurement Species....................Total hydrocarbons
Ranges (H
Analysis Temperature.....................Adjustable from 200
Repeatability....................................≤1% of fullscale for successive identical samples, at a constant
Min. Detectable Level......................0.10 ppm, CH
Noise ................................................≤1% of fullscale, pea k to peak
Linearity............................................≤±1% of fullscale, ≤±2% of data point (must be above the minimum
Response Time ...............................≤1.5 sec., 0% to 90% of fullscale
Drift
Effect of Temperature.................... ≤±2% of fullscale for any ambient temperature change of 10
Operating Temperature................. 59°F to 95°F (15°C to 35°C)
Power Requirements.......................+24 VDC ±5%, 120 W max. direct to Analyzer Module
/He Fuel)
2
Low range............................0 to 10 ppm, CH
High range...........................0 to 50 ppm, CH
Zero ..................................... ≤ ±1% of fullscale/24 hours at constant temperature, sample flow,
Span .................................... ≤ ±1% of fullscale/24 hours at constant temperature, sample flow,
Ripple and Noise.................<100 mV pp
Line and Load Regulations..<1%
Model NGA2000 HFID
, through 0 to 1%, CH4 at an oven setpoint between
4
113°C and 191°C
, through 0 to <5%, CH4 at an oven setpoint
4
between 113°C and 191°C
o
±11
F (±6oC) from the setpoint.
temperature, sample flow and fuel, burner air, regulated air and
sample pressures
detectable level)
hydrocarbon concentration of supply gases, and fuel, burner air,
regulated air and sample pressures.
hydrocarbon concentration of supply gases, and fuel, burner air,
regulated air and sample pressures.
rate of change less than 10
o
F to 400oF (93oC to 204oC), maintained within
4
o
o
C/hr.
C and
Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
1-4
Model NGA2000 HFID
b. Gas Requirements
Sample .......................................... Non-flammable, below 100% of LEL
Flow rate..............................1.0 to 2.5 L/min.
Supply pressure...................345 to 620 hPa-gauge (5 to 9 psig)
Temperature........................110
Particulates..........................filtered to <2 microns
Dewpoint..............................<15
Regulated Air................................. Instrument air or nitrogen
Flow rate..............................2 to 4 L/min.
THC .....................................≤2 ppm, CH
Supply pressure...................689 to 1723 hPa-gauge (10 to 25 psig)
Particulates..........................filtered to <2 microns
Purge Air:....................................... Instrument air, nitrogen or other nonflammable gas (refer to
Flow rate: ............................16 to 18 L/min.
Supply pressure:..................689 to 1378 hPa-gauge (10 to 20 psig)
Fuel Gas........................................ Premixed 40% hydrogen and 60% helium
Flow rate..............................80 to 100 ml/min
THC .....................................≤0.5 ppm, CH
Supply pressure...................3101 to 3446 hPa-gauge (45 to 50 psig)
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o
C to 230oC (230oF to 446oF), <20oC variance/24 hours, <10oC
variance/hr.
o
C below the setpoint
4
ANSI/NFPA 496 for the requirements for the Protective Gas System)
4
WARNING
EXPLOSION HAZARD
Do not use pure hydrogen fuel. An explosion resulting in severe personal injury or death could occur.
Burner Air ...................................... Zero-grade air
Flow rate..............................350 to 400 mL/min.
THC .....................................≤1 ppm, CH
4
Supply pressure...................1723 to 3446 hPa-gauge (25 to 50 psig)
c. Physical
Case Classification........................ General purpose for installation in weather-protected area
Maximum Separation .................... 1600m (1 mile) from Analyzer Module to Platform
Materials in Contact With Sample. Stainless steel and glass-filled teflon
Dimensions.................................... See Outline and Mounting Dimensions, Figure 2-5 on page 2-7
Weight ........................................... 15.9 kg (35 lbs.)
Mounting........................................Horizontally, custom-installed in a panel
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications
1-5
Instruction Manual
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d. Gas Connections
Sample In ...................................... 1/4" O.D. tube fitting, stainless steel
Regulated Air In ...............................1/4" O.D. tube fitting, brass
Burner Air In.....................................1/4" O.D. tube fitting, brass
Fuel In...............................................1/4" O.D. tube fitting, stainless steel
Purge Air In ......................................3/8" O.D. tube fitting, brass
Purge Air Out....................................3/8" O.D. tube fitting, brass
Bypass Out.......................................1/4" O.D. tube fitting, stainless steel
Burner Exhaust Out .........................3/8" O.D. tube connection, stainless steel (must slope downward
Burner Exhaust, Bypass Out and Purge Air Out to be vented to atmospheric pressure and to non classified location in accordance with ANSI/NFPA-496 guideline
Pressure Relief Valve.................... See Caution below
o
6
min. from horizontal)
Note
Model NGA2000 HFID
CAUTION
PRESSURE RELIEF VALVE
No connection shall be made to this fitting. If this caution is ignored, damage to the case seals
could occur, and the instrument will not operate properly
WARNING
HIGH TEMPERATURE
The Sample In, Bypass Out, and Burner Exhaust Out connections can reach temperatures of up to
250°C (480°F). Severe burns could result from touching these connections.
See the Preface section of the Platform Components manual for specifications regarding Platform related components and the Preface of the I/O Module manual for specifications regarding I/O (e.g.,
relay outputs.
Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
1-6
Model NGA2000 HFID
2-1 UNPACKING
Carefully examine the shipping carton and contents for signs of damage. Immediately notify
the shipping carrier if the carton or its contents
are damaged. Retain the carton and packing
material until the instrument is operational.
2-2 ASSEMBLY
If the Analyzer Module requires assembly with
other components, do so at this time.
Connect the network cable to either the NETWORK 1 or NETWORK 2 connection on the
Analyzer Module. Connect the power cable to
the Analyzer Module front panel and an electrical +24VDC power supply.
2-3 LOCATION
Install the Analyzer Module in a clean,
weather-proofed, non-hazardous, vibration-free
location free from extreme temperature variations. For best results, install the Analyzer Module near the sample stream to minimize sample
transport time.
WARNING
INSTALLATION RESTRICTIONS
For safety, the Analyzer Module should be
installed in a non-confined, ventilated space.
Do not block any of the rear panel outlets as
they are part of the safety system.
Operating ambient temperature is 15°C to
35°C, limited to temperature changes of less
than 10°C/hr. Acceptable dew point range is
less than 95% relative humidity, but not in excess of 45°C wet bulb temperature.
The cylinders of fuel, air, and calibration gas(es)
and the source of purge and regulated air
Instruction Manual
748297-E
June 2003
SECTION 2
INSTALLATION
should be located in an area of relatively
constant ambient temperature.
2-4 GASES
a. Overview
During normal operation, the Analyzer
Module requires fuel and air to maintain
the burner flame as well as suitable
standard gases for calibration and instrument air for purge requirements. In
addition, instrument air for regulated air
in is required to control the sample
pressure at the sample capillary. Criteria for selection of these gases follow in
this section.
After initial startup or after startup following a prolonged shutdown, the analyzer may display baseline drift for a
considerable period of time, particularly
on the most sensitive range. Commonly, the drift is caused by small
amounts of hydrocarbons in the inner
walls of the tubing in both the internal
flow system and the external gas supply
system. Drift results from any factor influencing the equilibrium of these absorbed hydrocarbons, such as
temperature or pressure.
Note that this type of drift occurs only
when the flame is burning. If drift occurs
when the flame is extinguished, the
electronic circuitry is at fault. To minimize drift, use clean fuel and air, keep
the analyzer clean, and locate the gas
cylinders in an area of relatively constant ambient temperature.
The cylinders supplying all gases each
should be equipped with a clean, hydrocarbon-free, two-stage regulator and
a shutoff valve.
Rosemount Analytical Inc. A Division of Emerson Process Management Installation
2-1
Instruction Manual
A
748297-E
June 2003
Model NGA2000 HFID
All new external gas tubing (except for
PURGE IN/OUT and SAMPLE BYPASS) is
strongly recommended, preferably precleaned, stainless steel, gas chromatograph-grade tubing. Thoroughly clean before use (if a hydrocarbon-based cleaning
solvent such as acetone is used, purge tubing with dry nitrogen or helium for several
tal. Otherwise, water may accumulate in
the line, causing back pressure and
noisy readings, or may back up in the
line and flood the burner. Depending on
the percent of water vapor in the sample, the sample bypass out connection
may have condensation. Proper drainage may be required.
minutes before using.)
If the sample is toxic or noxious, or is to
Gas line connections are compression fittings. Do not use pipe thread tape.
be reclaimed, connect the Bypass outlet
to a suitable disposal system. Do not
use any device that may cause back
Since the oxidation of hydrogen is accom-
pressure in the line.
panied by the formation of water vapor, the
Exhaust tubing always should be slanted
downward at least 6 degrees from horizon-
Purge air and burner air should be sup-
plied from separate sources.
PURGE
AIR OUT
REGULATE
D
!
!
BURNER
AIR IN
PURGE
AIR IN
TTENTION
WARNING
Possible electric shock, explosion or toxic gas hazard. See front of module
FUEL
BURNER
EXHAUST
OUT
VENT TO SAFE AREA
SLOPE DOWNWARD 6!
MINIMUM
HOT !
ATTENTION
CHAUD !
HEATED
SAMPLE IN
HEATED
SAMPLE
BYPASS OUT
Danger d'electrocution, d'explosion ou d'emanation de gaz
toxique. Se refere aux details inscrits surla face du module.
IN
MAXIMUM
INPUT
PRESSURE
FUEL: 50 psig(3445 hPa)
BURNER AIR: 50 psig (3445 hPa)
SAMPLE: 8 psig (551 hPa)
PURGE AIR: 20 psig (1378 hPa)
REG AIR: 25 psig (1722 hPa)
PRESSURE
RELIEF
VALVE
Figure 2-1. Back Panel Connections
Installation Rosemount Analytical Inc. A Division of Emerson Process Management
2-2
Model NGA2000 HFID
Instruction Manual
748297-E
June 2003
b. Pneumatic Connections
WARNING
HIGH TEMPERATURE
The Sample In, Sample Bypass Out, and
Burner Exhaust Out gases and fittings
can reach temperatures of up to 250°C.
Make connections to these fittings when
the oven heater is disabled or the module is powered down.
(See Figure 2-1 on page 2-2) Connect inlet
and outlet lines for sample, burner fuel and
air, exhaust, bypass, regulated air, and
purge to appropriately labeled fittings on the
rear panel. All connections are 1/4-inch ferrule-type compression fittings except the
PURGE AIR IN and OUT connections,
which are 3/8-inch compression fittings. The
Burner Exhaust is a 3/8-inch connection.
It is recommended that no connection be
made to the PURGE AIR OUT port. If, however, the analyzer's location requires interconnection with a venting system, the 3/8"
O.D. line should be kept as short as possible, and no longer than four feet.
CAUTION
POSSIBLE INSTRUMENT DAMAGE
c. Fuel Gas Specification
Standard analysis usually requires
mixed fuel, i.e., 40% ±2%) hydrogen
and 60% helium. H
recommended over H2/N2 fuel because
of better linearity in concentration output. Such blends are supplied by many
gas vendors specifically for this use,
with a guaranteed maximum total hydrocarbon content of 0.5 ppm, measured as methane. This specification
should be used when obtaining these
mixtures.
The fuel restrictor is marked with a
red dot, and the sample capillary is
marked with a red or green dot for
mixed fuel applications.
d. Burner Air Specification
In order to ensure a low background
signal, burner air should contain less
than 1 ppm maximum total hydrocarbon
content. An alternate source for burner
air and zero gas (see Section 2-4g
below) is a combination diaphragm
pump and heated palladium catalyst.
This process continuously removes
moderate amounts of hydrocarbons and
carbon monoxide from ambient air.
2/He mixed fuel is
Note
No connection should be made to the
PRESSURE RELIEF VALVE fitting. Doing
so may cause damage to the instrument.
CAUTION
PURGE AIR REQUIREMENTS
The front panel LEDs of the Analyzer
Module, as installed, are not visible, the
user should provide an indicator for the
safety system as per ANSI/NFPA 496
standards.
Rosemount Analytical Inc. A Division of Emerson Process Management Installation
e. Purge Air Specification
Instrument quality air or nitrogen is required for the safety purge system.
f. Regulated Air Specification
Instrument quality air or nitrogen is required. The air should contain less than
2 ppm maximum total hydrocarbon content.
g. Calibration Gases Specification
Calibration method and gases depend
on the operating range, and the desired
measurement accuracy. In all methods,
zero and span gases are used, and are
2-3
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