Manual: NGA 2000 HFID Analyzer Module Hardware Manual-1st Ed. | Rosemount
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Instruction Manual
HAS64E-IM-HW
September 2008
Instruction Manual HFID
Heated Flame Ionization Detector
NGA 2000 Hardware Manual for
HFID Analyzer Module
(combined with NGA 2000 Platform,
MLT, CAT 200 or TFID Analyzer)
1st Edition 09/2008
www.EmersonProcess.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management (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 to ensure
they continue to operate within their normal specifications. The following instructions MUST be
adhered to and integrated into your safety program when installing, using and maintaining
Emerson Process Management (Rosemount Analytical) products. Failure to follow the proper
instructions may cause any one of the following situations to occur: Loss of life; personal injury;
property damage; damage to this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Emerson Process Management
(Rosemount Analytical) representative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance
of the product.
• Install your equipment as specified in the Installation Instructions of the appropriate
Instruction Manual and per applicable local and national codes. Connect all products to the
proper electrical and pressure sources.
• 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 Emerson Process Management (Rosemount Analytical). Unauthorized parts and
procedures can affect the product’s performance, place the safe operation of your process at
risk, and VOID YOUR 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. Misprints reserved.
1st Edition: 09/2008
Emerson Process Management
GmbH & Co. OHG
Industriestrasse 1
D-63594 Hasselroth
Germany
T +49 (0) 6055 884-0
F +49 (0) 6055 884-209
Internet: www.EmersonProcess.com
Teflon® and Viton® are registered trademarks of E. I. duPont de Nemours and Co., Inc.
Kynar® is a registered trademark of Atochem North America, Inc.
SNOOP® is a registered trademark of NUPRO Co.
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
Table of Contents
PREFACE ...........................................................................................................................P - 1
DEFINITIONS......................................................................................................................P - 1
SAFETY INSTRUCTIONS WIRING AND INSTALLATION OF THIS APPARATUS ........P - 2
OPERATING AND MAINTAINING THIS APPARATUS ........................................................P - 3
GENERAL SAFETY NOTICE / RESIDUAL RISK ................................................................P - 4
AUTHORIZED PERSONNEL ..............................................................................................P - 4
GASES AND GAS CONDITIONING (SAMPLE HANDLING) ..............................................P - 8
POWER SUPPLY ................................................................................................................P - 9
ELECTROSTATIC DISCHARGE .......................................................................................P - 10
GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS
CYLINDERS ................................................................................................................. P - 11
DOCUMENTATION ...........................................................................................................P - 12
COMPLIANCES ................................................................................................................P - 12
GLOSSARY OF TERMS ...................................................................................................P - 13
ANALYZER SYSTEM ARCHITECTURE ............................................................................A - 1
SECTION 1 DESCRIPTION AND SPECIFICATIONS ....................................................... 1 - 1
1-1 OVERVIEW ................................................................................................................ 1 - 1
1-2 TYPICAL APPLICATIONS .......................................................................................... 1 - 1
1-3 SAFETY GAS FEATURES.......................................................................................... 1 - 1
1-4 THEORY OF TECHNOLOGY ..................................................................................... 1 - 2
1-5 SPECIFICATIONS ...................................................................................................... 1 - 5
a. General ................................................................................................................... 1 - 5
b. Physical .................................................................................................................. 1 - 5
c. Gas requirements ................................................................................................... 1 - 6
d. Gas Connections .................................................................................................... 1 - 7
ITable of ContentsEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
SECTION 2 INSTALLATION .............................................................................................. 2 - 1
2-1 UNPACKING ............................................................................................................... 2 - 1
2-2 ASSEMBLY................................................................................................................. 2 - 1
2-3 LOCATION.................................................................................................................. 2 - 2
2-4 GASES ....................................................................................................................... 2 - 2
a. Overview................................................................................................................. 2 - 2
b. Pneumatic Connections .......................................................................................... 2 - 3
c. Specifications.......................................................................................................... 2 - 4
Fuel Gas...............................................................................................................................2 - 4
Burner Air .............................................................................................................................2 - 4
Purge Air ..............................................................................................................................2 - 4
Regulated Air........................................................................................................................ 2 - 4
Calibration Gases.................................................................................................................2 - 4
Sample Gas .........................................................................................................................2 - 4
Flow Rate .............................................................................................................................2 - 4
Pressure / Filtration ..............................................................................................................2 - 5
2-5 LEAK TEST................................................................................................................. 2 - 5
2-6 ELECTRICAL CONNECTIONS .................................................................................. 2 - 6
2-7 INSTALLATION CONSIDERATIONS CHECKLIST ..................................................... 2 - 9
SECTION 3 OPERATION .................................................................................................. 3 - 1
3-1 OVERVIEW ................................................................................................................ 3 - 1
3-2 STARTUP & INITIALIZATION ..................................................................................... 3 - 1
a) Startup .................................................................................................................... 3 - 1
b) Temperature/Pressure Settings and Check ............................................................ 3 - 3
c) Ignition of the Flame ............................................................................................... 3 - 4
Auto-Ignition of the Flame ....................................................................................................3 - 4
Manual Ignition of the Flame ................................................................................................3 - 4
3-3 BINDING ..................................................................................................................... 3 - 4
3-4 CALIBRATION PROCEDURE .................................................................................... 3 - 5
a. Calibration Setup .................................................................................................... 3 - 5
Calibration Gas List ..............................................................................................................3 - 5
Calibration Parameters ........................................................................................................ 3 - 6
Check of capillary type .........................................................................................................3 - 6
b. Execution ................................................................................................................ 3 - 7
Zero Adjustment ...................................................................................................................3 - 7
Span Adjustment ..................................................................................................................3 - 8
c) Problems with Calibration ....................................................................................... 3 - 8
II Table of Contents Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
3-5 ROUTINE OPERATION .............................................................................................. 3 - 9
a) Operation ................................................................................................................ 3 - 9
b) Sensitivity ............................................................................................................... 3 - 9
c) Shutdown................................................................................................................ 3 - 9
3-6 SAFETY SYSTEM ...................................................................................................... 3 - 11
3-7 SYSTEM & NETWORK I/O MODULE CONTROLS (SETUP) - SYSTEM SIO ......... 3 - 14
a. Analog Output Setup ............................................................................................ 3 - 14
Output number: ..................................................................................................................3 - 14
Choose signal source module... .........................................................................................3 - 14
Choose Signal... .................................................................................................................3 - 14
Signal value for 0% (100%) output:.................................................................................... 3 - 15
Output current: ...................................................................................................................3 - 15
Hold output during calibration: ........................................................................................... 3 - 15
b. Serial interface Setup ........................................................................................... 3 - 17
c. Relay Outputs Setup............................................................................................. 3 - 18
Output number: ..................................................................................................................3 - 18
Invert signal: .......................................................................................................................3 - 18
Choose source module... ................................................................................................... 3 - 18
Choose signal... ................................................................................................................. 3 - 18
SECTION 4 MAINTENANCE AND SERVICE.................................................................... 4 - 1
4-1 OVERVIEW ................................................................................................................ 4 - 1
4-2 FUSES ........................................................................................................................ 4 - 3
4-3 OVEN.......................................................................................................................... 4 - 4
a. Removal ................................................................................................................. 4 - 4
b. Disassembly ........................................................................................................... 4 - 4
4-4 BURNER..................................................................................................................... 4 - 6
a. Temperature Sensor ............................................................................................... 4 - 6
b. RTD Detector.......................................................................................................... 4 - 6
c. Igniter ...................................................................................................................... 4 - 6
d. Flameout Sensor .................................................................................................... 4 - 6
4-5 BURNER INTERNAL COMPONENTS ....................................................................... 4 - 8
a. Disassembly of Burner / Thermal Block.................................................................. 4 - 8
b. Replacing Burner Jets ............................................................................................ 4 - 9
c. Burner Jet Installation ........................................................................................... 4 - 11
IIITable of ContentsEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
4-6 THERMAL BLOCK.................................................................................................... 4 - 12
a. Sample RTD ......................................................................................................... 4 - 12
b. Cartridge Heater ................................................................................................... 4 - 12
c. Thermostat ........................................................................................................... 4 - 13
d. Sample Capillary .................................................................................................. 4 - 13
4-7 ELECTRONICS ASSEMBLY .................................................................................... 4 - 14
a. Printed Circuit Boards........................................................................................... 4 - 15
b. Case Temperature Sensor .................................................................................... 4 - 16
c. Case Pressure Purge Switch ................................................................................ 4 - 16
d. Preamp Assembly................................................................................................. 4 - 17
4-8 FAN ASSEMBLY ....................................................................................................... 4 - 18
4-9 FLOW CONTROLLER .............................................................................................. 4 - 19
4-10 DC POWER SUPPLY MODULE ............................................................................... 4 - 20
4-11 FRONT PANEL COMPONENTS .............................................................................. 4 - 21
Replacing Front Panel Components ......................................................................... 4 - 22
a. LON/Power Module .......................................................................................................4 - 23
b. LED Indicator Assembly ................................................................................................4 - 23
c. Manual Ignite Toggle Switch ..........................................................................................4 - 23
d. Burner Air Sensor .......................................................................................................... 4 - 23
e. Fuel Sensor ...................................................................................................................4 - 23
f. Burner Air and Fuel Regulator .......................................................................................4 - 23
g. Purge Air Regulator ....................................................................................................... 4 - 23
h. Purge Air Flow Switch and Diffuser ...............................................................................4 - 24
i. Burner Air Solenoid Valve ..............................................................................................4 - 24
j. Air Ignite Restrictor ........................................................................................................4 - 24
4-12 REAR PANEL COMPONENTS................................................................................. 4 - 25
a. Fuel In 2-Way Solenoid Valve ............................................................................... 4 - 26
b. Burner Air In Filter................................................................................................. 4 - 26
c. Heated Bypass Sample Out and Heated Sample In Restrictors ........................... 4 - 26
d. Regulated Air In Check Valve ............................................................................... 4 - 26
4-13 LEAKAGE TEST ....................................................................................................... 4 - 27
a) Required Tools...................................................................................................... 4 - 27
b) Procedure ............................................................................................................. 4 - 27
IV Table of Contents Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
SECTION 5 TROUBLESHOOTING .................................................................................... 5 - 1
5-1 TROUBLESHOOTING CHECKLIST........................................................................... 5 - 1
a. Safety System ........................................................................................................ 5 - 1
b. Ignition .................................................................................................................... 5 - 1
c. Drift ......................................................................................................................... 5 - 2
d. Noise ...................................................................................................................... 5 - 2
SECTION 6 REPLACEMENT PARTS ................................................................................ 6 - 1
6-1 MATRIX ...................................................................................................................... 6 - 1
6-2 GENERAL................................................................................................................... 6 - 2
6-3 PNEUMATICS............................................................................................................. 6 - 2
6-4 OVEN COMPONENTS ............................................................................................... 6 - 3
SECTION 7 RETURN OF MATERIAL ............................................................................... 7 - 1
7-1 RETURN OF MATERIAL ............................................................................................ 7 - 1
7-2 CUSTOMER SERVICE............................................................................................... 7 - 2
7-3 TRAINING................................................................................................................... 7 - 2
LIST OF FIGURES AND TABLES....................................................................................... L -1
1 LIST OF FIGURES ...................................................................................................... L -1
2 LIST OF TABLES ......................................................................................................... L -2
SUPPLEMENT .....................................................................................................................S -1
1 EC DECLARATION OF CONFORMITY.......................................................................S -1
2 DECLARATION OF CONTAMINATION .......................................................................S -2
VTable of ContentsEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
VI Table of Contents Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
PREFACE
The purpose of this manual is to provide information concerning the components, functions, installation and
maintenance of the NGA 2000 HFID 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.
DEFINITIONS
The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication.
WARNING
Highlights on 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 on 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.
P - 1PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
IMPORTANT
SAFETY INSTRUCTIONS
WIRING AND INSTALLATION OF THIS APPARATUS
The following safety instructions apply specifically to all EU member states. They should be strictly adhered to
in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the
following unless superseded by local or National Standards.
1. Suitable grounding connections should be made at all connectors provided for this purpose.
2. All safety covers and grounding connections must be properly reinstated after maintenance work or trouble-
shooting. The integrity of all earth terminals must be maintained at all times.
3. To ensure safe operation of this equipment, connection to the mains supply should only be made through
a circuit breaker which will disconnect
breaker may also include a mechanically operated isolating switch. Circuit breakers or switches must
comply with a recognized standard such as IEC947. All wiring must conform with any local standards.
all circuits carrying conductors during a fault situation. The circuit
4. Where equipment or covers are marked with the symbol to the right, hazardous voltages
are likely to be present beneath. These covers should only be removed when power is
removed from the equipment — and then by trained service personnel only.
5. Where equipment or covers are marked with the symbol to the right, there is a danger
from hot surfaces beneath. These covers should only be removed by trained service
personnel when power is removed from the equipment. Certain surfaces may remain hot
to the touch.
6. Where equipment or covers are marked with the symbol to the right, refer to the Instruc-
tion Manual for instructions.
7. Further graphical symbols used in this product:
Elektrostatic discharge (ESD)
Harmful (to Health)!
Explosion Hazard!
Toxic!
Flammable!
Disconnect from Mains!
All graphical symbols used in this product are from one or more of the following standards:
EN61010-1, IEC417, and ISO3864.
P - 2 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
OPERATING AND MAINTAINING THIS APPARATUS
On leaving our factory, this instrument conformed to all applicable safety directives.
In order to preserve this state of affairs, the operator must take care to strictly follow all the instructions and
notes given in this manual and on the unit.
Before switching on the instrument, ensure that the local nominal mains voltage corresponds to the factory-set
operational voltage of this unit.
Any interruption of the protective earth connections, whether inside or outside of the unit, or removal or interruption of its ground line connection, may result in exposure to the risk of electricity. Deliberately disconnected
the protective earth is therefore strictly forbidden.
Removing covers and opening panels may expose components conducting electric current. Connectors may
also be energized. The unit therefore should be be disconnected from all electrical supplies before any kinds
of maintenance, repair or calibration work requiring access to the inside of the unit. Only trained personnel who
are aware of the risk involved may work on an open and energized unit!
Fuses may only be replaced by fuses of an identical type and with identical ratings. It is forbidden to use
repaired fuses or to bypass fuses.
Take note of all applicable regulations when using this unit with an autotransformer or a variable transformer.
Substances hazardous to health may escape from the unit‘s gas outlet.
Please pay attention to the safety of your operation personnel. Protective measures must be taken, if required.
NOTE
Software compatibility is necessary for all NGA 2000 components in your system to work together.
The version of your Platform’s software must be equal to or greater than the version of any other
module(s) for successful compatibility.
You can locate the version of each NGA 2000 component as follows:
Platform Controller Board
Turn power ON. The display should show „Control Module V3. ...“. This is the software version.
Analyzer Module
See note on the name plate label located on the right side of the Analyzer Module case.
P - 3PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
GENERAL SAFETY NOTICE / RESIDUAL RISK
If this equipment is used in a manner not specified in these instructions, protective systems may be
impaired.
Despite of incoming goods inspections, production control, routine tests and application of state-ofthe-art measuring and test methods, an element of risk remains when operating a gas analyzer!
Even when operated as intended and observing all applicable safety instructions some residual risks
remain, including, but not limited to, the following:
• An interruption of the protective earth line, e.g. in an extension cable, may result in risk to the
user.
• Live parts are accessible when operating the instrument with doors open or covers removed.
• The emission of gases hazardous to health may even be possible when all gas connections
have been correctly made.
Avoid exposure to the dangers of these residual risks by taking particular care when ins-talling, operating, maintaining and servicing the analyzer.
AUTHORIZED PERSONNEL
In-depth specialist knowledge is an absolutely necessary condition for working with and on the unit.
Authorized personnel for installing, operating, servicing and maintaining the analyzer are instructed
and trained qualified personnel of the operating company and the manufac-turer.
It is the responsibility of the operating company to
• train staff,
• observe safety regulations,
• follow the instruction manual.
Operators must
• have been trained,
• have read and understood all relevant sections of the instruction manual before commencing
work,
• know the safety mechanisms and regulations.
To avoid personal injury and loss of property, do not install, operate, maintain or service this instrument before reading and understanding this instruction manual and receiving appropriate training.
Save these instructions.
P - 4 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
WARNING
ELECTRICAL SHOCK HAZARD
Do not operate without covers secure. Do not open while energized. Installation and/or servicing
requires access to live parts which can cause death or serious injury.
Refer servicing to qualified personnel.
For safety and proper performace this instrument must be connected to a properly grounded threewire 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 continous dilution purge system is factoryinstalled and it must be functional at all times during operation.
Do not disable this purge system.
WARNING
POSSIBLE EXPLOSION HAZARD
Protection against explosion depends upon a special fuel flow restrictor in the fuel inlet fitting. Do
not remove fuel inlet restrictor. Use the correct fuel flow restrictor for the fuel being used.
Replace only with factory applied fitting.
WARNING
POSSIBLE EXPLOSION HAZARD
Ensure that all gas connections are made as labeled and described within this manual and leak free.
Improper gas connections may cause explosion, serious injury or death.
WARNING
FLAMMABLE SAMPLES
The internal compartment of the oven is vented to the main enclosure by the top and bottom vents.
DO NOT RESTRICT THOSE VENTS.
Consult the factory if flammable samples will be measured.
P - 5PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
WARNING
HIGH TEMPERATURES
This equipment is used in the analysis of sample gases at temperatures of up to 250°C. All components and material in contact with the sample, the oven and the burner can reach this temperature
level.
Operate this equipment only when covers are secured. Servicing requires access to "hot" parts
which can cause serious injury. Refer servicing to qualified personnel.
WARNING
HIGH TEMPERATURES
The Sample In, Byass Out and Burner Exhaust Out connections can reach temperatures of up to
250 °C (480 °F). Severe burns could result from touching these connections.
WARNING
UNAUTHORIZED SUBSTITUTION OF COMPONENTS
Tampering with or unauthorized substitution of components may adversely affect the safety of this
instrument. Use only factory documented/approved components for repair.
Because of the danger of introducing additional hazards, do not perform any unauthorized modification to this instrument!
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. The user is also responsible for leak-testing periodically and if any internal pneumatic components are adjusted or replaced.
WARNING
OVERBALANCE HAZARD
This analyzer module may tip instrument over if it is pulled out too far and the Platform is not
properly supported.
P - 6 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
CAUTION
POSSIBLE INSTRUMENT DAMAGE
Do not interchange gas inlets and outlet! All gases must be conditioned before supplying!
When supplying corrosive gases ensure that gas path components are not affected!
Exhaust lines must be installed in a descending way, need to be pressureless, frost-protected and
in compliance with applicable legislative requirements!
WARNING
HAZARDS BY SAMPLE GAS COMPONENTS!
Before opening gas paths they must be purged with ambient air or neutral
gas (N
) to avoid hazards caused by toxic, flammable, explosive or harmful to
2
health sample gas components!
CAUTION
PURGE AIR REQUIREMENT
This Analyzer Module must be used in conjuction with a device (Control Module or PC Interface)
that can actively monitor network variables related to pressure or flow of the continous dilution
purge, or the front panel LEDs of the Analyzer Module, as installed, must be visible. The purpose of
this requirement is to maintain adherence to ANSI/NFPA 496 standard which assures the continued
viability of the purge system. Under no circumstances should any pressure or flow indicator be
connected to the PURGE AIR OUT outlet of the Analyzer Module because this may affect the sealing
performance of the module.
CAUTION
PRESSURIZED ENCLOSURE
This enclosure shall not be opened unless the area is known to be free of flammable materials or
unless all devices within have been de-energized. Area classification for the protected enclosure:
Nonclassified.
Pressurization: Type Z
Temperature Identification Number: T4A
Power shall not be restored after enclosure has been opened (or loss of purge) until enclosure has
been purged for a minimum of 6 (six) minutes at the minimum pressure of 689 hPa (10 psig).
P - 7PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
GASES AND GAS CONDITIONING (SAMPLE HANDLING)
WARNING
GAS SAFETY
Take care of the safety instructions applicable for the gases
(sample gases, test gases and fuel gas)!
CAUTION
PRESSURIZED GAS
This module requires periodic use of pressurized gas. See General Precautions for Handling and
Storing High Pressure Gas Cylindes, page P-11.
WARNING
POSSIBLE EXPLOSION HAZARD
Do not use 100% hydrogen fuel in a 40% H
/ 60% He configured Analyzer Module.
2
An explosion resulting in severe personal injury or death could occur.
P - 8 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
POWER SUPPLY
CAUTION
ELECTRICAL HAZARD
Verify the power voltage at site of installation corresponds to the analyzer
module´s rated voltage as given on the nameplate label!
Verify the safety instruction given by power supply unit manufacturer !
CAUTION
ELECTRICAL HAZARD
The mains socket has to be nearby the power supply unit and easily accessible!
Disconnecting from power requires unplugging the power connector!
To comply with the CE mark requirements use only power supply units of type
SL5, SL10 or equivalent units. Equivalent units must provide SELV output
voltages!
Verify proper polarity when connecting DC 24 V operated analyzer modules !
P - 9PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
ELECTROSTATIC DISCHARGE
CAUTION
ELECTROSTATIC DISCHARGE
The electronic parts of the Analyzer Module can be irreparably damaged if exposed to
electrostatic discharge (ESD).
The instrument is ESD protected when the covers have been secured and safety precautions observed. When the housing is open, the internal components are not ESD
Although the electronic parts are reasonable safe to handle, you should be aware of the following considerations:
Best ESD example is when you walked across a carpet and then touched an electrical grounded metal
doorknob. The tiny spark which has jumped is the result of electrostatic discharge (ESD).
You prevent ESD by doing the following:
Remove the charge from your body before opening the housing and maintain during work with opened housing, that no electrostatic charge can be built up.
Ideally you are opening the housing and working at an ESD - protecting workstation. Here you can wear a wrist
trap.
However, if you do not have such a workstation, be sure to do the following procedure exactly:
Discharge the electric charge from your body. Do this by touching a device that is grounded electrically (any
device that has a three - prong plug is grounded electrically when it is plugged into a power receptacle).
This should be done several times during the operation with opened housing (especially after leaving the
service site because the movement on a low conducting floors or in the air might cause additional ESDs).
P - 10 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
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 52 °C (125 °F). A flame 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.
P - 11PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
DOCUMENTATION
The following HFID instruction materials are available. Contact Customer Service Center or the local representative to order.
HAS64E-IM-HW Instruction Manual NGA 2000 HFID (this document)
90002496 Instruction Manual NGA 2000 Platform
COMPLIANCES
This product may carry approvals from several certifying agencies, including the Canadian Standards Association*
(which is also an OSHA accredited, Nationally Recognized Testing Laboratory), for use in non-hazardous, indoor
locations.
Emerson Process Management 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).
NAMUR
This product satisfies all obligations of all relevant standards of the EMC framework in Australia and New Zealand.
)
P - 12 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
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 operate the Display and Keypad.
Distribution Assembly
The Backplane and the card cages that hold I/O and Expansion Modules.
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.
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.
P - 13PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
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, temperature and pressure.
Softkeys
The five function softkeys 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) and I/O Module(s).
P - 14 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
ANALYZER SYSTEM ARCHITECTURE
The NGA 2000 HFID is available as a "stand-alone analyzer" or as a "blind" Analyzer Module (AM). The HFID
analyzer module can be part of the stand-alone analyzer or a component of an analyzers system (Fig. A-1).
The NGA 2000 system made it possible, to configure
the HFID as a flexible "stand-alone analyzer" consisting
of a HFID "Analyzer Module", a Platform (complete with
front panel display/operator interface), and input/output
(I/O) modules.
The “analyzer module” is a “blind” analysis unit but retains all the advanced design features. The AM variant
is designed for integration as part of a NGA 2000 analysis system or special customer developed networks.
The platform/MLT´s front panel can act as operator interface for a stand-alone analyzer or as the a central
interface for multiple Analyzer Modules. In multi analyzer systems, this feature eliminates duplication of the
display/operator interface. In addition to the obvious operational benefits there are significant cost and system
packaging advantages not possible with conventional
analyser configurations.
This flexible network communication architecture is
shown in the schematic of Fig. A-2.
½ 19" MLT
Analyzer
ROSEMOUNT NGA 2000NGA 2000
Platform with MLT AM
or
19" MLT Analyzer
CLD
HFID
PMD
NGA Network
½ 19" MLT
Analyzer
ROSEMOUNT NGA 2000NGA 2000
NGA Network
MLT MLT
ROSEMOUNT NGA 2000NGA 2000
CLD HFID
NGA Network
ROSEMOUNT NGA 2000NGA 2000
ROSEMOUNT NGA 2000NGA 2000
ROSEMOUNT NGA 2000NGA 2000
ROSEMOUNT NGA 2000NGA 2000
NGA NetworkNGA Network
HFID PS
Platform with MLT AM
19" MLT Analyzer
HFID PS
CLD
or
Figure A-1: From separate analyzers to analyzer system
NGA Network
PS
A - 1Analyzer System ArchitectureEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
The modular configurable bi-directional network offers
the following options:
❏ Stand-alone analyzers (Single devices)
• analyzer modules in a platform including
optional inputs and outputs (SIO/DIO).
Platform
❏ Simple interconnection of analyzer modules to an
analyzer system based on one of the three structures - see below.
These structures can be distinguished by acting
of the host
• with platform as host including system inputs
and outputs (SIO/DIO)
• with MLT/TFID/CAT 200 analyzer as control-
ler including system inputs and outputs (SIO/
DIO)
• with customer owned specific control units
(not described in this manual, consult factory)
For combination possibilities of NGA 2000 I/O´s see table
A-1.
Analyzer Module
AC DC
Network Cable
Analyzer Module
Analyzer Module
Network Cable
24VDC Cable
Figure A-2: Example of NGA cabling
Power supply
24VDC Cable
DC
AC
A - 2 Analyzer System Architecture Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
Based on a platform, MLT or TFID analyzer the schematic on Figure A-3 illustrates the simplicity of a networked system which incorporates AM’s, such as Chemiluminesence Detectors, MLT's (NDIR/UV/VIS plus Oxygen or TCD) and Flame Ionisation Detectors.
The system I/O modules (SIO, DIO) of the platform (or
MLT/TFID analyzer) support all integrated analyzer modules with analog, digital and serial interfaces as well as
relay outputs.
Analyzer Modules (AM’s)
Other system functionality includes links to associated
sample handling (PLC) and Data Acquisition Systems
such as WinControl.
Local I/O are existing to MLT, TFID and CAT 200 analyzers only and support the corresponding analyzer module only.
Local I/O’s via Internal System Bus
DIO SIO
DIO SIO
DIO SIO
O
PMD
2
HC
HFID
System I/O’s via Internal System Bus
DIO SIO
8
Digital
Inputs
24
Digital
Outputs
Solenoid
Valves
NO
WCLD
Printer
or PLC
x
3
Relay
Outputs
NO/NO
CLD
RS 232 /
Computer
x
19" MLT 3/4
Analyzer
RS 485
Personal
ppm O
2
TO2
Alternatively
19" Platform/
TFID Analyzer
Alternatively
HC
FID
½ 19" MLT
Analyzer
HC
TFID
NGA
Network
NGA 2000ROSEMOUNT
NGA 2000ROSEMOUN T
NGA 2000ROSEMOUNT
CO/NO/SO /
EO - MLT
Alternatively to Platform
or MLT/TFID Analyzer
2
2
MLT 2
Analyzer
PO
2
MLT
Field PC
Workstation
NGA 2000ROSEMOUNT
Figure A-3: Example/Possibilities of NGA Analyzer Systems
A - 3Analyzer System ArchitectureEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
System unit SIO/DIO-Configuration
Instruction Manual
HAS64E-IM-HW
September 2008
CLD/FID/HFID analyzer module (AM):
• without front panel,
i.e. without control unit (host)
• can be combined with
a platform,
a MLT analyzer,
a TFID analyzer;
a CAT 200 analyzer or
a customer developed control unit
Platform (Control Module Software):
• Control unit with front panel
• Without measurement channels
HFID analyzer
• HFID analyzer module into a platform with
front panel
• HFID analyzer module combined with
MLT/TFID/CAT 200 analyzer
• No local CLD/FID/HFID I/O’s
• 1 SIO and up to 4 DIO's (or 5 DIO's)
can be installed in the platform
(CM I/O’s)
• SIO and DIO’s can be configured
for all AM channels connected to the
platform
• 1 SIO and 4 DIO’s (or 5 DIO’s) can be
installed in the platform
• 1 SIO and 1 DIO (or 2 DIO’s) can be
installed in the MLT/TFID/CAT 200
analyzer (CM I/O)
• SIO and DIO can be configured
for all AM’s connected to the
MLT/TFID/CAT 200 analyzer
Table A-1: Possibilities of NGA 2000 I/O combinations
A - 4 Analyzer System Architecture Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
1-1 OVERVIEW
NGA 2000 HFID
SECTION 1
DESCRIPTION AND SPECIFICATIONS
This manual describes the Heated Flame Ionization Detector (HFID) Analyzer Module of Emerson Process
Mangement´s NGA 2000 Series of gas analysis components (See Figure 1-2 and 1-3).
The HFID Analyzer Module is designed to continously
determine the concentration of hydrocarbons in a flowing gaseous mixture at a user-selectable temperature
setpoint between 93 °C and 204 °C (200 °F and 400 °F).
The concentration is expressed in parts-per-million or
percent of volume..
The HFID Analyzer Module is designed as a slide-in module (if configured in stand-alone instrument fashion), removable from the front of the Platform, with gas connections made from the rear. All electronics relative to sample
detection and conditioning are included in this module.
1-2 TYPICAL APPLICATIONS
The monitoring of carbon bed scrubber for low-level hydrocarbon contaminants, determining of the hydrocarbon content of exhaust emissions from internal combustion engines and continuous emissions monitoring of fluegas emissions (e.g. incinerators) are examples of typical
applications for the HFID Analyzer Module
1-3 SAFETY GAS FEATURES
The HFID Analyzer Module is designed with a factoryinstalled continous dilution purge system in accordance
with standard ANSI/NFPA 496-1993, Chapter 6. Frontpanel LEDs indicate that the burner flame is lit and that
the purge system is enabled. In addition, fuel gas is automatically shut off when a flame-out condition occurs of
the safety system is disabled.
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 through the combination of an inlet fuel flow restrictor
and purge gas flow.
This module is designed to use 40% H2/60% He fuel at a
maximum inlet pressure of 3446 hPa-gauge (50 psig).
A standard HFID Analyzer Module is only equipped to
analyze a non-flammable sample, below 100% of the
LEL.
WARNING
POSSIBLE EXPLOSION HAZARD
Protection against explosion depends upon a special fuel flow restrictor in the fuel inlet fitting. Do
not remove fuel inlet restrictor. Use the correct fuel
flow restrictor for the fuel being used.
Replace only with factory applied fitting.
Do not use 100 % hydrogen fuel in a 40 % H2 /
60 % He configured Analyzer Module.
An explosion resulting in severe personal injury
or death could occur.
The purge system is enabled only if there is proper purge
gas flow in, purge gas pressure, and internal case pressure, and after five times the case volume has been exchanged.
1 - 1Description and SpecificationsEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
1-4 THEORY OF TECHNOLOGY
Instruction Manual
HAS64E-IM-HW
September 2008
This Analyzer Module uses the flame ionization method
of detection. The sensor is a burner in which a regulated
flow of sample gas passes through a flame sustained by
regulated flows of a fuel gas (hydrogen or a hydrogen/
diluent mixture) and air.
With a 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.
+ 90 V
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.
This measure of concentration is placed on the network,
where it is can be shown on the Platform Display or on
other data aquisition devices.
Negative Ion Collection Ring
Signal Conditioning
Positive Carbon Ions
Air
Sample
Figure 1-1: Function Principle of FID Measurement
1 - 2 Description and Specifications Emerson Process Management GmbH & Co.OHG
Fuel
Instruction Manual
HAS64E-IM-HW
September 2008
PURGE
3/8T
BRASS
PLUG
1/8NPT
ELBOW
PURGE AIR
RESTRICTOR
BRASS
TUBING 1/4 OD
VITON
TUBING 1/4 OD
COPPER
AIR IN
REGULATOR,
PURGE AIR
PLUG
1/4NPT
SWITCH,
PURGE
FLOW
DIFFUSER
PURGE
PRESSURE
SENSOR
BULKHEAD
REDUCER
3/8T - 1/4T
BRASS
REGULATED
CHECK
VALVE
1/3 PSIG
ELBOW
1/4T - 1/4NPT
BRASS
ADAPTER
1/4T - 1/4NPT
BRASS
BULKHEAD
RESTRICTOR
1/4T - 1/4T
AIR IN
BULKHEAD
1/4T - 1/4T
BRASS
MANIFOLD,
SAMPLE
ELBOW
1/4T - 1/4FPT
BRASS
UNION
1/4T
BRASS
PRESSURE SENSOR,
REGULATED AIR
0 - 15 PSIG
SS
HEATED
SAMPLE
IN
FUEL RESTRICTOR
1/8T - 1/8T
TUBING 1/4 OD
COPPER
SAMPLE
BYPASS
OUT
BURNER
DETECTOR
TUBING 1/8 OD
COPPER
BURNER
EXHAUST
BULKHEAD
1/4T - 1/8T
SS
ELBOW
1/8T - 1/8T
BRASS
PRESSURE
RELIEF
VALV E
BULKHEAD
REDUCER
1/4T - 1/8T
BRASS
RESTRICTOR,
BYPASS
SENSOR,
SAMPLE
TEMPERATURE
SAMPLE
CAPILLARY
(see table 1-1)
CONNECTOR
1/16T - 1/8NPT
SS
TUBING 1/8 OD
COPPER
RUN TEE
1/8T - 1/8MPT
BRASS
AIR RESTRICTOR
SENSOR,
BURNER AIR
PRESSURE
0 - 30 PSIG
TUBING 1/8 OD
COPPER
BURNER
AIR IN
FILTER
RUN TEE
1/4T - 1/4FPT
BRASS
PORT CONNECTOR
1/4
TUBING 1/8 OD
COPPER
TUBING 1/8 OD, SS
NGA 2000 HFID
BULKHEAD
PURGE
AIR OUT
TUBING 1/4 OD
GA
INOUT
3/8T - 1/4MPT
BRASS
BULKHEAD
CONNECTOR
1/4T - 1/8NPT, SS
VITON
PRESSURE
SWITCH
SENSOR,
FUEL PRESSURE
0 - 30 PSIG
FUEL
SOLENOID
VALVE
OUT
GA
INOUT
REGULATOR,
FUEL PRESSURE
0 - 30 PSIG
IN
FUEL
RESTRICTOR
TUBING 1/8 OD
SS
ELBOW
1/4T - 1/4MPT
BRASS
FIXED FLOW CONTROLLER,
REGULATED AIR
Sample Capillaries
Sample C apillary 9.7 cc/min. @ 3. 5 psig 6574 86
Sample C apillary 2.5 cc/min. @ 3. 5 psig 6575 50
Table 1-1: Sample Capillary depending on Module Configuration
IN
OUT
RUN TEE
1/4T - 1/4MPT
BRASS
AIR IGNITE
RESTRICTOR
ELBOW
1/8T - 1/8MPT
BRASS
Figure 1-2: HFID Analyzer Module - Flow Diagram
Brief Description
PRESSURE REGULATOR,
BURNER AIR
0 - 60 PSIG
Part Number
1 - 3Description and SpecificationsEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Gas Lines
(See Figure 2-2)
Fuel Shutoff Solenoid Valve
Instruction Manual
HAS64E-IM-HW
September 2008
Purge Air Outlet
Detector (Burner)
Oven
Air circulation fan
Case Heater
Sample Flow Controller
Purge Air Flow Switch
Preamp Board
(in Shield)
Case pressure switch
Computer Board
Sensor Board
Safety Board
DC-DC-Module
Power Supply Board
Burner Air Solenoid Valve
Purge Air Regulator
Burner Air & Fuel Regulators
(Stacked Vertically)
Figure 1-3: HFID Analyzer Module - Top View
1 - 4 Description and Specifications Emerson Process Management GmbH & Co.OHG
Network & Power Module
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