Rosemount Manual: MLT Series Analyzer Hardware including CAT 200-11th Ed. | Rosemount Manuals & Guides

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Instruction Manual

90002929 04/2008

Instruction Manual

NGA 2000 Hardware Manual for ML T or CA T 200 Analyzer and ML T or CA T 200 Analyzer Module (combined with

NGA 2000 Platform, ML T , CA T 200 or TFID Analyzer)

Edition 04/2008

www.EmersonProcess.com

NGA 2000 ML T Hardware Instruction Manual

90002929

04/2008

ESSENTIAL INSTRUCTIONS

READ THIS P AGE BEFORE PROCEEDING!

Emerson Process Management (Rosemount Analytical) designs, manufactures and test s its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using and maintaining Emerson Process Management (Rosemount Analytical) products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Emerson Process

Management (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.

• T o ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson Process Management (Rosemount Analytical). Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR W ARRANTY. 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. Misprints reserved.

1st Edition 02/1997 2nd Edition 03/1997 3rd Edition 09/1997 4th Edition 04/1998

Edition 07/1999 6th Edition 10/1999 7th Edition 04/2003 8th Edition 08/2004

9th Edition 07/2006 10th Edition 01/2007 11th Edition 04/2008

Emerson Process Management GmbH & Co. OHG

Industriestrasse 1 D-63594 Hasselroth Germany T +49 (0) 6055 884-0 F +49 (0) 6055 884-209 Internet: www.EmersonProcess.com

Instruction Manual

90002929 01/2007

NGA 2000 MLT Hard ware

Table of Contents

PREAMBEL ....................................................................................S - 1

DEFINITIONS.................................................................................. S - 1

SAFETY INSTRUCTIONS ............................................................. S - 2

Operating and maintaining this apparatus...................................S - 3

Intended use statement .................................................................S - 4

Safety summary..............................................................................S - 4

Authorized personnel.....................................................................S - 4

Gases and Gas Conditioning (Sample Handling) ........................S - 6

Power Supply..................................................................................S - 7

Instruments with External Power Supply Unit...................................S - 7

Instruments with Internal Power Supply Unit....................................S - 7

General operating instructions .....................................................S - 9

Additional hints for UV measurement ........................................S - 10

Magnetically Operated Front Panel ............................................ S - 11

Electrostatic Discharge................................................................S - 12

CONTENTS

PREFACE........................................................................................ P - 1

a) Analyzer versions.........................................................................P - 1

Standard General Purpose Applications........................................ P - 1

b) Analyzer versions

Installation in Hazardous Areas .....................................................P - 2

c) Analyzer System Architecture....................................................... P - 4

DESCRIPTION

1. Technical Description .................................................................... 1 - 1

1.1 Standard General Purpose Applications .......................................... 1 - 1

1.2 Installation in Hazardous Areas........................................................ 1 - 1

1.3 Operating Front Panel ...................................................................... 1 - 2

1.3.1 Standard Version ........................................................................... 1 - 2

1.3.2 Magnetically Operated Touch Panel.............................................. 1 - 3

1.3.2.1 Magnetic Touch Panel Elements.................................................. 1 - 3

1.3.2.2 Accessories.................................................................................. 1 - 4

1.3.2.3 Operating the Touch Panel .......................................................... 1 - 4

Emerson Process Management GmbH & Co. OHG

NGA 2000 MLT Har dware

CONTENTS

Instruction Manual

1.4 MLT 1 ............................................................................................... 1 - 6

1.4.1 MLT 1 1/2 19" housing ................................................................... 1 - 6

1.4.2 MLT 1 ULCO................................................................................ 1 - 11

1.4.3 MLT 1 Housing for platform mounting .......................................... 1 - 13

1.5 MLT 2 (Field Housing).................................................................... 1 - 17

1.6 MLT 3 ............................................................................................. 1 - 21

1.6.1 MLT 3 (Gas purity measurement)................................................. 1 - 23

1.6.2 MLT 3HT (high temperature measurement).......................................1 - 24

1.7 MLT 4 ............................................................................................. 1 - 26

1.8 CAT 200 ......................................................................................... 1 - 28

1.9 Internal Gas Paths.......................................................................... 1 - 32

1.9.1 Gas Path Material ........................................................................ 1 - 32

1.9.2 Gas Path Layout (internal tubing)................................................. 1 - 33

1.9.3 MLT 3 (gas purity measurement) ................................................. 1 - 34

1.10 Printed Circuit Boards .................................................................... 1 - 36

1.10.1 ICB (Inter-Connection Board)....................................................... 1 - 37

1.10.2 PSV/PIC Combination ................................................................. 1 - 37

1.10.3 DSP (alternitavely to PSV/PIC Combination) .............................. 1 - 37

1.10.4 PIC (Physics Interface Card)........................................................ 1 - 38

1.10.5 Digital Signal Processing Card (DSP) ......................................... 1 - 39

1.10.6 ACU ............................................................................................. 1 - 40

1.10.7 SIO (Standard Inputs-/Outputs) .................................................... 1 - 41

1.10.8 DIO (Digital In-/Outputs)............................................................... 1 - 42

1.11 Network Termination ...................................................................... 1 - 43

1.12 Specifications at the Nameplate Label ........................................... 1 - 44

1.13 MLT 2HT (high temperature measurement)...................... ................ 1 - 46

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2. Measuring Principle ....................................................................... 2 - 1

2.1 IR Measurement ............................................................................... 2 - 1

2.1.1 Opto - Pneumatic Measuring Principle........................................... 2 - 3

2.1.2 Interference Filter Correlation (IFC Principle) ................................ 2 - 4

2.2 UV Measurement.............................................................................. 2 - 6

2.3 Oxygen Measurement ...................................................................... 2 - 7

2.3.1 Paramagnetic Measurement (PO2)................................................. 2 - 7

2.3.2 Electrochemical Measurement (EO2) ........................................... 2 - 11

2.3.3 Trace Electrochemical Measurement (TEO2)............................... 2 - 13

2.4 Thermal Conductivity ..................................................................... 2 - 15

2.4.1 Sensor Design ............................................................................. 2 - 15

2.4.2 Analysis Cell ................................................................................ 2 - 15

2.4.3 Measurement Method .................................................................. 2 - 16

3. (vacant)

4. (vacant)

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

OPERATION (START-UP)

5. Installation .................................................................................... 5 - 1

5.1 General........................................................................................... 5 - 1

5.1.1 Transfer Safety Lock of MLT 1/ULCO or MLT 2 .......................... 5 - 3

5.2 Gas Conditioning (Sample Handling) ............................................. 5 - 4

5.2.1 Fine Dust Filter (Option MLT 3) ................................................... 5 - 5

5.2.2 Gas Sampling Pump (Option MLT 3)........................................... 5 - 5

5.2.3 Pressure Sensor (Option) ............................................................ 5 - 5

5.2.4 Gas Flow...................................................................................... 5 - 5

5.3 Gas Connections............................................................................ 5 - 6

5.3.1 Internal Solenoid Valve Block (Option for MLT 1/CAT 200)......... 5 - 8

5.3.2 Purge Gas Connections............................................................... 5 - 8

5.4 Analyzer Specific Instructions......................................................... 5 - 9

5.4.1 MLT 1........................................................................................... 5 - 9

5.4.1.1 MLT 1, platform mounting only................................................... 5 - 9

5.4.1.2 MLT 1, external installation and 1/2-19" Housing....................... 5 - 10

5.4.2 MLT 2 (Field Housing) ................................................................. 5 - 13

5.4.2.1 Wall Mounting ............................................................................ 5 - 13

5.4.2.2 Electrical Connections................................................................ 5 - 15

a) Mains Supply ......................................................................... 5 - 16

b) optional Data Lines ................................................................ 5 - 16

c) Cable Gland Assembly Instruction for Shielded Cables ......... 5 - 19

d) Gas Connections ................................................................... 5 - 20

5.4.3 MLT 3........................................................................................... 5 - 21

5.4.3.1 MLT 3 for gas purity measurement ............................................ 5 - 22

a) Instrument with manual 4/2-way-valve................................... 5 - 22

b) Instrument with solenoid valve block...................................... 5 - 23

c) Instrument with quick shutoff connector ................................. 5 - 23

5.4.4 MLT 4........................................................................................... 5 - 24

5.4.5 CAT 200....................................................................................... 5 - 26

5.4.5.1 Wall Mounting ............................................................................ 5 - 27

5.4.5.2 Electrical Connections................................................................ 5 - 28

5.4.5.3 Gas Connections........................................................................ 5 - 31

5.5 Wiring Signal Terminals.................................................................. 5 - 32

5.5.1 Electrical Connections in General................................................ 5 - 32

5.5.2 Wiring Inductive Loads................................................................. 5 - 34

5.5.3 Driving Multiple Loads.................................................................. 5 - 35

5.5.4 Driving High Current Loads.......................................................... 5 - 36

CONTENTS

Emerson Process Management GmbH & Co. OHG

III

NGA 2000 MLT Hardware

CONTENTS

Instruction Manual

6. Switching On .................................................................................. 6 - 1

7. Measurement / Calibration / Switching Off .................................. 7 - 1

7.1 Measurement ................................................................................... 7 - 1

7.2 Calibration ........................................................................................ 7 - 2

7.2.1 Test Gases .................................................................................... 7 - 3

7.2.1.1 Zero Gas ...................................................................................... 7 - 3

7.2.1.2 Span Gas ..................................................................................... 7 - 3

7.3 Switching Off .................................................................................... 7 - 4

- (vacant)

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TROUBLESHOOTING

10. Troubleshooting ........................................................................... 10 - 1

10.1 Instrument has no function (LCD display is dark)........................... 10 - 1

10.2 No / Incorrect Measurement Screen............................................... 10 - 2

10.3 Display Messages .......................................................................... 10 - 3

10.3.1 Chopper Fail ................................................................................ 10 - 3

10.3.2 Raw Signal Too High / Low.......................................................... 10 - 3

10.3.3 Detector signal communication failed .......................................... 10 - 4

10.3.4 Light source ................................................................................. 10 - 4

10.3.5 Detector ....................................................................................... 10 - 4

10.3.6 Heater Unit Regulation................................................................. 10 - 5

10.3.7 Temperature Measurement ......................................................... 10 - 5

10.3.8 Invalid Pressure Measurement .................................................... 10 - 5

10.3.9 External Input............................................................................... 10 - 6

10.4 No or incorrect Analog Outputs / Digital I/O's................................. 10 - 6

10.5 Calibration not possible .................................................................. 10 - 7

10.6 Fluctuating or erroneous display .................................................... 10 - 8

10.7 Response time too long (t90 time)................................................. 10 - 9

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

11. Test Procedure / Test Points ....................................................... 11 - 1

11.1 Signal processing ........................................................................... 11 - 1

11.1.1 Internal Voltage Supply................................................................ 11 - 2

11.1.2 IR Source..................................................................................... 11 - 2

11.1.3 Chopper ....................................................................................... 11 - 3

11.1.4 Unamplified Measuring Signal at Detector................................... 11 - 3

11.1.5 Signal Processing on PCB “PSV” ................................................ 11 - 4

11.1.6 Physical Zero Alignment .............................................................. 11 - 5

11.1.6.1 IR Measurement......................................................................... 11 - 5

11.1.6.2 Paramagnetic Oxygen Measurement......................................... 11 - 5

11.1.6.3 Electrochemical Oxygen Measurement (EO2) ........................... 11 - 5

11.2 Heating Unit.................................................................................... 11 - 6

11.3 Troubleshooting Instructions for PCB DSP01 ................................ 11 - 7

11.3.1 Inspection of LEDs on component side of DSP01 ....................... 11 - 8

11.3.2 Inspection of soldering pads of DSP01...................................... 11 - 10

11.3.3 Evaluation.................................................................................. 11 - 11

11.3.4 Appendix.................................................................................... 11 - 12

11.3.4.1 Description of soldering pad DEF (LB3):.................................. 11 - 12

11.3.4.2 Definition of LEDs: ................................................................... 11 - 12

CONTENTS

12. Removal / Replacement of Components.................................... 12 - 1

12.1 Removal / Replacement of PCBs (in preparation).......................... 12 - 1

12.1.1 Rear Mounting Slots (in preparation) ........................................... 12 - 1

12.1.2 Internal Slots (in preparation)....................................................... 12 - 1

12.2 Removal / Replacement of Operation Front Panel......................... 12 - 2

12.3 Replacement of Buffer Battery on the ACU 02............................... 12 - 3

12.3.1 Removal of ACU 02 ..................................................................... 12 - 3

12.3.2 Replacement of Buffer Battery..................................................... 12 - 4

12.3.3 Installation of ACU 02 .................................................................. 12 - 4

12.4 Fuses.............................................................................................. 12 - 5

12.4.1 MLT 2........................................................................................... 12 - 5

12.4.2 MLT 1 / 4...................................................................................... 12 - 6

12.5 Connect/Disconnect UV Source/Power Supply for UV Source ...... 12 - 7

Emerson Process Management GmbH & Co. OHG

NGA 2000 MLT Hardware

CONTENTS

Instruction Manual

MAINTENANCE............................................................................. 13 - 1

14. Leak Testing ................................................................................. 14 - 1

15. Opening the Housing ................................................................... 15 - 1

15.1 MLT 1 ............................................................................................. 15 - 2

15.1.1 MLT 1 (Platform housing)............................................................... 15 - 2

15.1.1.1 Housing Cover ........................................................................... 15 - 2

15.1.1.2 Front Panel................................................................................. 15 - 3

15.1.2 MLT 1 (1/2 19" housing) .............................................................. 15 - 4

15.1.2.1 Housing Cover ........................................................................... 15 - 4

15.1.2.2 Front Panel................................................................................. 15 - 5

15.2 MLT 2 (Field Housing).................................................................... 15 - 6

15.3 MLT 3/4 (1/1 19" housing) .............................................................. 15 - 8

15.3.1 Housing Cover ............................................................................. 15 - 8

15.3.2 Front Panel (MLT 4 / MLT 3 standard version) ............................ 15 - 8

15.3.3 Front Panel (MLT 3 gas purity measurement) ............................. 15 - 9

15.3.3.1 Operation Front Panel................................................................ 15 - 9

15.3.3.2 Left Front Panel.......................................................................... 15 - 9

15.4 CAT 200 ....................................................................................... 15 - 10

15.4.1 Junction Box .............................................................................. 15 - 12

15.4.2 Dome ......................................................................................... 15 - 13

15.4.3 Magnetically Operated Front Panel ........................................... 15 - 16

15.4.3.1 Sliding the Analyzer into Position............................................. 15 - 16

15.4.3.2 Fixing the Analyzer................................................................... 15 - 16

15.4.3.3 Completing the Adjustment ...................................................... 15 - 16

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16. Fine Dust filter (MLT 3 Option) .................................................... 16 - 1

17. Replacement and Cleaning of Photometric Components ........ 17 - 1

17.1 Removal of the Photometer Assembly ........................................... 17 - 2

17.2 Light Source Replacement (IR) ...................................................... 17 - 3

17.3 Cleaning of Analysis Cells and Windows ....................................... 17 - 4

17.3.1 Removal of Analysis Cells ........................................................... 17 - 4

17.3.2 Cleaning....................................................................................... 17 - 5

17.3.3 Reinstalling of Analysis Cells....................................................... 17 - 6

17.4 Reinstalling of the Photometer Assembly....................................... 17 - 7

17.5 Physical Zeroing............................................................................. 17 - 8

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

18. Check / Replacement of electrochemical Oxygen Sensor........ 18 - 1

18.1 EO2-Sensor .................................................................................... 18 - 2

18.2 Check of the EO2-Sensor ............................................................... 18 - 3

18.3 Replacement of the EO2-Sensor .................................................... 18 - 4

18.3.1 Removal of the EO2-Sensor......................................................... 18 - 4

18.3.2 Replacing the EO2-Sensor ........................................................... 18 - 5

18.3.3 Reinstalling of the EO2-Sensor .................................................... 18 - 5

18.3.4 Basic conditions for the EO2-Sensor............................................ 18 - 6

18.4 TEO2-Sensor .................................................................................. 18 - 7

19. Cleaning of Housing Outside ...................................................... 19 - 1

CONTENTS

TECHNICAL DATA ........................................................................ 20 - 1

20.1 Housing .......................................................................................... 20 - 1

20.2 Options ........................................................................................... 20 - 2

20.3 General Specifications ................................................................... 20 - 3

20.4 Voltage supply.............................................................................. 20 - 11

20.4.1 Analyzers...................................................................................... 20 - 11

20.4.1.1 MLT 1/4.................................................................................... 20 - 11

20.4.1.2 MLT 2/3.................................................................................... 20 - 11

20.4.1.3 CAT 200................................................................................... 20 - 11

20.4.1.4 Electrical Safety ....................................................................... 20 - 11

20.4.2 Power Supplies.......................................................................... 20 - 12

20.4.2.1 UPS 01 T (Universal Power Supply) ........................................ 20 - 12

20.4.2.2 External 5A Power Supply Unit for DIN Rail Installation........... 20 - 14

20.4.2.3 External 10A Power Supply Unit for DIN Rail Installation......... 20 - 16

20.4.2.4 Tabletop Power Supply Units................................................... 20 - 18

Emerson Process Management GmbH & Co. OHG

VII

NGA 2000 MLT Hardware

CONTENTS

Instruction Manual

SUPPLEMENT

21. Pin Assignments ........................................................................ 21 - 1

21.1 24 V dc Input (MLT 1/4)................................................................ 21 - 1

21.2 230/120 V ac Input (MLT 3).......................................................... 21 - 1

21.3 Option SIO (Standard I/O)............................................................ 21 - 2

21.3.1 Analog Signal Outputs ............................................................... 21 - 2

21.3.2 Relay Outputs / Serial Interfaces ............................................... 21 - 2

21.4 Option DIO (Digitale I/O) .............................................................. 21 - 3

21.5 Terminal Assignment of CAT 200................................................. 21 - 4

21.6 CAT 200 Increased Safety Box - Label Schematic........................21 - 7

22. Calculation of Water Content from Dew-point to

Vol. -% or g/Nm³.......................................................................... 22 - 1

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Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

LIST OF FIGURES

Fig. Title Page

Fig. P-1: Analyzer Nameplate Label (example).............................................................................P - 3

Fig. P-2: From separate analyzers to analyzer system .................................................................P - 4

Fig. P-3: Example of NGA-cabling.................................................................................................P - 5

Fig. P-4: Example/possibilities of NGA analyzer system ...............................................................P - 6

Fig. 1-1: Operation front panel, Front view.................................................................................... 1 - 2

Fig. 1-2: Magnetically Operated Touch Panel, Front view ............................................................ 1 - 3

Fig. 1-3a: Magnetic actuator ........................................................................................................... 1 - 5

Fig. 1-3b: Magnetic actuator, view at magnets................................................................................ 1 - 5

Fig. 1-4a: Symbols showing actuator alignment ............................................................................. 1 - 4

Fig. 1-4b: Horizontally aligned, activating F4 .................................................................................. 1 - 5

Fig. 1-4c: Vertically aligned, activating F5....................................................................................... 1 - 5

Fig. 1-5: Actuator stored when not in use ..................................................................................... 1 - 4

Fig. 1-6: MLT analyzer, Front view.............................................................................................. .. 1 - 6

Fig. 1-7: MLT 1, Front panel, Rear view........................................................................................ 1 - 7

Fig. 1-8: MLT 1, Rear panel (standard) ......................................................................................... 1 - 7

Fig. 1-9: MLT 1, Rack/Table-top Housing, Top view (with electrochemical O2 Sensor) ................ 1 - 8

Fig. 1-10: MLT 1, Rack/Table-top Housing, Top viewA(with paramagnetic O2 Sensor).................. 1 - 9

Fig. 1-11: MLT 1, Rack/Table-top Housing extended, Top view (with paramagnetic O2 Sensor) . 1 - 10

Fig. 1-12: MLT 1 ULCO, Rack/Table-top Housing, Top view ........................................................ 1 - 12

Fig. 1-13: MLT 1 Analyzer module (Platform mounting), Front panel, Front view ......................... 1 - 13

Fig. 1-14: MLT 1, Platform mounting, Top view (with electrochemical O2 Sensor) ....................... 1 - 14

Fig. 1-15: MLT 1, Platform mounting, Top view (with paramagnetical O2 Sensor) ........................ 1 - 15

Fig. 1-16: MLT 1, Platform mounting extended, Top view (with paramagnetic O2 Sensor) ........... 1 - 16

Fig. 1-17a: Front view MLT 2 (Standard housing/Standard operation front panel) ......................... 1 - 19

Fig. 1-17b: Front view MLT 2 (Dual compartment housing/Standard operation front panel)........... 1 - 19

Fig. 1-18a: MLT 2, Inside view (drawing without front panel).......................................................... 1 - 20

Fig. 1-18b: MLT 2, Photometer sliding carriage, Top view.............................................................. 1 - 20

Fig. 1-19: MLT 3 (standard) (1/1 19" housing), front view ............................................................ 1 - 21

Fig. 1-20: MLT 3 (standard version), Rear view ........................................................................... 1 - 21

Fig. 1-21: MLT 3 (standard version), Top view ............................................................................. 1 - 22

Fig. 1-22: MLT 3 (gas purity measurement), front view................................................................. 1 - 23

Fig. 1-23: MLT 3 (gas purity measurement), Rear view ................................................................ 1 - 24

Fig. 1-24: MLT 3 (gas purity measurement), Top view.................................................................. 1 - 25

Fig. 1-25: MLT 4 (1/1 19" housing), front view .............................................................................. 1 - 26

Fig. 1-26: MLT 4, Rear view.......................................................................................................... 1 - 26

Fig. 1-27: MLT 4, Rack/Table-top Housing, Top view ................................................................... 1 - 27

Fig. 1-28: CAT 200, Exterior view ................................................................................................. 1 - 30

Fig. 1-29: CAT 200 (Dome and extender housing removed) ........................................................ 1 - 31

Fig. 1-30a: MLT 3 (gas purity measurement), gas path layout.................................................................

(3 measuring channels with solenoid valve block option) ............................................. 1 - 34

Fig. 1-30b: MLT 3 (gas purity measurement), gas path layout.................................................................

(3 measuring channels with valve block option and quick shuttoff connector option) ... 1 - 35

Fig. 1-30c: MLT 3 (gas purity measurement), gas path layout.................................................................

(2 measuring channels with manual 4/2-way-valve option) .......................................... 1 - 35

Fig. 1-31a: Cardcage MLT 1/3/4, Top View .................................................................................... 1 - 36

Fig. 1-31b: PCB arrangement MLT 2 [Inside view, detail (without front panel)] .............................. 1 - 37

CONTENTS

Emerson Process Management GmbH & Co. OHG

NGA 2000 MLT Hardware

CONTENTS

LIST OF FIGURES

Fig. Title Page

Fig. 1-32: Plug pin assignment PCB PIC ...................................................................................... 1 - 38

Fig. 1-33: Plug pin assignment PCB DSP ..................................................................................... 1 - 39

Fig. 1-34: Function blocks of SIO-PCB ......................................................................................... 1 - 41

Fig. 1-35: SIO-PCB with extension cards...................................................................................... 1 - 42

Fig. 1-36: RJ 45 network termination connector ........................................................................... 1 - 43

Fig. 1-37: Network termination (examples) ................................................................................... 1 - 43

Fig. 1-38: Analyzer Nameplate Label (example) ........................................................................... 1 - 44

Fig. 2-1: Measuring Principle for NDIR / UV Measurement........................................................... 2 - 2

Fig. 2-2: Principle Design of Gas Detector.................................................................................... 2 - 3

Fig. 2-3: Absorption Bands of Sample Gases and Transmittance of the .............................................

Interference Filters used ................................................................................................. 2 - 5

Fig. 2-4: Principle Construction of paramagnetic Analysis Cell ..................................................... 2 - 8

Fig. 2-5: Structure of electrochemical Oxygen Sensor................................................................ 2 - 11

Fig. 2-6: Reaction of galvanic cell ............................................................................................... 2 - 12

Fig. 2-7: Structure of electrochemical Trace Oxygen Sensor...................................................... 2 - 13

Fig. 2-8: Sensor block (thermal conductivity detector TCD)........................................................ 2 - 15

Fig. 2-9: Measuring principle Thermal Conductivity Sensor (Wheatstone bridge) ...................... 2 - 16

Instruction Manual

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Fig. 5-1a: Transfer safety lock MLT-ULCO (housing side view, detail sketch)................................ 5 - 3

Fig. 5-1c: MLT 2, Photometer safety lock ....................................................................................... 5 - 3

Fig. 5-1b: MLT 1, Rear panel (holder for safety lock)...................................................................... 5 - 3

Fig. 5-2: MLT, Bypass installation ................................................................................................. 5 - 7

Fig. 5-3: MLT 1 analysis module (platform mounting), front panel, front view ............................... 5 - 9

Fig. 5-4: MLT 1, standard gas connections ................................................................................. 5 - 11

Fig. 5-5: MLT 1, gas connections with solenoid valve option ...................................................... 5 - 12

Fig. 5-6a: Dimensional sketch / Drill drawing MLT 2 Standard version......................................... 5 - 14

Fig. 5-6b: Dimensional sketch / Drill drawing MLT 2 Dual housing version .................................. 5 - 14

Fig. 5-8: MLT 2, Data line connections Inside view from front (detail, without front door) ........... 5 - 17

Fig. 5-9: MLT 2, Connection data lines / mains line (inside view, left side panel) ....................... 5 - 18

Fig. 5-10: Cable Gland Assembly Instruction for Shielded Cables................................................ 5 - 19

Fig. 5-11: Cable gland sealing plug / Cable gland allen screw sealing plug ................................. 5 - 19

Fig. 5-12a: MLT 2, gas connections................................................................................................ 5 - 20

Fig. 5-12b: MLT 2, Gas fittings at analyzer’s bottom side ............................................................... 5 - 20

Fig. 5-13: MLT 3 (standard version), gas connections and voltage supply ................................... 5 - 21

Fig. 5-14: MLT 3 (gas purity measurement), Rear view ................................................................ 5 - 22

Fig. 5-15: Solenoid valve block MLT 3 (gas purity measurement) (side view) .............................. 5 - 23

Fig. 5-16: MLT 3 (gas purity measurement), front view................................................................. 5 - 23

Fig. 5-17: MLT 4, Voltage supply .................................................................................................. 5 - 24

Fig. 5-18: MLT 4, gas connections................................................................................................ 5 - 25

Fig. 5-19: Drill drawing CAT 200 [all dimensions in mm (Inch)]..................................................... 5 - 27

Fig. 5-20: CAT 200, Junction box, interior view............................................................................. 5 - 30

Fig. 5-21: CAT 200, Analyzer’s bottom view at gas fittings ........................................................... 5 - 30

Fig. 5-22: Shielded Signal Cable, shield connected at both ends ................................................. 5 - 32

Fig. 5-23: Shielded Signal Cable, shield connected at one end.................................................... 5 - 32

Fig. 5-24: Double-shielded Signal Cable, shields connected at both sides................................... 5 - 33

Fig. 5-25: Suppressor Diode for Inductive Loads .......................................................................... 5 - 34

Fig. 5-26: ”Serial” Wiring ............................................................................................................... 5 - 35

Fig. 5-27: Running Supply Lines "Parallel”.................................................................................... 5 - 35

Fig. 5-28: Driving High Current Loads........................................................................................... 5 - 36

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

Fig. Title Page

Fig. 11-1: Principle signal processing with PCB "PSV" ................................................................. 11 - 1

Fig. 11-2: PCB "VVS".................................................................................................................... 11 - 2

Fig. 11-3: PCB "MOP” (partial view).............................................................................................. 11 - 3

Fig. 11-4: PCB "BHZ” (position of signal LED's / heating transistors) ........................................... 11 - 6

Fig. 11-5: PCB "DSP01”................................................................................................................ 11 - 7

Fig. 11-6: LEDs on component side of PCB "DSP01”................................................................... 11 - 8

Fig. 11-6a: LEDs “V7” and “V9” (PCB "DSP01”) ............................................................................. 11 - 8

Fig. 11-6b: LEDs “V3” and “V4” (PCB "DSP01”) ............................................................................. 11 - 9

Fig. 11-6c: LEDs “V12” to “V17”, Jumper “P40” (PCB "DSP01”) .................................................... 11 - 9

Fig. 11-7: Soldering pads on soldering side of PCB "DSP01”..................................................... 11 - 10

Fig. 11-7a: Soldering pad “LB1” and “LB2 (PCB "DSP01”) ........................................................... 11 - 10

Fig. 11-7b: Soldering pad “LB18” (PCB "DSP01”) ........................................................................ 11 - 10

Fig. 11-8: Schematic diagram of inspection of PCB "DSP01” ..................................................... 11 - 11

Fig. 11-9: Soldering pad “DEF/LB3” (PCB "DSP01”) .................................................................. 11 - 12

NGA 2000 MLT Hardware

LIST OF FIGURES

CONTENTS

Fig. 12-1: Controller Board ACU (partial view, component side)................................................... 12 - 3

Fig. 12-2: Fuses MLT 2 (partial inside view, drawing without front panel)..................................... 12 - 5

Fig. 12-3a: Fuses PCB LEM 01 (component side).......................................................................... 12 - 6

Fig. 12-4a: Power Supply for UV Source (front view, front panel disassembled)............................ 12 - 8

Fig. 12-4b: UV Source and PCB ESP10 (top view, housing cover disassembled) ......................... 12 - 9

Fig. 14-1: Leak Testing with an U - Tube - Manometer................................................................. 14 - 1

Fig. 15-1: MLT 1 (Plattform housing) Fastening screws housing cover ........................................ 15 - 2

Fig. 15-2: MLT 1 (Plattform housing) Fastening screws front panel.............................................. 15 - 3

Fig. 15-3: MLT 1 (1/2 19" housing) Fastening screws housing cover ........................................... 15 - 4

Fig. 15-4: MLT 1 (1/2 19" housing) Fastening screws front panel................................................. 15 - 5

Fig. 15-5: MLT 2 (Field housing) fastener for front panel .............................................................. 15 - 7

Fig. 15-6: MLT 2, photometer carriage slide ................................................................................. 15 - 7

Fig. 15-7: MLT3 (standard version) / MLT 4 (1/1 19" housing) Fastening screws front panel....... 15 - 8

Fig. 15-8: MLT3 (gas purity measurement) (1/1 19" housing) Fastening screws front panel........ 15 - 9

Fig. 15-9: Cat 200 Enclosure Assembly...................................................................................... 15 - 11

Fig. 15-10: Cat 200 Junction box .................................................................................................. 15 - 12

Fig. 15-11: CAT 200 Dome, fixing screws..................................................................................... 15 - 13

Fig. 15-12: View at analyzer module............................................................................................. 15 - 14

Fig. 15-13: Plate with detents........................................................................................................ 15 - 14

Fig. 15-14: CAT 200, Cast Iron housing, Interior View.................................................................. 15 - 15

Fig. 17-1: Photometer Assembly, example (Top view, detail) ....................................................... 17 - 2

Fig. 17-2: Chopper Housing with IR light sources......................................................................... 17 - 3

Fig. 17-3: Photometer Assembly (1 mm to 10 mm analysisi cells)................................................ 17 - 4

Fig. 17-4: Photometer Assembly (30 mm to 200 mm analysisi cells)............................................ 17 - 4

Fig. 18-1: PCB “OXS”, assembled, horizontal projection .............................................................. 18 - 3

Fig. 18-2: MLT 1, front panel, rear view ........................................................................................ 18 - 4

Fig. 18-3: PCB “OXS”, assembled, horizontal projection .............................................................. 18 - 6

Emerson Process Management GmbH & Co. OHG

NGA 2000 MLT Hardware

CONTENTS

LIST OF FIGURES/LIST OF TABLES

Fig. Title Page

Fig. 20- 1: Dimensional sketch MLT 1 [all dimensions in mm] ........................................................ 20 - 6

Fig. 20- 2: Dimensional sketch / Drill drawing MLT 2 Standard version ........................................... 20 - 7

Fig. 20- 3: Dimensional sketch / Drill drawing MLT 2 Dual housing version..................................... 20 - 7

Fig. 20- 4: Dimensional sketch MLT 2 for Ex Zone 2 in standard housing ....................................... 20 - 8

Fig. 20- 5: Dimensional sketch MLT 2 for Ex Zone 1 in standard housing ....................................... 20 - 8

Fig. 20- 6: Dimensional sketch MLT 2 for Ex Zones with “Z Purge” (MLT 2-NF).......................................

or “Continuous purge” in standard housing................................................................... 20 - 9

Fig. 20- 7: Dimensional sketch MLT 3/4......................................................................................... 20 - 9

Fig. 20- 8: Dimensional sketch / Drill drawing CAT 200 ............................................................... 20 - 10

Fig. 20- 9: Dimensional sketch UPS 01 T (Universal Power Supply), table-top version .............. 20 - 13

Fig.20-10a: IEC mains input plug (UPS 01 T) ................................................................................ 20 - 13

Fig. 20-10b: 24 V DC output socket, Pin assignment (UPS 01 T)................................................... 20 - 13

Fig. 20-11: Power Supply SL5, Dimensions.................................................................................. 20 - 15

Fig. 20-12: Power Supply SL 10, Dimensions............................................................................... 20 - 17

Fig. 20-13: 10 A Tabletop Power Supply, Dimensions.................................................................. 20 - 18

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Fig. 21- 1: Pin assignments 24 V dc Input (MLT 1/4) ..................................................................... 21 - 1

Fig. 21- 2: Pin assignments 230/120 V ac Input (MLT 3) ............................................................... 21 - 1

Fig. 21- 3: Pin assignments Socket Analog Signal Outputs (Option SIO) ...................................... 21 - 2

Fig. 21-4a: Pin assignments Socket Relay Outputs / RS 232 Serial Interface (Option SIO) ........... 21 - 2

Fig. 21-4b: Pin assignments Socket Relay Outputs / RS 485 Serial Interface (Option SIO) ........... 21 - 2

Fig. 21- 5: Pin assignments Socket Digital Inputs/Outputs (Option DIO) ........................................ 21 - 3

Fig. 21- 6: CAT 200, Junction box, interior view.............................................................................. 21 - 4

LIST OF TABLES

Table Title Page

Table P-1: Possibilities of NGA 2000 MLT I/O combinations ...........................................................P - 7

Table 1-1: Possible internal tubings (examples with 3 measuring channels) ................................... 1 - 33

Table 2-1: Solvent Resistant Sensor: Approved solvents ................................................................. 2 - 9

Table 2-2: Medium affected Materials within Paramagnetic Oxygen Sensor .................................... 2 - 9

Table 2-3: Paramagnetic Oxygen Measurement, cross interference by accompanying gases ........ 2 - 10

Table 5-1: CAT 200, Assignment of gas fittings ............................................................................. 5 - 30

Table 11-1: Definition of LEDs/Default configuration of soldering pads (PCB "DSP01”) .................. 11 - 12

Table 11-2: Definition of LEDs/Normal configuration of soldering pads (PCB "DSP01”) .................. 11 - 13

Table 20-1: Specifications of MLT.................................................................................................... 20 - 4

Table 20-2: Altered NDIR/VIS/UV-Specifications of MLT-ULCO compared to table 1 ...................... 20 - 5

Table 21-1: CAT 200 Power Connections Terminal Assignments ..................................................... 21 - 5

Table 21-2: CAT 200 Analog Signal Outputs Terminal Assignments (Option SIO)............................ 21 - 5

Table 21-3: CAT 200 Relay Outputs Terminal Assignments (Option SIO) ........................................ 21 - 5

Table 21-4: CAT 200 Field Bus Terminal Assignments (Option) ....................................................... 21 - 5

Table 21-5: CAT 200 RS 232 / RS 485 Serial Interface Terminal Assignments (Option SIO)............ 21 - 6

Table 21-6: CAT 200 Digital Inputs/Outputs Terminal Assignments (Option DIO) ............................. 21 - 6

Table 21-7: CAT 200 Terminal Assignments - Bottom (Lower) Contacts........................................... 21 - 8

Table 21-8: CAT 200 Terminal Assignments - Top (Upper) Contacts ................................................ 21 - 8

Table 22-2: Calculation of Water Content from Dew-point to Vol. -% or g/Nm³ .................................. 22 - 1

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Instruction Manual

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

PREAMBEL / DEFINITIONS

Preambel

This instruction manual provides information about ML T and CAT200 series gas analyzers /analyzer modules concerning subassemblies, functions, procedures, installation, operation and maintenance. This instruction manual covers se veral ML T and CA T200 series gas analyzers /analyzer modules variations and therefore may describe configurations and/or options not part of your specific analyzer . Installation and operation of instruments intended to be installed and operated in HAZARDOUS AREAS is NOT CO VERED by this instruction manual, but part of the specific instruction manual shipped together with such analyzers because of the special requirements for working in hazardous environments!

Definitions

The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication.

Highlights an operation or maintenance procedure, practice, condition, statement, etc.

If not strictly observed, could result in injury , death, or longterm health hazards of personnel.

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.

Emerson Process Management GmbH & Co. OHG

NOTE

Highlights an essential operating procedure, condition or statement.

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

GENERAL

Instruction Manual

IMPORTANT

SAFETY INSTRUCTIONS

WIRING AND INSTALLA TION OF THIS APP ARATUS

The following safety instructions apply specifically to all EU member states. They should be

strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or National Standards.

1. Adequate earth connections should be made to all earthing points, internal and external,

where provided.

2. After installation or troubleshooting, all safety co vers and safety grounds must be replaced.

The integrity of all earth terminals must be maintained at all times.

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3. To ensure safe operation of this equipment, connection to the mains supply should only

be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards.

4. Where equipment or covers are marked with the symbol to the right,

hazardous voltages are likely to be present beneath. These cov ers should only be removed when po wer is removed from the equipment — and then by trained service personnel only.

5. Where equipment or cov ers are marked with the symbol to the right, there

is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.

6. Where equipment or cov ers are marked with the symbol to the right, refer

to the Instruction Manual for instructions.

7. Further graphical symbols used in this product:

Elektrostatic discharge (ESD)

Harmful (to Health)!

Explosion Hazard!

Toxic!

Heavy Instrument!

Disconnect from Mains!

All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.

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Instruction Manual

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OPERATING AND MAINTAINING THIS APPARATUS

NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

Operating and maintaining this apparatus

This instrument has left the factory in compliance with all applicable safety regulations. T o maintain this oper ating condition, the user must strictly follow the instructions and consider

the warnings in this manual or provided on the instrument. Before switching on the instrument, verify that the electrical supply voltage matches the

instrument´s operating voltage as set in the factory. Any interruption in the instrument´s ground line, whether inside or outside the instrument, or

removal or interruption of its ground line connection, could result in hazardous operating conditions. Intentionally interrupting the instrument´s protective ground is strictly prohibited.

Opening cover panels could expose voltage-carrying components. Connectors may also be under voltage. The instrument must be disconnected from all electrical supplies before attempting any calibrations, maintenance operations, repairs or component replacements requiring opening of the instrument. Any calibrations, maintenance operations , or repairs that need the instrument to be opened while connected to electrical supplies should be subject to qualified technicians familiar with the hazards involved only!

Use only fuses of the correct type and current ratings as replacements. Using repaired fuses and short circuiting of fuse holders is prohibited.

Observe all applicable regulations when operating the instrument from an auto-transformer or variac.

Substances hazardous to health may emerge from the instrument‘s exhaust. Please pay attention to the safety of y our oper ation personnel. Protectiv e measures must be taken, if required.

Emerson Process Management GmbH & Co. OHG

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

INTENDED USE STATEMENT / SAFETY SUMMARY / AUTHORIZED PERSONNEL

Instruction Manual

Intended use statement

MLT and CAT200 series gas analyzers/analyzer modules are intended to be used as analyzers for industrial purposes. They must not be used in medical, diagnostic or life support applications, and no independent agency certifications or approv als are to be implied as covering such applications!

Safety summary

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

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Authorized personnel

T o avoid loss of lif e, personal injury and damage to this equipment and on-site property , do not operate or service this instrument before reading and understanding this instruction manual and receiving appropriate training. Save these instructions.

ELECTRICAL SHOCK HAZARD !

Do not operate without covers secure. Do not open while energized. Installation requires access to live parts which can cause death or serious injury.

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

TOXIC GASES !

This unit’s exhaust may contain toxic gases such as sulfur dioxide. These gases can cause serious injuries.

Aviod inhalation of the exhaust gases at the exhaust fitting. Connect exhaust outlet to a safe vent. Check vent line and connections for leakage. Keep all fittings tight to avoid leaks. See section 14 for leak test information.

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Instruction Manual

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Do not operate nor install these instruments in hazardous areas without additional measures!

The analyzer variations MLT 2 and CAT 200 intended to be wall mounted and/or outdoor installed weigh up to 35 kg resp. 70 kg, depending on included options!

NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

EXPLOSION HAZARD !

MLT 2 and CAT 200 -- HEAVY INSTRUMENTS !

Use two person and/or suitable tools for transportation and lifting these instruments!

Take care to use anchors and bolts specified to be used for the weight of the units!

Take care the wall or stand the unit is intended to be installed at is solid and stable to hold the units!

HIGH TEMPERATURES !

While working at photometers and/or thermostated components inside the analyzers hot components may be accessible!

CAUSTIC !

The electrochemical O2-sensor contains electrolyte which is caustic and can cause serious burns to skin. Do not ingest contents of sensor !

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

Because of the danger of introducing additional hazards, do not perform any unauthorized modification to this instrument!

Emerson Process Management GmbH & Co. OHG

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

GASES AND GAS CONDITIONING (SAMPLE HANDLING)

Gases and Gas Conditioning (Sample Handling)

T ake care of the safety instructions applicable for the gases (sample gases and test gases) and for the gas bottles containing these gases!

Before opening gas paths they must be purged with ambient air or neutral gas (N2) to avoid hazards caused by toxic, flammable, explosive or harmful to health sample gas components!

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Flammable gases must not supplied without additional protective measures!

It is prohibited to supply e xplosive gases!

EXPLOSION HAZARD !

Supplying flammable gases of concentrations above 25 % of lower explosion limit (LEL) we recommend to utilize one or more of the following measures:

• Purging the housing with inert gas

• Internal tubing with stainless steel

• Flame arrestors at gas input and output fittings

• Intrinsically safe paramagnetical or thermal conductivity sensors

Supplying explosive gases is not permitted !

• Purge gas must be conditioned: Take care for purge gas temperature: Purge gas should have the same temperature as ambient temperature of the analyzer but NOT below 20 °C and above 35 °C! Otherwise it must be cooled or warmed up before let in into the instrument! Purge gas should be instrumental / synthetic air (free of oil, no corrosive, to xic or flammable gas componets) or nitrogen depending on application.

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Instruction Manual

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Power Supply

V erify the mains voltage at site of installation corresponds to the analyzer´s rated voltage as given on the nameplate label!

V erify the safety instruction given by power supply unit manufacturer !

Instruments with External Power Supply Unit

NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

POWER SUPPLY

The mains socket has to be nearby the power supply unit and easily accessible! Disconnecting from mains requires unplugging the power plug!

To comply with the CE mark requirements use only power supply units of type UPS 01 T, DP 157, SL5, SL10 (DP 157 for rack installation only) or equivalent units. Equivalent units must provide SELV output voltages!

V erify proper polarity when connecting DC 24 V operated analyzers !

Instruments with Internal Power Supply Unit

ELECTRICAL SHOCK HAZARD !

These instruments provide a protective earth terminal. T o prevent electrical shock hazards the instrument must be connected to a protective earth. Therefore the instrument has to be connected to mains by using a three wire mains cable with earth conductor!

Any interruption of the earth connector inside or outside the instrument or disconnecting the earth terminal may cause potential electrical shock hazzard! Intended interruption of protective earth connections is not permitted!

• For analyzer module (A) [external installation or platform mounting] it is not allowed to supply the module from front and rear simultaneously ! For e xternal installation connections on frontside absolutely have to closed with the blind plate delivered from our factory to be in agreement with the CE conformity.

Emerson Process Management GmbH & Co. OHG

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

ADDITIONAL HINTS FOR MLT 2 AND CAT 200

ADDITIONAL HINTS FOR MODELS MLT 2 AND CAT 200

Installation and connecting mains and signal cables are subject to qualified personnel only taking into account all applicable standards and legislative requirements!

Failure to follow may cause warranty invalidation, property damage and/or personal injury or death! Mains and signal cables need to be connected to internal srew terminals requiring to work at open housing near life parts!

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Installation of this instrument is subject to qualified personnel only , familiar with the resulting potential risks!

These gas analyzer do not provide a mains power switch and are operable when connected to power.

These gas analyzers do not provide a mains switch! A mains switch or circuit breaker has to be provided in the building installation. This switch has to be installed near by analyzer, must be easily operator accessible and has to be assigned as disconnector for the analyzer.

ADDITIONAL HINTS FOR MODEL MLT 2

Cables for external data processing must be double insulated for mains voltage when used inside the instrument! If double insulation is not available signal cables inside the analyzer must be installed in a way that a distance of at least 5 mm is ensured permanently (e.g. by utilizing cable ties).

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Instruction Manual

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V erify all gas lines are connected as described within this manual and tight! Improper gas connections may cause explosion, serious injury or death! Exhaust may contain hydrocarbons and other toxic gases, e.g. carbon

monoxide. Carbon monoxide is toxic!

NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

GENERAL OPERATING INSTRUCTIONS

General operating instructions

DANGER TO LIFE ! EXPLOSION HAZARD !

• Before start-up unscrew transfer safety lock (knurled-head screws) of the MLT 1 + 2 (section 5. of operation manual) !

• Installation area has to be clean, free from moisture, excessive vibration and frostprotected. Take care to meet the permissible ambient temperatures as given in the technical data section! Instruments must not be exposed to direct sunlight, fluorescent lamps nor sources of heat.For outdoor installation it is recommended to mount the instruments into a cabinet. At least sheltering against rain is required. Do not co v er v enting openings and tak e care to mount the instrument in a distance to walls not affecting venting.

• Free flow of air into and out of the MLT (ventilation slits) must not be hindered by nearby objects or walls !

• Do not interchange gas inlet and outlet! All gases must be conditioned before supplying! When supplying corrosive gases ensure that gas path components are not affected!

• Max. permissible gas pressure: 1,500 hPa, except instruments for gas purity measurement (see chapter 5.4.3.1), with integrated valve blocks (see page 5-8 and/or paramagnetic Oxygen sensor (see table page 20-4)!!

• Exhaust lines must be installed in a descending way, need to be pressureless, frostprotected and in compliance with applicable legislative requirements!

• When it is necessary to open gas paths seal the analyzer‘s gas fittings by using PVC caps to avoid pollution of the internal gas path by moisture, dust, etc.

• To stay in compliance with regulations regarding electromagnetic compatibility it is recommended to use only shielded cables, as optionally a vailable from Emerson Process Management or equivalent. Customer has to take care that the shield is connected in proper way. Shield and signal connector enclosure need to be conductively connected, submin-d plugs and sockets must be screwed to the analyzer.

• Using external submin-d-to-terminal adaptor elements (option) affects electromagnetic compatibility. In this case the customer has to take measures to stay in compliance and has to declare conformity, when required by legislation (e.g. European EMC Directive).

Emerson Process Management GmbH & Co. OHG

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

ADDITIONAL HINTS FOR UV MEASUREMENT

Additional hints for UV measurement

The optional UV lamp operates with high voltage (Power Supply UVS) !

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HIGH VOLTAGE !

UV SOURCE !

Ultraviolet light from UV lamp can cause permanent eye damage ! Do not look directly at the ultraviolet source !

TOXIC SUBSTANCE !

The optional UV lamp contains mercury. Lamp breakage could result in mercury exposure ! Mercury is highly toxic !

If the lamp is broken, avoid any skin contact to mercury and inhalation of mercury vapors !

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Instruction Manual

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Persons with cardiac pacemakers should absolutely avoid magnetic fields !

Negative effects on persons beyond those described above caused by magnetic fields are not known. It is presumed that persons showing allergic reaction on contact with ceramic or metallic material show the same behavior on contact with magnetic material.

NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

MAGNETICALLY OPERATED FRONT PANEL

Magnetically Operated Front Panel

DANGER TO LIFE !

Permanent magnets are surrounded by magnetic fields. These magnetic fields can disturb and even destroy sensitive electronic measuring devices, but also mechanical watches, credit cards, etc.

Usually a distance of 0.5 m is enough to avoid damages. All sintered permanent magnets are hard and brittle. Hitting of sintered permanent magnets by the magnetic attraction causes splitting into fragments with many sharp edges. This especially occurs with high energy magnets, and can also cause skin bruises by high attraction.

High energy magnets made of rare-earth materials have to be stored dry, otherwise the surfaces would oxidise. Unprotected operation in a humid environment may cause corrosion. Avoid damaging the protective galvanic coating.

A storage in a hydrogen atmosphere destroys these magnets. A demagnetisation is caused when permanent magnet materials have been exposed in a radioactive radiation for a long time.

For air transportation of magnetic material the IA TA instructions have to be observed:

Magnetic fields are not allowed to penetrate the package, if necessary the magnets have to be shorted using a metal plate.

Emerson Process Management GmbH & Co. OHG

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

ELECTROSTATIC DISCHARGE

Instruction Manual

Electrostatic Discharge

The electronic parts of the analyzer can be irreparably damaged if exposed to electrostatic discharge (ESD). The instrument is ESD protected when the covers have been secured and safety precautions observed. When the housing is open, the internal components are not ESD protected anymore.

Although the electronic parts are reasonable safe to handle, you should be aware of the following considerations:

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Best ESD example is when you walk ed across a carpet and then touched an electrical grounded metal doorknob. The tiny spark which has jumped is the result of electrostatic discharge (ESD).

You prevent ESD by doing the following: Remove the charge from your body before opening the housing and maintain during work

with opened housing, that no electrostatic charge can be built up. Ideally you are opening the housing and working at an ESD - protecting workstation.

Here you can wear a wrist trap.

Howev er , if you do not hav e such a workstation, be sure to do the following procedure exactly: Discharge the electric charge from your body. Do this by touching a device that is grounded

electrically (any device that has a three - prong plug is grounded electrically when it is plugged into a power receptacle). This should be done several times during the operation with opened housing (especially after leaving the service site because the movement on a low conducting floors or in the air might cause additional ESDs).

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Instruction Manual

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NGA 2000 ML T Hardware

PREFACE

Preface

a) Analyzer versions - Standard General Purpose Applications

The ML T series of NGA 2000 analyzers offers multi-component, multi-method analysis. Different measurement methods can be combined in one analyzer.

MLT 1, MLT 2 and ML T 4 (MLT 5) are designed to measure up to 5 gas components while ML T 1 ULCO, MLT 3 and CAT 200 allow up to 4 gas components (including photometer and nonphotometer channels).

For MLT (MLT 1, 2 & CAT 200) with Foundation Fieldbus (FF) a special FF instruction manual is provided.

NGA 2000 ML T 1 ULCO gas analyzer is specially designed to measure ultra low carbon monoxide. The analyzer is equipped with a 2

optical bench including a multi detector assembly (MDA block) for cross interf erence compensation in automotive and flue gas applications. W ater vapor and carbon dioxide measurement is used for internal cross interference compensation thus providing an ultra low CO and CO2 channel as standard. This solution is designed for automotive (Internal Combustion Engine Emissions, ICEE) and Continuous Emissions Monitoring Systems (CEMS). An additional CO

channel is available as option on automotive applications.

high

For gas purity measurement new quality standards require ultra low CO measurement but not such high dynamic ranging and cross compensation. Therefore the 2nd bench (MDA) is not used, b ut another channel, e.g. ultra low carbon dioxide (ULCO2) can be implemented in ML T 1.

All ML T 2 components are incorporated into a wall-mountable housing with ingress protection code IP 65 (designed to meet NEMA 4/4X) according to EN 60529. This housing is equipped with an impact tested front panel according to EN 50014 operated by a magnetically operated touch panel. The MLT 2 can be purged to remove corrosive or toxic gases with synthetic air or instrumental air (dry, free of oil, hydrocarbons and corrosive components; 20 to 35 °C purge gas temperature). If sample gas contains flammable gas components above the lower explosion limit, the required explosion protection measures (purge/pressurization system) must be approved b y an authorized person (ATEX/CSA-C/US purge system) . ML T 2 is available with a dual compartment enclosure, too, whereat electronics and photometer/ sensors are installed in two separate housings. Special high temperature variations of MLT 2 or 3 for physics temperatures up to 120 °C are optionally available (standard thermostat control: 55 °C; 65 °C as option). Special versions of MLT 3 are available with suppressed r anges for gas purity measurements and a corresponding additional manual too (special sample handlingrequirements).

Emerson Process Management GmbH & Co. OHG

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NGA 2000 ML T Hardware

PREFACE

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b) Analyzer versions - Installation in Hazardous Areas

Note!

This manual does not deal with special conditions for analyzers in hazardous areas , related to installation, operation, maintenance etc. For such applications refer to the separate instruc-

tion manuals, delivered together with the analyzers.

For installation in hazardous areas the ML T 2 can be equipped with the appropriate pressurization system acc. to the actual required explosion protection measures.

Solutions acc. to CENELEC (according to former European EN 50016) use combinations of ML T 2 and an appropriate pressurization system being individually certified (see separate manual about pressurization system and individual certification report - §10 Elex). In this case a magnetically operated touch panel or an intrinsically safe front panel (combined with approved PCB EXI 01for Zone 1, option for Zone 2) is implemented and ML T 2 is combined with a simplified pressurization for European Ex Zone 2 or with an approved pressurization system for European Ex Zone 1 (see separate instruction manual). Additionally the MLT 2 may be equipped with intrinsically safe I/O's (see separate instruction manual )

ML T 2-NF is a special analyzer version of ML T 2 with Z Purge system for North American Class 1 Zone 2 measurements of non-flammable gases in hazardous areas (CSA-C/US type approved for Zone 2, see separate instruction manual).

EEx p solutions acc. to ATEX (European Directive for Equipment to be used in Explosive Atmospheres; mandatory since July 1, 2003) use type approv ed combinations of MLT 2 and appropriate pressurization systems (see separate A TEX instruction manual about pressurization system and certification). The separate A TEX manual covers all EExp Ex Zone 1 solutions as well as solutions for Ex Zone 2 measuring non-flammable gases. Solutions for measuring flammable gases in Ex Zone 1 or 2 are described in a separate instruction manual. For installation acc. to ATEX in Ex Zone 1 and 2 the MLT 2 is always equipped with a magnetically operated touch panel (see separate manual too). Additionally the MLT 2 may be equipped with intrinsically safe I/O's (see separate instruction manual).

The CA T 200 analyzer or analyz er module is designed to be installed in hazardous areas, too, It is consisting of a 1/2-19" ML T 1 analyz er (analyzer module) installed into a flameproof Ex d enclosure with Ex em junction box. This model is CSA-C/US and ATEX approved for installation in North-American and European hazardous areas (Ex zone 1).

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Instruction Manual

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All analyzer versions are marked as follows: ML Tx y-CH1 CH2 CH3 CH4 CH5

with x = analyzer type 1, 2, 3, 4, 5, CA T 200 with

1 = 1/2 19", not thermostatted, external power supply 2 = Field housing, thermostatted, internal power supply 3 = 1/1 19"-housing, thermostatted, internal power supply 4 = 1/1 19"-housing, thermostatted, external power supply 5 = 19", 18 to 21 HU housing, thermostatted, internal power supply

CA T 200 = flameproof enclosure

NGA 2000 ML T Hardware

PREFACE

y = analyzer version T , M, A, R, TE, ME, AE, RE with

T = table top M = analyzer module, platform mounting

(net/electr. connections from front side only)

A = analyzer module, external installation or platform mounting

(net/electr. connections from rear side or front side) R = rack mounting E = extended housing (ML T 1 only)

CH1...5 = measuring method of the individual (max. 5) measuring channels with

IR = measurement at infrared spectral range UV = measurement at ultra violet spectral range VIS = measurement at visual spectral range PO2 = paramagnetic oxygen measurement EO2 = electrochemical oxygen measurement TC = thermal conductivity measurement TEO

Model and installed measuring principles (here: MLT 4 Rackmounting, 2 x IR, 2 x UV, 1 x PO2)

Channel 1: Gas and measuring range (here: CO, 60/600 ppm)

Channel 4: Gas and measuring range (here: CO, 150/1,500 ppm)

= trace electrochemical oxygen measurement

Serial number

Channel 2: Gas and measuring range (here: SO2, 26/260 ppm)

Channel 4: Gas and measuring range (here: NO2, 25/250 ppm)

Channel 5: Gas and measuring range (here: O2, 5/21 Vol-%)

Emerson Process Management GmbH & Co. OHG

International approval marks

Fig. P-1: Analyzer Nameplate Label (example)

P - 3

NGA 2000 ML T Hardware

PREFACE

Instruction Manual

90002929

12/2006

c) Analyzer System Architecture

The ML T´s flexibility facilitates the most cost-effective system architecture - elegantly accommodating either “stand-alone” or integrated multi-channel analyzer requirements. The ML T is availab le both as an “Analyzer Module” or as an “Analyzer”.

The “Analyzer Module” (AM) is a “b lind” analysis unit but retains all the adv anced MLT design features. The AM variant is designed for integration as part of a Multiple NGA 2000 analysis system or special customer developed networks. The MLT AM novel “blind” packaging and network functionality allows the user to easily exploit the ML T analyser´s advanced expansion capability.

The MLT Analyzers can be designed as single stand-alone analyzers - complete with control module functionality and front panel display/operator interface - or as an centr al interf ace f or multiple Analyzer Modules with a network board.

In ML T analyzer systems this feature eliminates duplication of the displa y/operator interface. In addition to the obvious operational benefits, MLT Analyzers offer significant cost and system packaging advantages not possible with conventional analyser configurations. This flexible network communication architecture is shown in Fig. P-4.

½ 19" MLT

Analyzer

ROSEMOUNT NGA 2000NGA 2000

Platform with MLT AM

19" MLT Analyzer

ROSEMOUNT NGA 2000NGA 2000

NGA NetworkNGA Network

NGA Network

½ 19" MLT

CLD

FID PS

Analyzer

ROSEMOUNT NGA 2000NGA 2000

NGA Network

P - 4

CLD

FID

PMD

ROSEMOUNT NGA 2000NGA 2000

Platform with MLT AM

ROSEMOUNT NGA 2000NGA 2000

19" MLT Analyzer

CLD PS

ROSEMOUNT NGA 2000NGA 2000

MLT MLT

CLD FID

NGA Network

Fig. P-2: From separate analyzers to analyzer system

Emerson Process Management GmbH & Co. OHG

NGA Network

+ 220 hidden pages

Rosemount Manual: MLT Series Analyzer Hardware including CAT 200-11th Ed. | Rosemount Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual