Rosemount Manual: NGA 2000 FID2 Hydrocarbon Analyzer Module SW 2.2-Rev D | Rosemount Manuals & Guides

NGA 2000

LAME IONIZATION

F

NALYZER

A

ETECTOR

D

ODULE

M

Rosemount Analytical

2

N

OTICE

T

HE INFORMATION CONTAINE D IN THIS DOCUMENT IS SUBJ E CT T O CHANGE WITHOUT NOTICE

.

Rosemount Analytical's NGA 2000 system of Modular G as Analyzers and Controllers are patented,
under U.S. Patent 5.787.015.

Manual Part Number 748364-D
November 1998
Printed in U.S.A.

Rosemount Analytical Inc.

4125 East La Palma Avenue
Anaheim, California 92807-1802

ONTENTS

C

PREFACE

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

GLOSSARY ......................................................................................................P-4

SPECIFICATIONS - GENERAL .........................................................................P-7

SPECIFICATIONS – GAS REQUIREMENTS .................................................... P-8

SPECIFICATIONS - PHYSICAL.........................................................................P-9

SPECIFICATIONS - GAS CONNECTIONS .......................................................P-9

CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE....P-10

RETURNING PARTS TO THE FACTORY.........................................................P-10

TRAINING ......................................................................................................P-10

DOCUMENTATION............................................................................................P-10

COMPLIANCES .................................................................................................P-11

QUICK STARTUP PROCEDURE.......................................................................P-13

SECTION 1. INTRODUCTION

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

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

1.3 THEORY OF TECHNOLOGY...................................................................1-2

1.4 GAS SAFETY FEATURES.......................................................................1-3

1.5 FUEL GAS OPTION.................................................................................1-4

S

ECTION

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

2.2 ASSEMBLY..............................................................................................2-1

2.3 LOCATION...............................................................................................2-1

2.4 GASES.....................................................................................................2-2

2. I

2.4.1 Connections................................................................................2-3

NSTALLATION

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

i

C

ONTENTS

SECTION 2. (CONTINUED)

2.4.2 Gas Specifications...................................................................... 2-3

2.5 ELECTRICAL CONNECTIONS ............................................................... 2-5

2.6 INSTALLATION GUIDELINES................................................................. 2-7

SECTION 3. STARTUP AND OPERATION

3.1 OVERVIEW ............................................................................................. 3-1

3.2 DISPLAYS ............................................................................................... 3-1

3.2.1 Run Mode Display...................................................................... 3-1

3.2.2 Menu Displays............................................................................ 3-2

3.2.3 Help Displays ............................................................................. 3-4

3.3 STARTUP PROCEDURE ........................................................................ 3-4

3.4 OPTIMIZATION PROCEDURE................................................................ 3-9

3.5 BINDING.................................................................................................. 3-9

3.6 CALIBRATION......................................................................................... 3-10

3.7 CALIBRATION DETAILS......................................................................... 3-12

3.8 ROUTINE OPERATION........................................................................... 3-13

3.9 SHUT DOWN PROCEDURE..................................................................... 3-14

3.10 SAFETY SYSTEM................................................................................... 3-14

3.11 ALARM INDICATIONS............................................................................. 3-14

3.12 CONFIGURATION STORAGE ................................................................ 3-15

SECTION 4. MAINTENANCE AND TROUBLESHOOTING

4.1 GENERAL................................................................................................ 4-1

4.2 FUSES..................................................................................................... 4-2

4.3 BURNER BLOCK REMOVAL AND INSTALLATION............................... 4-3

4.4 BURNER STARTUP TROUBLESHOOTING........................................... 4-4

4.5 MAINTENANCE SCHEDULE .................................................................. 4-7

S

ECTION

5.

REPLACEMENT PARTS

5.1 REPLACEMENT PARTS......................................................................... 5-1

ii

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

APPENDIX A. GAS SAFETY FEATURES

A.1 GAS SAFETY FEATURES.......................................................................A-1

A.2 FUEL GAS OPTION.................................................................................A-1

C

ONTENTS

A

PPENDIX

B.1 ANALYZER SETUP CHECKLIST............................................................B-1

B.2 AUXILIARY MODULE SETUP.................................................................B-3

B.3 COMPUTER INTERFACE SETUP ..........................................................B-3

B. A

B.1.1 System Setup.............................................................................B-1

B.1.2 Analyzer Module Setup..............................................................B-1

NALYZER SETUP CHECKLIST

APPENDIX C. USER INTERFACE HELP

C.1 INSTRUCTIONS......................................................................................C-1

C.2 MENU ITEMS ..........................................................................................C-1

APPENDIX D. FID 2 MENU STRUCTURE

D.1 BASIC CONTROLS MENUS ...................................................................D-1

D.2 EXPERT CONTROLS MENUS................................................................D-3

D.3 ANALYZER SETUP MENUS...................................................................D-6

D.4 ANALYZER TECHNICAL CONFIGURATION MENUS............................D-15

D.5 DIAGNOSTIC MENUS.............................................................................D-19

APPENDIX E. FID 2 IDENTIFICATION MATRIX

ENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE CYLINDERS

G

ARRANTY

W

IELD SERVICE AND REPAIR FACILITIES

F

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

iii

C

ONTENTS

FIGURES

P-1 FID 2 Front Panel.................................................................................... P-13

1-1 FID 2 Analyzer Module............................................................................ 1-1

1-2 Flame Ionization Detection Technology................................................... 1-2

1-3 FID 2 Analyzer Flow Diagram.................................................................. 1-3

2-1 FID 2 Outline and Mounting Dimensions................................................. 2-3

2-2 FID 2 Rear Panel..................................................................................... 2-4

2-3 FID 2 Front Panel .................................................................................... 2-6

3-1 Run Mode Display....................................................................................3-1

3-2 Main Menu............................................................................................... 3-2

3-3 Basic Controls Menu................................................................................ 3-3

3-4 Expert Controls Menu.............................................................................. 3-3

3-5 Analyzer Module Setup Menu.................................................................. 3-4

3-6 Typical Help Menu................................................................................... 3-4

3-7 Analyzer Diagnostics Menu ..................................................................... 3-5

3-8 Self Test Results Menu............................................................................ 3-5

3-9 Light Flame Menu.................................................................................... 3-6

3-10 Typical Curves of Module Response vs. Pressure Setting on

Sample Pressure Regulator.......................................................... 3-7

3-11 Typical Curves of Module Response vs. Pressure Setting on

Fuel Pressure Regulator............................................................... 3-8

3-12 Typical Curves of Module Response vs. Pressure Setting on

Air Pressure Regulator................................................................. 3-8

3-13 Typical Calibration Gas List Menu........................................................... 3-10

3-14 Zero and Span Calibration Menu............................................................. 3-10

3-15 Calibration Parameters Menu.................................................................. 3-10

3-16 Zero/Span Diagnostic Data (Span).......................................................... 3-11

3-17 Analyzer Manufacturing Data Menu......................................................... 3-13

3-18 Store/Restore User Settings Menu.......................................................... 3-16

3-19 Store Historical Data Menu...................................................................... 3-16

4-1 Locations of Major Components of the FID 2.......................................... 4-1

4-2 Removal of FID 2 Cover .......................................................................... 4-2

4-3 Main Power Fuse..................................................................................... 4-2

4-4 Fuse Locations on Module Board............................................................ 4-3

4-5 Physical Measurement Parameters Menu............................................... 4-4

4-6 FID 2 – Exploded View............................................................................ 4-5

4-7 Burner Block – Exploded View.................................................................4-6

4-8 Burner...................................................................................................... 4-7

iv

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

FIGURES (CONTINUED)

D-1 Main Menu...............................................................................................D-1

D-2 Basic Control Menu..................................................................................D-1

D-3 Zero “Are you sure?” Menu......................................................................D-2

D-4 Light Flame Menu....................................................................................D-2

D-5 Main Menu...............................................................................................D-3

D-6 Expert Controls and Setup Menu.............................................................D-3

D-7 Expert Controls Menu..............................................................................D-4

D-8 Range Settings Menu..............................................................................D-4

D-9 Zero/span Calibration Menu - Zero..........................................................D-5

D-10 Analyzer Zero Menu.................................................................................D-5

D-11 Zero/Span Diagnostic Data Menu............................................................D-6

D-12 Analyzer Module Set Up Menu ................................................................D-6

D-13 Calibration Gas List Menu........................................................................D-7

D-14 Calibration Parameters Menu..................................................................D-7

D-15 Gas Measurement Parameters Menu......................................................D-8

D-16 Linearization Parameters.........................................................................D-9

D-17 Linearity Coefficients Menu......................................................................D-9

D-18 Response Time/Delay Parameters Menu................................................D-10

D-19 Units Menu...............................................................................................D-11

D-20 Midpoint Correction Set Up Menu............................................................D-12

D-21 Physical Measurements Parameters Menu.............................................D-12

D-22 Physical Measurements Parameters (More) Menu .................................D-13

D-23 Pressure Limits Menu..............................................................................D-13

D-24 Temperature Limits Menu........................................................................D-14

D-25 Displayed Parameters Menu....................................................................D-14

D-26 Store/Restore User Settings Menu..........................................................D-15

D-27 Main Menu..............................................................................................D-15

D-28 Technical Configuration Menu.................................................................D-16

D-29 Control Module Service Menu..................................................................D-16

D-30 Control Module Manufacturing Data Selection Menu ..............................D-16

D-31 Analyzer Manufacturing Data ..................................................................D-17

D-32 Control Module Service History Selection Menu......................................D-17

D-33 Analyzer Service History Menu...............................................................D-18

D-34 Analyzer Module Service Notes...............................................................D-18

D-35 Control Module Diagnostic Selection Menu.............................................D-19

D-36 Analyzer Diagnostics Menu .....................................................................D-19

D-37 Power Supply Voltages Menu..................................................................D-20

D-38 Primary Variable Parameters Menu.........................................................D-20

D-39 Calibration Factors Selection Menu.........................................................D-21

C

ONTENTS

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

v

C

ONTENTS

FIGURES (CONTINUED)

D-40 Range 1 Factors Menu............................................................................ D-21

D-41 Range 1 Factors History Menu................................................................ D-22

D-42 Physical Measurements Parameters Menu............................................. D-22

D-43 Temperature Control Parameters Menu.................................................. D-23

D-44 Miscellaneous Control Parameters Menu ............................................... D-23

D-45 Miscellaneous Control parameters (more) Menu .................................... D-24

D-46 Pressure Settings Menu.......................................................................... D-24

D-47 Trend Storage Control............................................................................. D-25

D-48 Auto Ignition Parameters Menu............................................................... D-25

D-49 Self Test Results..................................................................................... D-26

D-50 Software Diagnostics............................................................................... D-26

D-51 Analyzer Starting Up Menu .................................................................... D-27

D-52 Re-Initialize Menu................................................................................... D-27

TABLES

1-1 Gas Flow Rates....................................................................................... 1-5

1-2 Analyzer Characteristics Relative to Fuel Gas......................................... 1-5

2-1 Gas Supply Pressures............................................................................. 2-5

3-1 FID 2 Analyzer Module Alarms ................................................................ 3-15

4-1 Maintenance Schedule............................................................................ 4-7

A-1 Typical Flow Rates with Premixed Fuel................................................... A-2

A-2 Analyzer Characteristics for Different Fuels............................................ A-3

vi

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

P

REFACE

PURPOSE/SAFETY SUMMARY

The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of this particular NGA 2000 module.

Some sections may describe equipment not used in your configuration. The user
should become thoroughly familiar with the operation of this module before operating
it. Read this instruction manual completely.

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 this
equipment 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

Operate this equipment only when covers are secured. Servicing requires
access to live parts which can cause death or serious injury. Refer servicing to
qualified personnel.

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

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

P-1

REFACE

P

WARNING: POSSIBLE EXPLOSION HAZARD

This equipment is used in the analysis of sample gases which may be
flammable, and the burner fuel used in the ionization process IS flammable. A
system of intrinsically safe electronics and an explosion proof tower are used to
prevent any ignition of a flammable gas leak. For this to be effective, the
module MUST be placed in a well-ventilated area, with unobstructed air flow
around it.

DO NOT place it within another enclosure without assuring this ventilation.
DO NOT obstruct the vent holes on the top and sides of the module.
DO NOT place the FID module within another enclosure unless the latter has a

guaranteed air circulation such as to dilute a worst case fuel or sample leak
below 25% of the LEL. Doing so will negate the safety features and may result
in an explosion, serious injury, property damage and death.

WARNING: FLAMMABLE SAMPLES

Consult the factory if flammable samples will be measured.

WARNING: PARTS INTEGRITY

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

WARNING: POSSIBLE EXPLOSION HAZARD

Ensure that all gas connections are made as labeled and are leak free. Improper
gas connections could result in explosion and death.

P-2

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

REFACE

P

WARNING: STATIC ELECTRICITY

Circuit boards in this instrument are static-sensitive. Take all static precautions
when handling the circuit boards.

WARNING: POSSIBLE EXPLOSION HAZARD

Protection against explosion depends upon a special fuel flow restrictor in the
fuel inlet fitting. DO NOT REMOVE THE FUEL INLET RESTRICTOR. Use the
correct fuel flow restrictor for the fuel being used. Do not use 100% hydrogen
fuel in a 40% H2/60% He configured FID module. Replace with factory supplied
fitting only.

CAUTION: PRESSURIZED GAS

This module requires calibration with a known standard gas. See General
Precautions for Handling and Storing High Pressure Gas Cylinders at the rear of
this manual.

CAUTION: CONTRO LLE D ENV I RO NMENT

This equipment is for use in a controlled environment. Refer to the
specifications (page P-7 ) in this manual for environmental conditions.

CAUTION: HOT OVEN COMPONENTS

The oven and sample manifold are controlled to 80
cool down before touching any of these components.

Note

°°°°

C. Allow the analyzer to

This Analyzer Module is completely leak-tested at the factory for gas leakage.
The user is responsible for testing for leakage at the inlet and outlet fittings on
the rear panel (with a test procedure chosen by the user). The user is also
responsible for leak-testing periodically and if any internal pneumatic
components are adjusted or replaced. See leak test instructions on page 2-5.

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

P-3

REFACE

P

GLOSSARY

NALYZER MODULE

A

The module that contains all sensor/detector components for development of a
Primary Variable signal; includes all signal conditioning and temperature control
circuitry.

ACKPLANE

B

The interconnect circuit board which the Controller Board, Power Supply, Analyzer
Module power and network cables, I/O Modules and Expansion Modules plug into.

ONTROL MODULE

C

The Operator Interface plus the Controller Board.

ONTROLLER BOARD

C

The computer board that serves as the Network Manager and operates the Display
and Keypad.

ILUENT

D

The material used to dilute another material. In air, nitrogen is the diluent for the
oxygen we need to breathe.

ISTRIBUTION ASSEMBLY

D

The Backplane and the card cages that hold I/O and Expansion Modules.

XPANSION MODULE

E

A circuit board that plugs into the Backplane from the front of the Platform and
performs special features not related to I/O functions.

LAME IONIZATION

F

A technique for measuring hydrocarbon gases. A flame is used to ionize the carbon
atoms, and the charge thus generated is measured.

AS CHROMATOGRAPHY

G

A technique of separating gas stream components using absorption media, allowing
the detector to measure individual species within the stream.

YDROCARBON

H

P-4

A chemical containing only hydrogen and carbon atoms. Methane, propane and
octane are hydrocarbons.

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

REFACE

P

YDROCARBONS

H

Organic molecules containing just carbon and hydrogen. Methane, propane and oils
are example of hydrocarbons.

I/O M

ODULE

A circuit board that plugs into the Backplane from the rear of the Platform. Has a
connector terminal for communication with external data acquisition devices and
provides an input/output function.

ONIZATION

I

Generation of electrically charged particles from a neutral material. In the FID, the
flame causes hydrocarbon molecules to split into such charged ions.

LED

Light Emitting Diode – a solid state indicator light.

PERATOR INTERFACE

O

The Display and Keyboard.

LATFORM

P

Any workable collection of the following: Controller Board, Power Supply, Distribution
Assembly, Enclosure and Operator Interface.

OWER SUPPLY

P

Any of a variety of components that provides conditioned power to other NGA 2000
components, from the Power Supply Board that plugs into the front of the Backplane
in a stand-alone instrument to several larger ones that can power larger collections of
modules and components.

RIMARY VARIABLE

P

The measured species concentration value from an Analyzer Module.

URGE

P

A safety system that uses an air flow to keep any fuel gas leak under the lower
explosive limit (LEL).

AMPLE CONDITIONING

S

The process of altering the state of the sample gas so as to make it suitable for an
analyzer. This includes removing condensable water, changing the pressure, and
filtering.

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

P-5

REFACE

P

ECONDARY VARIABLE

S

Data placed on the network by a module regarding current status, e.g., sample flow,
source voltage and other diagnostic information.

OFTKEYS

S

The five function keys located below the front panel display; they assume the function
displayed directly above each on the display, a function dictated by software.

PECIES

S

A particular gas within a mixture. Oxygen is a species in air.

UBNODE

S

A subsection of the analyzer devoted to measuring one of the species for which it is
set up. Analyzers with multiple subnodes can measure multiple gases.

YSTEM

S

Any collection of Analyzer Module(s), Platform(s), I/O Module(s) and Expansion
Module(s).

P-6

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

SPECIFICATIONS - GENERAL

REFACE

P

MEASUREMENT SPECIES
H2/HE

R

FUEL

EPEATABILITY

MINIMUM DETECTABLE LEVEL
N

OISE

L

INEARITY

R

ESPONSE TIME

Z

ERO DRIFT

S

PAN DRIFT

E

FFECT OF TEMPERATURE

Total hydrocarbons
low range: 0 to 4 ppm CH4, through 0 to 1% CH

high range:: 0 to 50 ppm CH4, through 0 to <5% CH

4

4

≤1% of fullscale at a constant temperature, sample flow
and fuel, burner air and sample pressure

0.04 ppm H2/He fuel

0.01 ppm H2 fuel – methane equivalent

≤1% of fullscale, peak to peak
≤ ±1% of fullscale for H2/He fuel and H2 fuel

<1 second for bypass flow rate of 500 cc/min (for a
sample change at the rear panel connector of the
instrument)

≤ ±1% of fullscale/24 hours at constant temperature,
hydrocarbon concentration of supply gases, sample flow
and fuel, burner air and sample pressure

≤ ±1% of fullscale/24 hours at constant temperature,
hydrocarbon concentration of supply gases, sample flow
and fuel, burner air and sample pressure

≤ ±2% of fullscale for any temperature change of 10°C
and rate of change less than 10°C/hour

O

PERATING TEMPERATURE

O

PERATING HUMIDITY

P

OWER REQUIREMENTS

41°F to 104°F (5°C to 40°C)
<95% relative humidity, non-condensing

+24 VDC ±5%, 120 W max.. direct to analyzer module;
Ripple and Noise: <100 mV peak to peak
Line and Load Regulations: <±1%

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

P-7

REFACE

P

SPECIFICATIONS - GAS REQUIREMENTS

BURNER AIR
F

LOW RATE

THC
S

UPPLY PRESSURE

FUEL GAS (STANDARD)
F

LOW RATE

THC
S

UPPLY PRESSURE

Hydrocarbon free grade air
350 to 400 ml/min
≤0.1 ppm CH

4

1725 to 3450 hPa-gauge (25 to 50 psig)
Premixed 40% hydrogen and 60% helium
110 to 110 ml/min.
≤0.5 ppm CH

4

3101 to 3450 hPa-gauge (45 to 50 psig)

WARNING: POSSIBLE EXPLOSION HAZARD

Unless this Analyzer Module is factory- or field-configured specifically
for using 100% hydrogen fuel, DO NOT USE PURE HYDROGEN FUEL.
An explosion resulting in severe personal injury or death could occur.
Also, each Analyzer Module is factory-configured for either mixed or
pure hydrogen fuel, and cannot use the fuel for which it was not
configured unless field reconfiguration is done.

S

AMPLE

F

LOW RATE

S

UPPLY PRESSURE

T

EMPERATURE

P

ARTICULATES

D

EWPOINT

Non-flammable (below 100% of LEL)

0.5 to 2.0 L/min.
483 to 1035 hPa-gauge (7 to 15 psig)

32°F to 248°F (0°C to 120°C), <20°C variance/24 hours,
<10°C variance/hour

Filtered to <2 microns
<45°C

P-8

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

SPECIFICATIONS - PHYSICAL

REFACE

P

MATERIALS IN CONTACT WITH

SAMPLE

D

IMENSIONS

W

EIGHT

MOUNTING
CASE CLASSIFICATION
MAX. S

P

EPARATION FROM

LATFORM

Stainless steel, Teflon, glass-filled Teflon, Viton
See Figure 2-5, Outline and Mounting Dimensions

10.43 kg (23 lbs.)
Horizontal

General Purpose for installation in weather
protected area

1600 m (1 mile)

SPECIFICATIONS - GAS CONNECTIONS

S

AMPLE IN

B

URNER AIR IN

F

UEL IN

B

YPASS OUT

1/4 inch O.D. tube fitting
1/4 inch O.D. tube fitting
1/4 inch O.D. tube fitting
1/4 inch O.D. tube fitting

B

URNER EXHAUST

O

UT

T

HE BURNER EXHAUST AND BYPASS OUT SHALL BE VENTED TO ATMOSPHERIC PRESSURE

AND TO A NON

-

CLASSIFIED LOCATION

3/8 inch O.D. tube slip-fit connection, tygon or equivalent
(this connection shall slope downward 6° minimum from
horizontal)

.

See the Preface Section of the Platform manual for specifications regarding Platform
related components.

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

P-9

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

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: [phone]

FAX: [phone]

D

OCUMENTATION

The following NGA 2000 Flame Ionization Detection Module instruction materials are
available. Contact Customer Service or the local representative to order.

748364 Instruction Manual (this document)

P-10

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

COMPLIANCES

This product may carry approvals from several certifying agencies, like The Canadian
Standards Association (CSA), which is also an OSHA accredited Nationally
Recognized Testing Laboratory (NRTL), and LCIE - a French Notified Body.

The certification marks appear on the product name-rating plate.

REFACE

P

NRTL /C

®

LCIE 98 ATEX 6004 X
EEx d ib IIB (+H
0°C Ta +40°C
Date of Manufacture:

0081

) T6

2

II 2 G

Rosemount Analytical has satisfied all obligations from the European Legislation to
harmonize the product requirement in Europe.

This product complies with the standard level of NAMUR EMC

NAMUR

Recommendations (1993).
This product satisfies all obligations of all relevant standards of the EMC framework in

Australia and New Zealand.

N96

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

P-11

REFACE

P

NOTES

P-12

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

REFACE

P

Q

UICK STARTUP PROCEDURE

The purpose of this reference guide is to provide a easy to follow, step by step
procedure through initial start up and ignition of the FID2 Analyzer Module. This
procedure assumes that the customer has already made all necessary electrical and
gas connections and established the proper network connections.

1. Turn on power to the instrument. The #1 LED (POWER) will illuminate. The #3
LED (BLOCK) will begin flas hing.

2. If sample gas has been connected and the sample pressure to the analyzer is
sufficient to provide an accurate reading, the #4 LED (SAMPLE) will be
illumninated.

3. Allow the analyzer module to warm up and the burner block temperature to reach
the proper minimum ignition temperature (50°C). When the burner block
temperature reaches the minimum ignition temperature, the #5 LED (IGNITE OK)
will come on.

FID 2

FUEL OVERRIDE

IGNITE

POWER FLAME BLOCK SAMPLE IGNITE FUEL/AIR
OK

IGURE

F

748364-D Rosemount Analytical November 1998

P-1. FID2 F

RONT PANEL

3 2 1 LON2 LON1

T 6A

24V

250 V

NGA 2000 FID 2 Analyzer Module

P-13

REFACE

P

4. The instrument is now ready to be lit. Lighting the burner can be conducted in one
of two methods: a) manual ignition from the front panel of the Analyzer Module or
b) autoignite from the Platform.

a) To light the instrument from the Analyzer Module, hold the "FUEL

OVERRIDE/IGNITE" switch (located to the left of the indicator lights) in the up
(FUEL OVERRIDE) position for 30 seconds. Immediately move the switch to
the down (IGNITE) position. The "IGNITE" mode is automatically set to stay on
for a preset time period and does not require the switch to be held down. If the
lighting procedure was successful, the #2 LED (FLAME) will begin flashing as
the flame temperature rises to the correct operating temperature. Once this
LED becomes solidly lit, the flame has reached operating temperature.

b) To light the instrument from the Platform using the autoignite mode, simply

press the "light" softkey shown in the "Light Flame" menu of the Platform. The
Analyzer Module will begin to go through an automated sequence of
enrichment and ignition similar to the manual mode described in step 5. If the
burner fails to light on the first try, the Analyzer Module will perform 2 more
tries before terminating the autoignite sequence. If the Analyzer Module fails to
light after 3 attem pts, an erro r me ssage will be displa yed sho wing th e cau se o f
the fault.

5. If the burner fails to light, check all gas connections for proper gas composition and
pressure, block temperature, and outlets for obstructions. Repeat step 4.

6. If the flame is lit, the #2 LED will begin f lashing. Once the flame temperature has
reached the correct operating temperature, the LED will remain on solid.

7. If the fuel and air pressures and ratios are within proper operating parameters to
support a continuous flame operation, the #6 LED (FUEL/AIR) will illuminate. This
light will not be on before or during fla me ignition.

8. Once the burner block temperature reaches the control temperature of 80°C, the
#3 LED will stay on solid.

9. If the instrument has been successfully lit, the temperatures are up to proper
operating levels, and the fuel, air, and sample gases are properly adjusted to
support the flame and achieve reliable results, all 6 indicator lights will be lit solid.

The unit is now ready for calibration or burner optimization.

P-14

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

I

NTRODUCTION

1

1.1 OVERVIEW

This manual describes the Flame Ionization Detector (FID 2) Analyzer Module of
Rosemount Analytical's NGA 2000 Series of gas analysis components. See Figure 1-

1.
The FID 2 Analyzer Module is designed to use a flame ionization technique to

measure the total concentration of hydrocarbon (including certain oxygenated
hydrocarbons) components within the sample stream.

The entire FID 2 Analyzer Module is designed as a module with electrical connections
at its front, and gas connections made from the rear. All electronics relative to sample
control and signal conditioning are included in this module.

F

IGURE

FRONT

Intrinsic Safety Board

1-1. FID 2 A

Module Board

Computer Board

Regulator

Burner

Oven
(Cover removed)

REAR

Flow Control Manifold

NALYZER MODULE

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

1-1

NTRODUCTION

+++++

I

1.2 TYPICAL APPLICATIONS

Typical applications for the FID 2 Analyzer Module include:

• The monitoring of atmospheric air for low-level total hydrocarbon contaminants

• Determining the total hydrocarbon content of exhaust emissions from internal

combustion engines

• Carbon bed monitoring

• Determining the total hydrocarbons content of process and product gases from

air separation plants

1.3 THEORY OF TECHNOLOGY

This Analyzer Module uses the flame ionization method of detection. The sensor is a
burner in which a regulated flow of gas sample passes through a flame sustained by
regulated flows of a fuel gas (hydrogen or a hydrogen/diluent mixture) and air.

Within the flame, the hydrocarbon components of the sample stream undergo a
complex ionization that produces electrons and positive ions. Polarized electrodes
collect these ions, causing current to flow through an electronic measuring circuit.

Igniter

Exhaust

-

Ions

Negative
Electrode

Flame

Fuel + Sample

F

IGURE

1-2. F

-

Positive
Electrode

-

-

-

Air

LAME IONIZA TION DETECTION TECHNOLOGY

The ionization current is proportional to the rate at which carbon atoms enter the
burner, and is therefore a measure of the concentration of hydrocarbons in the
sample.

1-2

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

The gas pressures are continuously monitored and controlled through electronic
pressure transducers.

The measurement of concentration is placed on the network, where it can be shown
on the Platform Display or on other data acquisition devices.

FID
EXHAUST

FUEL IN

Bulkhead
1/4T
w/Restrictor

AIR I N

Bulkhead
1/4T
w/Filter

FUEL FLOW

CONTROL

ELEMENT

FUEL FLOW

CONTROL

AIR FLOW
CONTROL

ELEMENT

FUEL PRESSURE
SENSOR 0-30 PSIG

SENSOR,AIR
PRESSURE
0 - 30 PSIG

Elbow 1/16T - 1/8 NPT
Cres

Elbow 1/16T - 1/8 NPT
Cres

Elbow
1/16T - 1/8 NPT
Cres

SENSOR,SAMPLE
PRESSURE
0 - 15 PSIG

NTRODUCTION

I

OVEN

Bulkhead 1/4T
External
Filter/Restrictor
Required

SAMPLE IN

SAMPLE
BYPASS

Bulkhead
1/4T

FOR STANDARD MIXED FUEL APPLICATION USE 658146 FUEL CAPILLARY AND 659031 SAMPLE CAPILLARY.

1

FOR 100% FUEL APPLICATION USE 658145 FUEL CAPILLARY AND 659033 SAMPLE CAPILLARY.

F

IGURE

1-3. FID 2 A

NALYZER FLOW DIAGRAM

Union
1/16T
Cres

Elbow
1/4T- 1/4MPT
Cres

Union
1/16T
Cres

Union
1/16T
Cres

Union
1/16T
Cres

FUEL

CAPILLARY

1

AIR CAPILLARY

SAMPLE

CAPILLARY

1

FLAME

IONIZATION

DETECTOR

(FID)

1.4 GAS SAFETY FEATURES

The FID 2 module is divided into two parts - a pneumatic section and an electronic
section. The two sections are separated by a pair of solid partitions to prevent any
leak of gas in the pneumatic section from reaching the electronics. The electrical

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

1-3

NTRODUCTION

I

connections into the pneumatic section are made intrinsically safe by a series of over­voltage protection devices and current limiting resistors. The burner itself is an
explosion-proof assembly. The combination of these two techniques allows the
analyzer to meet international safety standards without the use of an expensive
continuous-dilution purge - but ONLY when it is installed in a general purpose area
with good air circulation.

WARNING: POSSIBLE EXPLOSION HAZARD

Hydrocarbon concentration(s) in the sample gas must be below the Lower
Explosion Limit (LEL).

All tubing ahead of the burner is rigid m etallic tubing assembled with ferrule/nut type
compression fittings. However, should an internal fuel leak occur, a worst-case leak
would be dissipated below 25% of the LEL of hydrogen by natural dilution outside of
the pneumatic section before it could be ignited by any external ignition source, and
there is nothing within the pneumatic section to ignite it.

The FID 2 is designed to use 100% hydrogen fuel or 40% H2/60% He fuel at a
maximum inlet pressure of 3446 hPa-gauge (50 psig). A different flow restrictor is
used for each fuel type1.

WARNING: POSSIBLE EXPLOSION HAZARD

Protection against explosion depends upon a special fuel flow restrictor1 at the
fuel inlet. DO NOT REMOVE THE FUEL INLET RESTRICTOR.

1.5 FUEL GAS OPTION

The standard FID 2 Analyzer Module requires 40% hydrogen/60% helium burner fuel
gas. As an option, the analyzer module can be equipped to use 100% hydrogen fuel.
The particular application and characteristics of the sample gas to be measured will
dictate the preferred type of fuel. The following guidelines can be used for determining
fuel gas type:

For measuring low-level hydrocarbons in ambient air or in other sample gas with
relatively constant oxygen content, 100% hydrogen is preferable. It provides the
highest obtainable sensitivity and maximum stability.

1

The fuel restrictor is part of the Flow Control Manifold Assembly, which is specific to an application.

1-4

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

NTRODUCTION

I

For monitoring internal combustion exhaust emissions or other sample gas with
varying oxygen content, mixed fuel is preferable. In fact, a hydrogen/helium mixture is
more desirable than a hydrogen/nitrogen mixture. With this type of sample, the use of
mixed fuel gas minimizes the error introduced by oxygen synergism.

Changes in the burner air flow rate have little effect on signal strength. For a given
flow, the signal can be optimized by adjusting the fuel flow rate.

Typical flow rates to the burner:

2

MIXED FUEL

T

ABLE

F

UEL

S

AMPLE

A

IR

1-1. G

GAS FLOW PURE H

30 cc/min 100 cc/min
55 cc/min 13 cc/min
300 cc/min 400 cc/min

AS FLOW RATES

Note that with a 40/60 premixed fuel, the above flow rates amount to 40 cc (8%)
hydrogen, 73 cc (14%) inert plus sample and 400 cc (78%) air, which compare closely
to the 30 cc (8%) hydrogen, 55 cc (14%) inert/sample and 300 cc (78%) air noted
earlier for straight hydrogen fuel.

ANALYZER

CHARACTERISTICS

F

ULL SCALE SENSITIVITY

F

UEL CONSUMPTION

O

PERATING SETTING FOR

S

AMPLE PRESSURE

R

EGULATOR

1 ppm, CH4 to <2500 ppm CH
50 to 60 cc/min 100 to 110 cc/min

345 hPa-gauge (5 psig) 345 hPa-gauge (5 psig)

100% H

2

4

40% H2/60% He

4 ppm, CH4 to <1%,
CH

4

T

ABLE

748364-D Rosemount Analytical November 1998

1-2. A

NALYZER CHARACTERISTICS RELATIVE TO FUEL GAS

NGA 2000 FID 2 Analyzer Module

1-5

NTRODUCTION

I

N

OTES

1-6

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module

I

NSTALLATION

2

2.1 UNPACKING

When the FID 2 Analyzer Module is received, carefully examine the shipping carton
and contents for signs of damage. Immediately notify the shipping carrier if the carton
or contents is damaged. Retain the carton and packing material until all components
associated with the Analyzer Module are operational.

2.2 ASSEMBLY

The FID 2 analyzer module MUST NOT be placed within a conventional NGA platform,
single module enclosure or dual module enclosure since the latter would not allow free
flow of air around the module, thus violating its safety certification. The enclosure is
designed so that this would be very hard to do anyway.

There is a special platform specifically designed to accept this module; consult the
factory for details.

Install the Platform and I/O Module(s) according to guidelines in the Platform manual.

2.3 LOCATION

WARNING: POSSIBLE EXPLOSION HAZARD

Do not place the FID 2 module within another enclosure unless the latter has a
guaranteed air circulation such as to dilute a worst case fuel or sample leak
below 25% of the LEL. Failure to will negate the safety features and may result
in explosion, serious injury, material damage and death. Also, do not cover the
vent holes on the top and sides of the module.

Install the Analyzer Module in a clean, weather-proofed, non-hazardous, vibration-free
location free from extreme temperature variations. For best results, install the Analyzer
Module near the sample stream to minimize sample transport time.

Operating ambient temperature is 5 °C to 40 °C, limited to temperature changes of
less than 10 °C/hr. Acceptable dew point range is less than 95% relative humidity,
but not in excess of 40°C wet bulb temperature.

748364-D Rosemount Analytical November 1998

NGA 2000 FID 2 Analyzer Module

2-1

NSTALLATION

I

The cylinders of fuel, air, and calibration gases should be located in an area of
relatively constant ambient temperature.

2.4 GASES

During normal operation, the Analyzer Module requires fuel and air to maintain the
burner flame as well as suitable standard gases for. Refer to the criteria for selection
of these gases in Section 2.4.2.

After initial startup or after startup following a prolonged shutdown, the analyzer may
display baseline drift for a considerable period of time, particularly on the most
sensitive range.

Commonly, the drift is caused by small amounts of organics (such as hydrocarbons) in
the inner walls of the tubing in both the internal flow system and the external gas
supply system. Drift results from any factor influencing the equilibrium of these
adsorbed hydrocarbons, such as temperature or pressure. Hydrocarbons adsorbed
within the analyzer in the gas passageways (or in th e fuel or air lines) will elevate the
overall baseline.

Note that this type of drift occurs only when the flame is burning. If drift occurs when
the flame is extinguished, the electronic circuitry is at fault or the burner or cabling is
contaminated with a conductive film. To minimize drift, use clean fuel and air, keep the
analyzer clean, and locate the gas cylinders in an area of relatively constant ambient
temperature.

The cylinders supplying all gases each should be equipped with a clean, hydrocarbon­free, two-stage regulator and a shutoff valve.

All new external gas tubing (except for SAMPLE BYPASS) is strongly recommended,
preferably pre-cleaned, stainless steel, gas chromatograph-grade tubing. Thoroughly
clean before use (if a hydrocarbon-based cleaning solvent such as acetone is used,
purge tubing with dry nitrogen or helium for several minutes before using.)

Gas line connections are compression fittings. Do not use pipe thread tape on such
fittings.

Since the oxidation of hydrogen is accompanied by the formation of water vapor, the
exhaust tubing always should be slanted downward at least 6 degrees from horizontal.
Otherwise, water may accumulate in the line, causing back pressure and noisy
readings, or may back up in the line and flood the burner.

If the sample is toxic or noxious, or is to be reclaimed, connect the Bypass outlet to a
suitable disposal system. Do not use any device that may cause back pressure in the
line.

2-2

November 1998 Rosemount Analytical 748364-DNGA 2000 FID 2 Analyzer Module