NGA 2000
N
ON
-D
ISPERSIVE INFRARED
A
NALYZER
Rosemount Analytical
M
ODULE
N
OTICE
T
HE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE
Pyrex® is a registered trademark of Corning Glass Works
®
Irtran
is a registered trademark of Eastman Kodak Co.
®
Teflon
Ty-Rap
and Viton® is a registered trademark of E.I. duPont de Nemours and Co., Inc.
®
is a registered trademark of Thomas & Betts Corp.
.
Manual Part Number 748332-D
June 1997
Printed in U.S.A.
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
C
P
REFACE
PURPOSE/SAFETY SUMMARY........................................................................P-1
GLOSSARY ......................................................................................................P-4
SPECIFICATIONS..............................................................................................P-6
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE ....P-8
RETURNING PARTS TO THE FACTORY .........................................................P-8
TRAINING ......................................................................................................P-8
DOCUMENTATION............................................................................................P-8
COMPLIANCES..................................................................................................P-9
ONTENTS
S
ECTION
1.1 OVERVIEW ...............................................................................................1-1
1.2 TYPICAL APPLICATIONS.........................................................................1-1
1.3 THEORY OF TECHNOLOGY....................................................................1-2
1.4 SAMPLE REQUIREMENTS ......................................................................1-4
1-5 PURGE KITS.............................................................................................1-5
1.6 FEATURES................................................................................................1-5
S
ECTION
2.1 UNPACKING..............................................................................................2-1
2.2 ASSEMBLY................................................................................................2-1
2.3 LOCATION ................................................................................................2-2
2.4 GASES ......................................................................................................2-2
2.5 ELECTRICAL CONNECTIONS .................................................................2-5
1. I
2. I
2.4.1 Specifications...............................................................................2-2
2.4.2 Connections.................................................................................2-3
NTRODUCTION
NSTALLATION
748332-D Rosemount Analytical June 1997
NGA Non-Dispersive Infrared Analyzer
i
C
ONTENTS
S
ECTION
3.1 OVERVIEW............................................................................................... 3-1
3.2 DISPLAY SCREENS.................................................................................3-1
3.2.1 RUN MODE DISPLAY............................................................................3-1
3.3 STARTUP PROCEDURE..........................................................................3-2
3.4 BINDING ...................................................................................................3-5
3.5 CALIBRATION ..........................................................................................3-5
3.6 LINEARIZATION.......................................................................................3-8
3.7 ROUTINE OPERATION............................................................................3-9
S
ECTION
4.1 OVERVIEW............................................................................................... 4-1
4.2 PCB REPLACEMENT...............................................................................4-2
4.3 POWER FUSE REPLACEMENT ..............................................................4-2
3. S
3.2.2 Menu Displays.............................................................................3-1
3.2.3 Help Displays...............................................................................3-2
4. M
TARTUP AND OPERATION
AINTENANCE AND TROUBLESHOOTING
4.4 MODULE FAN REPLACEMENT...............................................................4-2
4.5 CHOPPER MOTOR REPLACEMENT ......................................................4-3
4.6 SOURCE REPLACEMENT.......................................................................4-3
4.7 DETECTOR REMOVAL............................................................................4-3
4.8 FLOW SENSOR REPLACEMENT............................................................4-3
4.9 CASE TEMPERATURE SENSOR REPLACEMENT ................................4-4
4.10 THERMAL FUSE REPLACEMENT...........................................................4-4
4.11 OSCILLATOR TUNE/SOURCE BALANCE SHUTTER ADJUSTMENT....4-4
4-12 CLEANING CELLS ...................................................................................4-8
4-13 CELL DESICCANT ...................................................................................4-10
4.14 MODULATION CHECK.............................................................................4-10
S
ECTION
5.1 REPLACEMENT PARTS ..........................................................................5-1
5.
REPLACEMENT PARTS
A
PPENDIX
ii
A. I
DENTIFICATION MATRIX
June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
NFRARED ANALYZER DATA SHEET
I
ENERAL PRECAUTIONS FOR HANDLING
G
ARRANTY
W
IELD SERVICE AND REPAIR FACILITIES
F
F
IGURES
1-1 NGA 2000 NDIR Analyzer Module (Typical - Actual configuration May
Vary)..............................................................................................1-3
1-2 NDIR Technology ......................................................................................1-4
2-1 Analyzer Module Installation Into Instrument Platform...............................2-1
2-2 Outline and Mounting Dimensions.............................................................2-4
2-3 NDIR Back Panel.......................................................................................2-5
2-4 NDIR Front Panel Electrical Connections..................................................2-5
2-5 NDIR Wiring Diagram................................................................................2-6
3-1 Run Mode Display.....................................................................................3-3
3-2 Main Menu Display....................................................................................3-3
3-3 Basic Controls Menu..................................................................................3-3
3-4 Expert Controls and Setup Menu...............................................................3-4
3-5 Technical Level Configuration Menu .........................................................3-4
3-6 Typical Help Screen...................................................................................3-4
3-7 Typical Linearization Curve, Linearizer OFF..............................................3-7
3-8 Operator-Determined Linearization Curve (Normalized)............................3-7
3-9 Display Screens (1 of 5)............................................................................3-10
3-10 Display Screens (2 of 5)............................................................................3-11
3-11 Display Screens (3 of 5)............................................................................3-12
3-12 Display Screens (4 of 5)............................................................................3-13
3-13 Display Screens (5 of 5)............................................................................3-14
4-1 Printed Circuit Board Fold-Out Panel Views..............................................4-2
4-2 Module Fan Assembly...............................................................................4-3
4-3 Motor/Source Assembly.............................................................................4-4
4-4 Cell, PCB Assembly (Exploded View)........................................................4-6
4-5 Oscillator Tune, Source Balance Shutter Adjustments..............................4-7
4-6 Detector Block (Exploded View) ................................................................4-7
4-7 Cell Disassembly.......................................................................................4-9
TORING HIGH PRESSURE CYLINDERS
& S
C
ONTENTS
T
ABLES
2-1. Cell Purging Times at Atmospheric Sample Pressure...............................2-2
3-1 NDIR Analyzer Module Alarms..................................................................3-6
4-1 Cell Desiccant............................................................................................4-10
748332-D Rosemount Analytical June 1997
NGA Non-Dispersive Infrared Analyzer
iii
C
ONTENTS
N
OTES
iv
June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
P
REFACE
P
URPOSE/SAFETY SUMMARY
The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of this particular NGA 2000 module.
Some sections may describe equipment not used in your configuration. The user
should become thoroughly familiar with the operation of this module before operating
it. Read this instruction manual completely.
To avoid explosion, loss of life, personal injury and damage to this equipment
and on-site property, all personnel authorized to install, operate and service this
equipment should be thoroughly familiar with and strictly follow the instructions
in this manual. SAVE THESE INSTRUCTIONS.
If this equipment is used in a manner not specified in these instructions,
protective systems may be impaired.
DANGER
personal injury, death, or substantial property damage if the warning is ignored.
WARNING
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION
personal injury or property damage if the warning is ignored.
NOTE
important but not hazard-related.
is used to indicate the presence of a hazard which
is used to indicate the presence of a hazard which
is used to indicate the presence of a hazard which
is used to indicate installation, operation or maintenance information which is
will
cause
can
cause
will or can
cause
severe
severe
minor
WARNING: ELECTRICAL SHOCK HAZARD
Operate this equipment only when covers are secured. Servicing requires
access to live parts which can cause death or serious injury. Refer servicing to
qualified personnel.
For safety and proper performance, this module must be connected to a
properly grounded three-wire source of electrical power.
748332-D Rosemount Analytical June 1997
NGA Non-Dispersive Infrared Analyzer
P-1
P
REFACE
WARNING: POSSIBLE EXPLOSION HAZARD
This equipment is not designed for and should not be used in the analysis of
flammable samples. Use of this equipment in this way could result in explosion
and death.
WARNING: POSSIBLE EXPLOSION HAZARD
Ensure that all gas connectors are made as labeled and are leak free. Improper
gas connections could result in explosion or death.
CAUTION: PRESSURIZED GAS
This module requires periodic calibration with a known standard gas. See
General Precautions for Handling and Storing High Pressure Gas Cylinders at
the rear of this manual.
CAUTION: HAND INJURY HAZARD
Dropping the front panel of the Platform while hand or fingers are inside either
case handle can cause serious injury.
P-2
June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
P
REFACE
CAUTION: PARTS INTEGRITY
Tampering with or unauthorized substitution of components may adversely
affect safety of this product. Use only factory approved components for repair.
CAUTION: OVERBALANCE HAZARD
This Analyzer Module may tip instrument over if it is pulled out too far and the
Platform is not properly supported.
WARNING: 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 over-voltage spiking and resultant fuse
blowing when powering up the instrument.
Note
Apply leak test liquid to cell or detectors only as a last resort.
748332-D Rosemount Analytical June 1997
NGA Non-Dispersive Infrared Analyzer
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P
REFACE
G
LOSSARY
NALYZER MODULE
A
The module that contains all sensor/detector components for development of a
Primary Variable signal; includes all signal conditioning and temperature control
circuitry.
ACKPLANE
B
The interconnect circuit board which the Controller Board, Power Supply, Analyzer
Module power and network cables, I/O Modules and Expansion Modules plug into.
ONTROL MODULE
C
The Operator Interface plus the Controller Board.
ONTROLLER BOARD
C
The computer board that serves as the Network Manager and operates the Display
and Keypad.
ISTRIBUTION ASSEMBLY
D
The Backplane and the card cages that hold I/O and Expansion Modules.
XPANSION MODULE
E
A circuit board that plugs into the Backplane from the front of the Platform and
performs special features not related to I/O functions.
I/O M
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.
ODULE
P-4
PERATOR INTERFACE
O
The Display and Keyboard.
June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
P
REFACE
LATFORM
P
Any workable collection of the following: Controller Board, Power Supply, Distribution
Assembly, Enclosure and Operator Interface.
OWER SUPPLY
P
Any of a variety of components that provides conditioned power to other NGA 2000
components, from the Power Supply Board that plugs into the front of the Backplane
in a stand-alone instrument to several larger ones that can power larger collections of
modules and components.
RIMARY VARIABLE
P
The measured species concentration value from an Analyzer Module.
ECONDARY VARIABLE
S
Data placed on the network by a module regarding current status, e.g., sample flow,
source voltage and other diagnostic information.
OFTKEYS
S
The five function keys located below the front panel display; they assume the function
displayed directly above each on the display, a function dictated by software.
YSTEM
S
Any collection of Analyzer M odule(s), Platform(s) , I/O Module(s) and Expansion Modul e(s).
748332-D Rosemount Analytical June 1997
NGA Non-Dispersive Infrared Analyzer
P-5
P
REFACE
S
PECIFICATIONS
M
EASUREMENT SPECIES
R
ANGES
R
EPEATABILITY
M
INIMUM DETECTABLE
L
EVEL
N
OISE
L
INEARITY
R
ESPONSE TIME
D
RIFT (ZERO AND SPAN
E
FFECT OF
T
EMPERATURE
E
NVIRONMENT
A
MBIENT TEMPERATURE
E
FFECT OF FLOW
P
OWER REQUIREMENTS
:
:
:
:
:
:
:
:
- G
ENERAL
Heteroatomic gases such as ammonia (NH3), carbon dioxide
:
(CO2), carbon monoxide (CO), carbon monoxide + carbon
dioxide ethylene (C2H4), hexane (C6H14), methane (CH4), nitric
oxide (NO) and sulfur dioxide (SO2)
10 ppm fullscale to 100% fullscale (application-dependent); 4
fullscale selections, including suppressed zero ranges
1% of fullscale (at constant temperature)
±
0.1% CO2 (at 1 atm. sample pressure; application dependent)
<1% of fullscale, peak-to-peak
1% of fullscale with 4th order polynomial
±
.05 to 30 seconds (selectable) for 0 to 90% of fullscale
<±1% of fullscale/24 hours at constant temperature
):
(application dependent);
<±2% of fullscale/week at constant temperature (application
dependent)
<±1% of fullscale over any 10°C interval for rate of change no
greater than 10°C per hour (application dependent)
Location - Class B controlled, indoor, non-hazardous
0 to 45°C (32 to 113°F)
:
:
<1% of range when sample flow rate is changed by ≤250
ml/min. (No effect if flow rate is between 0 and 500 ml/min.)
24 VDC ±5%, 100 W max.; ripple and noise: <100 mV peak-to-
:
peak; line and load regulations: <±1%
S
PECIFICATIONS
T
EMPERATURE
F
LOW RATE
P
RESSURE
P
ARTICULATES
D
EWPOINT
M
ATERIALS IN CONTACT
WITH SAMPLE
:
:
:
:
:
P-6
- S
AMPLE
Non-flammable;: 0°C to 55°C (32°F to 138°F)
500 to 1400 ml/min.
Maximum 690 hPa-gauge (10 psig), higher pressure in
pressurized cell applications
:
filtered to <2 microns
<40°C (104°F), no entrained liquid
Gold plated Pyrex, sapphire, quartz, Irtran, FEP Teflon, Viton-
A, 316 stainless steel
June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
P
REFACE
S
PECIFICATIONS
C
ASE CLASSIFICATION
D
IMENSIONS
W
EIGHT
M
OUNTING
M
AXIMUM LENGTH OF
LON C
:
:
ABLE
:
:
- P
HYSICAL
General purpose for installation in weather-protected areas
:
See Outline and Mounting Dimensions, Figure 2-3
Standard: 11 kg (24.2 lbs.); extended: 12.5 kg (27.5 lbs.)
Inside a Platform or custom-installed in a panel
1600 m (1 mile) between Analyzer Module and Platform
See the Preface Section of the Platform manual for specifications regarding Platform
related components.
748332-D Rosemount Analytical June 1997
NGA Non-Dispersive Infrared Analyzer
P-7
P
REFACE
C
USTOMER SERVICE
For order administration, replacement Parts, application assistance, on-site or factory
repair, service or maintenance contract information, contact:
R
ETURNING PARTS TO THE FACTORY
Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when
you call:
Number.
Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sender, freight collect.
When returning any product or component that has been exposed to a toxic, corrosive
or other hazardous material or used in such a hazardous environment, the user must
attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification
that the material has been decontaminated, disinfected and/or detoxified.
Model Number, Serial Number, and Purchase Order Number or Sales Order
, T
ECHNICAL ASSIST ANCE AND FIELD SERVICE
Rosemount Analytical Inc.
Process Analytical Division
Customer Service Center
1-800-433-6076
Return to:
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
T
RAINING
A comprehensive Factory Training Program of operator and service classes is
available. For a copy of the
the Technical Services Department at:
D
OCUMENTATION
The following NGA 2000 Non-Dispersive Infrared Analyzer instruction materials are
available. Contact Customer Service or the local representative to order.
748332 Instruction Manual (this document)
Current Operator and Service Training Schedule
Rosemount Analytical Inc.
Phone: 1-714-986-7600
FAX: 1-714-577-8006
contact
P-8
June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
C
9
6
OMPLIANCES
This product may carry approvals from several certifying agencies, including Factory
Mutual and the Canadian Standards Association (which is also an OSHA accredited,
Nationally Recognized Testing Laboratory), for use in non-hazardous, indoor locations
P
REFACE
FM
APPROVED
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.
®
97-C219
NAMUR
N
748332-D Rosemount Analytical June 1997
NGA Non-Dispersive Infrared Analyzer
P-9
P
REFACE
N
OTES
P-10
June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
I
NTRODUCTION
1
1.1 OVERVIEW
This manual describes the Non-Dispersive Infrared (NDIR) Analyzer Module of
Rosemount Analytical's NGA 200 Series of gas analysis components. See Figure 1-1.
The NDIR Analyzer Module is designed to continuously determine the concentration
of oxygen in a flowing gaseous mixture. The concentration is expressed in one of
three fashions:
parts-per-million
•
percent of composition
•
percent of fullscale
•
The user can obtain an output that is linear with concentration by initiating a linearizer,
which is based on a fourth-order polynomial. The linearizer is incorporated in the
Analyzer Module's electronic circuitry and is adjustable through interconnection with
the network.
The entire Analyzer Module is designed as a slide-in module (if configured in standalone 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 NDIR Analyzer Module is designed to cover a wide range of process, stack and
automotive applications. Typical measurements include:
HEMICAL AND PETROLEUM
C
Carbon dioxide: Manufacture of ethylene oxide, phthalic anhydride and
•
ammonia; nitrogen generation; and producer gas monitoring
Carbon Monoxide: Stack monitoring
•
Methane: Ammonia manufacture
•
Acetylene: Manufacture of acetylene, acrylonitrile, and vinyl chloride
•
Sulfur Dioxide: Sulf uric acid stack gas
•
748332-D Rosemount Analytical June 1997
NGA Non-Dispersive Infraraed Analyzer
1-1
I
NTRODUCTION
OOD AND AGRICULT URE
F
EROSPACE AND OCEANOGRAPHY
A
ETALS AND CERAMICS
M
Carbon Dioxide and Water Vapor: Blanketing of perishables, fermentation
•
processes, photosynthesis studies, personnel protection
Carbon Dioxide, Carbon Monoxide, and Water Vapor: Diving and space
•
chambers
Carbon Dioxide: Monitoring of producer gas, steel converting, manufacture of
•
cement, soaking pit, heat treating
Carbon Monoxide: Inert gas generation, producer gas monitoring, rotary kiln
•
roasting, tin plate annealing, steel converting, aluminum power processing,
porcelain kilns, tunnels
Water Vapor: Heat treating, hydrogen brazing, nickel and chrome plating
•
Sulfur Dioxide: Flash smelting
•
Ammonia: Ammonia dissociation
•
1.3 THEORY OF TECHNOLOGY
Inside of the Analyzer Module, two equal-energy infrared beams are directed through
two parallel optical cells, a flow-through sample cell and a reference cell. The
reference cell may be sealed or may contain a continuously flowing reference gas.
(See Figure 1-2.)
The infrared radiation is interrupted by a chopper at a frequency of 5 Hz.
During analysis, a portion of the infrared radiation is absorbed by the component of
interest in the sample. The quantity of infrared radiation that is absorbed is
proportional to the component concentration.
1-2
June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infraraed Analyzer
REFERENCE OUT
(
)
REFERENCE IN
PURGE GAS IN
CHOPPER MOTOR
FAN
SAMPLE OUT
(BOTTOM)
SAMPLE IN
POWER SUPPLY
BOARD
I
NTRODUCTION
SOURCE
CELLS
DETECTOR
THERMAL FUSE
DETECTOR COVER
CASE
TEMPERATURE
SENSOR
PRESSURE
COMPENSATION
BOARD
FLOW SENSOR
MICRO BOARD
DETECTOR
TEMPERATURE
CONTROL RTD
SIGNAL BOARD
OPTION
IGURE
F
748332-D Rosemount Analytical June 1997
1-1. NGA 2000 NDIR A
SHUTTER ADJUST
ACCESS HOLES
NALYZER MODULE (TYPICAL
ONFIGURATION MAY VARY
C
OSCILLATOR
TUNE ADJUST
)
OSCILLATOR
BOARD
NETWORK INPUT
MODULE
CTUAL
- A
NGA Non-Dispersive Infraraed Analyzer
1-3
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