Rosemount Manual: NGA 2000 TFID Hydrocarbon Analyzer Module Hardware -2nd Ed. | Rosemount Manuals & Guides

Instruction Manual

90003806
04/2008

Instruction Manual

Thermo Flame Ionization Detector
FID Analyzer or Analyzer Module (combined with NGA
2000 Platform, MLT or CAT 200)

nd

Edition 04/2008

2

www.EmersonProcess.com

TFID Thermo Flame Ionization Detector Instruction Manual

90003806

04/2008

ESSENTIAL INSTRUCTIONS

READ THIS P AGE BEFORE PROCEEDING!

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

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

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

Management (Rosemount Analytical) representative for clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and

maintenance of the product.

• Install your equipment as specified in the Installation Instructions of the appropriate

Instruction Manual and per applicable local and national codes. Connect all products

to the proper electrical and pressure sources.

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

• When replacement parts are required, ensure that qualified people use replacement parts
specified by Emerson Process Management (Rosemount Analytical). Unauthorized parts
and procedures can affect the product’s performance, place the safe operation of your
process at risk, and VOID YOUR W ARRANTY. Look-alike substitutions may result in fire,
electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except
when maintenance is being performed by qualified persons, to prevent electrical
shock and personal injury.

The information contained in this document is subject to change without notice. Misprints
reserved.

1st Edition 06/1998
2nd Edition 04/2008
© 2008 by Emerson Process Management

Emerson Process Management
GmbH & Co. OHG

Industriestrasse 1
D-63594 Hasselroth
Germany
T [phone]
F [phone]
Internet: www.EmersonProcess.com

Rosemount Analytical

SAFETY SUMMARY S - 1

General S - 2
Gases and Gas Conditioning (Sample Handling) S - 3
Supply Voltage S - 4
Analyzer specific notes for the user S - 5
Additional notes for service / maintenance S - 6
Electrostatic Discharge S - 7

CONTENTS

Table of Contents

PREFACE P - 1

DESCRIPTION

1. Technical Description 1 - 1

1.1 Front View 1 - 1

1.2 Rear Panel 1 - 3

1.3 Internal Construction 1 - 4

1.3.1 Thermo-FID Assembly 1 - 5

1.3.2 Printed Circuit Boards 1 - 6

1.4 Applications 1 - 8

2. Theory of Technology and Operation 2 - 1

2.1 Measuring Principle 2 - 1

2.2 TFID Mode of Operation 2 - 3

2.3 Sample Gas Transport 2 - 4

3. (vacant)

4. (vacant)

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I

CONTENTS

OPERATION

5. Preparation 5 - 1

5.1 Installation Site 5 - 2

5.2 Gas Conditioning (Sample Handling) 5 - 3

5.3 Gases 5 - 4

5.3.1 Supply Gases 5 - 4

5.3.2 Gas Connections 5 - 5

6. Switching On 6 - 1

7. Switching Off 7 - 1

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8.

- (vacant)

14.

MAINTENANCE

15. Opening the Housing 15 - 1

15.1 Housing Cover 15 - 1

15.2 Front Panel 15 - 1

16.

- (vacant)

18.

19. Cleaning of Housing Outside 19 - 1

II

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TECHNICAL DATA 20 - 1

20.1 Housing 20 - 1

20.2 Ambient Conditions 20 - 2

20.3 General Specifications 20 - 3

20.4 Voltage supply 20 - 3

20.4.1 Electrical Safety 20 - 4

20.5 Response Factors 20 - 4

SUPPLEMEMT

CONTENTS

21. Pin Assignments 21 - 1

21.1 230 or 115 Vac (Input and Output) 21 - 1

21.2 Pt 100 (external heater) 21 - 1

21.3 Option SIO (Standard Input/Output Module) 21 - 2

21.3.1 Analog Signal Outputs 21 - 2

21.3.2 Relay Outputs / Serial Interfaces 21 - 2

21.4 Option DIO (Digital Input/Output Module) 21 - 3

21.4.1 Wiring with external actors 21 - 4

21.5 COM - Ports (for service use only) 21 - 6

INDEX I - 1

List of Figures I - 4

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III

CONTENTS

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IV

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SAFETY SUMMARY

Safety Summary

Outside and/or inside TFID or at operation manual resp. different symbols gives you a hint to
special sources of danger.

Source of danger !

See Operation Manual!

High V oltage !

GENERAL

Electrostatic Discharge (ESD) !

Explosives !

Hot components !

T oxic !

Risk to health !

Analyzer specific notes for the user !

In operation manual we will give partly additional informations to these symbols.
Strictly follow these instructions please !

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S - 1

SAFETY SUMMARY

GENERAL

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1. General

◆ The following gener al safety precautions must be observed during all phases of operation,
service and repair of this instrument !
Failure to comply with these precautions or with specific w arnings elsewhere in this manual
violates safety standards of design, manufacture and intended use of this instrument !
Failure to comply with these precautions may lead to personal injury and damage to this
instrument !

◆ Fisher-Rosemount GmbH & Co. does not take responsibility (liability) for the customer´s
failure to comply with these requirements !

◆ Do not attempt internal service or adjustment unless other person, capable of rendering first
aid and resuscitation, is present !

◆ Because of the danger of introducing additional hazards, do not perform any unauthorized
modification to the instrument !
Return the instrument to a Fisher-Rosemount Sales and Service office for service or repair
to ensure that safety features are maintained !

◆ Instruments which appear damaged or defective should be made inoperativ e and secured
against unintended operation until they can be repaired by qualified service personnel.

S - 2

90003806(1) NGA-TFID e 16.06.98

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SAFETY SUMMARY

GENERAL / GASES AND GAS CONDITIONING (SAMPLE HANDLING)

Operating personnel must not remove instrument covers !
Component replacement and internal adjustments must be made by qualified
service personnel only !

Read all operation manuals before attempting to operate with the instrument !
Be sure to observe the additional notes, safety precautions and warnings given
in the individual operation manuals (e. g. platform, analyzer modules and
I/O-modules) !

Do not operate the instrument in the presence of flammable gases or explosive
atmosphere without supplementary protective measures !

At heated components there could be exist hot components !

If any moisture or objects come into the internal of the instrument disconnect
power and all supply gases.

2. Gases and Gas Conditioning (Sample Handling)

Be sure to observe the safety regulations for the respective gases
(sample gas and test gases / span gases) and the gas bottles !

All pneumatic supplies and mains, especially the hydrogen mains , have to be
tight ! All gases used must have the right input pressure !

Inflammable or explosiv e gas mixtures must not be purged into the instrument
without supplementary protective measures !

To avoid a danger to the operators by explosive, toxic or unhealthy gas
components, first purge the gas lines with ambient air or nitrogen (N2) before
cleaning or exchange parts of the gas paths.

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S - 3

SAFETY SUMMARY

SUPPLY VOLTAGE

3. Supply Voltage

The socket outlet shall be installed near the equipment and shall be easily
accessible to disconnect the device from the socket outlet.

Verify before operation whether the line voltage stated on the label of the
instrument ore power supply agrees with that of your mains line!

Do not put any object on the supply voltage cable . Install the line voltage cab le
in such a manner that nobody can step on it or fall over it.

Protect the line voltage and signal cables for damage and moisture ingress.

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◆ This product is a Safety Class 1 instruments

This product is provided with a protective earth terminal.
T o prevent shoc k hazard, the instrument chassis and cabinet must be connected
to an electrical ground. The instrument must be connected to the AC power
supply mains through a three-conductor power cable, with the third wire firmly
connected to an electrical ground (safety ground) at the power outlet.
If the instrument is to be energized via an external power supply , that goes for the
power supply too .
Any interruption of the protective (grounding) conductor or disconnection of the
protective earth terminal will cause a potential shock hazard that could result in
personal injury. Deliberate disconnection is inadmissible / prohibited !

S - 4

90003806(1) NGA-TFID e 16.06.98

Rosemount Analytical

4. Analyzer specific notes for the user

First of all operations unscrew transfer safety lock (knurled-head screws)
for the optional sucking pump of the analyzer (Item 5. of operation manual) !

The installation site for the instrument has to be dry and remain above freezing
point at all times.
The instrument must be exposed neither to direct sunlight nor to strong sources
of heat. Be sure to observe the permissible ambient temperature !
For outdoor sites, we recommend to install the instrument in a protective cabinet.
At least, the instrument has to be protected against rain (e.g., shelter).

SAFETY SUMMARY

ANALYZER SPECIFIC NOTES FOR USER

Free flow of air into and out of the equipment must not be hindered by
nearby objects or walls !

For rack installation be sure, that the TFID has space on top and on bottom of
min. 1/2 HU to avoid overheating !

Do not interchange gas inlets and gas outlets !
All gases have to be supplied to the analyzer as conditioned gases !
When the instrument is used with corrosive gases, it is to be verified that there
are no gas components which may damage the gas path components.

The exhaust gas lines have to be mounted in a declining, descending,
pressureless and frost-free and according to the valid emission legislation !

In case it is necessary to open the gas paths, close the analyzers
gas connections with PVC caps immediatly !

Use only from our factory optional delivered cables or equivalent shielded cables
to be in agreement with the CE - conformity.
The customer has to guarantee, that the shield is be connected bothsided.
Shield and connectors housing have to be connected conductive.
Sub.-min.-D-plugs/sockets have to be screwed to the analyzer.

By using of optional delivering terminal strip adapters the analyzer is not be in
agreement with the CE - conformity. In this case CE - conformity is to be declared
by customer as “manufacturer of system”.

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S - 5

SAFETY SUMMARY

ADDITIONAL NOTES FOR SERVICE / MAINTENANCE

5. Additional notes for service / maintenance

Operating personnel must not remove instrument covers !
Component replacement and internal adjustments must be made by qualified
service personnel only !

Always disconnect power, discharge circuits and remove external voltage
sources before troub leshooting, repair or replacement of any component !

Any work inside the instrument without switching off the power must be
performed by a specialist, who is familiar with the related danger, only !

Rosemount Analytical

In case of exchanging fuses the customer has to be certain that fuses of specified
type and rated current are used. It is prohibited to use repaired fuses or def ective
fuse holders or to short-circuit fuse carriers (fire hazard).

In case of exchanging optional suc king pump, verify whether the line voltage
stated on the label of the TFID agrees with that of the sucking pump !

At component replacement or installation the RF shielding contacts must not be
bended !

S - 6

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ELECTROSTATIC DISCHARGE

SAFETY SUMMARY

5.1 Electrostatic Discharge

The electronic parts of the analyzer can be irreparably damaged if exposed to electrostatic
discharge (ESD).

The instrument is ESD protected when the covers have been secured and safety precautions
observed. When the housing is open, the internal components are not ESD protected anymore.

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

Best ESD example is when you w alked 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).

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S - 7

SAFETY SUMMARY

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S - 8

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Rosemount Analytical

Preface

The Thermo-FID (TFID) as member of the NGA 2000 familiy has all the adv antages of a modular
analyzer system. A TFID Analyz er Module (AM) as “blind” analysis unit it can be part of a multiple
NGA analyzer system or special customer-dev eloped control unit. TFID with front panel displa y/
operator interface is a stand-alone analyzer or central interface (control module) for multiple
analyzer modules.

The TFID is used in se veral areas of industry , safety of environment, research and de velop-ment.
T ypical applications are the LEL control, the emission and ambient air control or the e xhaust gas

PREFACE

analysis in the chemistry and combustion engine development. But you can also use the TFID to
optimize a process or to control any limits at operating position.
A lot of auxiliary functions are available by the micro electronic of the TFID. The integrated CPU
allows the operation via menu, the automatic self control and error diagnostics. The displa y shows
all instruction notes and auxiliary reports in plain language. The very small currents of the FID
detector are always evaluated in the optimum range by the processor controlled dynamic amplifier.
The amplified signals will be digitalized directly at the detector and sent out to the CPU. So, a
falsification of the small detector signal will become impossible and the high resistant screened
cable will become unnecessary.

Technical Properties of Measurement

❏ Integrated licensed backfiring flame trap of the “Ex s IIC class”
❏ Electronic control of the sample gas flow
❏ Electronic control of the accelerating voltage
❏ Flame control with automatic ignition
❏ Electronic control of the ignition power
❏ Automatic calibration of the flame size
❏ Self calibration without any other valves or components
❏ Large range of linearization without switching of the coupling
❏ FID amplifier and A/D transformer are connected with the detector directly wireless
❏ Integrated thermic catalyst for burning air, zero gas and stripper
❏ Determination of organic carbon (org. C) in superheat vapor or condensate
❏ Determination of organically bound carbon down to LEL
❏ Determination of organically bound carbon according to “17

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th

BImSchV” (in progress)

P - 1

PREFACE

Rosemount Analytical

P - 2

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Rosemount Analytical

TECHNICAL DESCRIPTION

1. Technical Description

All components of analyzer or analyzer module are incorporated into a 1/1 19" housing.
The housing is availab le as rack mounting (R) or as table-top (T) v ersions. For analyzer modules
there is mounted a blind plate instead of an operation front panel.

The Flame Ionization Detector (FID) is designed to continuously determine concentrations of
hydrocarbons.

The TFID offers the following Adv antages:

a) The instrument is designed modular according to function groups resulting in:

❏ Easy troubleshooting
❏ Fast error removal
❏ High availability

b) The analyzer is sucking automatically sample gas via a pump system being installed behind

the detector.

c) The sample gas is sucked direct into the detector without using a superposed sample gas

pump. Therefrom:

❏ No heated sample gas pump
❏ No additional heating of sample gas inlet (or heated bypass as option)
❏ No “cold” connections leading to condensation; in that way avoiding corrosion and

signal falsification

❏ Fast response (to achie ve values)

1.1 Front View

The front panel of the analyzer is the operating front panel (see Fig. 1-1).
Measured values and the entire operating procedure are display ed on a LC display. The operation
and programming of the instrument is performed by using the four cursor ke ys , the ENTER k e y
and the five soft keys

For analyzer modules there is mounted a blind plate instead of an operation front panel.

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1 - 1

TECHNICAL DESCRIPTION

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

FRONT PANEL

Fastening screws for rack mounting or carrying-strap bracket

Rosemount Analytical

LC display

Cursor keys

(function is depending on Software Menu)

Fastening screws for rack mounting or carrying-strap bracket

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

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optional Fan

(together with internal sucking pump option)

Soft keys

ENTER key

Blind plate or

operation front panel

1 - 2

Fig. 1-2: TFID, Front view

90003806(1) NGA-TFID e 16.06.98

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TECHNICAL DESCRIPTION

1.2 Rear Panel

On the rear panel the connector for 230 or 115 Vac supply, the gas connections, the network
connections and the connectors of optional PCBs (see optional, separate Operation Manuals) are
accommodated.

Connection Pump Control

Network connection

(RJ 45 socket)

for optional internal sucking pump

(Sub. Min. D. 9 pin)

REAR PANEL

optional PCB

[SIO/DIO e.g.]

Gas connections

(optional internal

sucking pump)

Input 230 or 115 Vac

Fig. 1-3: TFID, Rear view

Output 230 or 115 Vac

(max. 4 A)

Gas connections

(Item 5.3)

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1 - 3

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION

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1.3 Internal Construction

By frontal view, the electronic unit with interconnection PCB and other PCBs is located on the right.
The analysis assembly and other parts are located on the left.

analysis assembly internal power supply optional I/O-boards

PCB LEM 02

(network in)

1 - 4

sucking pump

(option)

Fig. 1-4: TFID, internal construction

ACU PCB

front panel

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