Rosemount 951C NOx Analyzer-Rev N Manuals & Guides

Rosemount Analytical

ODEL

M

951C

NO

NSTRUCTION MANUAL

I

X ANALYZER

PN 748214

N

OTICE

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.
Alconox is a registered trademark of Alconox, Inc.

SNOOP® is a registered trademark of NUPRO Co.

Manual Part Number 748214-N
September 1997
Printed in U.S.A.

Rosemount Analytical Inc.

4125 East La Palma Avenue

NAHEIM

A

ALIFORNIA

, C

92807-1802

C

ONTENTS

P

REFACE

PURPOSE/SAFETY SUMMARY........................................................................P-1

SPECIFICATIONS - LO RANGE ........................................................................P-4

SPECIFICATIONS - HI RANGE .........................................................................P-5

CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE ....P-6

RETURNING PARTS TO THE FACTORY .........................................................P-6

TRAINING ......................................................................................................P-6

DOCUMENTATION............................................................................................P-6

COMPLIANCES..................................................................................................P-7

CONDENSED STARTUP AND CALIBRATION PROCEDURE..........................P-9

S

ECTION

1.1 OVERVIEW ...............................................................................................1-1

1.2 APPLICATIONS.........................................................................................1-2

S

ECTION

2.1 UNPACKING.............................................................................................2-1

2.2 LOCATION ...............................................................................................2-1

2.3 VOLTAGE REQUIREMENTS...................................................................2-1

2.4 ELECTRICAL CONNECTIONS ................................................................2-2

2.5 GAS REQUIREMENTS ............................................................................2-5

2.6 SAMPLE REQUIREMENTS .....................................................................2-6

2.7 GAS CONNECTIONS...............................................................................2-6

2.8 LEAK TEST ..............................................................................................2-7

1. I

2. I

2.4.1 Line Power Connections.............................................................2-2

2.4.2 Potentiometric Recorder Connections.........................................2-4

2.4.3 Current Recorder Connections....................................................2-4

NTRODUCTION

NSTALLATION

748214-N

September 1997

Rosemount Analytical

i

M

ODEL

951C NOX A

NALYZER

S

ECTION

3.1 FRONT PANEL INDICATORS AND CONTROLS.....................................3-1

3.2 STARTUP PROCEDURE.........................................................................3-2

3.3 CALIBRATION .........................................................................................3-4

3.4 ROUTINE OPERATION...........................................................................3-5

3.5 CONVERTER TEMPERATURE ADJUSTMENT PROCEDURE..............3-5

3.6 MEASUREMENT OF CONVERTER EFFICIENCY..................................3-7

3.7 RECOMMENDED CALIBRATION FREQUENCY....................................3-8

S

ECTION

3. I

3.1.1 Display ......................................................................................3-1

3.1.2 Range Selection.........................................................................3-1

3.1.3 Sample Pressure Gauge............................................................3-2

3.1.4 Ozone Pressure..........................................................................3-2

3.1.5 Zero and Span Potentiometers...................................................3-2

3.1.6 Ozone Interlock ..........................................................................3-2

3.3.1 Zero Calibration..........................................................................3-4

3.3.2 Upscale Calibration ....................................................................3-4

4. T

NITIAL STARTUP AND OPERATION

HEORY

4.1 NITRIC OXIDE DETERMINATION BY CHEMILUMINESCENCE

METHOD ...................................................................................... 4-1

4.2 ANALYZER FLOW SYSTEM....................................................................4-1

4.2.1 Flow of Sample, Standard Gas or Zero Gas to

Reaction Chamber........................................................4-1

4.2.2 Ozone Generation......................................................................4-2

4.3 SIGNAL PROCESSING ELECTRONICS SYSTEM.................................4-2

4.4 ANALYZER THERMAL SYSTEM.............................................................4-3

S

ECTION

5.1 SYSTEM CHECKS AND ADJUSTMENTS................................................5-1

5.2 SERVICING FLOW SYSTEM ..................................................................5-3

5. R

5.1.1 Display Fullscale Span Adjustment............................................5-1

5.1.2 Overall Sensitivity.......................................................................5-2

5.1.3 Ozone Output.............................................................................5-2

5.1.4 Background Current ...................................................................5-3

5.1.5 Excessive Photomultiplier Dark Current.....................................5-3

5.2.1 Cleaning Sample Capillary .........................................................5-3

5.2.2 Ozone Restrictor Fitting..............................................................5-4

OUTINE SERVICING

5.3 PHOTOMULTIPLIER TUBE/REACTION CHAMBER ..............................5-5

ii

Rosemount Analytical

September 1997

748214-N

C

ONTENTS

S

ECTION

5.4 OZONE GENERATION SYSTEM.............................................................5-8

5.5 CONVERTER ASSEMBLY.......................................................................5-9

5.6 SERVICING ELECTRONIC CIRCUITRY..................................................5-10

S

ECTION

6.1 CIRCUIT BOARD REPLACEMENT POLICY.............................................6-1

6.2 REPLACEMENT PARTS...........................................................................6-1

ENERAL PRECAUTIONS FOR HANDLING

G

ARRANTY

W

IELD SERVICE AND REPAIR FACILITIES

F

5. R

5.3.1 Photomultipler Tube/Reaction Chamber Removal......................5-5

5.3.2 Cleaning Reaction Chamber.......................................................5-5

5.3.3 Photomultiplier Tube and Housing..............................................5-7

5.3.4 Replacement of Photomultiplier Tube.........................................5-7

5.4.1 Lamp/Housing Removal..............................................................5-8

5.4.2 UV Lamp Replacement...............................................................5-9

5.4.3 Power Supply Removal...............................................................5-9

6. R

OUTINE SERVICING (CONTINUED

EPLACEMENT PARTS

TORING HIGH PRESSURE CYLINDERS

& S

)

F

IGURES

2-1 POWER SUPPLY BOARD VOLTAGE SELECT SWITCHES...................2-3

2-2 TEMPERATURE CONTROL BOARD .......................................................2-3

2-3 CABLE GLAND..........................................................................................2-4

2-4 REAR VIEW OF MODEL 951C (COVER REMOVED)...............................2-5

3-1 MODEL 951C CONTROLS, INDICATORS AND ADJUSTMENTS ...........3-1

3-2 SIGNAL BOARD.......................................................................................3-3

3-3 POWER SUPPLY BOARD.......................................................................3-4

4-1 ANALYZER SIGNAL CONDITIONING CIRCUIT......................................4-3

4-2 ANALYZER THERMAL SYSTEM.............................................................4-4

6-1 MAJOR ASSEMBLIES OF THE MODEL 951C........................................6-3

6-2 PHOTOMULTIPLIER HOUSING ASSEMBLY..........................................6-4

6-3 CONVERTER ASSEMBLY.......................................................................6-5

6-4 CASE HEATER TEMPERATURE CONTROL ASSEMBLY .....................6-6

748214-N

September 1997

Rosemount Analytical

iii

M

T

951C NOX A

ODEL

ABLES

NALYZER

3-1 RESISTANCE OF CONVERTER TEMPERATURE SENSOR VS.

TEMPERATURE...........................................................................3-6

D

RAWINGS (LOCATED IN REAR OF MANUAL

654063 INSTALLATION DRAWING
654090 FLOW DIAGRAM, LOW RANGE
654093 FLOW DIAGRAM, HIGH RANGE

)

iv

Rosemount Analytical

September 1997

748214-N

P

REFACE

P

URPOSE/SAFETY SUMMARY

To avoid explosi on, l oss of l i fe, per sonal i nj ury and damage to this equipment and on-site
property, all personnel authorized to install, operate and service the Model 951C NOx
Analyzer should be thoroughly familiar with and strictly follow the instructions in this
manual.

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

Save these instructions.

DANGER

personal injury, death, or substantial property damage if the warning is ignored.

WARNING

personal injury, death, or substantial property damage if the warning is ignored.

CAUTION
minor

NOTE

important but not hazard-related.

is used to indicate the presence of a hazard which

is used to indicate the presence of a hazard which

is used to indicate the presence of a hazard which

personal injury or property damage if the warning is ignored.

is used to indicate installation, operation or maintenance information which is

will

cause

can

cause

will or can

severe

severe

cause

WARNING: ELECTRICAL SHOCK HAZARD

Do not operate without doors and covers secure. Servicing requires
access to live parts which can cause death or serious injury. Refer
servicing to qualified personnel.

This instrument was shipped from factory set up to operate on 115 volt
50/60 Hz. For operation on 230 volt 50/60 Hz, refer to Section 2.3.

For safety and proper performance this instrument must be connected to
a properly grounded three-wire source of power.

WARNING: INTERNAL ULTRAVIOLET LIGHT HAZARD

Ultraviolet light from the ozone generator can cause permanent eye
damage. Do not look directly at the ultraviolet source in ozone generator.
Use of ultraviolet filtering glasses is recommended.

748214-N

September 1997

Rosemount Analytical

P-1

M

ODEL

951C NOX A

NALYZER

WARNING: TOXIC CHEMICAL HAZARD

This instrument generates ozone which is toxic by inhalation and is a
strong irritant to throat and lungs. Ozone is also a strong oxidizing agent.
Its presence is detected by a characteristic pungent odor.

The instrument exhaust contains both ozone and nitrogen dioxide, both
toxic by inhalation, and may contain other constituents of the sample gas
which may be toxic. Such gases include various oxides of nitrogen,
unburned hydrocarbons, carbon monoxide and other products of
combustion reactions. Carbon monoxide is highly toxic and can cause
headache, nausea, loss of consciousness, and death.

Avoid inhalation of the ozone produced within the analyzer and avoid
inhalation of the sample and exhaust products transported within the
analyzer. Avoid inhalation of the combined exhaust products at the
exhaust fitting.

Keep all tube fittings tight to avoid leaks. See Section 2.6 for Leak Test
Procedure.

Connect rear exhaust outlet to outside vent by a 1/4 inch (6.3 mm) or
larger stainless steel or Teflon* line. Check vent line and connections for
leakage.

WARNING: PARTS INTEGRITY

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

WARNING: HIGH PRESSURE GAS CYLINDERS

This instrument requires periodic calibration with a known standard gas.
See Paragraphs 2.5 and 3.3. See also General Precautions for Handling
and Storing High Pressure Gas Cylinders, following Section Six.

P-2

Rosemount Analytical

September 1997

748214-N

P

WARNING: TOXIC AND OXIDIZING GAS HAZARDS

The ozone generator lamp contains mercury. Lamp breakage could result
in mercury exposure. Mercury is highly toxic if absorbed through skin or
ingested, or if vapors are inhaled.

HANDLE LAMP ASSEMBLY WITH EXTREME CARE.

If lamp is broken, avoid skin contact and inhalation in the area of the lamp
or the mercury spill.

Immediately clean up and dispose of the mercury spill and lamp residue
as follows:

•

Wearing rubber gloves and goggles, collect all droplets of

mercury by means of a suction pump and aspirator bottle
with long capillary tube. Alternatively, a commercially
available mercury spill clean-up kit, such as J. T. Baker
product No. 4439-01, is recommended.

REFACE

•

Carefully sweep any remaining mercury and lamp debris into

a dust pan. Carefully transfer all mercury, lamp residue and
debris into a plastic bottle which can be tightly capped.
Label and return to hazardous material reclamation center.

•

Do not place in trash, incinerate or flush down sewer.

•

Cover any fine droplets of mercury in non-accessible

crevices with calcium polysulfide and sulfur dust.

CAUTION: TOPPLING HAZARD

This instrument’s internal pullout chassis is equipped with a safety stop
latch located on the left side of the chassis.

When extracting the chassis, verify that the safety latch is in its proper
(counter-clockwise) orientation.

If access to the rear of the chassis is required, the safety stop may be
overridden by lifting the latch; however, further extraction must be done
very carefully to insure the chassis does not fall out of its enclosure.

If the instrument is located on top of a table or bench near the edge, and
the chassis is extracted, it must be supported to prevent toppling.

Failure to observe these precautions could result in personal injury
and/or damage to the product.

748214-N

September 1997

Rosemount Analytical

P-3

M

ODEL

951C NOX A

NALYZER

S

PECIFICATIONS

R

ANGES

R

EPEATABILITY

Z

ERO/SPAN DRIFT

R

ESPONSE TIME

(ELECTRONIC

S

ENSITIVITY

D

ETECTOR OPERATING

P

RESSURE

T

OTAL SAMPLE FLOW RATE

S

AMPLE PRESSURE

O

ZONE GENERATOR GAS

A

MBIENT TEMPERATURE

R

ANGE

:

:

:

:

:

:

:

+ F

- LO R

)

LOW

:

:

ANGE

0 to 10, 0 to 25, 0 to 100, 0 to 250 ppm NOx
within 0.1 ppm or ±1% of fullscale, whichever is greater
less than ±0.1 ppm or ±1% of fullscale, whichever is

greater, in 24 hours at constant temperature
less than ±0.2 ppm or ±2% of fullscale, whichever is

greater, over any 10°C interval from 4 to 40°C (for rate
change of 10°C or less per hour)

90% of fullscale in less than 1 minute

less than 0.1 ppm or 1% of fullscale, whichever is greater
atmospheric

1 Liter per minute at 20 psig

:

138 kPa (20 psig)
U.S.P. breathing-grade air
4 to 40°C (40 to 104°F)

A

NALOG OUTPUT

P

OWER REQUIREMENTS

E

NCLOSURE

D

IMENSIONS

W

EIGHT

:

:

:

Potentiometric:
Isolated Current:

0 to +5 VDC, 2000 ohm minimum load

Field-selectable 0 to 20 or 4 to 20 mA,

700 ohm maximum load

Display

: Digital, 4-1/2 digit LCD, readout in engineering

units, backlighted

:

115/230 VAC ±10%, 50/60 ±3 Hz, 570 W maximum
General purpose for installation in weather-protected

areas

22.0 cm (8.7 in) H

48.3 cm (19 in.) W

48.3 cm (19 in.) D

22.2 kg (49 lbs) approximate

P-4

Rosemount Analytical

September 1997

748214-N

P

REFACE

S

PECIFICATIONS

R

ANGES

R

EPEATABILITY

Z

ERO/SPAN DRIFT

R

ESPONSE TIME

(ELECTRONIC

S

ENSITIVITY

D

ETECTOR OPERATING

P

RESSURE

T

OTAL SAMPLE FLOW RATE

S

AMPLE PRESSURE

O

ZONE GENERATOR GAS

A

MBIENT TEMPERATURE

R

ANGE

:

:

:

:

:

:

:

+ F

- HI R

)

LOW

:

:

ANGE

0 to 100, 0 to 250, 0 to 1000, 0 to 2500 ppm NOx
within 0.1 ppm or ±1% of fullscale, whichever is greater
less than ±1.0 ppm or ±1% of fullscale, whichever is

greater, in 24 hours at constant temperature
less than ±2.0 ppm or ±2% of fullscale, whichever is

greater, over any 10°C interval from 4 to 40°C (for rate
change of 10°C or less per hour)

90% of fullscale in less than 1 minute

less than 0.1 ppm or 1% of fullscale, whichever is greater
atmospheric

1 Liter per minute at 20 psig

:

138 kPa (20 psig)
U.S.P. breathing-grade air
4 to 40°C (40 to 104°F)

A

NALOG OUTPUT

P

OWER REQUIREMENTS

E

NCLOSURE

D

IMENSIONS

W

EIGHT

:

:

:

:

Potentiometric:
Isolated Current:

0 to +5 VDC, 2000 ohm minimum load

Field-selectable 0 to 20 or 4 to 20 mA,

700 ohm maximum load

Display:

Digital, 4-1/2 digit LCD, readout in engineering

units, backlighted

:

115/230 VAC ±10%, 50/60 ±3 Hz, 570 W maximum
General purpose for installation in weather-protected

areas

22.0 cm (8.7 in) H

48.3 cm (19 in.) W

48.3 cm (19 in.) D

22.2 kg (49 lbs) approximate

748214-N

September 1997

Rosemount Analytical

P-5

M

ODEL

951C NOX A

NALYZER

C

USTOMER SERVICE

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

R

ETURNING PARTS TO THE FACTORY

Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when
you call:

Order Number.

Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sender, freight collect.

When returning any product or component that has been exposed to a toxic,
corrosive or other hazardous material or used in such a hazardous environment, the
user must attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written
certification that the material has been decontaminated, disinfected and/or detoxified.

Model Number, Serial Number, and Purchase Order Number or Sales

, T

ECHNICAL ASSIST ANCE AND FIELD SERVICE

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

Return to:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

T

RAINING

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

D

OCUMENTATION

The following Model 951C NOx Analyzer instruction materials are available.
Contact Customer Service or the local representative to order.

748214 Instruction Manual (this document)

Current Operator and Service Training Schedule

Rosemount Analytical Inc.

Phone: [phone]

FAX: [phone]

contact

P-6

Rosemount Analytical

September 1997

748214-N

C

9

6

OMPLIANCES

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

N

P

REFACE

748214-N

September 1997

Rosemount Analytical

P-7

M

ODEL

N

OTES

951C NOX A

NALYZER

P-8

Rosemount Analytical

September 1997

748214-N

C

ONDENSED STARTUP AND CALIBRATION

P

ROCEDURE

The following summarized instructions on startup and calibration are intended for
operators already familiar with the analyzer.

For initial startup, refer to detailed instructions provided in Section 3.

1. Set slider switch on the Signal Board (Figure 3-2) to 250 ppm (see Figure 3-2).

2. Apply power to the analyzer. The analyzer will now require approximately one to two
hours for temperature equilibrium before being ready for calibration.

3. Verify that the pressure regulator on the cylinder of zero gas (nitrogen or air) or sample
gas is set for supply pressure of 10 to 17 psig.

4. Verify that the pressure regulator on the cylinder of air (ozonator supply) is set for
supply pressure of 20 to 25 psig.

5. Establish correct pressure of sample gas:

a. Supply sample gas to rear-panel SAMPLE inlet at 10 to 17 psig (normally 15

psig).

b. Adjust SAMPLE Back Pressure Regulator so that SAMPLE Pressure Gauge

indicates the value appropriate to the desired operating range (normal operating
pressure is 3 to 5 psig). See Figure 3-1.

6. Establish correct pressure of zero gas:

a. Supply zero gas to rear panel SAMPLE inlet and set to 15 psig.
b. Note reading on SAMPLE Pressure Gauge. It should be the same as in Step 5b.

If not, adjust output pressure regulator on the zero gas cylinder as required.

7. Establish correct pressure of upscale standard gas:

a. Supply upscale standard gas to rear panel SAMPLE inlet.
b. Note reading on SAMPLE Pressure Gauge. It should be the same as in Step 6b.

If not, adjust output regulator on cylinder of upscale standard gas as required.

748214-N

September 1997

Rosemount Analytical

P-9

M

ODEL

951C NOX A

NALYZER

Note
Supply pressure for sample, upscale standard gas and zero air must be

the same. If not, the readout will be in error.

8. Zero Calibration.
a. Set PPM RANGE Switch for range to be used for sample analysis. Set SPAN

Control at normal operating setting, if known, or at about mid-range if normal

setting is not known.
b. Supply zero gas to rear panel SAMPLE inlet.
c. Adjust ZERO Control for reading of zero on meter or recorder.

9. Upscale Calibration.
a. Set PPM RANGE Switch at setting appropriate to the particular span gas.
b. Supply upscale standard gas of accurately known NOx content to rear panel

SAMPLE inlet.

c. Adjust SPAN Control so that reading on meter or recorder is equal to the know

parts-per-million concentration of NOx in the span gas.

Note
It is the responsibility of the user to measure efficiency of the NO

-to-NO

2

converter during initial startup, and thereafter at intervals appropriate to
the application, normally once a month.

P-10

Rosemount Analytical

September 1997

748214-N

I

NTRODUCTION

1

1.1 OVERVIEW

The Model 951C NOx Analyzer is designed to measure NOx using one of two sets of
ranges designated as Hi or Lo. The Hi Range set consists of spans with ranges of
0-100, 0-250, 0-1000, and 0-2500 ppm NOx. The Lo Range set consists of spans
with ranges of 0-10, 0-25, 0-100, and 0-250 ppm NOx.

The NOx analyzer continuously analyzes a flowing gas sample for NOx [nitric oxide
(NO) plus nitrogen dioxide (NO2)]. The sum of the concentrations is continuously
reported as NOx.

The analyzer is based on the chemiluminescence method of NO detection. The
sample is continuously passed through a heated bed of vitreous carbon, in which
NO2 is reduced to NO. Any NO initially present in the sample passes through the
converter unchanged, and any NO2 is converted to an approximately equivalent
(95%) amount of NO.

The NO is quantitatively converted to NO2 by gas-phase oxidation with molecular
ozone produced within the analyzer from air supplied by an external cylinder. During
this reaction, approximately 10% of the NO2 molecules are elevated to an
electronically excited state, followed by immediate decay to the non-excited state,
accompanied by emission of photons. These photons are detected by a
photomultiplier tube, which in turn generates a DC current proportional to the
concentration of NOx in the sample stream. The current is then amplified and used
to drive a front panel display and to provide potentiometric and isolated current
outputs.

To minimize system response time, an internal sample-bypass feature provides
high-velocity sample flow through the analyzer.

The display blanks when the analyzer is 10% or more over-range. Selecting a less
sensitive (higher) range restores the display function.

The case heater assembly of the Model 951C maintains the internal temperature at
approximately 50oC (122oF).

748214-N

September 1997

Rosemount Analytical

1-1

M

ODEL

951C NOX A

NALYZER

1.2 APPLICATIONS

The Model 951C Analyzer has specific applications in the following areas:

Oxides of nitrogen (NOx) emissions from the combustion of fossil fuels in:

•

Vehicle engine exhaust
Incinerators
Boilers
Gas appliances
Turbine exhaust

Nitric acid plant emissions

•

Ammonia in pollution control equipment (with converter)

•

Nitric oxide emissions from decaying organic material (i.e., landfills)

•

1-2

Rosemount Analytical

September 1997

748214-N