Emerson Process Management ROSEMOUNT NGA2000 HFID User Manual

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Instruction Manual

748297-E June 2003

Model NGA2000 HFID

Heated Flame Ionization Detector Analyzer Module

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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

Instruction Manual

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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

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Instruction Manual

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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

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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

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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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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 -

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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.

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Instruction Manual

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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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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.

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Instruction Manual

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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)

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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.

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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.

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

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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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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.

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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

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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

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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%

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

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

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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

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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)

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

113°C and 191°C

, through 0 to <5%, CH4 at an oven setpoint

between 113°C and 191°C

±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.

rate of change less than 10

F to 400oF (93oC to 204oC), maintained within

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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C to 230oC (230oF to 446oF), <20oC variance/24 hours, <10oC

variance/hr.

C below the setpoint

ANSI/NFPA 496 for the requirements for the Protective Gas System)

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

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

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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

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

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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

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

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.

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

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

introduced through the sample inlet at the rear of the module.

Zero Gas - Analysis is affected by the background gas of the sample. Therefore, it is recommended to use zero gas with as close to the background composition of the sample as possible. Normally less than 0.5 THC as CH

is sufficient.

Span Gas - Span gas consists of a specified concentration of methane or other hydrocarbon in a background gas such as nitrogen. Analysis is affected by the background gas of the sample. Therefore, span gas containing the same background gas as the sample is recommended. Then, the background effect is canceled out.

h. Sample Gas Specification

Sample gas should be nonflammable (below 100% of the sample's LEL). For high sensitivity applications requiring background gas compensation, contact the factory.

regulator, 1723 hPa-gauge (25 psig) nominal for internal pressure.

Burner Air Pressure should be : 1725 to 3450 hPa-gauge (25 to 50 psig) for cylinder regulator, 1035 hPa-gauge (15 psig) nominal for internal pressure.

Regulated Air Pressure should be 689 to 1725 hPa-gauge (10 to 25 psig) for cylinder regulator.

Purge Air Pressure should be 689 to 1380 hPa-gauge (10 to 20 psig).

Nominal Internal Case Pressure is about 0.5 to 1.0 inch of water, and the pressure relief valve is set at 1/3 psig (nominal).

CAUTION

OVER-PRESSURE

Noncompliance with these specifications, particularly those concerning purge air, could cause over-pressure damage to the module.

i. Flow Rate Specification

Required sample flow rate is 1.0 L/min. to

2.5 L/min. for a supply pressure between 5 and 9 psig. Flow rate for purge gas should be 16 to 18 L/min. Flow rate for regulated air should be 2 to 4 L/min.

j. Pressure/Filtration Specification

Sample Pressure at the SAMPLE inlet should be within the range of 345 to 620 hPa-gauge (5 to 9 psig, 7.0 psig nominal), and internally, should be between 206.7 and 275.6 hPa-gauge (3.0 and 4.0 psig).

Burner Fuel Pressure should be: 3101 to 3450 hPa-gauge (45 to 50 psig) for cylinder

Note The sample gas and regulated air should be filtered for particulates down to 2 microns to prevent the plugging of pneumatic components.

k. Leak Test

The analyzer module is completely leak tested at the factory. The user is responsible for testing for leakage at the inlet and outlet fittings on the rear panel. The user is also responsible for internal leak testing periodically and if any internal pneumatic components are adjusted or replaced (with a test procedure chosen by the user).

Installation Rosemount Analytical Inc. A Division of Emerson Process Management

2-4

Model NGA2000 HFID

AIR

Instruction Manual

748297-E

June 2003

REGULATOR, PURGE AIR

PLUG 1/4NPT

SWITCH, PURGE FLOW

DIFFUSER

PURGE PRESSURE SENSOR

BULKHEAD 3/8T BRASS

REDUCE 3/8T - 1/4T BRASS

PURGE

AIR IN

PLUG 1/8NPT

1/4T - 1/8NPT BRASS

ELBOW PURGE AIR RESTRICTOR BRASS

TUBING 1/4 OD VITON

TUBING 1/4 OD COPPER

ELBOW 1/4T - 1/4MPT BRASS

CHECK VALVE 1/3 PSIG

DAPTER

REGULATED

AIR IN

ELBOW 1/4T - 1/4FPT BRASS

ELBOW 1/4T - 1/4NPT BRASS

PRESSURE SENSOR, REGULATED AIR 0 - 15 PSIG

FIXED FLOW CONTROLLER, REGULATED AIR

BULKHEAD RESTRICTOR 1/4T - 1/4T SS

BULKHEAD 1/4T - 1/4T BRASS

MANIFOLD, SAMPLE

UNION 1/4T BRASS

HEATED SAMPLE

OUT

RUN TEE 1/4T - 1/4MPT BRASS

SAMPLE BYPASS

OUT

BURNER

DETECTOR

FUEL RESTRICTOR 1/8T - 1/8T

TUBING 1/8 OD COPPER

TUBING 1/4 OD COPPER

IR IGNITE

RESTRICTOR

BURNER EXHAUST

BULKHEAD 1/4T - 1/8T SS

ELBOW 1/8T - 1/8T BRASS

RESTRICTOR, BYPASS

PRESSURE

RELIEF

VALVE

BULKHEAD REDUCER 1/4T - 1/8T BRASS

SENSOR, SAMPLE TEMPERATURE

SAMPLE CAPILLARY

CONNECTOR 1/16T - 1/8NPT SS

TUBING 1/8 OD COPPER

RUN TEE 1/8T - 1/8MPT BRASS

RESTRICTOR

SENSOR, BURNER AIR PRESSURE 0 - 30 PSIG

TUBING 1/8 OD COPPER

ELBOW 1/8T - 1/8MPT BRASS

BURNER

AIR IN

TUBING 1/8 OD COPPER

OUT

RUN TEE 1/4T - 1/4FPT BRASS

PURGE

AIR OUT

FILTE

PORT CONNECTOR 1/4

TUBING 1/8 OD SS

BULKHEAD 3/8T - 1/4MPT BRASS

TUBING 1/4 OD VITON

PRESSURE

SWITCH

SENSOR,

PRESSURE 0 - 30 PSIG

OUT

PRESSURE REGULATOR, BURNER AIR 0 - 60 PSIG

BULKHEAD CONNECTOR 1/4T - 1/8NPT SS

FUEL

REGULATOR, FUEL PRESSURE 0 - 30 PSIG

FUEL

SOLENOID

VALVE

OUT

TUBING 1/8 OD SS

FUEL RESTRICTOR

MALE CONNECTOR 1/8T - 1/8NPT SS

Figure 2-2. Flow Diagram

Rosemount Analytical Inc. A Division of Emerson Process Management Installation

2-5

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

2-5 ELECTRICAL CONNECTIONS

Two electrical connections are required on the Analyzer Module: POWER and NETWORK (See Figure 2-3 below). On the Analyzer Module, two NETWORK connectors are available, either of which is appropriate for: 1) interconnection with the control module or 2) "daisy-chaining" with other NGA2000 components. Connect Analyzer Module POWER to an external +24 VDC power source with a voltage tolerance of ±5% and a minimum power rating of 120 watts.

POSSIBLE EXPLOSION HAZARD

Hydrogen fuel gas is used in this instrument. Do not remove fuel restrictor or operate at greater than 50 psig. An explosion resulting

BURNER

FUEL

DANGER D

Cet instrument contient du gaz hydrogene. Ne retirez pas le lim itateur d′de combustible, et n′operez pas au plus de 50 psig Ces conditions

EXPLOSION

euvent provoquer une explosion

POWER

OVEN HEAT

FLAME ON

PURGE

FUEL OVERRIDE

IGNITE

NETWORK1

NETWORK2

POWER

FUSE

Figure 2-3. Front Panel Electrical

Connections

HFID

LON

24V

LON 2

1 + 2 3 GND

T 6A

250 V

POSSIBLE EXPLOSION HAZARD

Do not operate flammable sample without following instructions in the Manual.

n explosion resulting in severe personal injury or death could occur.

DANGE

Ne pas utiliser l′echantillon inflammable avant d′avoir pris connaissance des instructions contenues dans le manuel. Le non respect de ces instructions peut entrainer une explosion provoquant des blessure graves ou mortelles.

Figure 2-4. Front Panel Connections, Controls and Indicators

Installation Rosemount Analytical Inc. A Division of Emerson Process Management

2-6

Model NGA2000 HFID

[

]

[83]

[81]

[35]

[23]

[75]

FRONT VIEW

SIDE VIEW

[7]

REAR VIEW

Dimensions:

[17]

[6]

INCHES

[MM]

3.3

.25

DIA

[6]

3.2

1.1

4.3

2.0

110

[51]

1.4

Figure 2-5. HFID Outline and Mounting Dimensions

1.1 [27]

2.0

[52]

4.2

[107]

4.0

[103]

5.4

[137]

8.2

[208]

[152]

[571]

7.2

[183]

6.0

22.5

6.8

[174]

[18]

Instruction Manual

748297-E

June 2003

3.6

[91]

1.9

[48]

[15]

2.8

[71]

1.1 [28]

1.4 [34]

1.0

[25]

2.4 [60]

3.0

3.1

[78]

Rosemount Analytical Inc. A Division of Emerson Process Management Installation

2-7

Instruction Manual

HARNESS, GLOW PLUG

AIR

HEAT

FLAMEON

PURGE AIR

HARNESS

12345678

CABLE ASSEMBLY,FLAT3 COND

J5 +10VREF

SHIELD

R38

GRY

PUR

748297-E June 2003

Model NGA2000 HFID

CABLE ASSEMBLY, FLAT 3 COND

LON/POWER

MODULE J5

E2 24VOLT

E1 RTN

CABLE ASSEMBLY,

BLK

RED

GRN

FLAT 10 COND

P6 J6

FLAT 24 COND

P4J4P5

CABLE ASSEMBLY

CABLE ASSEMBLY, FLAT 20 COND

POWER

SUPPLY

BOARD

P9 J9

FUEL SOL.

+-+-+

P10

BRN

RED

ORN

J11

OVEN HEATER

YEL

BLU

GRN

P15

P11

BLK

RED

J15

AIR

3-WAY SOLENOID

HARNESS, CHASSIS

THERMOSTAT

FAN ASSEMBLY

HEATER

SENSOR,

AIR

PRESSUR

CABLE ASSEMBLY,

FLAT 16 COND

J16

P16

FUEL IN

2-WAY SOLENOID

J14

P14

SENSOR,

CASE TEMP

P4 J4

SAFETY BOARD

CABLE ASSEMBLY,

FLAT 30 COND

COMPUTER

ANALYSIS

BOARD

J1 P1

POWER

MTG STUD

CABLE ASSY,

PRESSURE

SWITCH

FLOW

CASE PRESS SWITCH

SWITCH

GND STRAP

FLOW SW

POL VOL

P10

J10

CABLE ASSEMBLY,

SENSOR BD TO HARNESS

P18

J18

P17

CHASSIS GND

SHIELD

PREAMP

BOARD

R37

OVEN

J17

CABLE ASSEMBLY, ANODE

CABLE ASSEMBLY, CATHODE

CABLE ASSEMBLY, THERMAL FUSE

POWEROVEN

SWITCH ASSEMBLY, MANUAL

LED INDICATOR

PWR MOD

ANODE

IGNITE

ASSEMBLY

SENSOR ASSEMBLY,

REF TEMP

OVEN

HEATER

SENSOR,

SAMPLE

PRESSURE

J12 P12

J14

SENSOR ASSEMBLY,

FLAME OUT

J12 P12

P3 J3

THERMAL OVEN SAMPLE

P2 J2

POWER MODULE

ASSEMBLY

J7 P7

DETECTOR BLOCK ASSEMBLY

SWITCH RTD RTD

J8 P8

CABLE ASSEMBLY,

OVEN HEATER

CATHODE

P1 J1

JP1

RTN

SENSOR,

FUEL

PRESSURE

J11 P11

J10 P10

J9 P9

J10 P10

J11

P11

SENSOR BOARD

J13

P13

J16

P16

J15

P15

P4 J4

P5 J5

SAMPLE RTD

CABLE ASSEMBLY, IGNITOR

J1 P1

Figure 2-6. HFID Wiring Diagram

Installation Rosemount Analytical Inc. A Division of Emerson Process Management

2-8

Model NGA2000 HFID

2-6 INSTALLATION CONSIDERATIONS

CHECKLIST

Verify the following:

Instruction Manual

748297-E

June 2003

• The bypass line connection must be slanted down a minimum of 6 degrees from horizontal for drainage of water condensation.

• The Analyzer’s location should be: Clean

A well ventilated area weatherproofed Non-hazardous Vibration-free Have stable ambient temperature

• The gas cylinders should be equipped

with a clean, hydrocarbon free two stage regulator and shut off valve.

• All external tubing, regulators, valves,

pumps, fittings, etc. are clean.

• The correct fuel type is being used.

• The THC content of the supply gases

are compatible with the analysis range.

• The calibration background gases are

similar to the sample.

• If required, thermal insulation around the bypass fitting to prevent condensation in the bypass restrictor.

• If required, thermal insulation for the sample inlet connection to minimize the cold spot.

• The heated line is at the correct tem- perature.

• The sample, zero, and span gases are at the correct temperature.

• The heated line to have over tempera- ture protection.

• The sample, bypass, and burner ex- haust tubing material must handle high temperature and have thermal insulation to protect from burns.

• The purge air out tubing to be 3/8 inch and less than 4 feet in length.

• The purge air out, burner exhaust, and bypass are vented to atmospheric pressure. The pressure should be constant.

• The burner exhaust tube must be slanted down a minimum of 6 degrees from horizontal.

Rosemount Analytical Inc. A Division of Emerson Process Management Installation

• All external gas connections have been leak checked.

• The dead volume for external sample and fuel lines have been minimized.

• The stainless steel tubing used for the fuel and sample lines is clean.

2-9

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

Installation Rosemount Analytical Inc. A Division of Emerson Process Management

2-10

Model NGA2000 HFID

STARTUP AND OPERATION

3-1 OVERVIEW

Prior to initial startup, the user should leak test the module as outlined in Section 2.

Instruction Manual

748297-E

June 2003

SECTION 3

3. Connect the LON cable(s) and the +24VDC power cable.

4. Turn power ON.

For the remainder of this section, Analyzer Module interconnection with a control module or some interfacing component will be assumed operational.

3-2 STARTUP PROCEDURE

WARNING

PRESSURIZED ENCLOSURE

This enclosure shall not be opened unless the area is known to be free of flammable materials or unless all devices within have been de-energized.

Area classification for the protected enclosure:

Nonclassified. Pressurization: Type Z Temperature Identification Number: T4A Power shall not be restored after enclo-

sure has been opened (or loss of purge) until enclosure has been purged for a minimum of 6 minutes at the minimum pressure of 689 hPa (10 psig). For safety, the Analyzer Module should be installed in a non-confined, ventilated space. Do not block any of the rear panel outlets as they are part of the safety system.

5. Check the 4 LEDs. The power green LED should be illuminated. The Oven amber LED should be blinking or on. The other LEDs should be OFF.

6. Allow the network to initialize. If the user's system contains only one

Analyzer Module, all system components, the Controller Board and the network "self-install" (bind together) during initial startup. If the system contains more than one Analyzer Module, the startup sequence will interrogate the network to locate and identify all components on the network. The user will have to bind appropriate combinations of components after the startup sequence. (See Section 3-3 on page 3-4.)

7. Check the general health of the analyzer by reviewing the status of the Self Tests. All “Pass” conditions should be obtained.

These test results can be found by selecting the following from the Main Menu: Technical Level Configuration, Diagnostic Menus, Analyzer Module Diagnostics, Self Test. All tested parameters should indicate "Pass."

Descriptions of the tests performed follow:

1. Connect supply gases and outlets to/from module.

2. Turn ON the purge gas only. Perform a leak check. Wait a minimum of 6 minutes.

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

• EEPROM test - Checks the EEPROM on the Analysis Computer PCB.

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

• EPROM test - Checks the EPROM on the Analysis Computer PCB.

• RAM test - Checks the RAM on the Analysis Computer PCB.

• Power supply test - Verifies that all internal DC voltages are within the required tolerances.

• Network test - Checks the inter- nal network interface.

• 20 bit ADC test - Checks the 20-bit ADC on the Analysis Computer PCB by sending a DC signal through the Preamp PCB and reading the signal back with the 20-bit ADC.

• 12 bit ADC test - Checks the 12-bit ADC on the Analysis Computer PCB by sending a DC signal and reading the signal back with the 12-bit ADC.

• Power Supply PCB test Checks the presence of the Power Supply PCB by activating the 3-way air solenoid.

• Safety PCB test - Checks the presence of the Safety PCB by sending a command and reading it back.

sensor. They must be within 10°C of each other. This test sometimes fails if the case is opened. The sensor in the Preamp will take longer to cool off since it is in an enclosure. Re-running the self-test after thermal equilibrium will produce a positive result if the sensors are working properly.

• Oven/Sample Temperature test

- Compares the temperature read between the sample temperature sensor and the oven temperature sensor. They must be within 50°C of each other.

• The self-test can be repeated at any time by activating the TEST softkey in the Self Test Results menu.

8. Set the desired oven setpoint in the range of 93°C to 204°C (200°F to 400°F).

9. Wait for the Purge Air green LED to illuminate.

10. Introduce the remaining supply gases. Perform leak check. (See Section 1-5 Specifications on page 1-4.)

11. Set and verify the internal gas pressures.

• Case temperature test - Com- pares the temperature read between the Preamp temperature sensor and the case temperature

INTERNAL PRESSURE REGULATOR TYPICAL OPERATING PRESSURES

Burner Air 965 to 1103 hPa-gauge (14 to 16 psig) Fuel 1516 to 1723 hPa-gauge (22 to 25 psig) Sample (non-adjustable) 206 to 290 hPa-gauge (3.0 to 4.0 psig)

Purge air of the following specifications must be present: Flow: 16 to 18 L/min.

Supply Pressure: 689 to 1378 hPa-gauge (10 to 20 psig)

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

Model NGA2000 HFID

Instruction Manual

748297-E

June 2003

Noncompliance could cause damage to the module. At the very least, the module's safety system, which requires a certain volume of purge air flowing through the case before allowing burner ignition, will not allow the instrument to operate. The lowest purge air flow/pressure setting possible during burner operation is preferable. Thus, the user should set the external purge air pressure initially at 689 hPa-gauge (10 psig). Check the Miscellaneous Control Parameters screen under Technical Diagnostics, and note whether the Purge Gas (switch) variable is "ON." If it is "OFF," increase purge air supply by 69 hPa-gauge (1 psig), and recheck the Purge Gas variable until it reads "ON."

DO NOT EXCEED 1378 hPa-GAUGE (20 PSIG). If the maximum setting is

reached, and the Purge Gas variable does not read "ON," contact factory. If the safety system is initiated successfully (Purge Gas variable is "ON"), continue with the remainder of the startup procedure.

Note Do not restrict the PURGE OUT port and the pressure relief valve. They must be vented to atmospheric pressure.

The manual ignition switch on the Analyzer Module front panel must be manipulated in the following ways:

• Press up and hold for one minute. This opens burner fuel and air solenoids.

• Press down to ignite burner glow plug for up to 10 seconds.

• Repeat as necessary (if fuel and air sources are farther away than 10 feet, several more attempts may be necessary).

• If the flame has been lit, but the flame temperature increases slowly, perform the following steps:

! After igniting flame, release

switch for 2 seconds

! Press switch down for

2 seconds

! Repeat release switch and

press down steps as necessary.

13. Allow the case and oven to warm up, approximately 1 to 2 hours.

14. Verify that all 4 LEDs are illuminated.

12. Manual or Auto-ignite the flame. The Flame-On green LED should be illuminated.

Note the four LEDs on the front panel of the Analyzer Module. They provide necessary information for either ignition

Two methods of burner ignition are possible: auto-ignition and manual ignition. (Note: The burner is easier to ignite when the oven has reached the desired setpoint temperature.)

Auto-ignition provides fuel override and three attempted ignitions (default setting), if necessary.

Before ignition and operation, Fuel Flow

procedure. The LEDs, when illuminated, denote the following information:

• Green - unit powered on

• Amber - continuous illumination im-

plies oven has reached operating temp. Within ±6°C of setpoint

• Green - Flame on

must be set to ON in "Light Flame" display screen under Basic Controls and oven temperature must be at least 85°C.

• Green - purge air system intact (it has filled five volumes of the module interior)

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

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

15. Check and re-adjust the internal pressures if required.

16. The unit is ready for operation.

3-3 BINDING

To achieve full coordination between Analyzer Modules and associated I/O Modules, the user must bind those components together in the System Set Up portion of the Technical Configuration Menu in software.

3-4 CALIBRATION

Calibration gas setup is as follows:

1. Set oven temperature setpoint.

2. Apply regulated air at a pressure be-

tween 10 and 25 psig.

3. Allow case, oven, and sample tem-

peratures to stabilize.

4. Supply heated zero gas to sample

inlet. Adjust external flow controller or throttle valve so that the sample inlet pressure is between 5 and 9 psig., 7 nominal.

2. Press the MENUS softkey to enter the Main Menu

3. Verify the fuel type in the Miscellaneous Control Parameters menu (under the Technical Configuration menu structure, select the following from the Main Menu Diagnostic menus, Analyzer Module Diagnostics and then Miscellaneous Control Parameters).

4. Verify the capillary type in the Analyzer Manufacturing Data menu (under the Technical Configuration menu structure, select the following from the Main Menu Technical Level Configuration, Service Menus, Manufacturing Data, Analyzer Module Data).

5. In the Calibration Gas List the Main Menu

, select Expert Controls

menu (from

and Setup, Analyzer Module Setup, then Calibration Gas List), enter necessary data, including the Operational Sample Pressure and the Calibration Gas HC Response Factor. Common HC factor s are: methane (CH

1.90, propane (C

), 1.0, ethane (C2H6),

), 3.00. These fac-

3H8

tors are not used to compensate the reading, but are used to select the proper preamp sense resistor.

5. Supply heated span gas to sample input. Repeat adjustment described in step 3. The reading of the sample pressure, oven, and sample temperatures should be the same as that used during the adjustment of the zero gas.

See Section 2-4g on page 2-3 for a description of the method for choosing calibration zero and span gases.

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

1. If more than one Analyzer Module is

functional and the split Run Mode display is shown, press the DISPLAY softkey until the desired Analyzer's Run

6. Press HOME to re-enter the Main Menu enter the Basic Controls menu, select desired range, introduce zero gas and allow its response to stabilize, press the ZERO softkey to enter the Analyzer Zero menu, press ZERO again and wait.

7. Press the SPAN softkey to enter the Analyzer Span

menu, introduce span gas and allow its response to stabilize, press SPAN again and wait.

8. Repeat steps 6 and 7.

9. Press the HOME softkey to re-enter the Main Menu.

10. Press DISPLAY softkey for the Run Mode display.

Mode display is acquired.

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

Model NGA2000 HFID

Instruction Manual

748297-E

June 2003

If the user is unable to calibrate the Analyzer Module (i.e., when ZERO or SPAN is initiated, nothing happens), several possible solutions present themselves. One solution relates to the use of an incorrect gas for zeroing or spanning (e.g., using a high concentration gas to zero or a zero gas to span the Analyzer Module). Simply recalibrating with the appropriate gas(es) will not correct the problem because the ZERO OFFSET or SPAN FACTOR has been set to an extreme value in the process.

To remedy the problem, do the following:

1. Verify that correct zero and span calibration gases are being used properly. If so, attempt to recalibrate according to instructions at the beginning of Section 3-4 on page 3-4, ensuring that the oven, sample and case temperatures and displayed measurement reading are stable before initiating the calibration routine. If incorrect gases were used in the initial, failed calibration, skip to Step 2.

Supply heated sample gas to SAMPLE INLET. Adjust external flow controller or throttle valve so that the sample inlet pressure is between 5 and 9 psig, 7 psig nominal. The reading on the SAMPLE pressure gauge and sample and oven temperatures should be the same as that used during adjustment of the zero and span calibration gas control.

Adjust the Range Number setting. The Analyzer Module will now automatically and continuously output the measured hydrocarbon content of the sample. Output is in terms of the particular hydrocarbon present in the span gas. Note that readings obtained during operation depend on the concentration of total hydrocarbons in the sample.

If maximum sensitivity is required from the HFID Analyzer Module, use an optimum combination of settings on the FUEL, and AIR pressure regulators. Settings must be determined experimentally, but the curves in Figure 3-1 on page 3-7 and Figure 3-2 on page 3-7 may be used as guides.

2. Make the following selections from the Main Menu Analyzer Module Setup, then Calibration Parameters. Disable Calibration Adjustment Limits.

3. Recalibrate the analyzer module according to instructions at the beginning of section 3-4 on page 3-4, ensuring that oven, sample, and case temperatures and displayed measurement reading are stable before initiating the calibration routine.

4. Enable Calibration Adjustment Limits in the Calibration Parameters menu.

If the range selections straddle 725 ppm, CH

, the zero and span calibration for each

range must be done separately.

3-5 ROUTINE OPERATION

After case, oven, and sample temperature stabilization, calibration, and binding, proceed as follows:

: Expert Controls and Setup,

Note

The Analyzer Module will not allow the user to increase the upper limit of a range beyond the "maximum range" software setting. To change the "maximum range" value, select the following from the Main Menu tion Menu, Service Menus, Manufacturing Data, and Analyzer Module Data. Select Maximum Range, and use the arrow keys to scroll the indicated value. The same applies for Minimum Range settings.

During shutdown, always turn off fuel gas first, then the air and sample gases. The flame can also be turned off by setting Ignition System Enable to "Off" in the Light Flame menu (under Basic Controls). Subsequently, remember to set Ignition System Enable to "On" before attempting to ignite the flame.

After initial startup, or startup following a prolonged shutdown, the Analyzer Module requires about one day's continuous operation to stabilize. For several days afterwards, calibrate daily. The frequency of subsequent calibrations can be reduced as experience dictates, consistent with the accuracy requirements of the particular application.

: Technical Configura-

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

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

3-6 SAFETY SYSTEM

The HFID Analyzer Module safety system will not allow ignition or continuous burner function unless the following conditions are present:

• The internal purge gas pressure is at least 380 hPa - gauge (5.5 psig). (Monitor display message, Purge Gas Pressure in Physical Measurements for proper setting.)

• Flow rate for purge air in is at least 16 L/min. and case pressure is greater than 0.5 inches of water. (Monitor display message, Purge Gas (ON) in Miscellaneous Control Parameters menu for correct state. Proper sealing hardware must be used in order to obtain the required purge air in flow rate and case pressure).

menu,

• Five case volumes of purge air have been achieved and the three above conditions are present. The time duration to achieve a safe system is a minimum of 6 min. The elapsed time can be monitored in the Technical Startup Analyzer menu. (Monitor the Purge Air Green LED (ON), Purge Control Status (ON), or Purge Air Alarm for indication of the state of the safety system.)

As stated above, proper sealing hardware is crucial to the successful operation of the safety system. Therefore, a specific torque sequence (shown in Figure 3-3 on page 3-8) must be followed when the front panel of the module is being reinstalled after removal. All front and rear panel screws must be installed.

Note

Do not over-torque rear panel screws.

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

Model NGA2000 HFID

)

Instruction Manual

748297-E

June 2003

1.0

0.8

RESPONSE

(100 ppm CH

fullscale)

0.6

0.4

0.2

IR: 30 psig (2064 hPa

IR: 20 psig (1376 hPa)

IR: 10 psig (688 hP a)

SAMPLE: 100 ppm CH4 in N

at 3.5 psig (241 hP a)

344

688

1032

1376

1726

psig

FUEL PRESSURE

hPa

Figure 3-1. Typical Curves of Module Response vs. Pressure Setting on Fuel Pressure Regulator

2064

1.0

0.8

FUEL: 30 psig ( 2064 hP a ) H

FUEL: 25 psig ( 1726 hP a ) H

RESPONSE

(100 ppm CH

fullscale)

0.6

0.4

0.2

FUEL: 20 psig ( 1376 hP a ) H

SAMPLE: 100 ppm CH4 in N

at 3.5 psig (241 hP a)

344

688

1032

1376

1726

2064

psig

AIR PRESSURE

hPa

Figure 3-2. Typical Curves of Module Response vs. Pressure Setting on Air Pressure Regulator

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

Instruction Manual

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DISPLAY MESSAGE DESCRIPTION TYPE

AIR FET AIR PRESS BAIR FLOW BAROMETER BFUEL FLOW BLOCK FET CASE TEMP CRUDE NOISE CURRENTRNGHI CURRENTRNGLO CURRENTSFAC FLAME TEMP FUEL PRES LIN ERROR N15 VOLTS P10 VOLTS P15 VOLTS POL VOLTS SAMP PRES CALRESULT PURGE AIR SW ERROR

Model NGA2000 HFID

FID Air FET current WARNING FID Air Pressure WARNING Burner Air Flow WARNING System Barometer WARNING Burner Fuel Flow WARNING Heater current WARNING Case Temperature WARNING Calculated Noise WARNING Current, High Range WARNING Current, Low Range WARNING Current Range WARNING Flame Temperature WARNING Fuel Pressure WARNING Linearizer Error WARNING Power Supply -15V WARNING Power Supply +10V REF WARNING Power Supply +15V WARNING Polarizing Volts WARNING Sample Pressure WARNING Calibration Error FAILURE FID Purge Air FAILURE Software Error FAILURE

Table 3-1. HFID Analyzer Module Alarms

6 1 4

2 3 5

Torque Sequence:

Screw #1, 4 to 5 turns Screw #2, 4 to 5 turns Screw #3, 4 to 5 turns Screw #4, 4 to 5 turns Screw #5, 4 to 5 turns Screw #6, 4 to 5 turns

Repeat torque sequence until all screws are tight.

The gasket must fill in between the front panel plate and the enclosure.

Figure 3-3. Front Panel Torque Sequence

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

Instruction Manual

748297-E

Model NGA2000 HFID

June 2003

SECTION 4

MAINTENANCE AND TROUBLESHOOTING

WARNING

QUALIFIED PERSONNEL

1. Remove power to the unit; shut off gases and disconnect lines. Allow module to cool.

This equipment should not be adjusted or repaired by anyone except properly qualified service personnel.

4-1 OVERVIEW

This section contains instructions and procedures for troubleshooting and maintaining the HFID analyzer module. To access the internal components of the analyzer module, perform the following:

PURGE AIR OUT

REGULATED AIR IN

WARNING

BURNER AIR IN PURGE AIR IN

WARNING ATTENTION

HEATED SAMPLE BYPASS

BURNER EXHAUST OUT

HEATED SAMPLE IN

FUEL IN PRESSURE RELIEF VALVE

Cover/Rear Panel Securing Screws (6)

Cover

Securing Screw (4)

2. Refer to Figure 4-1 below. Remove the six screws securing the front panel, then the six screws securing the cover to the rear panel. Slide cover towards rear panel to remove. Loosen four screws securing inner insulation shield to base, lift up to remove.

Figure 4-2 on page 4-2 illustrates the locations of major components of the HFID.

Insulation Shield

Front Panel Securing Screws (6)

Figure 4-1. Removal of Cover and Insulation Shield

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Instruction Manual

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Rear Panel Assembly 656954

Oven Assembly 659551

Model NGA2000 HFID

Electronics Assembly 656943

DC Power Supply Module Assembly 657413

Fan Assembly 657414

Fixed Flow Controller Assembly 657434

Front Panel Assembly 656949

Figure 4-2. Locations of Major Assemblies of the HFID

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

Model NGA2000 HFID

4-2 COMPONENT REPLACEMENT

Instruction Manual

748297-E

June 2003

cal cables, noting location of mating connectors for re-installation.

a. Oven

Though the oven can be replaced as a complete unit, all internal components are field replaceable.

Oven Removal

Refer to Figure 4-3 below, disconnect the oven's three gas lines and seven electri-

Note DO NOT remove the fittings from the gas lines on the detector.

Remove the two hex nuts securing the oven to the chassis and the two screws securing oven to the rear panel. Lift oven assembly from analyzer.

Oven Assembly 659551

Figure 4-3. Removal of Oven from Chassis

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Instruction Manual

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Model NGA2000 HFID

Oven Disassembly

1. Refer to Figure 4-4A on page 4-5. Remove the four retaining screws on the oven cover, remove cover.

2. Remove the two screws and one nut securing the outer oven front panel to the outer oven, remove front panel.

3. Remove the nuts and ferrules from sample in and sample bypass out.

CAUTION

PREAMP CONNECTORS

The electrical preamp connectors are fragile, handle with care to avoid breaking solder connection.

4. Refer to Figure 4-4B on page 4-5. Remove the two nuts and washers from the electrical preamp connectors on the inner oven front panel. Do not unsolder these connections.

Temperature Sensor

1. Refer to Figure 4-4A on page 4-5. Remove the four screws on the oven cover, remove cover.

2. Refer to Figure 4-5 below. Remove the burner cap retainer.

3. Disconnect the temperature sensor wiring connector, note location.

4. Remove the temperature sensor.

5. Insert replacement sensor.

Note The leads of the temperature sensor must be leading away and down from the sensor to enable proper fit of burner cap retainer.

6. Install the burner cap retainer. U-slot

must be located above temperature sensor.

7. Re-attach wiring connector.

5. Unscrew the three screws from inner front panel and remove it.

6. Refer to Figure 4-4C on page 4-5. Remove the two hex nuts securing the burner to the bottom of the inner oven.

7. Disconnect the sample input and output bypass fittings.

8. Lift the burner/thermal block up and out, while disconnecting exhaust.

Reverse procedure for installation.

b. Burner Sensor, Detectors and Ignitor

This section covers burner components which can be replaced without removal of oven from the chassis.

8. Install oven cover.

RTD Detector

1. Refer to Figure 4-4A on page 4-5. Remove the four screws on the oven cover, remove cover.

2. Refer to Figure 4-5 below. Loosen the set screw securing RTD detector.

3. Disconnect RTD detector wiring connector, note location.

4. Gently grasp RTD detector wires and pull out of hole.

5. Insert replacement RTD detector into hole, snug down set screw.

6. Re-attach wiring connector.

7. Install oven cover.

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

Model NGA2000 HFID

Nuts and Ferrules (2 ea)

Outer Oven

For clarity, outer oven not shown in Figures B and C.

Outer Oven Front Panel 657356

Oven Cover 657105 (with insulation 657346)

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June 2003

Exhaust

Inner Oven Retaining Screw (2) and Washer (2)

Inner Oven

Inner Oven Front Panel 657352

Preamp connector nut, washer (typ 2)

Burner 657359

Spring, Heated Bridge 904294

Heated Bridge 659555

Heater/Cable Assembly 659643

Jam Nuts 659550

Insulating Washers 073737

Figure 4-4. Oven Assembly

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Model NGA2000 HFID

Ignitor

1. Refer to Figure 4-4A on page 4-5. Remove the four screws on the oven cover, remove cover.

2. Refer to Figure 4-5 below. Disconnect the ignitor wiring connector, note location.

3. Using an open-end wrench, unscrew the ignitor assembly from the burner. Verify that o-ring is also removed.

Flameout Sensor

1. Refer to Figure 4-4A on page 4-5. Remove the four screws on the oven cover, remove cover.

2. Refer to Figure 4-5 below. Disconnect the flameout detector wiring connector, note location.

3. Lift up the burner cap until flameout sensor is accessible. Using an openend wrench, unscrew the flameout detector from the burner. Verify that

4. Install replacement ignitor and new o-

o-ring is also removed.

ring. Using open-end wrench, snug down. Do not over-tighten!

4. Install replacement flameout detector and new o-ring. Using open-end

5. Re-attach wiring connector.

wrench, snug down. Do not over- tighten!

6. Install oven cover

5. Re-attach wiring connector.

6. Install oven cover.

Retainer, Burner Cap

O-Ring 903736

Burner Cap

Temperature Sensor 657468

O-Ring 903737

Ignitor Assembly 657205

Flameout Sensor 657199

RTD Detector 657063

The components shown can be replaced without removing burner/thermal block from oven. Oven not shown for clarity. Thermal block shown in phantom for clarity.

Set Screw M3X0.5 x 10mm 903125

Figure 4-5. Burner - Sensor, Flameout Detector, RTD Detector and Ignitor

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

Model NGA2000 HFID

c. Burner Internal Components

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June 2003

2. Remove burner/thermal block from oven per Section 4-2b on page 4-4.

WARNING

BURNER CONTAMINATION

Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates.

3. Refer to Figure 4-6 below. Disconnect sample capillary nut at base of burner.

4. Remove screw securing thermal block to burner.

Carefully pull burner away from thermal

Disassembly of Burner/Thermal Block

1. Remove oven from analyzer module per Section 4-2a on page 4-3.

block.

Burner

Sample capillary input

Thermal Block

Sample capillar

Figure 4-6. Burner/Thermal Block Disassembly

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

Instruction Manual

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Model NGA2000 HFID

Replacing Burner Jets

Disassemble the burner only if contaminants are evident. Combustion products or other contaminates which accumulate inside the burner may form electrical leakage paths between the collector and the burner contact, resulting in noisy readings.

If the analyzer module is to be operated at the highest sensitivity, traces of such contaminates can cause erroneous readings. For best performance, replace the burner jet follows:

1. Remove oven from analyzer module per Section 4-2a on page 4-3.

2. Remove burner/thermal block from oven per 4-2b on page 4-4.

3. Remove thermal block from burner per Section 4-2c on page 4-7.

4. Refer to Figure 4-7A below. Remove screws (2) holding burner cap retainer, remove retainer.

WARNING

BURNER CONTAMINATION

Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates.

Burner Cap Retainer

Combustion Chamber

Gasket 656931

Burner Cap

O-Ring 904373

Burner Base

Figure 4-7. Burner Disassembly

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

Model NGA2000 HFID

Instruction Manual

748297-E

June 2003

5. Holding burner base, lift burner cap off of assembly, set aside.

6. Remove gasket.

8. Refer to Figure 4-8 below. Lift air baffle out of burner base.

9. Remove the sample jet and gasket from the bottom of the burner base.

7. Refer to Figure 4-7B on page 4-8. Holding burner base, lift combustion chamber off, set aside.

10. Remove the jet nut. Grasp jet assembly and lift out (along with upper gasket) of burner base. Remove bottom gasket.

Air Baffle (Ref) 102260 See Detail

Nut, Jet 657016

Gasket 102273

Jet Assembly 657012

Gasket 102256

Air Baffle

End bent to raise it above the tab a distance equal to the hei

ht of the tab.

Sample Jet 657005

≈ .06

Position with tab over the air hole (approximately 1/16” to the right).

Figure 4-8. Burner Jets

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

Instruction Manual

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Model NGA2000 HFID

Installation

WARNING

BURNER CONTAMINATION

Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates.

1. Install new lower gasket, jet assembly and upper gasket into burner base, finger-tight jet nut.

2. Install new sample jet (with gasket) and tighten.

3. Tighten jet nut.

4. Install air baffle per Figure 4-8 on page 4-9.

Note Incorrect installation of air baffle will cause ignition failure.

5. See Figure 4-7B on page 4-8. Insert

new o-ring into burner base.

6. Set combustion chamber into burner

base being careful not to move air baffle.

7. See Figure 4-7A on page 4-8. Insert

new gasket on combustion chamber, install burner cap and burner cap retainer, torque screws to 6 inch lbs.

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

Model NGA2000 HFID

d. Thermal Block

The sample RTD can be replaced with the thermal block attached to burner and mounted in oven. The cartridge heater and thermostat are also replaceable with thermal block secured to burner, but must be removed from the oven.

Sample RTD

1. Refer to Figure 4-4A on page 2-1. Remove the four screws securing the oven cover, remove cover.

Instruction Manual

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June 2003

2. Disconnect the sample RTD wiring connector, note location.

3. Refer to Figure 4-9 below. Remove the two screws securing the sample RTD, pull sample RTD out.

4. Install replacement sample RTD, secure with screws.

5. Attach sample RTD wiring connector.

6. Re-attach oven cover.

Sample RTD 657061

Cartridge Heater 659643

Thermostat 657065

Figure 4-9. Thermal Block – Sample RTD, Cartridge Heater and Thermostat

Cartridge Heater

1. Remove oven from analyzer module per Section 4-2a on page 4-3.

2. Remove burner/thermal block from oven per Section 4-2b on page 4-4.

3. Refer to Figure 4-9 above. Loosen retaining set screw, pull out cartridge heater.

4. Install replacement cartridge heater, snug down set screw.

5. Install burner/thermal block into oven.

6. Install oven into analyzer module.

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Instruction Manual

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Model NGA2000 HFID

Thermostat

1. Remove oven from analyzer module per Section 4-2a on page 4-3.

2. Remove burner/thermal block from oven per Section 4-2b on page 4-4.

3. Refer to Figure 4-9 on page 4-11. Remove the two retaining screws, pull thermostat out.

4. Install replacement thermostat, attach with the two retaining screws.

5. Install burner/thermal block into oven.

6. Install oven into analyzer module.

Sample Capillary

1. Remove oven from analyzer module per Section 4-2a on page 4-3.

2. Remove burner/thermal block from oven per Section 4-2b on page 4-4.

3. Remove burner from thermal block per Section 4-2c on page 4-7.

4. Refer to Figure 4-10 below. Remove the two screws securing the capillary cover to thermal block, remove cover.

5. Remove capillary nut, remove capillary.

6. Install replacement capillary.

7. Insert capillary into thermal block. The capillary may require bending to fit.

8. Install cover.

Capillary

Figure 4-10. Thermal Block Assembly

Cover

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

Model NGA2000 HFID

e. Electronics Assembly

The electronics assembly must be removed from the chassis if replacement of any of the following components is necessary:

Power Supply Board Safety Board Computer Analysis Board Preamp Assembly Sensor Board Case Temperature Sensor Case Pressure Switch

Instruction Manual

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June 2003

1. Remove the hex nut and screw as shown in Figure 4-11 below.

2. Lay electronics assembly on bench, do not disconnect cables or tubing.

Electronics Assembly 656943

Screw

Hex Nut

Figure 4-11. Removing Electronics Assembly from Chassis

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Instruction Manual

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Preamp Assembly 656945

Case Pressure Purge Switch 903690

Computer Analysis Board 659149

Sensor Board 657060

Safety Board 657499

Case Temperature Sensor 656026

Model NGA2000 HFID

Power Supply Board 655764

Figure 4-12. Electronics Assembly – Exploded View

Printed Circuit Boards

When replacing a circuit board, the following procedure is recommended:

1. Per Section 4-2e on page 4-13, remove securing hardware from electronics assembly and lay on bench.

2. Remove securing hardware from printed circuit board to be replaced, do not disconnect cable(s).

3. One at a time, remove the wiring connectors and attach to replacement board.

Mount replacement board to electronics assembly.

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Instruction Manual

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Case Temperature Sensor

1. Per Section 4-2e on page 4-13, remove securing hardware from electronics assembly and lay on bench.

2. Disconnect case temperature sensor cable.

3. Remove screw securing cable clamp holder to signal board.

4. Remove case temperature sensor from cable clamp holder.

5. Per Figure 4-13 below insert replacement case temperature sensor into cable clamp holder.

Re-assemble to signal board mounting screw.

Center

sensor in

cable clamp

Figure 4-13. Case Temperature Sensor Installation

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Instruction Manual

748297-E June 2003

Model NGA2000 HFID

Case Pressure Purge Switch

1. Per Section 4-2e on page 4-13, remove securing hardware from electronics assembly and lay on bench.

2. Disconnect the two electrical terminals, note location.

Case Pressure Purge Switch 903690

The bracket does not have to be removed from the electronics assembly for this procedure.

3. Disconnect tube at pressure switch.

4. Remove mounting screws (2) and washers (2).

Reverse procedure for installation of replacement switch.

Figure 4-14. Case Pressure Purge Switch Installation

4-16 Maintenance and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 HFID

Preamp Assembly

1. Per Section 4-2e on page 4-13, remove securing hardware from electronics assembly and lay on bench.

2. Disconnect and note location of cables.

Instruction Manual

748297-E

June 2003

4. Remove the lower bracket from the preamp assembly and install on replacement preamp assembly.

5. Slide replacement preamp assembly into top bracket and secure with mounting hardware.

Top Bracket

Preamp Assembly 656945

3. Remove the two screws and washers from the top bracket and slide the preamp assembly out.

Bottom Bracket

6. Re-connect cables.

Figure 4-15. Preamp Assembly Installation

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Instruction Manual

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f. Fan Assembly

1. Disconnect and note location of cables.

Model NGA2000 HFID

2. Remove the two hex nuts securing the fan to the chassis, lift fan assembly out.

Fan Assembly 657414

Figure 4-16. Fan Assembly Installation

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Model NGA2000 HFID

g. Flow Controller

1. Disconnect the all tubing and wiring connectors, note locations.

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June 2003

2. Remove the four hex nuts securing the flow controller assembly to the analyzer module chassis.

Flow Controller Assembly 657434

Figure 4-17. Flow Controller Replacement

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-19

Instruction Manual

748297-E June 2003

Remove and discard bracket supplied with regulator, assembly as shown.

Regulated Air In

Remove red cap after installation

Model NGA2000 HFID

Regulator 250 psi 023382

FLOW

Regulated Air Out

Sample Sensor 656418

Figure 4-18. Flow Controller Assembly – Exploded View

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Model NGA2000 HFID

h. DC Power Supply Module

1. Disconnect and note location of all wiring to DC power supply module.

Instruction Manual

748297-E

June 2003

2. Remove the two hex nuts securing module to chassis, remove module.

Figure 4-19. DC Power Supply Module Replacement

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-21

Instruction Manual

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i. Front Panel Components

The following components are mounted to the front panel:

LON/Power Module Manual Ignite Toggle Switch LED Indicator Assembly Purge Air Regulator

Connector fitting

Air Measurement Restrictor 656888

Air Ignite Restrictor 655794

Burner Air Sensor 656443

Fuel Sensor 656444

Burner Air Solenoid Valve 656219

Diffuser 657548

Purge Air Flow Switch 656533

Purge Air Regulator 871672

Male Adapter Fitting

Manual Ignite Toggle Switch 657053

Sensor Fittings 657412

Burner Air Regulator 902832

Fuel Regulator 902832

O-Rings 008025

Figure 4-20. Front Panel – Exploded View

Model NGA2000 HFID

Purge Air Flow Switch Burner Air Solenoid Valve Burner Air Regulator Fuel Regulator Burner Air Sensor Fuel Sensor Air Ignite Restrictor Air Measurement Restrictor

Regulator Mounting Nut

Regulator Mounting Bracket

LON/Power Module 656560

Plugs

O-Ring 010177

LED Indicator Assembly 657029

O-Ring 011167

Toggle Switch Seal 898980

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Instruction Manual

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Replacing front panel components

1. To access components, remove the four front panel mounting screws (two on front, one on each side).

2. Remove the burner air regulator and fuel regulator mounting nuts.

4. The front panel can now be pulled away from the chassis.

Note The wiring from front panel components is still connected. Do not disconnect unless replacing that component.

3. Remove the purge air regulator mounting bracket screws.

Front panel attaching screw (opposite side also)

Front panel attaching screws

Figure 4-21. Accessing Front Panel Components

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-23

Instruction Manual

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Model NGA2000 HFID

LON/Power Module

1. Disconnect wiring connectors, note locations.

2. Refer to Figure 4-20 on page 4-22. From the outside of the front panel, remove the two mounting screws.

3. Install replacement module in reverse order.

LED Indicator Assembly

1. Disconnect wiring connector, note location.

2. Refer to Figure 4-20 on page 4-22. From the inside of the front panel, remove the two hex nuts securing LED indicator assembly to front panel. Remove indicator assembly and orings (four).

3. Inspect o-rings for damage, replace if necessary. Install o-rings on replacement indicator assembly, mount assembly on mounting studs with hex nuts.

4. Re-connect wiring connector.

Burner Air Sensor

1. Disconnect wiring connector, note location.

2. Using an open-end wrench to hold the sensor fitting while using another open-end wrench to remove the sensor.

3. Replace the Teflon pipe thread tape on the treads of the sensor fitting.

4. Install sensor onto sensor fitting.

5. Re-connect wiring connector.

Fuel Sensor

1. Disconnect wiring connector, note location.

2. Using an open-end wrench to hold the sensor fitting while using another open-end wrench to remove the sensor.

3. Replace the Teflon pipe thread tape on the treads of the sensor fitting.

Manual Ignite Toggle Switch

1. Disconnect wiring connector, note location.

2. Refer to Figure 4-20 on page 4-22. From the outside of the front panel, remove the toggle switch seal.

3. Pull the switch and o-ring out from inside the front panel.

4. Inspect o-ring for damage, replace if necessary. Install o-ring on replacement switch, insert through front panel from the inside.

5. Install switch seal.

6. Re-connect wiring connector.

4-24 Maintenance and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

4. Install sensor onto sensor fitting.

5. Re-connect wiring connector.

Model NGA2000 HFID

Instruction Manual

748297-E

June 2003

Burner Air and Fuel Regulators

1. Disconnect the two tubes and the sensor fitting on the rear of the regulator, note locations.

2. Replace the Teflon pipe thread tape on the threads of the sensor fitting.

3. Remove the regulator and o-ring.

4. The replacement regulator comes with two panel mounting nuts, remove both and discard one of them.

5. Inspect o-ring for damage, replace if necessary. Install o-ring onto regulator threaded shaft.

6. Insert regulator into front panel, secure with mounting nut.

7. Re-attach the three tubes.

Purge Air Regulator

1. Remove the regulator mounting nut, remove mounting bracket.

2. Loosen nut on tee fitting attached to purge air flow switch.

3. Disconnect tube at elbow, remove regulator.

4. Remove the two plugs, elbow and male adapter fittings from the regulator.

5. Replace the Teflon pipe thread tape on the two plugs, the elbow and the male adapter and install into replacement regulator.

Purge Air Flow Switch and Diffuser

1. Unscrew flow switch from tee fitting.

2. Replace Teflon pipe thread tape on tee fitting.

3. Remove diffuser from flow switch and install into replacement flow switch.

4. Install replacement flow switch.

5. Install purge switch onto tee fitting.

6. Re-connect tubes.

Burner Air Solenoid Valve

1. Disconnect the tube at the top elbow fitting.

2. Disconnect the tube at the tee fitting, remove valve analyzer module.

3. Holding the air ignite restrictor, unscrew the solenoid valve.

4. On the solenoid valve, remove the connector fitting.

5. Replace the Teflon pipe thread tape on the elbow, connector and restrictor.

6. Verify replacement solenoid valve wires (flat side of body) are exiting on the same side as the COM port as shown in Figure 4-20 on page 4-22. If not, use an open-end wrench to hold the N.O. hex port while rotating body.

7. Install air ignite restrictor into N.C. port.

6. Connect tube to elbow, insert male adapter into tee fitting.

7. Install mounting bracket onto regulator, hand snug mounting nut.

8. Attach mounting bracket to front panel, tighten regulator mounting nut.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-25

8. Install elbow into COM port and connector fitting into N.O. port.

9. Re-connect tubes.

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

Air Ignite Restrictor

1. On the burner air solenoid valve: a. Disconnect the tube at the top

elbow fitting. b. Disconnect tube at tee fitting. c. Lift solenoid valve from ana-

lyzer module.

2. Disconnect tube going to air ignite restrictor.

3. Remove restrictor from solenoid valve.

4. Add Teflon pipe thread tape to replacement restrictor, install into solenoid.

5. Re-connect tubes to restrictor, elbow and tee fitting.

4-26 Maintenance and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 HFID

j. Rear Panel Components

The following components are mounted to the rear panel:

Fuel In 2-Way Solenoid Valve

VIEW FROM INSIDE ANALYZER MODULE

VIEW FROM OUTSIDE ANALYZER MODULE

Filter, Burner Air In 017154

Restrictor, Heated Sample Bypass Out – 10 Micron 619615

Solenoid Valve, Fuel In 656218

Restrictor, Heated Sample In – 40 Micron 619616

Instruction Manual

748297-E

June 2003

Regulated Air In Check Valve Burner Air In Filter Heated Sample Bypass Out Restrictor Heated Sample In Restrictor

Check Valve, Regulated Air In 903728

Figure 4-22. Rear Panel Components

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-27

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

Fuel In 2-Way Solenoid Valve

1. Disconnect wiring solenoid valve wiring connector, note location.

2. Inside the analyzer module, disconnect the tube going to the connector on the “out” port of the solenoid valve.

3. On the rear of the analyzer module at the fuel in port:

a. Disconnect the fuel in tube. b. Remove nuts and washers.

4. Remove solenoid valve from analyzer module

5. Remove the fittings from the solenoid valve and replace the Teflon pipe thread tape.

6. Verify that body of replacement solenoid valve is oriented as shown in Figure 4-22 on page 4-27. If not, rotate till wires are in-line with “out” port.

7. Install fittings into replacement solenoid valve, re-install in analyzer module.

Heated Bypass Sample Out and Heated Sample In Restrictors

1. On the outside of the rear panel, disconnect tube and remove nut.

2. Insert a small spade screwdriver into the bulkhead and remove the restrictor.

3. Install in reverse order.

Regulated Air In Check Valve

1. Disconnect tube at elbow.

2. Remove check valve from female connector.

3. Remove elbow from check valve.

4. Add Teflon pipe thread tape to check valve threads.

5. Install elbow onto check valve.

6. Install check valve into female connector, verifying orientation of elbow fitting as shown in Figure 4-22 on page 4-27.

Burner Air In Filter

1. Leaving the bulkhead fitting secured to the rear panel, remove the tubes, nuts and ferrules from the fitting.

2. Insert a clean, rigid piece of tube or rod (smaller than .25 inch diameter) into the bulkhead fitting to force out the filter disc.

3. Install the replacement filter in the same manner, through the rear of the bulkhead fitting.

4. Re-connect tubes.

4-28 Maintenance and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 HFID

4-3 TROUBLESHOOTING CHECKLIST

a. Safety System

1. Verify purge supply pressure at bulkhead is between 10 and 20 psig.

2. Check case for leaks.

Instruction Manual

748297-E

June 2003

b. Ignition

1. Verify that the fuel pressure/flow is correct.

2. Verify that the burner air pressure/flow is correct.

3. Verify that the ignitor is generating enough heat.

3. Check burner for leaks.

4. Verify purge pressure sensor tube connection.

5. Verify purge out port is vented to atmospheric pressure.

6. Verify Safety PCB connector J2 is attached.

7. Check for a +24V power glitch.

8. Verify that there is no large vibration shock.

9. Check for external leak in purge line.

10. Verify case pressure is greater than

0.5” of water.

11. Check case for over-pressurization.

12. Verify the purge flow/pressure switch harness is routed away from the solenoid valves.

13. Verify the purge timer is counting.

4. Verify the burner exhaust is vented to atmosphere.

5. Verify safety system has been activated.

6. Verify the manual switch is operating correctly.

7. Verify auto-ignite parameters are properly set.

8. Verify burner is properly sealed.

9. Verify quality of air supply is good.

10. Verify quality of fuel supply is good.

11. Check burner tip for damage.

12. Check air and fuel restrictor for correct flow.

13. Check burner tip alignment.

14. Verify burner cone is tight.

15. Check burner air and fuel lines for leaks.

14. Verify purge timer jumper is correctly installed.

15. Verify Internal purge pressure is greater than 5.5 psig.

16. Verify the purge gas switch has been activated.

Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-29

16. Verify oven temperature is greater than 85°C.

17. Verify the reference thermistor is 100K ohm ±15% at 25°C.

18. Verify that there is +10VDC to the reference thermistor.

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

c. Drift

1. Verify that the sample, burner air,

2. Check that the tubing, regulators,

3. Verify that the oxygen level in the

4. Verify the THC level is correct for

5. Check that the ambient tempera-

6. Verify the burner is clean.

7. Verify temperature of the sample

8. Verify the Preamp PCB is clean.

and fuel supply pressures are constant.

pumps, fittings, and valves are clean of hydrocarbons.

burner air and sample are constant.

the burner air and fuel supply.

ture is changing <10°C per hour.

gas, case, burner, and oven has stabilized.

d. Noise

1. Check that the burner exhaust is free from water condensation.

2. Verify connection to the collector is correct.

3. Verify connection to the polarizing voltage is correct.

4. Check the ambient temperature is changing <10°C per hour.

5. Verify the +24VDC is clean and grounded properly.

6. Verify there are no strong magnetic fields near.

7. Check for excessive vibration.

8. Verify burner exhaust is vented to a constant atmospheric pressure.

9. Verify bypass line is vented to a constant atmospheric pressure.

9. Verify atmospheric pressure at burner exhaust is constant.

10. Verify purge gas pressure is constant.

11. Verify burner has been on and stabilized.

12. Check for gas leaks.

10. Verify purge out port vented to a constant atmospheric pressure.

11. Verify the collector wires are routed away from the heater.

12. Verify the collector wires are clean and not damaged.

4-30 Maintenance and Troubleshooting Rosemount Analytical Inc. A Division of Emerson Process Management

Instruction Manual

Model NGA2000 HFID

SECTION 5

REPLACEMENT PARTS

WARNING

PARTS INTEGRITY

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

5-1 MATRIX

Each analyzer is configured per the customer sales order. Below is the HFID sales matrix which lists the various configurations available.

To identify the configuration of an analyzer, locate the analyzer name-rating plate. The 12-position sales matrix identifier number appears on the analyzer name-rating plate.

748297-E

June 2003

HFID Heated Flame Ionization Detection Analyzer Module

01 Standard 02 2.3 Version Software 99 Special

A1 Mixed Fuel, 4 Selectable Ranges: 0-10 to 0-10,000 ppm CH4 A2 Mixed Fuel, 4 Selectable Ranges: 0-100 to 0-10,000 ppm CH4 H1 Mixed Fuel, 4 Selectable Ranges: 0-100 ppm to 0-5% CH4 99 Special Calibrated Ranges

00 None

B1 System (10 ft LON and Pwr AM to 30A PS) Code Special Requirements

00 None G1 Customer Option 99 Special

HFID 01 A1 A1 00 Example

Code Software Version

Code Configuration Identifier

Code Cable Selection

A1 Standard (3 ft LON and Pwr AM to Platform)

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

Instruction Manual

748297-E June 2003

5-2 REPLACEMENT PARTS

a. General

813344 Fuse, 6A 903107 657029 LED Indicator Assembly 656560 LON/Power Module 657413 DC Power Supply Module 657053 Manual Ignite Switch Assembly 657414 Fan Assembly 656943 Electronics Assembly

b. Pneumatics

017154 Filter, .25 DIA x .06 -.09 THK 50-100 Microns (Burner Air) 902832 Regulator 0 - 60 psi (Fuel and Burner Air) 657434 Fixed Flow Controller Assembly

871672 Purge Air Regulator 655794 Air Ignite Restrictor 656888 Air Measurement Restrictor 656443 Burner Air Sensor 656444 Fuel Sensor 656418 Flow Control Sample Pressure Sensor 656219 Burner Air 3-Way Solenoid Valve 656218 Fuel In Solenoid Valve 903690 Case Pressure Purge Switch 656533 Purge Air Flow Switch 903728 Regulated Air In Check Valve 903647 Case Pressure Relief Valve

Fuse, Thermal Cutoff 72° (2 Required - Safety and Power Supply PCB’s)

659149 Computer Board 656945 Preamp Assembly 657499 Safety Board 655764 Power Supply Board 657060 Sensor Board 656026 Case Temperature Sensor

023382 Regulator 250 psi 656418 Sample Sensor

Model NGA2000 HFID

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

Model NGA2000 HFID

c. Oven Components

659551 Oven Assembly

657359 Burner Assembly

657205 Ignitor Assembly 903736 O-Ring (Ignitor Assembly) 657063 RTD Detector 903125 Set Screw M3X0.5 x 10mm (RTD Detector) 657468 Temperature Sensor 657199 Flameout Sensor 903737 O-Ring (Flameout Sensor) 656931 Gasket 904373 O-Ring 102260 Air Baffle 657016 Jet Nut 102273 Gasket 657012 Jet Assembly 102256 Gasket 657005 Sample Jet

659614 Thermal Block Assembly

657486 Capillary, Mixed Fuel (Lo) 9.7 cc/min @ 3.5 psig 657550 Capillary, Mixed Fuel (Hi) 2.5 cc/min @ 3.5 psig 657061 Sample RTD 659618 Heated Bypass Sample Out Restrictor Assembly – 10 Microns

659619 Heated Sample In Restrictor Assembly – 40 Microns 657065

659643 Cartridge Heater

Instruction Manual

748297-E

June 2003

659615 Restrictor, Heated Bypass Sample Out – 10 Microns 659616 Restrictor, Heated Sample In – 40 Microns

Thermostat 450°F

Rosemount Analytical Inc. A Division of Emerson Process Management Replacement Parts 5-3

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

5-4 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management

Model NGA2000 HFID

RETURN OF MATERIAL

6-1 RETURN OF MATERIAL

If factory repair of defective equipment is required, proceed as follows:

1. Secure a return authorization from a Rosemount Analytical Inc. Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted.

Rosemount CSC (Customer Service Center) will provide the shipping address for your instrument.

In no event will Rosemount be responsible for equipment returned without proper authorization and identification.

2. Carefully pack the defective unit in a sturdy box with sufficient shock absorbing material to ensure no additional damage occurs during shipping.

3. In a cover letter, describe completely:

• The symptoms that determined the

equipment is faulty.

• The environment in which the equip-

ment was operating (housing, weather, vibration, dust, etc.).

• Site from where the equipment was

removed.

• Whether warranty or non-warranty

service is expected.

• Complete shipping instructions for the

return of the equipment.

4. Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in the Rosemount Return Authorization, prepaid, to the address provided by Rosemount CSC.

Rosemount Analytical Inc.

Process Analytic Division

Customer Service Center

1-800-433-6076

Instruction Manual

748297-E

June 2003

SECTION 6

If warranty service is expected, the defective unit will be carefully inspected and tested at the factory. If the failure was due to the conditions listed in the standard Rosemount warranty, the defective unit will be repaired or replaced at Rosemount’s option, and an operating unit will be returned to the customer in accordance with the shipping instructions furnished in the cover letter.

For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions.

6-2 CUSTOMER SERVICE

For order administration, replacement Parts, application assistance, on-site or factory repair, service or maintenance contract information, contact:

Rosemount Analytical Inc.

Process Analytic Division

Customer Service Center

1-800-433-6076

6-3 TRAINING

A comprehensive Factory Training Program of operator and service classes is available. For a copy of the Current Operator and Service

Training Schedule contact :

Rosemount Analytical Inc.

Process Analytic Division

Customer Service Center

1-800-433-6076

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

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

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

WARRANTY

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

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

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

Limitations of Remedy.

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

Force Majeure.

Seller's direct control.

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

SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY

Instruction Manual

748297-E June 2003

Model NGA2000 HFID

EMERSON PROCESS MAN

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

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

http://www.processanalytic.com

GEMENT

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

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

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

Emerson Process Management ROSEMOUNT NGA2000 HFID User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Model NGA2000 HFID

ESSENTIAL INSTRUCTIONS

TABLE OF CONTENTS

LIST OF ILLUSTRATIONS

LIST OF TABLES

PREFACE

DEFINITIONS

SAFETY SUMMARY

AUTHORIZED PERSONNEL

DOCUMENTATION

COMPLIANCES

GLOSSARY

DESCRIPTION AND SPECIFICATIONS

1-1 OVERVIEW

1-2 TYPICAL APPLICATIONS

1-3 THEORY OF TECHNOLOGY

Figure 1-1. Flame Ionization Detection Technology

1-4 GAS SAFETY FEATURES

1-5 SPECIFICATIONS

a. General

b. Gas Requirements

c. Physical

d. Gas Connections

2-1 UNPACKING

2-2 ASSEMBLY

2-3 LOCATION

INSTALLATION

2-4 GASES

a. Overview

Figure 2-1. Back Panel Connections

b. Pneumatic Connections

d. Burner Air Specification

e. Purge Air Specification

f. Regulated Air Specification

g. Calibration Gases Specification

h. Sample Gas Specification

i. Flow Rate Specification

j. Pressure/Filtration Specification

k. Leak Test

Figure 2-2. Flow Diagram

2-5 ELECTRICAL CONNECTIONS

Figure 2-4. Front Panel Connections, Controls and Indicators

Figure 2-5. HFID Outline and Mounting Dimensions

Figure 2-6. HFID Wiring Diagram

STARTUP AND OPERATION

3-1 OVERVIEW

3-2 STARTUP PROCEDURE

3-3 BINDING

3-4 CALIBRATION

3-5 ROUTINE OPERATION

3-6 SAFETY SYSTEM

Figure 3-1. Typical Curves of Module Response vs. Pressure Setting on Fuel Pressure Regulator

Figure 3-2. Typical Curves of Module Response vs. Pressure Setting on Air Pressure Regulator

Table 3-1. HFID Analyzer Module Alarms

Figure 3-3. Front Panel Torque Sequence

MAINTENANCE AND TROUBLESHOOTING

4-1 OVERVIEW

Figure 4-1. Removal of Cover and Insulation Shield

Figure 4-2. Locations of Major Assemblies of the HFID

4-2 COMPONENT REPLACEMENT

a. Oven

Oven Removal

Figure 4-3. Removal of Oven from Chassis

Oven Disassembly

Temperature Sensor

b. Burner Sensor, Detectors and Ignitor

RTD Detector

Figure 4-4. Oven Assembly

Ignitor

Flameout Sensor

Figure 4-5. Burner - Sensor, Flameout Detector, RTD Detector and Ignitor

c. Burner Internal Components

Disassembly of Burner/Thermal Block

Figure 4-6. Burner/Thermal Block Disassembly

Replacing Burner Jets

Figure 4-7. Burner Disassembly