Rosemount Analytical
M
ODEL
NO
I
NSTRUCTION MANUAL
X ANALYZER
951C
748214-P
OTICE
N
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-P
December 2000
Printed in U.S.A.
Rosemount Analytical Inc.
4125 East La Palma Avenue
A
NAHEIM
, C
ALIFORNIA
92807-1802
C
P
REFACE
PURPOSE/SAFETY SUMMARY........................................................................P1
SPECIFICATIONS - LO RANGE........................................................................P4
SPECIFICATIONS - HI RANGE.........................................................................P5
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE............P6
RETURNING PARTS TO THE FACTORY.........................................................P6
TRAINING ......................................................................................................P6
DOCUMENTATION............................................................................................P6
COMPLIANCES .................................................................................................P7
CONDENSED STARTUP AND CALIBRATION PROCEDURE..........................P9
ONTENTS
S
ECTION
1.1 OVERVIEW.................................................................................................1
1.2 APPLICATIONS ..........................................................................................2
S
ECTION
2.1 UNPACKING...............................................................................................3
2.2 LOCATION..................................................................................................3
2.3 VOLTAGE REQUIREMENTS......................................................................3
2.4 ELECTRICAL CONNECTIONS...................................................................4
2.5 GAS REQUIREMENTS...............................................................................7
2.6 SAMPLE REQUIREMENTS........................................................................8
1. I
2. I
2.4.1 Line Power Connections................................................................4
2.4.2 Potentiometric Recorder Connections...........................................6
2.4.3 Current Recorder Connections......................................................6
NTRODUCTION
NSTALLATION
748214-P Rosemount Analytical December 2000
Model 951C NOx Analyzer
i
ONTENTS
C
2.7 GAS CONNECTIONS................................................................................. 8
2.8 LEAK TEST................................................................................................. 9
S
ECTION 3. INITIAL STARTUP AND OPERATION
3.1 FRONT PANEL INDICATORS AND CONTROLS ...................................... 11
3.1.1 Display ..................................................................................... 11
3.1.2 Range Selection............................................................................ 11
3.1.3 Sample Pressure Gauge............................................................... 12
3.1.4 Ozone Pressure ............................................................................ 12
3.1.5 Zero and Span Potentiometers ..................................................... 12
3.1.6 Ozone Interlock............................................................................. 12
3.2 STARTUP PROCEDURE ........................................................................... 13
3.3 CALIBRATION............................................................................................ 16
3.3.1 Zero Calibration............................................................................. 16
3.3.2 Upscale Calibration....................................................................... 16
3.4 ROUTINE OPERATION.............................................................................. 16
3.5 CONVERTER TEMPERATURE ADJUSTMENT PROCEDURE................. 17
3.6 MEASUREMENT OF CONVERTER EFFICIENCY .................................... 19
3.7 RECOMMENDED CALIBRATION FREQUENCY....................................... 20
S
ECTION
4.1 NITRIC OXIDE DETERMINATION BY CHEMILUMINESCENCE
4.2 ANALYZER FLOW SYSTEM...................................................................... 21
4.3 SIGNAL PROCESSING ELECTRONICS SYSTEM.................................... 22
4.4 ANALYZER THERMAL SYSTEM............................................................... 23
4. T
4.2.1 Flow of Sample, Standard Gas or Zero Gas to Reaction
4.2.2 Ozone Generation......................................................................... 22
HEORY
METHOD...................................................................................... 21
Chamber....................................................................... 21
SECTION 5. ROUTINE SERVICING
5.1 SYSTEM CHECKS AND ADJUSTMENTS ................................................. 25
5.1.1 Display Fullscale Span Adjustment............................................... 25
5.1.2 Overall Sensitivity.......................................................................... 26
5.1.3 Ozone Output................................................................................ 26
5.1.4 Background Current...................................................................... 27
5.1.5 Excessive Photomultiplier Dark Current........................................ 27
5.2 SERVICING FLOW SYSTEM..................................................................... 28
5.2.1 Cleaning Sample Capillary............................................................ 28
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December 2000 Rosemount Analytical 748214-PModel 951C NOx Analyzer
5.2.2 Ozone Restrictor Fitting.................................................................29
5.3 PHOTOMULTIPLIER TUBE/REACTION CHAMBER..................................30
5.3.1 Photomultiplier Tube/Reaction Chamber Removal........................30
5.3.2 Cleaning Reaction Chamber..........................................................30
5.3.3 Photomultiplier Tube and Housing.................................................32
5.3.4 Replacement of Photomultiplier Tube............................................32
5.4 OZONE GENERATION SYSTEM ...............................................................33
5.4.1 Lamp/Housing Removal.................................................................33
5.4.2 UV Lamp Replacement..................................................................34
5.4.3 Power Supply Removal..................................................................34
5.5 CONVERTER ASSEMBLY..........................................................................35
5.6 SERVICING ELECTRONIC CIRCUITRY ....................................................35
SECTION 6. REPLACEMENT PARTS
6.1 CIRCUIT BOARD REPLACEMENT POLICY ..............................................37
6.2 REPLACEMENT PARTS.............................................................................37
ONTENTS
C
ENERAL PRECAUTIONS FOR HANDLING
G
ARRANTY
W
IELD SERVICE AND REPAIR FACILITIES
F
TORING HIGH PRESSURE CYLINDERS
& S
FIGURES
2-1. Power Supply Board Voltage Select Switches ...........................................5
2-2. Temperature Control Board........................................................................5
2-3. Cable Gland ...............................................................................................6
2-4. Rear View of Model 951C...........................................................................7
3-1. Model 951C Controls, Indicators and Adjustments ....................................11
3-2. Signal Board...............................................................................................14
3-3. Power Supply Board...................................................................................15
4-1. Analyzer Signal Conditioning Circuit...........................................................23
4-2. Analyzer Thermal System..........................................................................24
6-1. Major Assemblies of the Model 951C.........................................................39
6-2. Photomultiplier Housing Assembly.............................................................40
6-3. Converter Assembly...................................................................................41
6-4. Case Heater Temperature Control Assembly.............................................42
748214-P Rosemount Analytical December 2000
Model 951C NOx Analyzer
iii
ONTENTS
C
TABLES
3- 1 . R e s ist a n c e o f C o n ver t e r Te mp e rat u r e S e n sor vs. T e m p e r a t u r e.............................18
D
RAWINGS (LOCATED IN REAR OF MANUAL
654063 Installation Drawing
654090 Flow Diagram, Low Range
654093 Flow Diagram, High Range
)
iv
December 2000 Rosemount Analytical 748214-PModel 951C NOx Analyzer
P
REFACE
PURPOSE/SAFETY SUMMARY
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 Model
951C NOx Analyzer should be thoroughly familiar with and strictly follow the
instructions in this manual. Save these instructions.
If this equipment is used in a manner not specified in these instructions, protective
systems may be impaired.
DANGER is used to indicate the presence of a hazard which will cause severe
personal injury, death, or substantial property damage if the warning is ignored.
WARNING is used to indicate the presence of a hazard which can cause severe
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION is used to indicate the presence of a hazard which will or can cause
minor personal injury or property damage if the warning is ignored.
NOTE is used to indicate installation, operation or maintenance information which is
important but not hazard-related.
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.
748214-P Rosemount Analytical December 2000
Model 951C NOx Analyzer
P1
REFACE
P
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.
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
P2
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.
December 2000 Rosemount Analytical 748214-PModel 951C NOx Analyzer
REFACE
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. 443901, is recommended.
• 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 (counterclockwise) 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-P Rosemount Analytical December 2000
Model 951C NOx Analyzer
P3
REFACE
P
SPECIFICATIONS - LO RANGE
RANGES:
0 to 10, 0 to 25, 0 to 100, 0 to 250 ppm NOx
REPEATABILITY:
within 0.1 ppm or ±1% of fullscale, whichever is greater
Z
ERO/SPAN DRIFT
:
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)
R
ESPONSE TIME
: (E
LECTRONIC
90% of fullscale in less than 1 minute
S
ENSITIVITY
:
less than 0.1 ppm or 1% of fullscale, whichever is greater
D
ETECTOR OPERATING PRESSURE
atmospheric
T
OTAL SAMPLE FLOW RATE
:
1 Liter per minute at 20 psig
S
AMPLE PRESSURE
:
138 kPa (20 psig)
O
ZONE GENERATOR GAS
:
U.S.P. breathing-grade air
A
MBIENT TEMPERATURE RANGE
+ F
:
LOW
:
)
P4
4 to 40°C (40 to 104°F)
A
NALOG OUTPUT
:
Potentiometric: 0 to +5 VDC, 2000 ohm minimum load
Isolated Current: Field-selectable 0 to 20 or 4 to 20 mA, 700 ohm max load
Display: Digital, 4-1/2 digit LCD, readout in engineering units, back-lighted
P
OWER REQUIREMENTS
115/230 VAC ±10%, 50/60 ±3 Hz, 570 W maximum
E
NCLOSURE
:
General purpose for installation in weather-protected areas
D
IMENSIONS
:
8.7 in. x 19.0 x 19.0 in. (H x W x D)
22.0 cm x 48.3 cm x 48.3 cm (H x W x D)
W
EIGHT
22.2 kg (49 lbs) approximate
:
December 2000 Rosemount Analytical 748214-PModel 951C NOx Analyzer
SPECIFICATIONS - HI RANGE
RANGES:
0 to 100, 0 to 250, 0 to 1000, 0 to 2500 ppm NOx
REPEATABILITY:
within 0.1 ppm or ±1% of fullscale, whichever is greater
REFACE
P
Z
ERO/SPAN DRIFT
:
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)
R
ESPONSE TIME
S
ENSITIVITY
90% of fullscale in less than 1 minute
: (E
LECTRONIC
:
less than 0.1 ppm or 1% of fullscale, whichever is greater
D
ETECTOR OPERATING PRESSURE
atmospheric
T
OTAL SAMPLE FLOW RATE
:
1 Liter per minute at 20 psig
S
AMPLE PRESSURE
:
138 kPa (20 psig)
O
ZONE GENERATOR GAS
:
U.S.P. breathing-grade air
A
MBIENT TEMPERATURE RANGE
4 to 40°C (40 to 104°F)
+ F
:
LOW
:
)
A
NALOG OUTPUT
:
Potentiometric: 0 to +5 VDC, 2000 ohm minimum load
Isolated Current: Field-selectable 0 to 20 or 4 to 20 mA, 700 ohm max load
Display: Digital, 4-1/2 digit LCD, readout in engineering units, back-lighted
P
OWER REQUIREMENTS
:
115/230 VAC ±10%, 50/60 ±3 Hz, 570 W maximum
E
NCLOSURE
:
General purpose for installation in weather-protected areas
D
IMENSIONS
:
8.7 in. x 19.0 x 19.0 in. (H x W x D)
22.0 cm x 48.3 cm x 48.3 cm (H x W x D)
W
EIGHT
:
22.2 kg (49 lbs) approximate
748214-P Rosemount Analytical December 2000
Model 951C NOx Analyzer
P5
REFACE
P
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE
For order administration, replacement Parts, application assistance, on-site or factory
repair, service or maintenance contract information, contact:
Rosemount Analytical Inc.
Process Analytical Division
Customer Service Center
1-800-433-6076
RETURNING 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: Model Number, Serial Number, and Purchase Order Number or Sales 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.
Return to:
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
USA
TRAINING
A comprehensive Factory Training Program of operator and service classes is
available. For a copy of the Current Operator and Service Training Schedule contact
the Technical Services Department at:
Rosemount Analytical Inc.
Phone: 1-714-986-7600
FAX: 1-714-577-8006
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)
P6
December 2000 Rosemount Analytical 748214-PModel 951C NOx Analyzer
COMPLIANCES
9
6
This product satisfies all obligations of all relevant standards of the EMC framework in
Australia and New Zealand.
N
REFACE
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748214-P Rosemount Analytical December 2000
Model 951C NOx Analyzer
P7
REFACE
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NOTES
P8
December 2000 Rosemount Analytical 748214-PModel 951C NOx Analyzer
C
ONDENSED STARTUP AND CALIBRATION
PROCEDURE
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:
748214-P Rosemount Analytical December 2000
Model 951C NOx Analyzer
P9
ONDENSED STARTUP AND CALIBRATION PROCEDURE
C
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.
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 NO2-to-NO
converter during initial startup, and thereafter at intervals appropriate to the
application, normally once a month.
P10
December 2000 Rosemount Analytical 748214-PModel 951C NOx Analyzer
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-P Rosemount Analytical December 2000
Model 951C NOx Analyzer
1
NTRODUCTION
I
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)
2
December 2000 Rosemount Analytical 748214-PModel 951C NOx Analyzer
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