Manual: NGA 2000 FID2 Hydrocarbon Analyzer Module SW 3.3-Rev E | Rosemount
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Instruction Manual
748412-E
March 2003
Model NGA2000 FID2
Flame Ionization Detector Module
http://www.processanalytic.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you
MUST properly install, use, and maintain them
normal specifications. The following instructions MUST be adhered to and integrated into your
safety program when installing, using, and maintaining Rosemount Analytical products. Failure to
follow the proper instructions may cause any one of the following situations to occur: Loss of life;
personal injury; property damage; damage to this instrument; and warranty invalidation.
to ensure they continue to operate within their
• Read all instructions
prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Rosemount Analytical repre-
sentative 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 mainte-
nance of the product.
• Install your equipment as specified in the Installation Instructions of the appropriate In-
struction Manual and per applicable local and national codes. Connect all products to the
proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel
to install, operate, update, program,
and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts
specified by Rosemount. Unauthorized parts and procedures can affect the product’s per-
formance, place the safe operation of your process at risk, and VOID YOUR WARRANTY
.
Look-alike substitutions may result in fire, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except
when maintenance is being performed by qualified persons, to prevent electrical shock
and personal injury.
The information contained in this document is subject to change without notice.
Teflon® is a registered trademark of E.I. duPont de Nemours and Co., Inc.
Kynar® is a registered trademark of Pennwalt, Inc.
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com
Model NGA2000 FID2
TABLE OF CONTENTS
Instruction Manual
748412-E
March 2003
PREFACE...........................................................................................................................................P-1
Definitions ...........................................................................................................................................P-1
Safety Summary .................................................................................................................................P-2
General Precautions For Handling And Storing High Pressure Gas Cylinders .................................P-5
Documentation....................................................................................................................................P-6
Compliances .......................................................................................................................................P-6
Glossary of Terms ............................................................................................................................P-7
Quick Startup Procedure ....................................................................................................................P-9
1.0 DESCRIPTION AND SPECIFICATIONS..............................................................................1-1
1-1 Overview................................................................................................................................1-1
1-2 Typical Applications...............................................................................................................1-1
1-3 Theory of Technology............................................................................................................1-2
1-4 Gas Safety Features..............................................................................................................1-5
1-5 Fuel Gas Option ....................................................................................................................1-5
1-6 Specifications.........................................................................................................................1-7
a. General ...........................................................................................................................1-7
b. Physical...........................................................................................................................1-7
c. Gas Requirements ..........................................................................................................1-8
d. Gas Connections.............................................................................................................1-8
2.0 INSTALLATION ....................................................................................................................2-1
2-1 Unpacking..............................................................................................................................2-1
2-2 Assembly ...............................................................................................................................2-1
2-3 Location .................................................................................................................................2-1
2-4 Gases ....................................................................................................................................2-1
a. Overview .........................................................................................................................2-1
b. Connections ....................................................................................................................2-2
c. Gas Specifications ..........................................................................................................2-2
2-5 Electrical Connections ...........................................................................................................2-5
2-6 Analytical Leak Check ...........................................................................................................2-6
a. Flow Indicator Method.....................................................................................................2-6
b. Manometer Method.........................................................................................................2-6
c. Troubleshooting Leaks....................................................................................................2-6
2-7 Installation Guidelines ...........................................................................................................2-7
3.0 OPERATION .........................................................................................................................3-1
3-1 Overview................................................................................................................................3-1
3-2 Displays .................................................................................................................................3-1
a. Run Mode Display...........................................................................................................3-1
b. Menu Displays.................................................................................................................3-1
c. Help Displays ..................................................................................................................3-3
3-3 Startup Procedure .................................................................................................................3-4
3-4 Optimization Procedure .........................................................................................................3-7
3-5 Binding...................................................................................................................................3-8
3-6 Calibration..............................................................................................................................3-8
3-7 Calibration Details .................................................................................................................3-10
3-8 Routine Operation .................................................................................................................3-11
Rosemount Analytical Inc. A Division of Emerson Process Management Contents i
Instruction Manual
748412-E
March 2003
3-9 Shut Down Procedure ...........................................................................................................3-12
3-10 Safety System .......................................................................................................................3-12
3-11 Alarm Indications ...................................................................................................................3-13
3-12 Configuration Storage............................................................................................................3-14
4.0 MAINTENANCE AND SERVICE ..........................................................................................4-1
4-1 General ..................................................................................................................................4-1
4-2 Overview................................................................................................................................4-1
4-3 Disassembly ..........................................................................................................................4-2
4-4 Fuses .....................................................................................................................................4-2
4-5 Burner Block Removal And Installation .................................................................................4-4
4-6 Burner Startup And Troubleshooting.....................................................................................4-4
4-7 Maintenance Schedule ..........................................................................................................4-8
5.0 REPLACEMENT PARTS......................................................................................................5-1
5-1 Matrix .....................................................................................................................................5-1
5-2 Replacement Parts ................................................................................................................5-2
6.0 RETURN OF MATERIAL......................................................................................................6-1
6-1 Return Of Material .................................................................................................................6-1
6-2 Customer Service ..................................................................................................................6-1
6-3 Training..................................................................................................................................6-1
Model NGA2000 FID2
7.0 APPENDIX A. MENU SCREENS.........................................................................................7-1
ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 FID2
LIST OF ILLUSTRATIONS
Figure 1-1. Flame Ionization Detection Technology ................................................................ 1-1
Figure 1-2. FID2 Analyzer Flow Diagram................................................................................. 1-3
Figure 1-3. FID2 Wiring Diagram ............................................................................................. 1-4
Figure 2-1. FID2 Outline and Mounting Dimensions................................................................ 2-3
Figure 2-2. FID2 Rear Panel .................................................................................................... 2-4
Figure 2-3. FID2 Front Panel .................................................................................................. 2-5
Figure 2-4. Leak Test - Flow Indicator Method ........................................................................ 2-6
Figure 2-5. Leak Test - Manometer Method............................................................................. 2-6
Figure 3-1. Run Mode Display ................................................................................................. 3-1
Figure 3-2. Main Menu ............................................................................................................. 3-1
Figure 3-3. Basic Controls Menu.............................................................................................. 3-2
Figure 3-4. Expert Controls Menu ............................................................................................ 3-2
Figure 3-5. Analyzer Module Setup Menu................................................................................ 3-2
Figure 3-6. Typical Help Menu ................................................................................................. 3-3
Figure 3-7. Analyzer Diagnostics Menu ................................................................................... 3-4
Figure 3-8. Self Test Results Menu.......................................................................................... 3-4
Figure 3-9. Light Flame Menu .................................................................................................. 3-5
Figure 3-10. Typical Module Response vs. Sample Pressure Setting....................................... 3-6
Figure 3-11. Typical Module Response vs. Fuel Pressure Setting ............................................ 3-6
Figure 3-12. Typical Curves of Module Response vs. Pressure Setting on Air Pressure
Regulator ............................................................................................................... 3-7
Figure 3-13. Typical Calibration Gas List Menu......................................................................... 3-8
Figure 3-14. Zero and Span Calibration Menu........................................................................... 3-8
Figure 3-15. Calibration Parameters Menu................................................................................ 3-8
Figure 3-16. Zero/Span Diagnostic Data.................................................................................... 3-8
Figure 3-17. Analyzer Manufacturing Data Menu .................................................................... 3-11
Figure 3-18. Store/Restore User Settings Menu...................................................................... 3-14
Figure 3-19. Store Historical Data Menu.................................................................................. 3-14
Figure 4-1. Location of Major Components.............................................................................. 4-1
Figure 4-2. Removal of FID2 Cover ......................................................................................... 4-2
Figure 4-3. Main Power Fuse Location .................................................................................... 4-3
Figure 4-4. Fuse Locations on Module Board.......................................................................... 4-3
Figure 4-5. Physical Measurements Menu............................................................................... 4-4
Figure 4-6. Removal of Oven Cover ........................................................................................ 4-5
Figure 4-7. FID2 – Exploded View ........................................................................................... 4-6
Figure 4-8. Burner Block -Exploded View ................................................................................ 4-7
Figure 4-9. Burner .................................................................................................................... 4-8
Instruction Manual
748412-E
March 2003
LIST OF TABLES
Table 1-1. Gas Flow Rates ..................................................................................................... 1-5
Table 1-2. Analyzer Characteristics Relative to Fuel Gas ...................................................... 1-6
Table 2-1. Gas Supply Pressures ........................................................................................... 2-4
Table 3-1. FID2 Analyzer Module Alarms............................................................................. 3-13
Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii
Instruction Manual
748412-E
March 2003
Model NGA2000 FID2
iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 FID2
The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of the NGA2000 FID2 and the System Accessories
of the NGA 2000 System.
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.
The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout
this publication.
Instruction Manual
748412-E
March 2003
PREFACE
DEFINITIONS
DANGER .
Highlights the presence of a hazard which will cause severe personal injury, death, or substantial
property damage if the warning is ignored.
WARNING .
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.
CAUTION.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.
NOTE
Highlights an essential operating procedure,
condition or statement.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-1
Instruction Manual
748412-E
March 2003
Model NGA2000 FID2
SAFETY SUMMARY
If this equipment is used in a manner not specified in these instructions, protective systems may be impaired.
AUTHORIZED PERSONNEL
To avoid explosion, loss of life, personal injury and damage to this equipment and on-site property,
all personnel authorized to install, operate and service the this equipment should be thoroughly
familiar with and strictly follow the instructions in this manual. SAVE THESE INSTRUCTIONS.
DANGER.
ELECTRICAL SHOCK HAZARD
Do not operate without doors and covers secure. Servicing requires access to live parts which can
cause death or serious injury. Refer servicing to qualified personnel. For safety and proper performance this instrument must be connected to a properly grounded three-wire source of power.
WARNING .
POSSIBLE EXPLOSION HAZARD
This equipment is used in the analysis of sample gases which may be flammable, and the burner
fuel used in the ionization process IS flammable. A 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 circu-
lation 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.
P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 FID2
Tampering or unauthorized substitution of components may adversely affect safety of this produc t.
Use only factory documented components for repair.
Do not place hands or fingers in the Platform front handles when front panel is open. Dropping the
front panel of the Platform while hand or fingers are inside either handle can cause serious injury.
Ensure that all gas connections are made as labeled and are leak free. Improper gas connections
could result in explosion or death.
Instruction Manual
748412-E
March 2003
WARNING.
PARTS INTEGRITY
WARNING.
HAND INJURY HAZARD
WARNING.
POSSIBLE EXPLOSION HAZARD
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 periodic use of pressurized gas. See General Precautions for Handling and
Storing High Pressure Gas Cylinders, page P-5.
CAUTION .
OVERBALANCE HAZARD
This analyzer module may tip instrument over if it is pulled out too far and the Platform is not properly supported.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3
Instruction Manual
748412-E
March 2003
Model NGA2000 FID2
CAUTION.
CONTROLLED ENVIRONMENT
This equipment is for use in a controlled environment. Refer to Section 1-6 Specifications (page 1-
7) in this manual for environmental conditions.
CAUTION.
HOT OVEN COMPONENTS
The oven and sample manifold are controlled to 80°C. Allow the analyzer to cool down before
touching any of these components.
CAUTION.
OVER-VOLTAGE SPIKING
If this analyzer module is used with a non-Rosemount Analytical power supply, adding Rosemount
Analytical PN 903341 Current Protector in series with the 24V positive power line will prevent overvoltage spiking and resultant fuse blowing when powering up the instrument.
CAUTION .
STATIC ELECTRICITY
Circuit boards in this instrument are static-sensitive. Take all static precautions when handling the
circuit boards
NOTE
This Analyzer Module is completely leak-tested at the factory for gas leakage. The user is responsible for testing for leakage at the inlet and outlet fittings on the rear panel (with a test procedure
chosen by the user). The user is also responsible for leak-testing periodically and if any internal
pneumatic components are adjusted or replaced. See leak test instructions in Section 2-6 on page
2-6.
P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Instruction Manual
748412-E
Model NGA2000 FID2
March 2003
GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH
PRESSURE GAS CYLINDERS
Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed
Gases" published in 1981
Compressed Gas Association
1235 Jefferson Davis Highway
Arlington, Virginia 22202
Used by Permission
1. Never drop cylinders or permit them to strike each other violently.
2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather and, to prevent rusting, from the dampness of the ground. Cylinders
should be stored in the shade when located in areas where extreme temperatures are prevalent.
3. The valve protection cap should be left on each cylinder until it has been secured against a
wall or bench, or placed in a cylinder stand, and is ready to be used.
4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved
by using a suitable hand-truck.
5. Never tamper with safety devices in valves or cylinders.
6. Do not store full and empty cylinders together. Serious suckback can occur when an empty
cylinder is attached to a pressurized system.
7. No part of cylinder should be subjected to a temperature higher than 125
should never be permitted to come in contact with any part of a compressed gas cylinder.
8. Do not place cylinders where they may become part of an electric circuit. When electric arc
welding, precautions must be taken to prevent striking an arc against the cylinder.
°
F (52°C). A flame
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5
Instruction Manual
9
6
748412-E
March 2003
Model NGA2000 FID2
DOCUMENTATION
The following NGA2000 FID2 instruction materials are available. Contact Customer Service Center or the
local representative to order.
748412 Instruction Manual (this document)
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.
®
NRTL /C
Rosemount Analytical Inc. has satisfied all obligations from the European Legislation to harmonize the
product requirements in Europe.
This product complies with the standard level of NAMUR EMC. Recommendation (May 1993).
This product satisfies all obligations of all relevant standards of the EMC framework in Australia and New
Zealand.
LCIE 98 ATEX 6004 X
EEx d ib IIB (+H
0°C Ta +40°C
Date of Manufacture:
0081
NAMUR
) T6
2
II 2 G
N
P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 FID2
GLOSSARY OF TERMS
Analyzer Module
The module that contains all sensor/detector components for development of a Primary Variable signal; includes all signal conditioning and temperature control circuitry.
Backplane
The interconnect circuit board which the Controller Board, Power Supply, Analyzer Module power and network cables, I/O Modules and Expansion Modules plug into.
Control Module
The Operator Interface plus the Controller Board.
Controller Board
The computer board that serves as the Network Manager and operates the Display and Keypad.
Distribution Assembly
Instruction Manual
748412-E
March 2003
The Backplane and the card cages that hold I/O and Expansion Modules.
Expansion Module
A circuit board that plugs into the Backplane from the front of the Platform and performs special features
not related to I/O functions.
I/O Module
A circuit board that plugs into the Backplane from the rear of the Platform. Has a connector terminal for
communication with external data acquisition devices and provides an input/output function.
Operator Interface
The Display and Keyboard.
Platform
Any workable collection of the following: Controller Board, Power Supply, Distribution Assembly, Enclosure
and Operator Interface.
Power Supply
Any of a variety of components that provides conditioned power to other 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.
Primary Variable
The measured species concentration value from an Analyzer Module.
Secondary Variable
Data placed on the network by a module regarding current status, e.g., sample flow, source voltage and
other diagnostic information.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-7
Instruction Manual
748412-E
March 2003
Model NGA2000 FID2
Softkeys
The five function keys located below the front panel display; they assume the function displayed directly
above each on the display, a function dictated by software.
System
Any collection of Analyzer Module(s), Platform(s), I/O Module(s) and Expansion Module(s).
P-8 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 FID2
QUICK STARTUP PROCEDURE
Instruction Manual
748412-E
March 2003
The purpose of this reference guide is to provide a easy to follow, step-by-step procedure
through initial start-up an 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 flashing.
2. If sample gas has been connected and
the sample pressure to the analyzer is
sufficient to provide and accurate reading, the #4 LED (SAMPLE) will be illuminated.
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.
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) auto-ignite 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 the LED becomes solidly lit,
the flame has reached operating
temperature.
b. To light the instrument from the Plat-
form using the auto-ignite 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 the first try, the Analyzer
Module will perform 2 more tries before terminating the auto-ignite sequence. If the Analyzer Module fails
to light after 3 attempts, an error
message will be displayed showing
the cause of 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
flashing. 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 flame 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 be 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 instrument is now ready for calibration
or burner optimization.
Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-9
Instruction Manual
748412-E
March 2003
Model NGA2000 FID2
P-10 Preface Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 FID2
DESCRIPTION AND SPECIFICATIONS
1-1 OVERVIEW
Instruction Manual
748412-E
March 2003
SECTION 1
This manual describes the Flame Ionization
Detector (FID2) Analyzer Module of Rosemount Analytical's NGA 2000 Series of gas
analysis components.
The FID2 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 FID2 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.
Igniter
Positive
Electrode
1-2 TYPICAL APPLICATIONS
Typical applications for the FID2 Analyzer
Module include:
• The monitoring of atmospheric air for lowlevel 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.
Exhaust
+
-
Ions
+
+
+
-
Negative
Electrode
+
Flame
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1
Air
Fuel + Sample
Figure 1-1. Flame Ionization Detection Technology
Instruction Manual
748412-E
March 2003
Model NGA2000 FID2
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 (a hydrogen/diluent
mixture) and air.
Within the flame, the hydrocarbon components of the sample stream undergo a complex ionization that produces electrons and
positive ions. Polarized electrodes collect
these ions, causing current to flow through an
electronic measuring circuit.
The ionization current is proportional to the
rate at which carbon atoms enter the burner,
and is therefore a measure of the concentration of hydrocarbons in the sample.
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.
1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 FID2
A
FLOW CONTROL
MANIFOLD ASSEMBLY
659043
5 REAR PANEL IS INCLUDED IN FLOW CONTROL MANIFOLD ASSEMBLY 659043.
4 MANIFOLD ASSEMBLY 659043 MUST BE RETURNED TO FACTORY WHEN REPLACMEN T OF AIR AND/OR FUEL FLOW FLUISTER VALVES IS REQUIRED .
3 15 PSI 2 L/MIN.: 659178
2 PSI 1 L/MIN.: 659 073
NO RESTRICTOR : 008435
2 STD MIXED FU EL: 659514
1 STD MIXED FUEL: 658146 FUEL CAP ILLARY, 659031 SAMP LE CAPILLARY
FID EXHAUST
FTG, BULKHEAD
W/RESTRICTOR
1/4T-1/8MP T
FTG, MALE CONN
1/4T-1/8MPT
008435
W/FILTER 017154
REAR PANEL5
SAMPLE IN
FTG, BULKH EAD
SAMPLE OUT
FTG, MALE CONN
1/4T-1/8MP T
008435
FUEL IN
AIR IN
FUEL FLOW
CONTROL
FLUISTER
VALVE
659541
2
IR FLOW
CONTROL
FLUISTER
VALVE
659541
3
4
4
MANIFOLD
SENSOR, AIR
PRESSURE
0-30 PSIG
659498
SENSOR, FUEL
PRESSURE
0-30 PSIG
659498
BACK PRESSURE
REGULATOR
659063
FTG, ELBOW
1/16T-1/8M PT
904582
(3)
659072
SENSOR, SAMPLE
PRESSURE
0-15 PSIG
659497
659038
659037
FTG, UNION
1/16T
818270
FTG ASSEMBLY
659173
FTG, FLBOW
1/4T-1/4MP T
902147
Figure 1-2. FID2 Analyzer Flow Diagram
FTG, UNION
1/16T
818270
Instruction Manual
748412-E
March 2003
FTG, UNION
1/16T
818270
FTG, UNION
1/16T
818270
FUEL
CAPILLARY
AIR
CAPILLARY
SAMPLE
CAPILLARY11
FLAME
IONIZATION
DETECTOR
(FID)
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3
Instruction Manual
748412-E
March 2003
FLOW CONTROL
FLUISTOR
CABLE
CONTINUITY
NCNC
J7J2
J9
J16
J8 J5
IGNITER
POLARIZED
COLLECTOR
BURNER BLOCK
BURNER BLOCK ASSEM BLY
1
CONNECTORS J5 AND J6 ON INTRINSICALLY SAFE BOARD ARE INTERCHANGEABLE.
FACTORY REPLACEMENT.
2
REAR SECTION OF ANALYZER FRONT SECTION OF ANALYZER
FUEL
FLOW CONTROL
FLUISTOR
AIR
659070
FLAME
THERMISTOR
BURNER
BLOCK HEATER
2
J1
FUEL
PRESSURE
SENSOR
0-30 PSIG
J12 J13J3 J11 J4
2
AIR
PRESSURE
SENSOR
0-30 PSIG
INTRINSICALLY SAFE BOARD
1
RTD
MIDDLE
SECTION OF
ANALYZER
SAMPLE
RESSURE
SENSOR
0-15 PSIG
THIS SECTION OF INTRINSICALLY
SAFE BOARD CONTAINS CURRENT-
LIMITING RESISTORS
J6
POLARIZED
COLLECTOR
1
J15
Figure 1-3. FID2 Wiring Diagram
Model NGA2000 FID2
THIS SECTION OF
INTRINSICALLY SAFE BOARD
CONTAINS ±15 SUPPLIES,
+90V SUPPLY AND LOW-
LEVEL ANALOG CIRCUITS
J15
J15 J14 J25
MODULE BOARD 659060
J6 J5
COMPUTER BOARD
J7
J8J11
NCNC
658350
J14 J17
J1J4
J2
J3
J22
J24
J22
LON1
LON2
24V POWER
1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 FID2
Instruction Manual
748412-E
March 2003
1-4 GAS SAFETY FEATURES
The FID2 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 connections into the
pneumatic section are made intrinsically safe
by a series of over-voltage 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).
The FID2 is designed to use 40% H
fuel at a maximum inlet pressure of 3446 hPagauge (50 psig).
1
WARNING
POSSIBLE EXPLOSION HAZARD
Protection against explosion depends
upon a special fuel flow restrictor at the
fuel inlet. DO NOT REMOVE THE FUEL
INLET RESTRICTOR.
1-5 FUEL GAS OPTION
The standard FID2 Analyzer Module requires
40% hydrogen/60% helium burner fuel gas.
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.
/60% He
2
All tubing ahead of the burner is rigid metallic
tubing assembled with ferrule/nut type compression fittings. However, should an internal
fuel leak occur, a worst-case leak would be
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.
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.
Refer to Table 1-1. Gas Flow Rates below.
GAS FLOW MIXED FUEL
FUEL
SAMPLE
AIR
100 cc/min
10 cc/min
400 cc/min
Table 1-1. Gas Flow Rates
1
The fuel restrictor is part of the Flow Control Manifold
Assembly, which is specific to an application.
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5
Instruction Manual
748412-E
March 2003
ANALYZER CHARACTERISTICS
Full Scale Sensitivity
Fuel Consumption
Operating Setting For Sample Pressure Regulator
Model NGA2000 FID2
40% H
4 ppm, CH
100 to 110 cc/min
345 hPa-gauge (5 psig)
Table 1-2. Analyzer Characteristics Relative to Fuel Gas
to <1%, CH4
4
/60% He
2
1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 FID2
1-6 SPECIFICATIONS
a. General
Measurement Species .................. Total hydrocarbons
Range H
Repeatability.................................. ≤1% of fullscale at a constant temperature, sample flow and fuel,
Min. Detectable Level ................... 0.04 ppm H
Noise ............................................ <1% of fullscale, peak to peak
Linearity ........................................ ≤ ±1% of fullscale
Response Time ............................
Zero Drift ....................................... ≤ ±1% of fullscale/24 hours at constant temperature, hydrocarbon
Span Drift ...................................... ≤ ±1% of fullscale/24 hours at constant temperature, hydrocarbon
Effect of Temperature ................... ≤ ±2% of fullscale for any temperature change of 10°C and rate of
Operating Temperature ................ 41°F to 104°F (5°C to 40°C)
Operating Humidity........................ <95% relative humidity, non-condensing
Power Requirements .................... +24 VDC ±5%, 120 W max.. direct to analyzer module;
b. Physical
/He fuel
2
Low range.............................. 0 to 4 ppm CH
High range ............................. 0 to 50 ppm CH
Ripple and Noise ................... <100 mV peak to peak
Line and Load Regulations.... <±1%
Instruction Manual
748412-E
March 2003
, through 0 to 1% CH4
4
, through 0 to <5% CH4
4
burner air and sample pressure
/He fuel – methane equivalent
2
≤1 sec. for bypass flow rate of 500 cc/min (for a sample change at
the rear panel connector of the instrument)
concentration of supply gases, sample flow and fuel, burner air and
sample pressure
concentration of supply gases, sample flow and fuel, burner air and
sample pressure
change less than 10°C/hour
Case Classification ........................ General purpose for installation in weather-protected area
Dimensions ................................... See Outline and Mounting Dimensions, Figure 2-1, on page 2-3
Weight .......................................... 10.43 kg (23 lbs.)
Mounting ....................................... Inside a Platform or custom-installed in a panel
Max. Length of LON Cable ........... 1600m (1 mile) between Analyzer Module and Platform
Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7
Instruction Manual
748412-E
March 2003
c. Gas Requirements
Sample .......................................... Non-flammable, below 100% LEL
Temperature ......................... 32°F to 248°F (0°C to 120°C), <20°C variance/24 hours, <10°C
Flow Rate............................... 0.5 to 2.0 ml/min.
Supply Pressure .................... 483 to 1035 hPa-gauge (7 to 15 psig)
Particles ................................. Filtered to <2 microns
Dewpoint ............................... <45°C
Materials in contact
with Sample ................ Stainless steel, Teflon, glass-filled Teflon, Viton
Fuel Gas ....................................... Premixed 40% hydrogen and 60% helium
Flow Rate............................... 75 to 110 ml/min.
THC ....................................... ≤0.5 ppm, CH
Supply Pressure .................... 3101 to 3450 hPa-gauge (45 to 50 psig)
variance/hour
Model NGA2000 FID2
4
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 mixed, and cannot use the fuel for which it was not configured unless field reconfiguration is done.
Burner Air ...................................... Hydrocarbon-free grade air
Flow Rate............................... 350 to 400 ml/min.
THC ....................................... ≤ 0.1 ppm, CH
Supply Pressure .................... 1725 to 3450 hPa-gauge (25 to 50 psig)
d. Gas Connections
Sample In ...................................... 1/4” O.D. tube fitting
Burner Air In .................................. 1/4” O.D. tube fitting
Fuel In............................................ 1/4” O.D. tube fitting
Bypass Out .................................... 1/4” O.D. tube fitting
Burner Exhaust Out....................... 3/8” O.D. tube slip-fit connection, tygon or equivalent (this connec-
WARNING.
POSSIBLE EXPLOSION HAZARD
4
tion shall slope downward 6° minimum from horizontal)
NOTE
The burner exhaust and bypass out shall be vented to atmospheric pressure and to a nonclassified location. .
See the Preface section of the Platform manual for specifications regarding Platform-related components
(e.g., case dimensions) and the I/O Module manual for specifications regarding I/O (e.g., relay outputs).
1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 FID2
Instruction Manual
748412-E
March 2003
SECTION 2
INSTALLATION
2-1 UNPACKING
When the FID2 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 FID2 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.
2-3 LOCATION
WARNING.
POSSIBLE EXPLOSION HAZARD
Do not place the FID2 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, vibrationfree 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.
The cylinders of fuel, air, and calibration
gases should be located in an area of relatively constant ambient temperature.
CAUTION .
PRESSURIZED GAS
See General Precautions for Handling and
Storing High Pressure Gas Cylinders, page
P-5.
2-4 GASES
a. Overview
During normal operation, the Analyzer
Module requires fuel and air to maintain
the burner flame as well as suitable standard gases for. Refer to the criteria for
selection of these gases in Section 2-4c
on page 2-2.
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 the fuel or air lines)
will elevate the overall baseline.
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1
Instruction Manual
748412-E
March 2003
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, hydrocarbon-free, 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.
Model NGA2000 FID2
exhaust and bypass must be vented at
atmospheric pressure to a non-classified
location in accordance with ANSI/NFPA-
496.
c. Gas Specifications
Fuel Gas — Standard analysis usually
requires mixed fuel, i.e., 40% (±2 %) hydrogen and 60% helium. H
is recommended over H
of better linearity in concentration output.
Such blends are supplied by many gas
vendors specifically for this use, with a
guaranteed maximum total hydrocarbon
content of 0.5 ppm, measured as methane. This specification should be used
when obtaining these mixtures.
Burner Air — In order to ensure a low
background signal, hydrocarbon free
grade air with less than 1 ppm maximum
total hydrocarbon content is highly recommended. An alternative source for
burner air and zero gas (see Calibration
Gases below) is a combination diaphragm
pump and heated palladium catalyst. This
process continuously removes moderate
amounts of hydrocarbons and carbon
monoxide from ambient air.
Calibration Gases — Calibration method
and gases depends on the type of fuel
gas used, the operating range, and the
desired measurement accuracy. In all
methods, zero and span gases are used,
and are introduced through the sample
inlet at the rear of the module.
Zero Gas It is recommended that the
gas should have a composition as close
to the background composition of the
sample as possible.
/He mixed fuel
2
fuel because
2/N2
b. Connections
Refer to Figure 2-2 on page 2-4. Con-
nect inlet and outlet lines for sample,
burner fuel and air, exhaust, and bypass
to appropriately labeled fittings on the rear
panel. All connections are 1/4-inch ferrule-type compression fittings. Burner
2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Span Gas
specified concentration of methane and
other hydrocarbons in a background gas
such as nitrogen.
Span gas consists of a
Model NGA2000 FID2
Sample Gas — Sample gas must be non-
flammable (below 100% of the sample's
LEL).
Flow Rate — The sample flow rate must
be between 0.5 L/min. and 2 L/min.
Instruction Manual
748412-E
March 2003
sample be filtered for particulates
down to 0.1 microns. A suitable filter is
the Balston type 95S6 with 0.1 micron filter element. It should normally be replaced on a two week schedule,
depending on the sample.
Pressure/Filtration — See Table 2-1 on
page 2-4 for input pressure specifications.
Noncompliance with these specifications
could cause over-pressure damage to the
module.
Leak Test — The Analyzer Module is
completely 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. The user is also
responsible for internal leak testing periAll internal pressure settings are preset at
the factory, but the operator should check
for accuracy. It is essential that the
odically and if any internal pneumatic
components are adjusted or replaced
(with a test procedure chosen by the
user).
8.2
[208]
4.3
[110]
22.6
[573]
2.9
[73]
.8
[19]
[17]
.6
[16]
.7
1.2
[31]
[23]
.9
3.1
[78]
1.0
[25]
2.2
[55]
[23]
2.8
.8
[71]
[20]
.9
Figure 2-1. FID2 Outline and Mounting Dimensions
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3
Instruction Manual
748412-E
March 2003
MIXED
FUEL IN
AIR IN
Gas supply External Pressure Internal Pressure
Fuel
Burner air
Sample
Model NGA2000 FID2
SAMPLE IN
Figure 2-2. FID2 Rear Panel
50 – 55 psig
1035 - 2070 hPa
50 - 55 psig
1380 - 4140 hPa
5 - 10 psig
345 - 690 hPa
Table 2-1. Gas Supply Pressures
SAMPLE BYPASS OUT
BURNER EXHAUST
5 psig
345 hPa
15 psig
1035 hPa
5 psig
345 hPa
2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
Model NGA2000 FID2
2-5 ELECTRICAL CONNECTIONS
NOTE
Electrical installation must be in compliance with National Electrical Code
(NEC/NFPA 70) and/or any state or local
codes.
Two electrical connections are required on the
Analyzer Module: POWER and NETWORK.
See Figure 2-3 below. On the Analyzer Module, two NETWORK connectors are available,
either of which is appropriate for: 1) interconnection with the Back plane of the Platform or
2) "daisy-chaining" with other NGA 2000
components, or 3) connection to a PC via a
suitable LONTALK adapter and software such
as the NGA DDE server and client. Connect
Analyzer Module POWER to Back plane
POWER or external 24 VDC power source.
Connect the network cable to either the
NETWORK 1 or NETWORK 2 connection on
the Analyzer Module front panel, and the
NETWORK connection on the LON I/O module if used with a Platform, or directly to a
computer using appropriate LONTALK
adapter hardware and software such as the
NGA DDE server. Connect the power cable to
both the Analyzer Module front panel and to a
24V 5A minimum power supply.
FUSE
Figure 2-3. FID2 Front Panel
24V POWER
Instruction Manual
748412-E
March 2003
NETWORK
Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5
Instruction Manual
748412-E
March 2003
2-6 ANALYTICAL LEAK CHECK
Model NGA2000 FID2
b. Manometer Method
The FID2 Analyzer Module is completely
tested at the factory for gas leakage. The user
is responsible for testing for leakage only at
the inlet and outlet fittings on the rear panel.
CAUTION
SENSOR PRESSURE
Do not expose the sensor to pressure in
excess of 1.0 psig as this may cause damage.
a. Flow Indicator Method
Supply air or inert gas such as nitrogen,
at 1 psig (6.8 hPa), to the analyzer
through a flow indicator with a range of 0
to 250 cc/min. Install a shut-off valve at
the sample gas outlet. Set the flow rate to
125 cc/min.
FID2 Analyzer Module
Install a water-filled U-tube manometer at
the sample gas outlet. Install a shut-off
valve at the sample gas inlet. Admit air or
inert gas to the inlet shut-off valve until
the analyzer is pressurized to approxi-
mately 50 hPa. The water column will be
about 500 mm.
FID2 Analyzer Module
Inlet Outlet
Overpressure
Water
N
2
approx. 50 hPa
N
2
1 psig
(6.9 kPa)
Inlet Outlet
Flow
Meter
Figure 2-4. Leak Test - Flow Indicator
Method
Close the outlet shut-off valve and notice
that the flow reading drops to zero. If the
flow reading does not drop to zero, the
system is leaking and must be corrected
before the introduction of sample gas or
the application of power.
Outlet
Gas
Figure 2-5. Leak Test - Manometer Method
Close the inlet shut-off valve and, follow-
ing a brief period for pressure equilibrium,
verify that the height of the water column
does not drop over a period of about 5
minutes. If the water column height drops,
the system is leaking and must be cor-
rected before the introduction of any
flammable sample gas or application of
power.
c. Troubleshooting Leaks
Liberally cover all fittings, seals, and other
possible sources of leakage with a suit-
able leak test liquid such as SNOOP (part
837801). Bubbling or foaming indicates
leakage. Checking for bubbles will locate
most leaks but could miss some, as some
areas are inaccessible to the application
of SNOOP. For positive assurance that
system is leak free, perform one of the
tests in Section 2-6 above.
2-6 Installation Rosemount Analytical Inc. A Division of Emerson Process Management
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