Rosemount MLT Series Analyzer Hardware including CAT 200-11th Ed. Manuals & Guides

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Instruction Manual

90002929 04/2008

Instruction Manual

NGA 2000 Hardware Manual for ML T or CA T 200 Analyzer and ML T or CA T 200 Analyzer Module (combined with

NGA 2000 Platform, ML T , CA T 200 or TFID Analyzer)

Edition 04/2008

www.EmersonProcess.com

NGA 2000 ML T Hardware Instruction Manual

90002929

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 02/1997 2nd Edition 03/1997 3rd Edition 09/1997 4th Edition 04/1998

Edition 07/1999 6th Edition 10/1999 7th Edition 04/2003 8th Edition 08/2004

9th Edition 07/2006 10th Edition 01/2007 11th Edition 04/2008

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

Instruction Manual

90002929 01/2007

NGA 2000 MLT Hard ware

Table of Contents

PREAMBEL ....................................................................................S - 1

DEFINITIONS.................................................................................. S - 1

SAFETY INSTRUCTIONS ............................................................. S - 2

Operating and maintaining this apparatus...................................S - 3

Intended use statement .................................................................S - 4

Safety summary..............................................................................S - 4

Authorized personnel.....................................................................S - 4

Gases and Gas Conditioning (Sample Handling) ........................S - 6

Power Supply..................................................................................S - 7

Instruments with External Power Supply Unit...................................S - 7

Instruments with Internal Power Supply Unit....................................S - 7

General operating instructions .....................................................S - 9

Additional hints for UV measurement ........................................S - 10

Magnetically Operated Front Panel ............................................ S - 11

Electrostatic Discharge................................................................S - 12

CONTENTS

PREFACE........................................................................................ P - 1

a) Analyzer versions.........................................................................P - 1

Standard General Purpose Applications........................................ P - 1

b) Analyzer versions

Installation in Hazardous Areas .....................................................P - 2

c) Analyzer System Architecture....................................................... P - 4

DESCRIPTION

1. Technical Description .................................................................... 1 - 1

1.1 Standard General Purpose Applications .......................................... 1 - 1

1.2 Installation in Hazardous Areas........................................................ 1 - 1

1.3 Operating Front Panel ...................................................................... 1 - 2

1.3.1 Standard Version ........................................................................... 1 - 2

1.3.2 Magnetically Operated Touch Panel.............................................. 1 - 3

1.3.2.1 Magnetic Touch Panel Elements.................................................. 1 - 3

1.3.2.2 Accessories.................................................................................. 1 - 4

1.3.2.3 Operating the Touch Panel .......................................................... 1 - 4

Emerson Process Management GmbH & Co. OHG

NGA 2000 MLT Har dware

CONTENTS

Instruction Manual

1.4 MLT 1 ............................................................................................... 1 - 6

1.4.1 MLT 1 1/2 19" housing ................................................................... 1 - 6

1.4.2 MLT 1 ULCO................................................................................ 1 - 11

1.4.3 MLT 1 Housing for platform mounting .......................................... 1 - 13

1.5 MLT 2 (Field Housing).................................................................... 1 - 17

1.6 MLT 3 ............................................................................................. 1 - 21

1.6.1 MLT 3 (Gas purity measurement)................................................. 1 - 23

1.6.2 MLT 3HT (high temperature measurement).......................................1 - 24

1.7 MLT 4 ............................................................................................. 1 - 26

1.8 CAT 200 ......................................................................................... 1 - 28

1.9 Internal Gas Paths.......................................................................... 1 - 32

1.9.1 Gas Path Material ........................................................................ 1 - 32

1.9.2 Gas Path Layout (internal tubing)................................................. 1 - 33

1.9.3 MLT 3 (gas purity measurement) ................................................. 1 - 34

1.10 Printed Circuit Boards .................................................................... 1 - 36

1.10.1 ICB (Inter-Connection Board)....................................................... 1 - 37

1.10.2 PSV/PIC Combination ................................................................. 1 - 37

1.10.3 DSP (alternitavely to PSV/PIC Combination) .............................. 1 - 37

1.10.4 PIC (Physics Interface Card)........................................................ 1 - 38

1.10.5 Digital Signal Processing Card (DSP) ......................................... 1 - 39

1.10.6 ACU ............................................................................................. 1 - 40

1.10.7 SIO (Standard Inputs-/Outputs) .................................................... 1 - 41

1.10.8 DIO (Digital In-/Outputs)............................................................... 1 - 42

1.11 Network Termination ...................................................................... 1 - 43

1.12 Specifications at the Nameplate Label ........................................... 1 - 44

1.13 MLT 2HT (high temperature measurement)...................... ................ 1 - 46

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2. Measuring Principle ....................................................................... 2 - 1

2.1 IR Measurement ............................................................................... 2 - 1

2.1.1 Opto - Pneumatic Measuring Principle........................................... 2 - 3

2.1.2 Interference Filter Correlation (IFC Principle) ................................ 2 - 4

2.2 UV Measurement.............................................................................. 2 - 6

2.3 Oxygen Measurement ...................................................................... 2 - 7

2.3.1 Paramagnetic Measurement (PO2)................................................. 2 - 7

2.3.2 Electrochemical Measurement (EO2) ........................................... 2 - 11

2.3.3 Trace Electrochemical Measurement (TEO2)............................... 2 - 13

2.4 Thermal Conductivity ..................................................................... 2 - 15

2.4.1 Sensor Design ............................................................................. 2 - 15

2.4.2 Analysis Cell ................................................................................ 2 - 15

2.4.3 Measurement Method .................................................................. 2 - 16

3. (vacant)

4. (vacant)

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

OPERATION (START-UP)

5. Installation .................................................................................... 5 - 1

5.1 General........................................................................................... 5 - 1

5.1.1 Transfer Safety Lock of MLT 1/ULCO or MLT 2 .......................... 5 - 3

5.2 Gas Conditioning (Sample Handling) ............................................. 5 - 4

5.2.1 Fine Dust Filter (Option MLT 3) ................................................... 5 - 5

5.2.2 Gas Sampling Pump (Option MLT 3)........................................... 5 - 5

5.2.3 Pressure Sensor (Option) ............................................................ 5 - 5

5.2.4 Gas Flow...................................................................................... 5 - 5

5.3 Gas Connections............................................................................ 5 - 6

5.3.1 Internal Solenoid Valve Block (Option for MLT 1/CAT 200)......... 5 - 8

5.3.2 Purge Gas Connections............................................................... 5 - 8

5.4 Analyzer Specific Instructions......................................................... 5 - 9

5.4.1 MLT 1........................................................................................... 5 - 9

5.4.1.1 MLT 1, platform mounting only................................................... 5 - 9

5.4.1.2 MLT 1, external installation and 1/2-19" Housing....................... 5 - 10

5.4.2 MLT 2 (Field Housing) ................................................................. 5 - 13

5.4.2.1 Wall Mounting ............................................................................ 5 - 13

5.4.2.2 Electrical Connections................................................................ 5 - 15

a) Mains Supply ......................................................................... 5 - 16

b) optional Data Lines ................................................................ 5 - 16

c) Cable Gland Assembly Instruction for Shielded Cables ......... 5 - 19

d) Gas Connections ................................................................... 5 - 20

5.4.3 MLT 3........................................................................................... 5 - 21

5.4.3.1 MLT 3 for gas purity measurement ............................................ 5 - 22

a) Instrument with manual 4/2-way-valve................................... 5 - 22

b) Instrument with solenoid valve block...................................... 5 - 23

c) Instrument with quick shutoff connector ................................. 5 - 23

5.4.4 MLT 4........................................................................................... 5 - 24

5.4.5 CAT 200....................................................................................... 5 - 26

5.4.5.1 Wall Mounting ............................................................................ 5 - 27

5.4.5.2 Electrical Connections................................................................ 5 - 28

5.4.5.3 Gas Connections........................................................................ 5 - 31

5.5 Wiring Signal Terminals.................................................................. 5 - 32

5.5.1 Electrical Connections in General................................................ 5 - 32

5.5.2 Wiring Inductive Loads................................................................. 5 - 34

5.5.3 Driving Multiple Loads.................................................................. 5 - 35

5.5.4 Driving High Current Loads.......................................................... 5 - 36

CONTENTS

Emerson Process Management GmbH & Co. OHG

III

NGA 2000 MLT Hardware

CONTENTS

Instruction Manual

6. Switching On .................................................................................. 6 - 1

7. Measurement / Calibration / Switching Off .................................. 7 - 1

7.1 Measurement ................................................................................... 7 - 1

7.2 Calibration ........................................................................................ 7 - 2

7.2.1 Test Gases .................................................................................... 7 - 3

7.2.1.1 Zero Gas ...................................................................................... 7 - 3

7.2.1.2 Span Gas ..................................................................................... 7 - 3

7.3 Switching Off .................................................................................... 7 - 4

- (vacant)

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TROUBLESHOOTING

10. Troubleshooting ........................................................................... 10 - 1

10.1 Instrument has no function (LCD display is dark)........................... 10 - 1

10.2 No / Incorrect Measurement Screen............................................... 10 - 2

10.3 Display Messages .......................................................................... 10 - 3

10.3.1 Chopper Fail ................................................................................ 10 - 3

10.3.2 Raw Signal Too High / Low.......................................................... 10 - 3

10.3.3 Detector signal communication failed .......................................... 10 - 4

10.3.4 Light source ................................................................................. 10 - 4

10.3.5 Detector ....................................................................................... 10 - 4

10.3.6 Heater Unit Regulation................................................................. 10 - 5

10.3.7 Temperature Measurement ......................................................... 10 - 5

10.3.8 Invalid Pressure Measurement .................................................... 10 - 5

10.3.9 External Input............................................................................... 10 - 6

10.4 No or incorrect Analog Outputs / Digital I/O's................................. 10 - 6

10.5 Calibration not possible .................................................................. 10 - 7

10.6 Fluctuating or erroneous display .................................................... 10 - 8

10.7 Response time too long (t90 time)................................................. 10 - 9

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

11. Test Procedure / Test Points ....................................................... 11 - 1

11.1 Signal processing ........................................................................... 11 - 1

11.1.1 Internal Voltage Supply................................................................ 11 - 2

11.1.2 IR Source..................................................................................... 11 - 2

11.1.3 Chopper ....................................................................................... 11 - 3

11.1.4 Unamplified Measuring Signal at Detector................................... 11 - 3

11.1.5 Signal Processing on PCB “PSV” ................................................ 11 - 4

11.1.6 Physical Zero Alignment .............................................................. 11 - 5

11.1.6.1 IR Measurement......................................................................... 11 - 5

11.1.6.2 Paramagnetic Oxygen Measurement......................................... 11 - 5

11.1.6.3 Electrochemical Oxygen Measurement (EO2) ........................... 11 - 5

11.2 Heating Unit.................................................................................... 11 - 6

11.3 Troubleshooting Instructions for PCB DSP01 ................................ 11 - 7

11.3.1 Inspection of LEDs on component side of DSP01 ....................... 11 - 8

11.3.2 Inspection of soldering pads of DSP01...................................... 11 - 10

11.3.3 Evaluation.................................................................................. 11 - 11

11.3.4 Appendix.................................................................................... 11 - 12

11.3.4.1 Description of soldering pad DEF (LB3):.................................. 11 - 12

11.3.4.2 Definition of LEDs: ................................................................... 11 - 12

CONTENTS

12. Removal / Replacement of Components.................................... 12 - 1

12.1 Removal / Replacement of PCBs (in preparation).......................... 12 - 1

12.1.1 Rear Mounting Slots (in preparation) ........................................... 12 - 1

12.1.2 Internal Slots (in preparation)....................................................... 12 - 1

12.2 Removal / Replacement of Operation Front Panel......................... 12 - 2

12.3 Replacement of Buffer Battery on the ACU 02............................... 12 - 3

12.3.1 Removal of ACU 02 ..................................................................... 12 - 3

12.3.2 Replacement of Buffer Battery..................................................... 12 - 4

12.3.3 Installation of ACU 02 .................................................................. 12 - 4

12.4 Fuses.............................................................................................. 12 - 5

12.4.1 MLT 2........................................................................................... 12 - 5

12.4.2 MLT 1 / 4...................................................................................... 12 - 6

12.5 Connect/Disconnect UV Source/Power Supply for UV Source ...... 12 - 7

Emerson Process Management GmbH & Co. OHG

NGA 2000 MLT Hardware

CONTENTS

Instruction Manual

MAINTENANCE............................................................................. 13 - 1

14. Leak Testing ................................................................................. 14 - 1

15. Opening the Housing ................................................................... 15 - 1

15.1 MLT 1 ............................................................................................. 15 - 2

15.1.1 MLT 1 (Platform housing)............................................................... 15 - 2

15.1.1.1 Housing Cover ........................................................................... 15 - 2

15.1.1.2 Front Panel................................................................................. 15 - 3

15.1.2 MLT 1 (1/2 19" housing) .............................................................. 15 - 4

15.1.2.1 Housing Cover ........................................................................... 15 - 4

15.1.2.2 Front Panel................................................................................. 15 - 5

15.2 MLT 2 (Field Housing).................................................................... 15 - 6

15.3 MLT 3/4 (1/1 19" housing) .............................................................. 15 - 8

15.3.1 Housing Cover ............................................................................. 15 - 8

15.3.2 Front Panel (MLT 4 / MLT 3 standard version) ............................ 15 - 8

15.3.3 Front Panel (MLT 3 gas purity measurement) ............................. 15 - 9

15.3.3.1 Operation Front Panel................................................................ 15 - 9

15.3.3.2 Left Front Panel.......................................................................... 15 - 9

15.4 CAT 200 ....................................................................................... 15 - 10

15.4.1 Junction Box .............................................................................. 15 - 12

15.4.2 Dome ......................................................................................... 15 - 13

15.4.3 Magnetically Operated Front Panel ........................................... 15 - 16

15.4.3.1 Sliding the Analyzer into Position............................................. 15 - 16

15.4.3.2 Fixing the Analyzer................................................................... 15 - 16

15.4.3.3 Completing the Adjustment ...................................................... 15 - 16

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16. Fine Dust filter (MLT 3 Option) .................................................... 16 - 1

17. Replacement and Cleaning of Photometric Components ........ 17 - 1

17.1 Removal of the Photometer Assembly ........................................... 17 - 2

17.2 Light Source Replacement (IR) ...................................................... 17 - 3

17.3 Cleaning of Analysis Cells and Windows ....................................... 17 - 4

17.3.1 Removal of Analysis Cells ........................................................... 17 - 4

17.3.2 Cleaning....................................................................................... 17 - 5

17.3.3 Reinstalling of Analysis Cells....................................................... 17 - 6

17.4 Reinstalling of the Photometer Assembly....................................... 17 - 7

17.5 Physical Zeroing............................................................................. 17 - 8

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

18. Check / Replacement of electrochemical Oxygen Sensor........ 18 - 1

18.1 EO2-Sensor .................................................................................... 18 - 2

18.2 Check of the EO2-Sensor ............................................................... 18 - 3

18.3 Replacement of the EO2-Sensor .................................................... 18 - 4

18.3.1 Removal of the EO2-Sensor......................................................... 18 - 4

18.3.2 Replacing the EO2-Sensor ........................................................... 18 - 5

18.3.3 Reinstalling of the EO2-Sensor .................................................... 18 - 5

18.3.4 Basic conditions for the EO2-Sensor............................................ 18 - 6

18.4 TEO2-Sensor .................................................................................. 18 - 7

19. Cleaning of Housing Outside ...................................................... 19 - 1

CONTENTS

TECHNICAL DATA ........................................................................ 20 - 1

20.1 Housing .......................................................................................... 20 - 1

20.2 Options ........................................................................................... 20 - 2

20.3 General Specifications ................................................................... 20 - 3

20.4 Voltage supply.............................................................................. 20 - 11

20.4.1 Analyzers...................................................................................... 20 - 11

20.4.1.1 MLT 1/4.................................................................................... 20 - 11

20.4.1.2 MLT 2/3.................................................................................... 20 - 11

20.4.1.3 CAT 200................................................................................... 20 - 11

20.4.1.4 Electrical Safety ....................................................................... 20 - 11

20.4.2 Power Supplies.......................................................................... 20 - 12

20.4.2.1 UPS 01 T (Universal Power Supply) ........................................ 20 - 12

20.4.2.2 External 5A Power Supply Unit for DIN Rail Installation........... 20 - 14

20.4.2.3 External 10A Power Supply Unit for DIN Rail Installation......... 20 - 16

20.4.2.4 Tabletop Power Supply Units................................................... 20 - 18

Emerson Process Management GmbH & Co. OHG

VII

NGA 2000 MLT Hardware

CONTENTS

Instruction Manual

SUPPLEMENT

21. Pin Assignments ........................................................................ 21 - 1

21.1 24 V dc Input (MLT 1/4)................................................................ 21 - 1

21.2 230/120 V ac Input (MLT 3).......................................................... 21 - 1

21.3 Option SIO (Standard I/O)............................................................ 21 - 2

21.3.1 Analog Signal Outputs ............................................................... 21 - 2

21.3.2 Relay Outputs / Serial Interfaces ............................................... 21 - 2

21.4 Option DIO (Digitale I/O) .............................................................. 21 - 3

21.5 Terminal Assignment of CAT 200................................................. 21 - 4

21.6 CAT 200 Increased Safety Box - Label Schematic........................21 - 7

22. Calculation of Water Content from Dew-point to

Vol. -% or g/Nm³.......................................................................... 22 - 1

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Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

LIST OF FIGURES

Fig. Title Page

Fig. P-1: Analyzer Nameplate Label (example).............................................................................P - 3

Fig. P-2: From separate analyzers to analyzer system .................................................................P - 4

Fig. P-3: Example of NGA-cabling.................................................................................................P - 5

Fig. P-4: Example/possibilities of NGA analyzer system ...............................................................P - 6

Fig. 1-1: Operation front panel, Front view.................................................................................... 1 - 2

Fig. 1-2: Magnetically Operated Touch Panel, Front view ............................................................ 1 - 3

Fig. 1-3a: Magnetic actuator ........................................................................................................... 1 - 5

Fig. 1-3b: Magnetic actuator, view at magnets................................................................................ 1 - 5

Fig. 1-4a: Symbols showing actuator alignment ............................................................................. 1 - 4

Fig. 1-4b: Horizontally aligned, activating F4 .................................................................................. 1 - 5

Fig. 1-4c: Vertically aligned, activating F5....................................................................................... 1 - 5

Fig. 1-5: Actuator stored when not in use ..................................................................................... 1 - 4

Fig. 1-6: MLT analyzer, Front view.............................................................................................. .. 1 - 6

Fig. 1-7: MLT 1, Front panel, Rear view........................................................................................ 1 - 7

Fig. 1-8: MLT 1, Rear panel (standard) ......................................................................................... 1 - 7

Fig. 1-9: MLT 1, Rack/Table-top Housing, Top view (with electrochemical O2 Sensor) ................ 1 - 8

Fig. 1-10: MLT 1, Rack/Table-top Housing, Top viewA(with paramagnetic O2 Sensor).................. 1 - 9

Fig. 1-11: MLT 1, Rack/Table-top Housing extended, Top view (with paramagnetic O2 Sensor) . 1 - 10

Fig. 1-12: MLT 1 ULCO, Rack/Table-top Housing, Top view ........................................................ 1 - 12

Fig. 1-13: MLT 1 Analyzer module (Platform mounting), Front panel, Front view ......................... 1 - 13

Fig. 1-14: MLT 1, Platform mounting, Top view (with electrochemical O2 Sensor) ....................... 1 - 14

Fig. 1-15: MLT 1, Platform mounting, Top view (with paramagnetical O2 Sensor) ........................ 1 - 15

Fig. 1-16: MLT 1, Platform mounting extended, Top view (with paramagnetic O2 Sensor) ........... 1 - 16

Fig. 1-17a: Front view MLT 2 (Standard housing/Standard operation front panel) ......................... 1 - 19

Fig. 1-17b: Front view MLT 2 (Dual compartment housing/Standard operation front panel)........... 1 - 19

Fig. 1-18a: MLT 2, Inside view (drawing without front panel).......................................................... 1 - 20

Fig. 1-18b: MLT 2, Photometer sliding carriage, Top view.............................................................. 1 - 20

Fig. 1-19: MLT 3 (standard) (1/1 19" housing), front view ............................................................ 1 - 21

Fig. 1-20: MLT 3 (standard version), Rear view ........................................................................... 1 - 21

Fig. 1-21: MLT 3 (standard version), Top view ............................................................................. 1 - 22

Fig. 1-22: MLT 3 (gas purity measurement), front view................................................................. 1 - 23

Fig. 1-23: MLT 3 (gas purity measurement), Rear view ................................................................ 1 - 24

Fig. 1-24: MLT 3 (gas purity measurement), Top view.................................................................. 1 - 25

Fig. 1-25: MLT 4 (1/1 19" housing), front view .............................................................................. 1 - 26

Fig. 1-26: MLT 4, Rear view.......................................................................................................... 1 - 26

Fig. 1-27: MLT 4, Rack/Table-top Housing, Top view ................................................................... 1 - 27

Fig. 1-28: CAT 200, Exterior view ................................................................................................. 1 - 30

Fig. 1-29: CAT 200 (Dome and extender housing removed) ........................................................ 1 - 31

Fig. 1-30a: MLT 3 (gas purity measurement), gas path layout.................................................................

(3 measuring channels with solenoid valve block option) ............................................. 1 - 34

Fig. 1-30b: MLT 3 (gas purity measurement), gas path layout.................................................................

(3 measuring channels with valve block option and quick shuttoff connector option) ... 1 - 35

Fig. 1-30c: MLT 3 (gas purity measurement), gas path layout.................................................................

(2 measuring channels with manual 4/2-way-valve option) .......................................... 1 - 35

Fig. 1-31a: Cardcage MLT 1/3/4, Top View .................................................................................... 1 - 36

Fig. 1-31b: PCB arrangement MLT 2 [Inside view, detail (without front panel)] .............................. 1 - 37

CONTENTS

Emerson Process Management GmbH & Co. OHG

NGA 2000 MLT Hardware

CONTENTS

LIST OF FIGURES

Fig. Title Page

Fig. 1-32: Plug pin assignment PCB PIC ...................................................................................... 1 - 38

Fig. 1-33: Plug pin assignment PCB DSP ..................................................................................... 1 - 39

Fig. 1-34: Function blocks of SIO-PCB ......................................................................................... 1 - 41

Fig. 1-35: SIO-PCB with extension cards...................................................................................... 1 - 42

Fig. 1-36: RJ 45 network termination connector ........................................................................... 1 - 43

Fig. 1-37: Network termination (examples) ................................................................................... 1 - 43

Fig. 1-38: Analyzer Nameplate Label (example) ........................................................................... 1 - 44

Fig. 2-1: Measuring Principle for NDIR / UV Measurement........................................................... 2 - 2

Fig. 2-2: Principle Design of Gas Detector.................................................................................... 2 - 3

Fig. 2-3: Absorption Bands of Sample Gases and Transmittance of the .............................................

Interference Filters used ................................................................................................. 2 - 5

Fig. 2-4: Principle Construction of paramagnetic Analysis Cell ..................................................... 2 - 8

Fig. 2-5: Structure of electrochemical Oxygen Sensor................................................................ 2 - 11

Fig. 2-6: Reaction of galvanic cell ............................................................................................... 2 - 12

Fig. 2-7: Structure of electrochemical Trace Oxygen Sensor...................................................... 2 - 13

Fig. 2-8: Sensor block (thermal conductivity detector TCD)........................................................ 2 - 15

Fig. 2-9: Measuring principle Thermal Conductivity Sensor (Wheatstone bridge) ...................... 2 - 16

Instruction Manual

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Fig. 5-1a: Transfer safety lock MLT-ULCO (housing side view, detail sketch)................................ 5 - 3

Fig. 5-1c: MLT 2, Photometer safety lock ....................................................................................... 5 - 3

Fig. 5-1b: MLT 1, Rear panel (holder for safety lock)...................................................................... 5 - 3

Fig. 5-2: MLT, Bypass installation ................................................................................................. 5 - 7

Fig. 5-3: MLT 1 analysis module (platform mounting), front panel, front view ............................... 5 - 9

Fig. 5-4: MLT 1, standard gas connections ................................................................................. 5 - 11

Fig. 5-5: MLT 1, gas connections with solenoid valve option ...................................................... 5 - 12

Fig. 5-6a: Dimensional sketch / Drill drawing MLT 2 Standard version......................................... 5 - 14

Fig. 5-6b: Dimensional sketch / Drill drawing MLT 2 Dual housing version .................................. 5 - 14

Fig. 5-8: MLT 2, Data line connections Inside view from front (detail, without front door) ........... 5 - 17

Fig. 5-9: MLT 2, Connection data lines / mains line (inside view, left side panel) ....................... 5 - 18

Fig. 5-10: Cable Gland Assembly Instruction for Shielded Cables................................................ 5 - 19

Fig. 5-11: Cable gland sealing plug / Cable gland allen screw sealing plug ................................. 5 - 19

Fig. 5-12a: MLT 2, gas connections................................................................................................ 5 - 20

Fig. 5-12b: MLT 2, Gas fittings at analyzer’s bottom side ............................................................... 5 - 20

Fig. 5-13: MLT 3 (standard version), gas connections and voltage supply ................................... 5 - 21

Fig. 5-14: MLT 3 (gas purity measurement), Rear view ................................................................ 5 - 22

Fig. 5-15: Solenoid valve block MLT 3 (gas purity measurement) (side view) .............................. 5 - 23

Fig. 5-16: MLT 3 (gas purity measurement), front view................................................................. 5 - 23

Fig. 5-17: MLT 4, Voltage supply .................................................................................................. 5 - 24

Fig. 5-18: MLT 4, gas connections................................................................................................ 5 - 25

Fig. 5-19: Drill drawing CAT 200 [all dimensions in mm (Inch)]..................................................... 5 - 27

Fig. 5-20: CAT 200, Junction box, interior view............................................................................. 5 - 30

Fig. 5-21: CAT 200, Analyzer’s bottom view at gas fittings ........................................................... 5 - 30

Fig. 5-22: Shielded Signal Cable, shield connected at both ends ................................................. 5 - 32

Fig. 5-23: Shielded Signal Cable, shield connected at one end.................................................... 5 - 32

Fig. 5-24: Double-shielded Signal Cable, shields connected at both sides................................... 5 - 33

Fig. 5-25: Suppressor Diode for Inductive Loads .......................................................................... 5 - 34

Fig. 5-26: ”Serial” Wiring ............................................................................................................... 5 - 35

Fig. 5-27: Running Supply Lines "Parallel”.................................................................................... 5 - 35

Fig. 5-28: Driving High Current Loads........................................................................................... 5 - 36

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

Fig. Title Page

Fig. 11-1: Principle signal processing with PCB "PSV" ................................................................. 11 - 1

Fig. 11-2: PCB "VVS".................................................................................................................... 11 - 2

Fig. 11-3: PCB "MOP” (partial view).............................................................................................. 11 - 3

Fig. 11-4: PCB "BHZ” (position of signal LED's / heating transistors) ........................................... 11 - 6

Fig. 11-5: PCB "DSP01”................................................................................................................ 11 - 7

Fig. 11-6: LEDs on component side of PCB "DSP01”................................................................... 11 - 8

Fig. 11-6a: LEDs “V7” and “V9” (PCB "DSP01”) ............................................................................. 11 - 8

Fig. 11-6b: LEDs “V3” and “V4” (PCB "DSP01”) ............................................................................. 11 - 9

Fig. 11-6c: LEDs “V12” to “V17”, Jumper “P40” (PCB "DSP01”) .................................................... 11 - 9

Fig. 11-7: Soldering pads on soldering side of PCB "DSP01”..................................................... 11 - 10

Fig. 11-7a: Soldering pad “LB1” and “LB2 (PCB "DSP01”) ........................................................... 11 - 10

Fig. 11-7b: Soldering pad “LB18” (PCB "DSP01”) ........................................................................ 11 - 10

Fig. 11-8: Schematic diagram of inspection of PCB "DSP01” ..................................................... 11 - 11

Fig. 11-9: Soldering pad “DEF/LB3” (PCB "DSP01”) .................................................................. 11 - 12

NGA 2000 MLT Hardware

LIST OF FIGURES

CONTENTS

Fig. 12-1: Controller Board ACU (partial view, component side)................................................... 12 - 3

Fig. 12-2: Fuses MLT 2 (partial inside view, drawing without front panel)..................................... 12 - 5

Fig. 12-3a: Fuses PCB LEM 01 (component side).......................................................................... 12 - 6

Fig. 12-4a: Power Supply for UV Source (front view, front panel disassembled)............................ 12 - 8

Fig. 12-4b: UV Source and PCB ESP10 (top view, housing cover disassembled) ......................... 12 - 9

Fig. 14-1: Leak Testing with an U - Tube - Manometer................................................................. 14 - 1

Fig. 15-1: MLT 1 (Plattform housing) Fastening screws housing cover ........................................ 15 - 2

Fig. 15-2: MLT 1 (Plattform housing) Fastening screws front panel.............................................. 15 - 3

Fig. 15-3: MLT 1 (1/2 19" housing) Fastening screws housing cover ........................................... 15 - 4

Fig. 15-4: MLT 1 (1/2 19" housing) Fastening screws front panel................................................. 15 - 5

Fig. 15-5: MLT 2 (Field housing) fastener for front panel .............................................................. 15 - 7

Fig. 15-6: MLT 2, photometer carriage slide ................................................................................. 15 - 7

Fig. 15-7: MLT3 (standard version) / MLT 4 (1/1 19" housing) Fastening screws front panel....... 15 - 8

Fig. 15-8: MLT3 (gas purity measurement) (1/1 19" housing) Fastening screws front panel........ 15 - 9

Fig. 15-9: Cat 200 Enclosure Assembly...................................................................................... 15 - 11

Fig. 15-10: Cat 200 Junction box .................................................................................................. 15 - 12

Fig. 15-11: CAT 200 Dome, fixing screws..................................................................................... 15 - 13

Fig. 15-12: View at analyzer module............................................................................................. 15 - 14

Fig. 15-13: Plate with detents........................................................................................................ 15 - 14

Fig. 15-14: CAT 200, Cast Iron housing, Interior View.................................................................. 15 - 15

Fig. 17-1: Photometer Assembly, example (Top view, detail) ....................................................... 17 - 2

Fig. 17-2: Chopper Housing with IR light sources......................................................................... 17 - 3

Fig. 17-3: Photometer Assembly (1 mm to 10 mm analysisi cells)................................................ 17 - 4

Fig. 17-4: Photometer Assembly (30 mm to 200 mm analysisi cells)............................................ 17 - 4

Fig. 18-1: PCB “OXS”, assembled, horizontal projection .............................................................. 18 - 3

Fig. 18-2: MLT 1, front panel, rear view ........................................................................................ 18 - 4

Fig. 18-3: PCB “OXS”, assembled, horizontal projection .............................................................. 18 - 6

Emerson Process Management GmbH & Co. OHG

NGA 2000 MLT Hardware

CONTENTS

LIST OF FIGURES/LIST OF TABLES

Fig. Title Page

Fig. 20- 1: Dimensional sketch MLT 1 [all dimensions in mm] ........................................................ 20 - 6

Fig. 20- 2: Dimensional sketch / Drill drawing MLT 2 Standard version ........................................... 20 - 7

Fig. 20- 3: Dimensional sketch / Drill drawing MLT 2 Dual housing version..................................... 20 - 7

Fig. 20- 4: Dimensional sketch MLT 2 for Ex Zone 2 in standard housing ....................................... 20 - 8

Fig. 20- 5: Dimensional sketch MLT 2 for Ex Zone 1 in standard housing ....................................... 20 - 8

Fig. 20- 6: Dimensional sketch MLT 2 for Ex Zones with “Z Purge” (MLT 2-NF).......................................

or “Continuous purge” in standard housing................................................................... 20 - 9

Fig. 20- 7: Dimensional sketch MLT 3/4......................................................................................... 20 - 9

Fig. 20- 8: Dimensional sketch / Drill drawing CAT 200 ............................................................... 20 - 10

Fig. 20- 9: Dimensional sketch UPS 01 T (Universal Power Supply), table-top version .............. 20 - 13

Fig.20-10a: IEC mains input plug (UPS 01 T) ................................................................................ 20 - 13

Fig. 20-10b: 24 V DC output socket, Pin assignment (UPS 01 T)................................................... 20 - 13

Fig. 20-11: Power Supply SL5, Dimensions.................................................................................. 20 - 15

Fig. 20-12: Power Supply SL 10, Dimensions............................................................................... 20 - 17

Fig. 20-13: 10 A Tabletop Power Supply, Dimensions.................................................................. 20 - 18

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Fig. 21- 1: Pin assignments 24 V dc Input (MLT 1/4) ..................................................................... 21 - 1

Fig. 21- 2: Pin assignments 230/120 V ac Input (MLT 3) ............................................................... 21 - 1

Fig. 21- 3: Pin assignments Socket Analog Signal Outputs (Option SIO) ...................................... 21 - 2

Fig. 21-4a: Pin assignments Socket Relay Outputs / RS 232 Serial Interface (Option SIO) ........... 21 - 2

Fig. 21-4b: Pin assignments Socket Relay Outputs / RS 485 Serial Interface (Option SIO) ........... 21 - 2

Fig. 21- 5: Pin assignments Socket Digital Inputs/Outputs (Option DIO) ........................................ 21 - 3

Fig. 21- 6: CAT 200, Junction box, interior view.............................................................................. 21 - 4

LIST OF TABLES

Table Title Page

Table P-1: Possibilities of NGA 2000 MLT I/O combinations ...........................................................P - 7

Table 1-1: Possible internal tubings (examples with 3 measuring channels) ................................... 1 - 33

Table 2-1: Solvent Resistant Sensor: Approved solvents ................................................................. 2 - 9

Table 2-2: Medium affected Materials within Paramagnetic Oxygen Sensor .................................... 2 - 9

Table 2-3: Paramagnetic Oxygen Measurement, cross interference by accompanying gases ........ 2 - 10

Table 5-1: CAT 200, Assignment of gas fittings ............................................................................. 5 - 30

Table 11-1: Definition of LEDs/Default configuration of soldering pads (PCB "DSP01”) .................. 11 - 12

Table 11-2: Definition of LEDs/Normal configuration of soldering pads (PCB "DSP01”) .................. 11 - 13

Table 20-1: Specifications of MLT.................................................................................................... 20 - 4

Table 20-2: Altered NDIR/VIS/UV-Specifications of MLT-ULCO compared to table 1 ...................... 20 - 5

Table 21-1: CAT 200 Power Connections Terminal Assignments ..................................................... 21 - 5

Table 21-2: CAT 200 Analog Signal Outputs Terminal Assignments (Option SIO)............................ 21 - 5

Table 21-3: CAT 200 Relay Outputs Terminal Assignments (Option SIO) ........................................ 21 - 5

Table 21-4: CAT 200 Field Bus Terminal Assignments (Option) ....................................................... 21 - 5

Table 21-5: CAT 200 RS 232 / RS 485 Serial Interface Terminal Assignments (Option SIO)............ 21 - 6

Table 21-6: CAT 200 Digital Inputs/Outputs Terminal Assignments (Option DIO) ............................. 21 - 6

Table 21-7: CAT 200 Terminal Assignments - Bottom (Lower) Contacts........................................... 21 - 8

Table 21-8: CAT 200 Terminal Assignments - Top (Upper) Contacts ................................................ 21 - 8

Table 22-2: Calculation of Water Content from Dew-point to Vol. -% or g/Nm³ .................................. 22 - 1

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Instruction Manual

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

PREAMBEL / DEFINITIONS

Preambel

This instruction manual provides information about ML T and CAT200 series gas analyzers /analyzer modules concerning subassemblies, functions, procedures, installation, operation and maintenance. This instruction manual covers se veral ML T and CA T200 series gas analyzers /analyzer modules variations and therefore may describe configurations and/or options not part of your specific analyzer . Installation and operation of instruments intended to be installed and operated in HAZARDOUS AREAS is NOT CO VERED by this instruction manual, but part of the specific instruction manual shipped together with such analyzers because of the special requirements for working in hazardous environments!

Definitions

The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication.

Highlights an operation or maintenance procedure, practice, condition, statement, etc.

If not strictly observed, could result in injury , death, or longterm health hazards of personnel.

Highlights an operation or maintenance procedure, practice, condition, statement, etc.

If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

Emerson Process Management GmbH & Co. OHG

NOTE

Highlights an essential operating procedure, condition or statement.

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

GENERAL

Instruction Manual

IMPORTANT

SAFETY INSTRUCTIONS

WIRING AND INSTALLA TION OF THIS APP ARATUS

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. Adequate earth connections should be made to all earthing points, internal and external,

where provided.

2. After installation or troubleshooting, all safety co vers and safety grounds must be replaced.

The integrity of all earth terminals must be maintained at all times.

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3. To ensure safe operation of this equipment, connection to the mains supply should only

be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit 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.

4. Where equipment or covers are marked with the symbol to the right,

hazardous voltages are likely to be present beneath. These cov ers should only be removed when po wer is removed from the equipment — and then by trained service personnel only.

5. Where equipment or cov ers 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 cov ers are marked with the symbol to the right, refer

to the Instruction Manual for instructions.

7. Further graphical symbols used in this product:

Elektrostatic discharge (ESD)

Harmful (to Health)!

Explosion Hazard!

Toxic!

Heavy Instrument!

Disconnect from Mains!

All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.

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Instruction Manual

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OPERATING AND MAINTAINING THIS APPARATUS

NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

Operating and maintaining this apparatus

This instrument has left the factory in compliance with all applicable safety regulations. T o maintain this oper ating condition, the user must strictly follow the instructions and consider

the warnings in this manual or provided on the instrument. Before switching on the instrument, verify that the electrical supply voltage matches the

instrument´s operating voltage as set in the factory. Any interruption in the instrument´s ground line, whether inside or outside the instrument, or

removal or interruption of its ground line connection, could result in hazardous operating conditions. Intentionally interrupting the instrument´s protective ground is strictly prohibited.

Opening cover panels could expose voltage-carrying components. Connectors may also be under voltage. The instrument must be disconnected from all electrical supplies before attempting any calibrations, maintenance operations, repairs or component replacements requiring opening of the instrument. Any calibrations, maintenance operations , or repairs that need the instrument to be opened while connected to electrical supplies should be subject to qualified technicians familiar with the hazards involved only!

Use only fuses of the correct type and current ratings as replacements. Using repaired fuses and short circuiting of fuse holders is prohibited.

Observe all applicable regulations when operating the instrument from an auto-transformer or variac.

Substances hazardous to health may emerge from the instrument‘s exhaust. Please pay attention to the safety of y our oper ation personnel. Protectiv e measures must be taken, if required.

Emerson Process Management GmbH & Co. OHG

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

INTENDED USE STATEMENT / SAFETY SUMMARY / AUTHORIZED PERSONNEL

Instruction Manual

Intended use statement

MLT and CAT200 series gas analyzers/analyzer modules are intended to be used as analyzers for industrial purposes. They must not be used in medical, diagnostic or life support applications, and no independent agency certifications or approv als are to be implied as covering such applications!

Safety summary

If this equipment is used in a manner not specified in these instructions, protective systems may be impaired.

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Authorized personnel

T o avoid loss of lif e, personal injury and damage to this equipment and on-site property , do not operate or service this instrument before reading and understanding this instruction manual and receiving appropriate training. Save these instructions.

ELECTRICAL SHOCK HAZARD !

Do not operate without covers secure. Do not open while energized. Installation requires access to live parts which can cause death or serious injury.

For safety and proper performace this instrument must be connected to a properly grounded three-wire source of power.

TOXIC GASES !

This unit’s exhaust may contain toxic gases such as sulfur dioxide. These gases can cause serious injuries.

Aviod inhalation of the exhaust gases at the exhaust fitting. Connect exhaust outlet to a safe vent. Check vent line and connections for leakage. Keep all fittings tight to avoid leaks. See section 14 for leak test information.

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Instruction Manual

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Do not operate nor install these instruments in hazardous areas without additional measures!

The analyzer variations MLT 2 and CAT 200 intended to be wall mounted and/or outdoor installed weigh up to 35 kg resp. 70 kg, depending on included options!

NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

EXPLOSION HAZARD !

MLT 2 and CAT 200 -- HEAVY INSTRUMENTS !

Use two person and/or suitable tools for transportation and lifting these instruments!

Take care to use anchors and bolts specified to be used for the weight of the units!

Take care the wall or stand the unit is intended to be installed at is solid and stable to hold the units!

HIGH TEMPERATURES !

While working at photometers and/or thermostated components inside the analyzers hot components may be accessible!

CAUSTIC !

The electrochemical O2-sensor contains electrolyte which is caustic and can cause serious burns to skin. Do not ingest contents of sensor !

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

Because of the danger of introducing additional hazards, do not perform any unauthorized modification to this instrument!

Emerson Process Management GmbH & Co. OHG

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

GASES AND GAS CONDITIONING (SAMPLE HANDLING)

Gases and Gas Conditioning (Sample Handling)

T ake care of the safety instructions applicable for the gases (sample gases and test gases) and for the gas bottles containing these gases!

Before opening gas paths they must be purged with ambient air or neutral gas (N2) to avoid hazards caused by toxic, flammable, explosive or harmful to health sample gas components!

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Flammable gases must not supplied without additional protective measures!

It is prohibited to supply e xplosive gases!

EXPLOSION HAZARD !

Supplying flammable gases of concentrations above 25 % of lower explosion limit (LEL) we recommend to utilize one or more of the following measures:

• Purging the housing with inert gas

• Internal tubing with stainless steel

• Flame arrestors at gas input and output fittings

• Intrinsically safe paramagnetical or thermal conductivity sensors

Supplying explosive gases is not permitted !

• Purge gas must be conditioned: Take care for purge gas temperature: Purge gas should have the same temperature as ambient temperature of the analyzer but NOT below 20 °C and above 35 °C! Otherwise it must be cooled or warmed up before let in into the instrument! Purge gas should be instrumental / synthetic air (free of oil, no corrosive, to xic or flammable gas componets) or nitrogen depending on application.

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Instruction Manual

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Power Supply

V erify the mains voltage at site of installation corresponds to the analyzer´s rated voltage as given on the nameplate label!

V erify the safety instruction given by power supply unit manufacturer !

Instruments with External Power Supply Unit

NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

POWER SUPPLY

The mains socket has to be nearby the power supply unit and easily accessible! Disconnecting from mains requires unplugging the power plug!

To comply with the CE mark requirements use only power supply units of type UPS 01 T, DP 157, SL5, SL10 (DP 157 for rack installation only) or equivalent units. Equivalent units must provide SELV output voltages!

V erify proper polarity when connecting DC 24 V operated analyzers !

Instruments with Internal Power Supply Unit

ELECTRICAL SHOCK HAZARD !

These instruments provide a protective earth terminal. T o prevent electrical shock hazards the instrument must be connected to a protective earth. Therefore the instrument has to be connected to mains by using a three wire mains cable with earth conductor!

Any interruption of the earth connector inside or outside the instrument or disconnecting the earth terminal may cause potential electrical shock hazzard! Intended interruption of protective earth connections is not permitted!

• For analyzer module (A) [external installation or platform mounting] it is not allowed to supply the module from front and rear simultaneously ! For e xternal installation connections on frontside absolutely have to closed with the blind plate delivered from our factory to be in agreement with the CE conformity.

Emerson Process Management GmbH & Co. OHG

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

ADDITIONAL HINTS FOR MLT 2 AND CAT 200

ADDITIONAL HINTS FOR MODELS MLT 2 AND CAT 200

Installation and connecting mains and signal cables are subject to qualified personnel only taking into account all applicable standards and legislative requirements!

Failure to follow may cause warranty invalidation, property damage and/or personal injury or death! Mains and signal cables need to be connected to internal srew terminals requiring to work at open housing near life parts!

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Installation of this instrument is subject to qualified personnel only , familiar with the resulting potential risks!

These gas analyzer do not provide a mains power switch and are operable when connected to power.

These gas analyzers do not provide a mains switch! A mains switch or circuit breaker has to be provided in the building installation. This switch has to be installed near by analyzer, must be easily operator accessible and has to be assigned as disconnector for the analyzer.

ADDITIONAL HINTS FOR MODEL MLT 2

Cables for external data processing must be double insulated for mains voltage when used inside the instrument! If double insulation is not available signal cables inside the analyzer must be installed in a way that a distance of at least 5 mm is ensured permanently (e.g. by utilizing cable ties).

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Instruction Manual

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V erify all gas lines are connected as described within this manual and tight! Improper gas connections may cause explosion, serious injury or death! Exhaust may contain hydrocarbons and other toxic gases, e.g. carbon

monoxide. Carbon monoxide is toxic!

NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

GENERAL OPERATING INSTRUCTIONS

General operating instructions

DANGER TO LIFE ! EXPLOSION HAZARD !

• Before start-up unscrew transfer safety lock (knurled-head screws) of the MLT 1 + 2 (section 5. of operation manual) !

• Installation area has to be clean, free from moisture, excessive vibration and frostprotected. Take care to meet the permissible ambient temperatures as given in the technical data section! Instruments must not be exposed to direct sunlight, fluorescent lamps nor sources of heat.For outdoor installation it is recommended to mount the instruments into a cabinet. At least sheltering against rain is required. Do not co v er v enting openings and tak e care to mount the instrument in a distance to walls not affecting venting.

• Free flow of air into and out of the MLT (ventilation slits) must not be hindered by nearby objects or walls !

• Do not interchange gas inlet and outlet! All gases must be conditioned before supplying! When supplying corrosive gases ensure that gas path components are not affected!

• Max. permissible gas pressure: 1,500 hPa, except instruments for gas purity measurement (see chapter 5.4.3.1), with integrated valve blocks (see page 5-8 and/or paramagnetic Oxygen sensor (see table page 20-4)!!

• Exhaust lines must be installed in a descending way, need to be pressureless, frostprotected and in compliance with applicable legislative requirements!

• When it is necessary to open gas paths seal the analyzer‘s gas fittings by using PVC caps to avoid pollution of the internal gas path by moisture, dust, etc.

• To stay in compliance with regulations regarding electromagnetic compatibility it is recommended to use only shielded cables, as optionally a vailable from Emerson Process Management or equivalent. Customer has to take care that the shield is connected in proper way. Shield and signal connector enclosure need to be conductively connected, submin-d plugs and sockets must be screwed to the analyzer.

• Using external submin-d-to-terminal adaptor elements (option) affects electromagnetic compatibility. In this case the customer has to take measures to stay in compliance and has to declare conformity, when required by legislation (e.g. European EMC Directive).

Emerson Process Management GmbH & Co. OHG

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

ADDITIONAL HINTS FOR UV MEASUREMENT

Additional hints for UV measurement

The optional UV lamp operates with high voltage (Power Supply UVS) !

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HIGH VOLTAGE !

UV SOURCE !

Ultraviolet light from UV lamp can cause permanent eye damage ! Do not look directly at the ultraviolet source !

TOXIC SUBSTANCE !

The optional UV lamp contains mercury. Lamp breakage could result in mercury exposure ! Mercury is highly toxic !

If the lamp is broken, avoid any skin contact to mercury and inhalation of mercury vapors !

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Instruction Manual

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Persons with cardiac pacemakers should absolutely avoid magnetic fields !

Negative effects on persons beyond those described above caused by magnetic fields are not known. It is presumed that persons showing allergic reaction on contact with ceramic or metallic material show the same behavior on contact with magnetic material.

NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

MAGNETICALLY OPERATED FRONT PANEL

Magnetically Operated Front Panel

DANGER TO LIFE !

Permanent magnets are surrounded by magnetic fields. These magnetic fields can disturb and even destroy sensitive electronic measuring devices, but also mechanical watches, credit cards, etc.

Usually a distance of 0.5 m is enough to avoid damages. All sintered permanent magnets are hard and brittle. Hitting of sintered permanent magnets by the magnetic attraction causes splitting into fragments with many sharp edges. This especially occurs with high energy magnets, and can also cause skin bruises by high attraction.

High energy magnets made of rare-earth materials have to be stored dry, otherwise the surfaces would oxidise. Unprotected operation in a humid environment may cause corrosion. Avoid damaging the protective galvanic coating.

A storage in a hydrogen atmosphere destroys these magnets. A demagnetisation is caused when permanent magnet materials have been exposed in a radioactive radiation for a long time.

For air transportation of magnetic material the IA TA instructions have to be observed:

Magnetic fields are not allowed to penetrate the package, if necessary the magnets have to be shorted using a metal plate.

Emerson Process Management GmbH & Co. OHG

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NGA 2000 MLT Hardware

SAFETY INSTRUCTIONS

ELECTROSTATIC DISCHARGE

Instruction Manual

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 aware of the following considerations:

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Best ESD example is when you walk ed 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.

Howev er , if you do not hav e 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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Instruction Manual

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NGA 2000 ML T Hardware

PREFACE

Preface

a) Analyzer versions - Standard General Purpose Applications

The ML T series of NGA 2000 analyzers offers multi-component, multi-method analysis. Different measurement methods can be combined in one analyzer.

MLT 1, MLT 2 and ML T 4 (MLT 5) are designed to measure up to 5 gas components while ML T 1 ULCO, MLT 3 and CAT 200 allow up to 4 gas components (including photometer and nonphotometer channels).

For MLT (MLT 1, 2 & CAT 200) with Foundation Fieldbus (FF) a special FF instruction manual is provided.

NGA 2000 ML T 1 ULCO gas analyzer is specially designed to measure ultra low carbon monoxide. The analyzer is equipped with a 2

optical bench including a multi detector assembly (MDA block) for cross interf erence compensation in automotive and flue gas applications. W ater vapor and carbon dioxide measurement is used for internal cross interference compensation thus providing an ultra low CO and CO2 channel as standard. This solution is designed for automotive (Internal Combustion Engine Emissions, ICEE) and Continuous Emissions Monitoring Systems (CEMS). An additional CO

channel is available as option on automotive applications.

high

For gas purity measurement new quality standards require ultra low CO measurement but not such high dynamic ranging and cross compensation. Therefore the 2nd bench (MDA) is not used, b ut another channel, e.g. ultra low carbon dioxide (ULCO2) can be implemented in ML T 1.

All ML T 2 components are incorporated into a wall-mountable housing with ingress protection code IP 65 (designed to meet NEMA 4/4X) according to EN 60529. This housing is equipped with an impact tested front panel according to EN 50014 operated by a magnetically operated touch panel. The MLT 2 can be purged to remove corrosive or toxic gases with synthetic air or instrumental air (dry, free of oil, hydrocarbons and corrosive components; 20 to 35 °C purge gas temperature). If sample gas contains flammable gas components above the lower explosion limit, the required explosion protection measures (purge/pressurization system) must be approved b y an authorized person (ATEX/CSA-C/US purge system) . ML T 2 is available with a dual compartment enclosure, too, whereat electronics and photometer/ sensors are installed in two separate housings. Special high temperature variations of MLT 2 or 3 for physics temperatures up to 120 °C are optionally available (standard thermostat control: 55 °C; 65 °C as option). Special versions of MLT 3 are available with suppressed r anges for gas purity measurements and a corresponding additional manual too (special sample handlingrequirements).

Emerson Process Management GmbH & Co. OHG

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NGA 2000 ML T Hardware

PREFACE

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b) Analyzer versions - Installation in Hazardous Areas

Note!

This manual does not deal with special conditions for analyzers in hazardous areas , related to installation, operation, maintenance etc. For such applications refer to the separate instruc-

tion manuals, delivered together with the analyzers.

For installation in hazardous areas the ML T 2 can be equipped with the appropriate pressurization system acc. to the actual required explosion protection measures.

Solutions acc. to CENELEC (according to former European EN 50016) use combinations of ML T 2 and an appropriate pressurization system being individually certified (see separate manual about pressurization system and individual certification report - §10 Elex). In this case a magnetically operated touch panel or an intrinsically safe front panel (combined with approved PCB EXI 01for Zone 1, option for Zone 2) is implemented and ML T 2 is combined with a simplified pressurization for European Ex Zone 2 or with an approved pressurization system for European Ex Zone 1 (see separate instruction manual). Additionally the MLT 2 may be equipped with intrinsically safe I/O's (see separate instruction manual )

ML T 2-NF is a special analyzer version of ML T 2 with Z Purge system for North American Class 1 Zone 2 measurements of non-flammable gases in hazardous areas (CSA-C/US type approved for Zone 2, see separate instruction manual).

EEx p solutions acc. to ATEX (European Directive for Equipment to be used in Explosive Atmospheres; mandatory since July 1, 2003) use type approv ed combinations of MLT 2 and appropriate pressurization systems (see separate A TEX instruction manual about pressurization system and certification). The separate A TEX manual covers all EExp Ex Zone 1 solutions as well as solutions for Ex Zone 2 measuring non-flammable gases. Solutions for measuring flammable gases in Ex Zone 1 or 2 are described in a separate instruction manual. For installation acc. to ATEX in Ex Zone 1 and 2 the MLT 2 is always equipped with a magnetically operated touch panel (see separate manual too). Additionally the MLT 2 may be equipped with intrinsically safe I/O's (see separate instruction manual).

The CA T 200 analyzer or analyz er module is designed to be installed in hazardous areas, too, It is consisting of a 1/2-19" ML T 1 analyz er (analyzer module) installed into a flameproof Ex d enclosure with Ex em junction box. This model is CSA-C/US and ATEX approved for installation in North-American and European hazardous areas (Ex zone 1).

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Instruction Manual

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All analyzer versions are marked as follows: ML Tx y-CH1 CH2 CH3 CH4 CH5

with x = analyzer type 1, 2, 3, 4, 5, CA T 200 with

1 = 1/2 19", not thermostatted, external power supply 2 = Field housing, thermostatted, internal power supply 3 = 1/1 19"-housing, thermostatted, internal power supply 4 = 1/1 19"-housing, thermostatted, external power supply 5 = 19", 18 to 21 HU housing, thermostatted, internal power supply

CA T 200 = flameproof enclosure

NGA 2000 ML T Hardware

PREFACE

y = analyzer version T , M, A, R, TE, ME, AE, RE with

T = table top M = analyzer module, platform mounting

(net/electr. connections from front side only)

A = analyzer module, external installation or platform mounting

(net/electr. connections from rear side or front side) R = rack mounting E = extended housing (ML T 1 only)

CH1...5 = measuring method of the individual (max. 5) measuring channels with

IR = measurement at infrared spectral range UV = measurement at ultra violet spectral range VIS = measurement at visual spectral range PO2 = paramagnetic oxygen measurement EO2 = electrochemical oxygen measurement TC = thermal conductivity measurement TEO

Model and installed measuring principles (here: MLT 4 Rackmounting, 2 x IR, 2 x UV, 1 x PO2)

Channel 1: Gas and measuring range (here: CO, 60/600 ppm)

Channel 4: Gas and measuring range (here: CO, 150/1,500 ppm)

= trace electrochemical oxygen measurement

Serial number

Channel 2: Gas and measuring range (here: SO2, 26/260 ppm)

Channel 4: Gas and measuring range (here: NO2, 25/250 ppm)

Channel 5: Gas and measuring range (here: O2, 5/21 Vol-%)

Emerson Process Management GmbH & Co. OHG

International approval marks

Fig. P-1: Analyzer Nameplate Label (example)

P - 3

NGA 2000 ML T Hardware

PREFACE

Instruction Manual

90002929

12/2006

c) Analyzer System Architecture

The ML T´s flexibility facilitates the most cost-effective system architecture - elegantly accommodating either “stand-alone” or integrated multi-channel analyzer requirements. The ML T is availab le both as an “Analyzer Module” or as an “Analyzer”.

The “Analyzer Module” (AM) is a “b lind” analysis unit but retains all the adv anced MLT design features. The AM variant is designed for integration as part of a Multiple NGA 2000 analysis system or special customer developed networks. The MLT AM novel “blind” packaging and network functionality allows the user to easily exploit the ML T analyser´s advanced expansion capability.

The MLT Analyzers can be designed as single stand-alone analyzers - complete with control module functionality and front panel display/operator interface - or as an centr al interf ace f or multiple Analyzer Modules with a network board.

In ML T analyzer systems this feature eliminates duplication of the displa y/operator interface. In addition to the obvious operational benefits, MLT Analyzers offer significant cost and system packaging advantages not possible with conventional analyser configurations. This flexible network communication architecture is shown in Fig. P-4.

½ 19" MLT

Analyzer

ROSEMOUNT NGA 2000NGA 2000

Platform with MLT AM

19" MLT Analyzer

ROSEMOUNT NGA 2000NGA 2000

NGA NetworkNGA Network

NGA Network

½ 19" MLT

CLD

FID PS

Analyzer

ROSEMOUNT NGA 2000NGA 2000

NGA Network

P - 4

CLD

FID

PMD

ROSEMOUNT NGA 2000NGA 2000

Platform with MLT AM

ROSEMOUNT NGA 2000NGA 2000

19" MLT Analyzer

CLD PS

ROSEMOUNT NGA 2000NGA 2000

MLT MLT

CLD FID

NGA Network

Fig. P-2: From separate analyzers to analyzer system

Emerson Process Management GmbH & Co. OHG

NGA Network

Instruction Manual

90002929 12/2006

NGA 2000 ML T Hardware

PREFACE

The modular erection with a bi-direction network makes possible

❏ Single devices (stand-alone analyzers)

- analyzer modules in a platform (separate manual) including optional inputs and outputs (e.g. SIO/DIO).

- MLT analyzer including optional inputs and outputs (e.g. SIO/DIO).

❏ The interconnection on simple way of analyzer modules including optional local inputs and

outputs (e.g. SIO/DIO) to analyzer systems

- with platform (separate instruction) including system inputs and outputs (SIO/DIO)

- with MLT analyzer including system inputs and outputs (SIO/DIO)

- with customer own control units

For combination possibilities of NGA 2000 ML T I/O´s look at tab le P-1, please.

AC DC

Network Cable

Platform

Analyzer Module

Network Cable

Analyzer Module

Power supply

Emerson Process Management GmbH & Co. OHG

24VDC Cable

Fig. P-3: Example of NGA-cabling

P - 5

NGA 2000 ML T Hardware

PREFACE

Instruction Manual

90002929

12/2006

Local I/O’s via Internal System Bus

PMD

HFID

System I/O’s via Internal System Bus

DIO SIO

8 Digital Inputs

Digital

Outputs

Solenoid

Valves

WCLD

Printer or PLC

Analyzer Modules (AM’s)

NO/NO

CLD

Relay

Outputs

19" MLT 3/4

Analyzer

RS 232 /

RS 485

Personal

Computer

ppm O

TO2

Alternatively

19" Platform/

TFID Analyzer

Alternatively

FID

½ 19" MLT

Analyzer

DIO SIO

MLT

Field PC

Workstation

NGA 200 0ROSEM OUNT

DIO SIO

TFID

NGA Network

NGA 2000ROSEMOUNT

NGA 2000RO SEMOUN T

DIO SIO

CO/NO/SO /

EO - MLT

Alternatively to Platform

or MLT/TFID Analyzer

MLT 2

Analyzer

Fig. P-4: Example/possibilities of NGA analyzer system

Based on a typical ML T analyzer the schematic illustrates the simplicity of a networked system which incorporates additional AMs, such as Chemiluminescence and Flame Ionisation. Other system functionalty includes links to associated sample handling, auxiliary I/O and PC Databases. Fig. P-4 illustrates the historical background including all AM's and I/O's. Actually we offer the platf orm, MLT, CLD, WCLD, FID, HFID (TFID) and SIO & DIO. ML T includes the capability for NDIR/UV/VIS (f otometric), PO2 (PMD , paramagnetic Oxygen), EO2 (electrochemical oxygen), TEO2 (trace oxygen) and TCD (thermal conductivity) benches.

P - 6

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 12/2006

NGA 2000 ML T Hardware

PREFACE

System Unit SIO/DIO Configuration

MLT analyzer module (AM):

• without front panel,

i.e. "blind" without control unit

• can be combined with

a platform, a MLT analyzer, a TFID analyzer or a customer developed control unit

Platform (Control Module Software):

• Control unit with front panel

• Without measurement channels

MLT analyzer (CM plus MLT AM sof tware = MCA software):

• Analyzer with front panel

• CM and AM software in the same analyzer,

i.e. all functions of the control unit and of the AM are combined in one controller board

⇒ 1 local SIO and 1 local DIO

(or 2 local DIO’s) can be installed in the MLT analyzer module

⇒ SIO and DIO can be configured

for the MLT AM channels module only

⇒ 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 can be configured

for all MLT channels & AM’s combined with the platform

⇒ 1 SIO and 1 DIO (or 2 DIO’s) can be

installed in the MLT analyzer (CM I/O)

⇒ SIO and DIO can be configured

for all MLT channels & AM’s combined with the MLT analyzer

Table P-1: Possibilities of NGA 2000 MLT I/O combinations

Emerson Process Management GmbH & Co. OHG

P - 7

NGA 2000 ML T Hardware

PREFACE

Instruction Manual

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P - 8

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 01/2007

STANDARD GENERAL PURPOSE APPLICATIONS/INSTALLATION IN HAZARDOUS AREAS

NGA 2000 ML T Hardware

TECHNICAL DESCRIPTION

1. Technical Description

1.1 Standard General Purpose Applications

The different analyzers and analyzer modules are assembled in principle identically . All components of analyzers or analyzer modules are incorporated into a housing for platform mounting (ML T 1), a 1/2 19" housing (ML T 1) or a 1/1 19" housing (MLT 3/4). MLT 1 analyzer module housings for platform mounting are available to built-in into a NGA platform only (M) or for external installation and platf orm mounting (A) connected via NGA network. The 1/2 19" and 1/1 19" housings are available as rack mounting (R) or as table-top (T) versions. For analyzer modules there is mounted a b lind plate instead of an operation front panel.

An IP 65 protected field housing (ML T 2) for outdoor installation is available, too.This enclosure is intended to be wall mounted.

1.2 Installation in Hazardous Areas

Note!

This manual does not deal with special conditions for analyzers in hazardous areas , related to installation, operation, maintenance etc. For such applications refer to the separate instruc-

tion manuals, delivered together with the analyzers.

For installation in hazardous areas the ML T 2 analyz er or analyzer module is provided with an adapted pressurization system (A TEX type approved for Zone 1 resp . Zone 2 in Europe) and an impact tested magnetically operated front panel. Optionally intrinsically safe signal couplers are available, too. A simplified Z Purge system permits installation in North America Zone 2 environments. The ML T 2-NF is type approv ed for non-flammable sample gas acc. to CSA-C/US f or both Canada and US.

The CAT 200 analyzer or analyzer module, designed to be installed in hazardous areas, too, comprised of a 1/2-19" analyzer analyzer installed into a flameproof enclosure. This model is CSAC/US and A TEX approved for installation in North-American and European hazardous areas.

Emerson Process Management GmbH & Co. OHG

1 - 1

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

OPERATING FRONT PANEL: STANDARD VERSION

Instruction Manual

1.3 Operating Front Panel

1.3.1 Standard Version

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 ke ys

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

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Fastening screws for rack mounting or carrying-strap bracket

LC display

Cursor keys

1 - 2

Soft keys

(function is depending on Software Menu)

Fastening screws for rack mounting or carrying-strap bracket

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

ENTER key

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

OPERATING FRONT PANEL: MAGNETICALLY OPERATED TOUCH PANEL

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

1.3.2 Magnetically Operated Touch Panel

Analyzers intended either to be used in hazardous area or for outdoor usage (e.g. MLT 2 or CA T 200) are provided with a magnetically operated touch panel. This special version ensures ingress protection (IP) and resistance against mechanical shocks. On account of its design it requires some special measures to operate the corresponding analyzer in a safe manner , so read the f ollowing instructions carefully!

1.3.2.1 Magnetic Touch Panel Elements

Whereas standard front panels are using keys for operating the analyzer the magnetically operated touch panel uses contactless technology instead. This results in a slightly different design: Each standard panel key is replaced by a reed relay located behind the front panel design foil. (CA T 200, MLT 2 only: The sequence of the 4 keys at the right side has changed due to ergonomic reasons.)

Fig. 1-2: Magnetically Operated Touch Panel, Front view

Emerson Process Management GmbH & Co. OHG

1 - 3

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

OPERATING FRONT PANEL: MAGNETICALLY OPERATED TOUCH PANEL

Instruction Manual

1.3.2.2 Accessories

T o operate the magnetically operated touch panel a special tool (actuator) is required. The following picture shows this tool as it should be provided together with your analyz er. If it is missing please contact your local sales office.

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Fig. 1-3a: Magnetic actuator

Fig. 1-3b: Magnetic

actuator,

view at magnets

1.3.2.3 Operating the Touch Panel

The touch panel is operated by activating the reed relays using the actuator. This is done by holding that actuator’ s end in front of the key that is equipped with 2 small magnets. As the reed relays are installed alternating vertical and horizontal to prevent accidentally activation of an adjacent key, the actuator has to be aligned the same way. The design foil shows for each key how the actuator has to be aligned using the symbols

„ “ and „ “ :

Fig. 1-4a: Symbols showing actuator alignment

1 - 4

Fig. 1-4c: Vertically aligned, activating F5Fig. 1-4b: Horizontally aligned, activating F4

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

OPERATING FRONT PANEL: MAGNETICALLY OPERATED TOUCH PANEL

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

1.3.2.4 Storing the actuator tool

The tool is provided with a chain and a special fixture to be installed at one of the analyzer’s mounting screws (see Fig. 1-5).

It is recommended to place the actuator tool on the fixture as shown to avoid unintended interference while not in use.

Emerson Process Management GmbH & Co. OHG

Fig. 1-5: Actuator stored when not in use

1 - 5

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

MLT 1 (1/2 19" HOUSING)

Instruction Manual

1.4 MLT 1

The different analyzers and analyz er modules are assembled in principle identically . All components of analyzers or analyzer modules are incorporated into a housing for platform mounting (MLT 1) or a 1/2 19" housing (MLT 1). The equipment is specified for an operating v oltage of 24 V DC (± 5 %). There are mounted optional different components at the rear side of the front panel (Fig. 1-7).

1.4.1 MLT 1 1/2 19" housing

The 1/2 19" and 1/1 19" housings are 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. On the rear panel the connector for 24 V dc supply (MLT 1 [not ML T (M)]), the gas connections, the network connections and the connectors of optional PCBs (see optional, separate Operation Manuals) are accommodated.

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Fastening screws for rack mounting or carrying-strap bracket

1 - 6

Fastening screws for rack mounting or carrying-strap bracket

Fig. 1-6: MLT analyzer, Front view

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

MLT 1 (1/2 19" HOUSING)

[Option]

FanUVS (Voltage Supply for UV Source)

OUT

O2 Sensor, electrochemical

Pressure Sensor

[Option]

Fig. 1-7: MLT 1, Front panel, Rear view

[Option]

Network connection (RJ 45 socket)

[not for platform mounting module] Gas connections

Emerson Process Management GmbH & Co. OHG

Input 24 V dc [not for platform mounting module]optional PCBs [SIO / DIO e. g.]

Fig. 1-8: MLT 1, Rear panel (standard)

1 - 7

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION MLT1 (1/2 19" HOUSING)

Instruction Manual

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Gas Connections

Photometer

(MLT specific assembly)

Flow Sensor

(Option)

Gas Connections Solenoid Valves

(Option in preparation)

Cardcage

(see section 1.10)

O2 Sensor, electrochemical

(Option)

Pressure Sensor

(Option)

Operating Front Panel (analyzer) or Blind Plate (analyzer module)

1 - 8

Voltage Supply for

UV Source (Option)

Fan

Fig. 1-9: MLT 1, Rack/Table-top Housing, Top view

(with electrochemical O2 Sensor)

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

Flow Sensor

(Option)

O2 Sensor, paramagnetic

(Option)

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION MLT1 (1/2 19" HOUSING)

Gas Connections

Cardcage

(see section 1.10)

Photometer

(MLT specific assembly)

Pressure Sensor

(Option)

Operating Front Panel (analyzer) or Blind Plate (analyzer module)

Voltage Supply for

UV Source (Option)

Fan

Fig. 1-10: MLT 1, Rack/Table-top Housing, Top view

Emerson Process Management GmbH & Co. OHG

(with paramagnetic O2 Sensor)

1 - 9

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION MLT1 (1/2 19" HOUSING)

Gas Connections

Photometer

(MLT specific assembly)

Instruction Manual

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07/2006

Gas Connections Solenoid Valves

(Option in preparation)

Cartridge

(see Item 1.10)

Flow Sensor

(Option)

O2 Sensor, paramagnetic

(Option)

Pressure Sensor

(Option)

Operating Front Panel

(analyzer) or

Blind Plate (analyzer mod-

ule)

Fig. 1-11: MLT 1, Rack/Table-top Housing extended, Top view

1 - 10

Voltage Supply for

UV Source (Option)

Fan

(with paramagnetic O2 Sensor)

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 01/2007

NGA 2000 ML T Hardware

TECHNICAL DESCRIPTION

MLT1 ULCO

1.4.2 MLT 1 ULCO

NGA 2000 MLT 1 ULCO gas analyzer is specially designed to measure ultra low carbon monoxide in a matrix with high water vapor and/or carbon dioxide contents. The analyzer is equipped with a 2nd optical bench including a multi detector assembly (MDA block) for cross interference compensation, especially being designed for automotive and flue gas applications. Water vapor and carbon dioxide measurement is used for internal cross interference compensation thus providing an ultra low CO and percentage CO2 channel as standard. This solution is designed for automotive (Internal Combustion Engine Emissions, ICEE) and Continuous Emissions Monitoring Systems (CEMS). An additional CO

channel

high

is available as option on automotive applications. The water vapor channel is designed for measuring crossinterferences only but coudl be used as a measuring channel too but without offering the same accuracy as a "normal" measuring channel. This means that teh standard specifications are not applicable for this special water vapor channel.

Emerson Process Management GmbH & Co. OHG

1 - 11

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION MLT1-ULCO

Instruction Manual

90002929

07/2006

Gas Connections

Detector CO

low

Flow Sensor

(Option)

Detector CO

high

(Option, ICEE/CEMS only)

Multi Detector Assembly MDA

(CO2/H2O detector for

cross compensation

and CO2 measurement,

ICEE/CEMS only)

Cardcage

(see Item 1.10)

1 - 12

Fan

Pressure Sensor

(Option)

Operating Front Panel (analyzer) or Blind Plate (analyzer module)

Fig. 1-12: MLT 1 ULCO, Rack/Table-top Housing, Top view

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

MLT1 (HOUSING FOR PLATFORM MOUNTING)

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

1.4.3 MLT 1 Housing for platform mounting

ML T 1 analyzer module housings for platform mounting are available to built-in into a NGA platform only (M) or for external installation and platform mounting (A) connected via NGA network. Analyzer modules for platform mounting have a b lind plate too (Fig. 1-x). Additional the necessary electrical connections for platform mounting (24 V dc and network) are brought out to this blind plate. For e xternal installation of analyzer module (A) the connections on frontside are closed with a blind plate to be in agreement with the CE conformity. For platform mounting of the module remove this b lind plate.

For analyzer module (A) [external installation or platform mounting] it is not allowed to supply the module from front and rear simultaneously !

For external installation connections on frontside absolutely have to closed with the blind plate delivered from our factory to be in agreement with the CE conformity .!

Network

CAUTION !

Use either front rear supply

24 V dc

Fig. 1-13: MLT 1 analyzer module (Platform mounting), Front panel, Front view

Emerson Process Management GmbH & Co. OHG

Retention pins

1 - 13

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION MLT1 (HOUSING FOR PLATFORM MOUNTING)

Instruction Manual

90002929

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Gas Connections

Photometer

(MLT specific assembly)

Flow Sensor

(Option)

Gas Connections Solenoid Valves

(Option in preparation)

Cardcage

(see Item 1.10)

O2 Sensor, electrochemical

(Option)

Pressure Sensor

(Option)

1 - 14

Voltage Supply for

UV Source (Option)

Fan

24 V dc Input / Network

Fig. 1-14: MLT 1, Platform mounting, Top view

(with electrochemical O2 Sensor)

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

Flow Sensor

(Option)

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION MLT1 (HOUSING FOR PLATFORM MOUNTING)

Gas Connections

O2 Sensor, paramagnetic

(Option)

Photometer

(MLT specific assembly)

Cardcage

(see Item 1.10)

Voltage Supply for

UV Source (Option)

Pressure Sensor

(Option)

Emerson Process Management GmbH & Co. OHG

Fan

24 V dc Input / Network

Fig. 1-15: MLT 1, Platform mounting, Top view

(with paramagnetical O2 Sensor)

1 - 15

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION MLT1 (HOUSING FOR PLATFORM MOUNTING)

Gas Connections Solenoid Valves

Gas Connections

Photometer

(MLT specific assembly)

(Option in preparation)

Instruction Manual

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Cardcage

(see Item 1.10)

Flow Sensor

(Option)

Fan

O2 Sensor, paramagnetic

(Option)

1 - 16

Pressure Sensor

(Option)

24 V dc Input /

Network

Voltage Supply for

UV Source (Option)

Fig. 1-16: MLT 1, Platform mounting extended, Top view

(with paramagnetic O2 Sensor)

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

MLT2 (FIELD HOUSING)

1.5 MLT 2 (Field Housing)

With ML T 2 Emerson Process Management offers a gas analyzer designed f or wall mounting and outdoor installation due to it‘s stainless steel enclosure. All ML T 2 components are incorporated into a wall-mountable housing with ingress protection code IP 65 (approx. NEMA 4/4X) according to EN 60529. The optional impact protected front panel enables installation at harsh locations (or even in hazardous area when combined with a pressurization system for the enclosure). Such analyzers are contactless operated using a special magnetic tool. All interface signals (partial options) are accessible on internal screw terminal blocks. That applies to mains power supply, too.. The ML T 2 can be purged to remov e corrosive or toxic gases with synthetic air or instrumental air (dry , free of oil, hydrocarbons and corrosiv e components; 20 to 35 °C purge gas temperature). If sample gas contains flammable gas components above the lower explosion limit, the required explosion protection measures (purge system) must be approv ed by an authorized person (purge system) . ML T 2 is av ailable with a dual compartment enclosure, too, whereat electronics and photometer/ sensors are installed in two separate housings. A special high temperature variation of ML T 2 for temperatures up to 120 °C is optionally a vailable (standard: 55 °C; 65 °C as option).

The analyzer is specified for an operating voltage of 230 V AC or 120 V A C resp., 47-63 Hz. Built-in power supply (manual switch between 230/120 VAC) is either po w er supply of type SL5 or of type SL10

For installation in hazardous areas the MLT 2 is provided with an adapted pressurization system (ATEX type approved for Zone 1 resp. Zone 2 in Europe) and an impact tested magnetically operated front panel. Optionally intrinsically saf e signal couplers are a v ailab le , too. A simplified z-purge system permits installation in North America Zone 2 environments.

This current instruction manual covers using the MLT 2 analyzer for general purpose applications only!

Installation, startup and maintenance for operation in hazardous areas are described in detail in a separate instruction manual, shipped together with each such analyzer and are not subject of the current instruction manual!

Emerson Process Management GmbH & Co. OHG

1 - 17

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

MLT2 (FIELD HOUSING)

Connection of mains and interface signals are to be established via internal screw terminal blocks. This requires working inside an opened analyzer, near by potentially live components!

Installation of this analyzer is allowed by qualified personnel only, familiar with the potential risks of working near live components!

The model ML T 2 (field housing) does not provide a mains switch. A mains switch or circuit breaker must be provided in the building installation. This switch has to be installed near by the analyzer, must be easily operator accessible and has to be designated as disconnector for the analyzer .

Cables for external data processing must be double insulated for mains voltage. If not available, signal cables inside the analyzer must be installed with a distance of at least 5 mm to mains cables. Distance has to be ensured permanently, e.g. by using cable ties!

Instruction Manual

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07/2006

MLT 2 -- HEAVY INSTRUMENTS !

The analyzer variation MLT 2 intended to be wall mounted and/or outdoor installed weigh up to 35 kg, depending on included options!

Use two person and/or suitable tools for transportation and lifting these instruments!

Take care to use anchors and bolts specified to be used for the weight of the units!

Take care the wall or stand the unit is intended to be installed at is solid and stable to hold the units!

Risk of electric shock!

MLT 2 analyzers provide earth connection terminals. To minimize risk of electric shock the enclosure must be connected to earth! Therefore connecting the analyzer is allowed only by using a 3 pole mains cable providing a separate earthing conductor.

1 - 18

Any interruption of the earthing conductor inside or outside the analyzer as well as loosening the earthing connection may cause serious injury! Intended interruption of earthing connections is not permissible!

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

Wall mounting

holder

Fastener

front panel

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

MLT2 (FIELD HOUSING)

OpenOpenOpen

Operation front

panel

OpenOpenOpen

Front panel

Fig. 1-17a: Front view MLT 2 (Standard housing/Standard operation front panel)

Fig. 1-17b: Front view MLT 2 (Dual compartment housing/Standard operation front panel)

Emerson Process Management GmbH & Co. OHG

1 - 19

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION MLT2 (FIELD HOUSING)

Instruction Manual

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Fuses (T 6.3A/250V)

X11

F100.1

F100.2

Terminal Strips Option SIO

(RS 232/485 and Relay Contacts)

X10

Serial out

4321

Circuit Boards

(see Item 1.10)

O2-Sensor,

paramagnetic

(Option)

Terminal Strips

Option DIO

Terminal Strips Option SIO

(analog outputs)

Photometer sliding carriage

Fig. 1-18a: MLT 2, Inside view (drawing without front panel)

Photometer (MLT specific assembly)

(Fig. 1-18b)

1 - 20

Physical interface PIC

(alternative position)

Fig. 1-18b: MLT 2, Photometer sliding carriage, Top view

Heating Unit

(Option)

Photometer

(MLT specific assembly)

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

07/2006

1.6 MLT 3

All components of analyzers or analyzer modules are incorporated into a 1/1 19" housing. The housings are available as rack mounting (R) or as table-top (T) versions. For analyzer modules there is mounted a blind plate instead of an operation front panel. The equipment has an internal power supply with “autoranging” f or operating v oltages of 230 V AC or 120 V AC resp., 47-63 Hz.

MLT3

Fig. 1-19: MLT 3 (standard) (1/1 19" housing), front view

Network connection

(RJ 45 socket)

F 3F 1 F 2 F 4 F 5

NGA 2000

Ch 1

OUT

Ch 2

OUT

Emerson Process Management GmbH & Co. OHG

Input 230/120 V ac (UPS 01 T) Gas connectionsoptional PCB [SIO/DIO e.g.]

Fig. 1-20: MLT 3 (standard version), Rear view

1 - 21

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION MLT3

Instruction Manual

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O2 Sensor,

paramagnetic

(Option)

Flow Sensor

(Option)

Heating

Unit

Gas Connections Photometer

(MLT specific assembly)

Power Supply

(UPS 01 T)

Cardcage

(see Item 1.10)

Pressure Sensor

(Option)

Voltage Supply for

UV Source (Option)

Fine Dust Filter

(Option)

O2 Sensor (Option),

electrochemical

Operating Front Panel (ana-

Blind Plate (analyzer module)

Fig. 1-21: MLT 3 (standard version), Top view

Gas Sampling Pump

(Option)

Fan

lyzer) or

1 - 22

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 01/2007

MLT3 (GAS PURITY MEASUREMENT)

NGA 2000 ML T Hardware

TECHNICAL DESCRIPTION

1.6.1 MLT 3 (Gas purity measurement)

Special versions of ML T 3 are available with suppressed ranges for gas purity measurements and measurements requiring physics thermostated up to 120 °C - see separate manual for gas purity with suppressed ranges.

Example and short description of the main deviations from standard MLT 3: Compared with “standard MLT 3 version” the “MLT 3 for gas purity measurement” can be equipped with a divided front panel. On the right side there is the operation front panel (analyzer) or a blind plate (analyzer module) resp. On the left side there is built-in one flow meter and as option one quick shutoff connector as sample gas inlet. Is the instrument is not equipped with a solenoid valve block, there can be b uilt-in as option a manual 4/2-way-valve to switch to sample gas, zero gas or span gas. For more detailed informations use the special instruction manual for this application.

F3 F4 F5F2

NGA 2000

Flow meter Operation front panelQuick shutoff connector

(sample ges input, option)

Fig. 1-22a: MLT 3 (example for gas purity measurement), front view

Rosemount Analytical

Manual 4/2-way-valve

(option)

Additional to “standard MLT 3 version” (identical on the left part) the “MLT 3 for gas purity measurement” is equipped with a solenoid valve block for the supply of sample gas, zero gas and span gas, controlled by the analyzer. The control will be done with the relay outputs of I/ O Board “SIO” via an external connection cable “SIO ➞ Solenoid Valve Block” (pin assignments look at Fig. 21-4).

The necessary gas connections are placed here too and are used and marked analyzer specific (see Fig. 1-23). The outlet of the valv e b loc k is connected to the MLT 3 gas inlet.

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NGA 2000 ML T Hardware

TECHNICAL DESCRIPTION

MLT3 (GAS PURITY MEASUREMENT)

Instruction Manual

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Sub.-min. D, 9 pole

(to Solenoid Valve Block Option)

NETWORK

Sub.-min. D, 9 pole

(connection to PCB “SIO”)

Span gas

Exhaust

230/120 V

50/60 Hz

DIGITAL I/O

ANALOG I/O SERIAL I/O

PCB “SIO” Gas connections

max. 240 VA

Input 230/120 V ac

(PS UPS 01 T)

Sample gas

Zero gas

Solenoid Valve Block (Option)

(analyzer specific)

Fig. 1-22b: MLT 3 (example for gas purity measurement), Rear view

1.6.2 MLT 3HT (high temperature measurement)

As a special versions MLT 3HT is availab le for measurements requiring physics thermostated up to 120 °C. The physical section is parted in a HT part (special heating and isolation) for all components being in contact with sample gas - SS tubing, fine dust/safety filter , needle valve , calibration valve (depending on options). The isolation (filter) cell, chopper & detector are outside of the heated room together with a temperature controller and ventilator . The heated line and external pump (with heated head) need isolation at any connection/ fitting:

Heated Section with SS tubing, safety filter,

sample gas cell

Isolation cell, chopper & detector

Gas inlet/ outlet fittings

Temperature Controller/ Ventilator (outlet filter)

Fig. 1-23: MLT 3HT (example for high temperature measurement), Top/ front view

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Instruction Manual

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION MLT3 (GAS PURITY MEASUREMENT)

Gas connections Photometer

O2 Sensor,

paramagnetic

(Option)

Heating

Unit

(MLT specific assembly)

Solenoid valve block

(Option)

Power Supply

(UPS 01 T)

Cardcage

(see Item 1.10)

Pressure regulator

Flow meter Pressure sensor

Manual 4/2-way-valve

(Option)

Fig. 1-24: MLT 3 (gas purity measurement), Top view

Fan

Operating Front Panel

(analyzer) or

Blind Plate (analyzer module)

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NGA 2000 MLT Hardware

Instruction Manual

TECHNICAL DESCRIPTION

MLT4

1.7 MLT 4

All components of analyzers or analyzer modules are incorporated into a 1/1 19" housing. The housings are available as rack mounting (R) or as table-top (T) versions. For analyzer modules there is mounted a blind plate instead of an operation front panel. The equipment is specified for an operating v oltage of 24 V DC (± 5 %).

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Fig. 1-25: MLT 4 (1/1 19" housing), front view

Network connection (RJ 45 socket)

13/Purge

IN OUT IN

F 3F 1 F 2 F 4 F 5

NGA 2000

23/Purge

OUT IN OUT

optional PCB [SIO/DIO e.g.] Input 24 V dc

Fig. 1-26: MLT 4, Rear view

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Gas connections

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL CONSTRUCTION MLT4

Gas Connections

Photometer

(MLT specific

assembly)

Heating

Unit

Gas Connections O2 Sensor, paramagnetic

(Option)

Photometer

(MLT specific assembly)

Cardcage

(see Item 1.10)

Voltage Supply for

UV Source (Option)

O2 Sensor (Option),

Fig. 1-27: MLT 4, Rack/Table-top Housing, Top view

Emerson Process Management GmbH & Co. OHG

electrochemical

Voltage Supply for

UV Source (Option)

Fan

Operating Front Panel (ana-

lyzer) or

Blind Plate (analyzer module)

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

CAT 200

Instruction Manual

1.8 CAT 200

The CAT 200 is an analyzer with flameproof enclosure, designed especially for operation in hazardous areas. It is approved to meet the requirements of the European Directive for equipment intended to be used in hazardous areas (commonly know as "A TEX 95“) and of the North American Standards (certified by the Canadian Standards Association, CSA International). The enclosure meets IP 65 (optional: IP 66, tropicalisation), has rob ust design and is prepared for wall mounting. Therefore the analyzer may be used for general purpose applications requiring outdoor installation, too.

This current instruction manual covers using the CA T 200 analyzer for general purpose applications only!

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Installed inside the flameproof enclosure an analyzer module holds all measuring components. As the module corresponds to a 1/2-19" MLT 1 analyzer/analyzer module, a CAT 200 analyzer offers almost the same options. This analyzer model is supplied by an internal wide range power supply, automatically adapting to the voltage at site (Rated input voltage: 115-230 V 50/60 Hz, Input voltage range: 85 - 264 V , 47 - 63 Hz).

Because of the intention to used in hazardous areas the front panel is located behind a safety glas window . The analyzer is touchless oper ated by using a magnetically tool, whereat the standard pushbuttons are replaced by sensor fields (see fig. 1-2).

All interface signals (partial options) are accessible on screw terminal blocks, located in a separate junction box. That applies to mains power supply, too.

T ake care of the special installation instructions in c hapter 5 "Installation“!

Located below the junction box is a second volume consisting of dome housing, extender housing and base, containing analyzer module, pow er supply unit, fuses and gas pipes (see fig. 1-28). All three parts of the enclosure are threated together. Unthreading the parts gives access to the internal components.

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Emerson Process Management GmbH & Co. OHG

Instruction Manual

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Connection of mains and interface signals are to be established via internal screw terminal blocks. This requires working inside an opened analyzer, near by potentially live components!

Installation of this analyzer is allowed by qualified personnel only, familiar with the potential risks of working near live components!

The model CAT 200 does not provide a mains switch. A mains switch or circuit breaker must be provided in the building installation. This switch has to be installed near by the analyzer , must be easily operator accessible and has to be designated as disconnector for the analyzer .

The Junction Box must be protected by fuse supply which has a breaking capacity adjusted to the short circuit of the equipment. The 10 A fuse has to be installed in the building installation!

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

CAT 200

CAT 200 -- HEAVY INSTRUMENTS !

The analyzer variation CA T 200 intended to be wall mounted and/or outdoor installed weigh up to 70 kg, depending on included options!

Use two person and/or suitable tools for transportation and lifting these instruments!

Take care to use anchors and bolts specified to be used for the weight of the units!

Take care the wall or stand the unit is intended to be installed at is solid and stable to hold the units!

Risk of electric shock!

CAT 200 analyzers provide earth connection terminals. To minimize risk of electric shock the enclosure must be connected to earth! Therefore connecting the analyzer is allowed only by using a 3 pole mains cable providing a separate earthing conductor .

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

CAT 200

Instruction Manual

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567

Fig. 1-28: CAT 200, Exterior view

1 Eye bolts (2 pcs) 2 Cable glands for signal cables (3 pcs max) 3 Eye bolts (2 pcs) 4 Mounting holes (4 pcs.) 5 Base 6 Extender housing

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7 Dome housing 8 Front panel behind safety glass 9 Interlock screw 10 Interlock screw 11 Junction box

Emerson Process Management GmbH & Co. OHG

Instruction Manual

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6 5

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

CAT 200

4 3

Fig. 1-29: CAT 200

(Dome and extender housing removed)

1 Analyzer module 2 Gas fittings with internal flame arrestors 3 Bracket for analyzer module 4 Nameplate label

5 Cable gland for mains cable 6 External earth connector

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL GAS PATHS

Instruction Manual

1.9 Internal Gas Paths

The materials used for the gas paths may be selcted to suit the intendend application. In marking such selection the diffusion rates of the individual gas components, their corrosivity, and the temperature and pressure of the sampled gas must be taken into account.

1.9.1 Gas Path Material

The physical and chemical properties of the sampled gas and the operating conditions (temperature and pressure) of the analyzer determine the materials which may be used for gas paths and gas fittings.

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Fittings

For standard the analyzers are provided with PVDF fitting, 6/4 mm. The analyzers can to be delivered with sw agelok® fittings, stainless steel, 6/4 mm or 1/4" as option. Additional fittings to be delivered on request, consult f actory.

Tubing

For standard the analyzers are pro vided with Viton tubing or PVDF tubing (6/4 mm). Additional tubings (e.g. stainless steel) to be delivered on request, consult factory.

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Instruction Manual

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL GAS PATHS

1.9.2 Gas Path Layout (internal tubing)

The principle various possible layouts of the internal gas lines are summarized in the table 1-1.

OutIn

tubing in series

tubing in parallel

combined tubing:

series and parallel

(special tubing)

ULCO

special tubing:

external in series,

internal parallel

low ultra

OutOut In In

Out In

O /H

high

OutIn

2 2

Note:

Tubing must not be

changed by customer !

Table 1-1: Possible internal tubings (examples with 3 measuring channels)

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NGA 2000 MLT Hardware

Instruction Manual

TECHNICAL DESCRIPTION

INTERNAL GAS PATHS MLT 3 (GAS PURITY MEASUREMENT)

1.9.3 MLT 3 (gas purity measurement)

The necessary gas connections are marked analyzer specific (see section 5.3.and 5.4.3.1). Different possibilities of internal layout and e xternal tubing are shown in Fig. 1-30, depending on instrument specific features. Up to the internal pressure regulator the gas paths are designed as stainless steel tubings. Behind the flow meter the gas paths are viton tubings.

All external fittings are swagelok®, stainless steel, 6/4 mm, 1/8 " or 1/4 ".

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span gas

sample gas

zero gas

tubing SS

gas outlet

6 mm

rear side

6 mm

tube piece

Viton tubing

safety dust filter

1/8" 1/8"

SS tubing

Viton tubing

analysis cell

threated plug 1/8"

1/8"

PO2

Viton tubing

pressure

sensor

Viton tubing

1/16"

SS capillary

front side

1/16"

1 - 34

Fig. 1-30a: MLT 3 (gas purity measurement), gas path layout

(3 measuring channels with solenoid valve block option)

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

INTERNAL GAS PATHS MLT 3 (GAS PURITY MEASUREMENT)

tubing SS

span gas

zero gas

tubing SS

6 mm

gas outlet

6 mm

rear side

6 mm

tube piece

SS tubing

Viton tubing

saftey dust filter

1/8"

SS tubing

Viton tubing

1/8"

Viton tubing

analysis cell

threated plug 1/8"

1/8"

PO2

Viton tubing

1/8"

pressure

sensor

Viton tubing

1/16"

SS capillary

1/16"

sample gas

quick shutoff connector

front side

Fig. 1-30b: MLT 3 (gas purity measurement), gas path layout

(3 measuring channels with solenoid valve block option and quick shuttoff connector option)

zero gas

span gas

sample gas

gas outlet

6 mm

rear side

6 mm

tube piece

SS tubing

Viton tubing

SS tubing

1/8"

safety dust filter

analysis cell

Viton tubing

analysis cell

threated plug 1/8"

1/8"

SS tubing

1/8"

SS tubing

pressure

sensor

Viton tubing

1/16"

SS capillary

front side

1/16"

4/2-way-valve

Fig. 1-30c: MLT 3 (gas purity measurement), gas path layout

(2 measuring channels with manual 4/2-way-valve option)

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

PRINTED CIRCUIT BOARDS

Instruction Manual

1.10 Printed Circuit Boards

All necessary PCBs are pushed in into a cardcage, which is identically for all MLT versions (see Fig. 1-31).

MLT Rear Panel

Cardcage

Network Inlet Module

(LEM)

optional PCB

(e.g. SIO / DIO)

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Physical Interface (PIC)

Digital Signal Processing (DSP)

Signal Processing (PSV)

(free if using DSP)

Fig. 1-31a: Cardcage MLT 1/3/4, Top View

Interconnection Board

(ICB)

Controller Board (ACU)

MLT Front Side

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Emerson Process Management GmbH & Co. OHG

Instruction Manual

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

PRINTED CIRCUIT BOARDS

optional PCB

[e.g. SIO / DIO]

out

Network Inlet Module

(LEM, Option)

Signal Processing

(PSV)

(free if using DSP)

Controller Board

(ACU)

Digital Signal Processing (DSP)

Fig. 1-31b: PCB arrangement MLT 2

[Inside view, detail (without front panel)]

Inter Connection Board

Physical Interface (PIC)

(ICB)

1.10.1 ICB (Inter-Connection Board)

ICB is an interconnection board consisting of six 64-pin ICB bus slots to accommodate printed circuit boards (PCB of Euro standard format).

1.10.2 PSV/PIC Combination

The PSV card (signal processing) carries out the A/D conversion and the real ev aluation of each measuring signal. The PIC card (Physics Interf ace Card, page 1-38) supplies the photometer components and the individual sensors with the individual required operating voltages and transmits all measuring signals to the signal processing unit PSV.

1.10.3 DSP (alternitavely to PSV/PIC Combination)

The DSP card (Digital Signal Processing) page 1-39) supplies the photometer components and the individual sensors with the individual required operating voltages and carries out the A/D conversion and the real e v aluation of each measuring signal.

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

PHYSICS INTERFACE CARD (PIC)

Instruction Manual

1.10.4 PIC (Physics Interface Card)

The PIC card (Physics Interf ace Card) supplies the photometer components and the individual sensors with the individual required operating voltages and transmits all measuring signals to the signal processing unit PSV.

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1 2 3

Fig. 1-32: Plug pin assignment PCB PIC

The plugs shown in Fig. 1-20 are used as follows:

Plug No. used

34 Chopper 1 (channel 1+2) 2 Chopper 2 (channel 3+4) 47 Flow sensor 1 45 Flow sensor 2 20 Temperature sensor 1 (chopper 1) 10 Temperature sensor 2 3 Source channel 4 4 Source channel 3 11 Source channel 2 12 Source channel 1 8 Detector channel 4 7 Detector channel 3 6 Detector channel 2 5 Detector channel 1 23 Detector channel 5 (O

or H2)

Plug No. used

1 Pressure senor 1 9 Pressure senor 2

24 PCB OKI (P2) Flow sensor 3

PCB OKI (P1) Flow sensor 4 (P1)

or PCB OKI (P4) Temperature sensor 3 PCB OKI (P3) Temperature sensor 4

21.2 T estpeak channel 1

21.3 Ground ( )

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Emerson Process Management GmbH & Co. OHG

Instruction Manual

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DIGITAL SIGNAL PROCESSING CARD (DSP)

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

1.10.5 Digital Signal Processing Card (DSP)

Instead of using the 2 PCB's PIC and PSV alternatively those can be replaced by ONE board containing both functions in the Digital Signal Processing Board DSP.

NGA Bus connector

Input DC sensors

(e.g. O2/H2 sensors)

Input AC sensors

(e.g. IR/VIS/UV sensors)

Temp. sensor 4/IR(UV) source 4 Temp. sensor 3/IR(UV) source 3

Temp. sensor 2/IR(UV) source 2

Temp. sensor 1/IR(UV) source 1

Pressure sensor 2/Pressure sensor 1

Flow sensor 4/Flow sensor 2

Flow sensor 3/Flow sensor 1

not used/Chopper 2 not used/Chopper 1

Emerson Process Management GmbH & Co. OHG

not used/not used

Serial interface (BSI10) connector

Local SPI connector

24 VDC input/Heater (BHZ10) connector

Fig. 1-33: Plug pin assignment PCB DSP

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

PCB ACU

Instruction Manual

1.10.6 ACU

The ACU 02 board is the main part of the MLT both Analyzer Module or Analyzer! It is a one-board CPU card. All user data are safe loaded via a battery buffer , e ven when the v oltage supply is disconnected.

This card contains the complete software for controlling and operating the analyzer module . For MLT analyzers (with operation front panel) additional the Control Module Softw are [platf orm (CM) functions (network managment, LCD display control e. g.)] is included.

The board contains the following function b locks:

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◆ 32 / 16-bit micro controller

◆ Floating point co-processor

◆ dependent on platform version different RAM / Flash-EEPROM

(Standard: 1 MB RAM extension for up to 15 software channels*); Option: additional 0.5 MB RAM extension if more than 15 software channels*) [contact factory if more than 20 SW channels are requested])

◆ Real-time Clock with Calendar function Alarm function

◆ Watchdog function

◆ Serial interface RS 232 C

◆ A network interface with ECHELON chip

◆ System bus:

Parallel b us A6 : D8 12 TPU wiring network bus Synchron serial bus

◆ Buffered parallel interface for LCD control

◆ Local bus interface (e.g. storage extension)

◆ Switch-mode power supply for 5 V supply (on board)

*) Calculate software channels (SW) as follows: MLT = 1 SW ch. for each mesuring channel; all other NGA analyzer modules like CLD, FID, etc. = 1 SW ch.; SIO/DIO = zero SW ch.; Network I/O's = 1/2 SW ch.

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Instruction Manual

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SIO (STANDARD INPUTS-/OUTPUTS)

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

1.10.7 SIO (Standard Inputs-/Outputs)

Every platform, every MLT analyzer or every MLT analysis module can be equipped with max. 1 SIO (see table P-1, too)! At mounting into a platform or an analyzer the SIO serves system functionallity of I/O´s and supports all analysis modules of the NGA system. Only the analysis module itself is supported at mounting into an analysis module. To the programming we refer to the accompanying softw are instruction. The pin assigments are described in section 21 of this instruction.

The SIO as standard consists of:

◆ 2 galvanically isolated analogous outputs Simultaneous 0(4) - 20 mA (± 22 mA, burden < 500 Ω) and

0(2) - 10 V (± 11 VDC, burden > 2 kΩ)

◆ 3 relay outputs Load max. 30 V/1 A/30 W

◆ 1 serial interface (over e xtension card SIF) RS 232 (standard) or RS 485 (option, 2-wire or 4-wire)

Every SIO can be upgraded on 4, 6 or 8 analogous outputs via respective SIA modules with two analogous outputs each.

5 V DC

supply

NGA system

bus interface

Analog output 1+2

Analog output 3+4

Analog output 5+6 Analog output 7+8

option

SIA

option

SIA

option

SIA

digital Function

and Autoconfiguration

Emerson Process Management GmbH & Co. OHG

RS 232

or RS 485

Relay

outputs

Status LEDs

Fig. 1-34: Function blocks of SIO-PCB

SIF

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

DIO (DIGITAL IN-/OUTPUTS)

Instruction Manual

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Analog output 5 + 6

Position of SIA module

Fig. 1-35: SIO-PCB with extension cards

Analog output 3 + 4

Position of SIA module

Analog output 7 + 8

Position of SIA module

Position of

SIF module

RS232 or RS485

1.10.8 DIO (Digital In-/Outputs)

Every platform can be equipped with max. 1 to 5 DIOs . Every ML T analyz er or every ML T analysis module can be equipped with max. 1-2 DIOs (see table P-1, too)! For maximum assemb ly with DIOs (5 or 2 DIOs resp.) there is no place for SIO PCB! At mounting into a platform or an analyzer the DIO serves system functionallity of I/O´s and supports all analysis modules of the NGA system. Only the analysis module itself is supported at mounting into an analysis module. To the programming we refer to the accompanying softw are instruction. The pin assigments are described in chapter 21 of this instruction.

On DIO PCB are integrated:

◆ 8 digital Inputs, 5 - 30 VDC / 2,2 mA Low level: 0,3 - 3,0 VDC / High level > 4 VDC

◆ 27 digital Outputs, 5 - 30 VDC / max. 500 mA

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Instruction Manual

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

NETWORK TERMINATION

1.11 Network Termination

The network module LEM (see Fig. 1-19) connects the analyzer with external modules via network. RJ 45 sockets are serving for network interconnection between analyzer or platf orm and analyzer modules (see Fig. 1-8, 1-13, 1-20, 1-23 and 1-31b).

It is necessary to terminate the ends of a twisted pair bus to minimize reflections (see Fig. 1-37). Failure to terminate the bus will degr ade network performance. Termination will be done via RJ 45 connectors (see Fig. 1-36).

Fig. 1-36: RJ 45 network termination connector

Termination Termination

AM AM AM Analyzer AM AM

Termination Termination

AM AM AM AM AM

Analyzer

Emerson Process Management GmbH & Co. OHG

Termination

Analyzer

Fig. 1-37: Network termination (examples)

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NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

SPECIFICATIONS AT THE NAMEPLATE LABEL

Instruction Manual

1.12 Specifications at the Nameplate Label

The analyzer nameplate label gives important information about the instrument‘s configuration, installed measuring principle(s), sample gas(es) and measuring range(s). In case an instrument is built according a suitability approval the related certificate number is given, too. The nameplate label is located either on the instruments left or right housing side or at the inner side of the front door (ML T 2). The CA T nameplate label is located at the housings left side whereat the label as it is shown below is affixed to the inner analyzer module.

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Model and installed measuring principles (here: MLT 4 Rackmounting, 2 x IR, 2 x UV, 1 x PO2)

Channel 1: Gas and measuring range (here: CO, 60/600 ppm)

Channel 4: Gas and measuring range (here: CO, 150/1,500 ppm)

Channel 5: Gas and measuring range (here: O2, 5/21 Vol-%)

Serial number

Channel 2: Gas and measuring range (here: SO2, 26/260 ppm)

Channel 4: Gas and measuring range (here: NO2, 25/250 ppm)

International approval marks

Fig. 1-38: Analyzer Nameplate Label (example)

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Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

All analyzer versions are marked as f ollows: ML Tx y-CH1 CH2 CH3 CH4 CH5

with x = analyzer type 1, 2, 3, 4, 5, CAT 200 with

CA T 200 = flameproof enclosure

y = analyz er v ersion T, M, A, R, TE, ME, AE, RE with

T = table top M = analyz er module, platform mounting

(net/electr. connections from front side only)

A = analyzer module, external installation or platform mounting

(net/electr. connections from rear side or front side) R = rack mounting E = extended housing (MLT 1 only)

NGA 2000 MLT Hardware

TECHNICAL DESCRIPTION

SPECIFICATIONS AT THE NAMEPLATE LABEL

CH1...5 = measuring method of the individual (max. 5) measuring channels with

IR = measurement at infrared spectral range UV = measurement at ultraviolet spectral range VIS = measurement at visual spectral range PO2 = paramagnetic oxygen measurement EO2 = electrochemical oxygen measurement TC = thermal conductivity measurement TEO

= trace electrochemical oxygen measurement

Emerson Process Management GmbH & Co. OHG

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NGA 2000 ML T Hardware

TECHNICAL DESCRIPTION

Instruction Manual

1.13 MLT 2HT (high temperature measurement)

As a special version MLT 2HT is available f or measurements requiring physics thermostated up to 120 °C. The physical compartment is parted into 2 sections:

- A high temperature (HT) part with special heating and isolation for all components being in contact with sample gas - SS tubing/fittings, fine dust/safety filter, needle valve, calibration valve (depending on options). The heated lines are connected in the heated room with sample gas inlet and outlet fittings.

- The isolation (filter) cell, chopper & detector are located in the lower physical part but outside of the heated room (need protection from high temperature). The temperature controller is located in the upper electronical section. An optional external pump with heated pump head may be located outside of the analyzer being connected with heated samplegas lines (need of isolation at any connection/ fitting).

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Temperature controller in electronical section

Optional purge gas inlet

Heated section with SS tubing, safety filter and sample gas cell

Gas inlet/ outlet fittings

Isolation cell,chopper & detector

1 - 46

Isolated inlet for heated gas sampling line to be connected te gas inlet and outlet fittings

Emerson Process Management GmbH & Co. OHG

Instruction Manual

90002929 07/2006

NGA 2000 MLT Hardware

MEASURING PRINCIPLE

IR MEASUREMENT

2. Measuring Principle

Depending on analyzer model different measuring methods will be used.

2.1 IR Measurement

The measuring effect devided from absorption of infrared radiation is due to the gas being measured. The gas - specific wavelengths of the absorption bands characterize the type of gas while the strength of the absorption gives a measure of the concentration of the component measured. Due to a rotation chopper wheel, the r adiation intensities coming from measuring and reference side of the analysis cell produce periodically changing signals within the detector.

The detector signal amplitude thus alternates between concentration dependent and concentration independent values. The difference between the two is a reliable measure of the concentration of the absorbing gas component.

The principle photometer assembly is shown in Fig. 2-1.

Emerson Process Management GmbH & Co. OHG

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NGA 2000 MLT Hardware

MEASURING PRINCIPLE

IR MEASUREMENT

Instruction Manual

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to electronic

12 11 10

Fig. 2-1: Measuring Principle for NDIR / UV Measurement

1 IR source with reflector 2 VIS / UV source with reflector 3 Chopper wheel 4 Eddy current drive 5 Filter cell with dividing wall (IR channel) 6 Filter cell with dividing wall (UV channel) 7 Analysis cell

8 Measuring side 9 Reference side 10 Filter cell without dividing wall

(for IFC measurement with optical filters) 11 Window 12 Pneumatic or pyroelectrical (solid-state) detector 13 VIS / UV semiconductor detector 14 Preamplifier

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Emerson Process Management GmbH & Co. OHG

Instruction Manual

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NGA 2000 MLT Hardware

MEASURING PRINCIPLE

IR MEASUREMENT

2.1.1 Opto - Pneumatic Measuring Principle

For measurement a heating coil in the light source generates the necessary infrared radiation (1). This radiation passes through the chopper wheel [light chopper wheel (3)]. Due to the special shape of the chopper wheel, the IR radiation passes through a filter cell (5) and alternatively reaches the measuring side (8) and reference side (9) of the analysis cell [(7) separated in the middle into two halves by an internal separating wall] with equal intensity. The filter cell (5) screens interfering radiation areas out of the radiation spectrum.

Behind this analysis cell the radiation passes a second filter cell (10) towards the gas detector (12), which compares the IR radiation intenisities from measuring side and reference side and converts it into an AC v oltage signal.

The detector (Fig. 2-2) consists of a gas-filled absorption chamber and a compensation chamber which are connected together via a flow channel. In principle the detector is filled with the infrared active gas to be measured and is only sensitive to this distinct gas with its characteristic absorption spectrum. The absorption chamber is sealed with a window which are transparent for infr ared radiation [usually CaF2 (Calcium fluoride)].

Absorption chamber

Flow channel with Microflow sensor

CaF2 window

Gas intake connection

Compensation chamber

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Fig. 2-2: Principle Design of Gas Detector

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MEASURING PRINCIPLE

IR MEASUREMENT

Instruction Manual

When the IR radiation passes through the measurement side of the analysis cell into the detector, a part of it is absorbed depending on gas concentration. Absorption chamber gas become colder, gas pressure in the absorption chamber is reduced and some gas of compensation chamber passes through the flow channel into the absorption chamber.

When the IR radiation passes through the reference side of the analysis cell into the detector , no preabsorption occurs. Thus the gas inside the absorption chamber is heated, expands and some of it passes through the flow channel into the compensation chamber.

The flow channel geometry is designed in such a way that it hardly impedes the gas flow by restriction. Due to the radiation of chopper wheel, the different radiation intensities lead to

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periodically repeated flow pulses within the detector.

The microflow sensor ev aluates this flow and converts it into electrical voltages. The electronics, which follow , evaluate the signals and convert them into the corresponding display format.

In addition to simply light chopper, the chopper wheel has a special structure f or measuring side and reference side, that simulates an absorption in the analysis cell. This absorption signal is be cut out of the normal measuring signal and is be used for automatically sensitivity control. The result is a high long-term stability of sensitivity .

2.1.2 Interference Filter Correlation (IFC Principle)

The undivided analysis cell is alternately illuminated with filtered light concentrated in one of two spectral separated wav e length ranges. One of these two spectrally separated w ave length bands is chosen to coincide with an absorption band of the sample gas, and the other is chosen such that none of the gas constituents expected to be encountered in practice absorbs anywhere within the band.

The spectral transmittance curves of the interference filters used in the MLT and the spectral absorption of the gases CO and CO2 are shown in Fig. 2-3. It can be seen that the absorption bands of these gases each coincide with the passbands of one of the interference filters.

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Instruction Manual

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MEASURING PRINCIPLE

IR MEASUREMENT

9075604530150

Transmittance [%]

Reference

4400 460042004000 48003000 3200 3400 3600 3800 5000 5200 5400 5600 5800 6000

Wave Length [nm]

Interference

Absorption band

Filter

18 36 54 72 900

Fig. 2-3: Absorption Bands of Sample Gases and Transmittance of the

Interference Filters used

The interference filter, used for generating a ref erence signal, has its passband in a spectral region where none of these gases absorb. Most of the other gases of interest also do not absorb within the passband of this reference filter.

The photometer assembly is similar to the assembly with “gas detector” (Fig. 2-1) with the exception of the analysis cell. For analysis cell a non-sparated version is used. Behind this analysis cell the radiation passes a second filter cell (10) to the pyroelectrical detector (12). In front of this filter cell there are the individually optical filters.

The detector records the incoming IR radiation. This radiation will be reduced b y the absorption of the gas in the analysisi cell at this wavelength. The comparison between the measuring wav elength and reference wavelength leads to an alternating voltage signal. This signal results from cooling and heating the pyroelectrical material.

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MEASURING PRINCIPLE

UV MEASUREMENT

Instruction Manual

2.2 UV Measurement

The absorption measurement in the UV spectral range is based on the same principle as the IR measurement (Fig. 2-1).

A glow-discharge lamp [2] is used as radiation source. The UV radiation passes through the chopper [3] and a filter cell [6] into the dual-section analysis cell [7].

A second filter cell [6] is installed after the analysis cell. The photodetector [13], which follows, converts the pulsating radiation intensities from measuring [8] and reference side [9] of the analysis

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cell into electrical voltages.

As the glow-discharge lamp needs a specific and as constant as possible temperature, the UV lamp is thermostatted to about 55 °C for ML T 1 or the lamp is built-in into a thermostatted ambiente (MLT 2/3/4).

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Instruction Manual

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MEASURING PRINCIPLE

OXYGEN MEASUREMENT

2.3 Oxygen Measurement

Depending on analyzer model different two measuring methods will be used.

2.3.1 Paramagnetic Measurement (PO2)

Oxygen measurement is based on the paramagnetical characteristics of Oxygen molecules: T wo nitrogen filled quartz spheres (N2 is not paramagnetic) are arranged in a dumbbell configuration and, hinged to a platinum wire, placed inside a cell. Fixed to the wire a small mirror reflects a light beam to a photo detector (fig. 2-4). The measuring cell is placed inside an inhomogeneous magnetical field generated by a strong permanent magnet of specific design. Oxygen molecules within the sample gas now due to their paramagnetic characteristics are deflected into the area of highest field strength. This generates different forces on both spheres and the resulting torque turns dumbbell and mirror out of the rest position. This generates a photodetector signal because the beam is deflected, too. Initiated by the photodetector signal a preamplifier drives a compensation current through a loop surrounding the dumbbell to turn back the dumbbell into the rest position by effect of a magnetic field So the current compensating the torque affecting the dumbbell is a direct measure f or the oxygen concentration within the sample gas. In addition to measuring cell, permanent magnet, electronics and enclosure the paramagnetic oxygen detector contains a temperature sensor and a heating element to hold the detector at approx. 55 °C. Several v ariations are available including corrosion resistant, solv ent resistant and/or intrinsically safe (f or measuring flammable gases) versions .

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MEASURING PRINCIPLE

OXYGEN MEASUREMENT

10 11 7 9

Instruction Manual

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4153 6 8

Fig. 2-4: Principle Construction of paramagnetic Analysis Cell

1 Permanentmagnet 2 Platinum wire 3 Mirror 4 Glass ball 5 Loop 6 Photodetector 7 Light source 8 Preamplifier 9 Display

10 Gas inlet

11 Gas outlet

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Instruction Manual

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Solvent-resistan t Paramagnetic Oxygen Cell Solvents being tested: up to 20%

Name Name Name Name Name

Acetone Propane Methanol Carbon dioxide Toluene Acrolein n-Butane Ethylene Dimethyl sulfide Benzene Argon Pentane Ethylene oxide Dimethyl ether Vinyl acetate Aromatics Hexane Acetylene Hydrogen Vinyl acetylene Butadiene Heptane Butene Propadiene Xylene Butadiene-1 Methyl bromide i Butyr acid Cyclohexane Methyl ethyl ketone Butadiene-2 Iso propanol i-Butyr aldehyde Cyclohexanone Methyl acetate Methane Acetic acid i-Propyl formiat Propylene Methyl kaptane Ethane Ethanol Formaldehyde Propylene oxide

Conditions: The maximum concentrations need not to exceed 20% Assumption: a sample gas cooler lowers the dew point to approx. 5 °C. A solvent resistant measuring cell is a consumable part!

as single or sum values!

NGA 2000 ML T Hardware

MEASURING PRINCIPLE

OXYGEN MEASUREMENT

Chlorine-resistant Paramagnetic Oxygen Cell Components being tested:

Name

Chlorine (dry) up to 99% Dichloroethyle up to 20%

Table 2-1: Solvent Resistant Sensor: Approved solvents

Table 2-2: Medium affected Materials within Paramagnetic Oxygen Sensor

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OXYGEN MEASUREMENT

Instruction Manual

Special Hints on Paramagnetical Oxygen Sensors

The table below shows how accompan ying gases interf ere the paramagnetic o xygen measurement. If the concentration of such gases is already given at time of enquiry this interference may be taken into account during factory startup and thus minimized (option).

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Table 2-3: Paramagnetic Oxygen Measurement,

cross interference by accompanying gases

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Instruction Manual

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2.3.2 Electrochemical Measurement (EO2)

This sensor uses the principle of galvanic cells, fig. 2-5 shows the design.

NGA 2000 MLT Hardware

MEASURING PRINCIPLE

OXYGEN MEASUREMENT

5 7

12 12

Fig. 2-5: Structure of electrochemical Oxygen Sensor

The electrochemical oxygen sensor‘s ke y components are a lead anode (1) and a gold cathode (2) surrounded by a special acid electrolyte (3). The gold electrode is integrated solid with the membrane,which is a non-porous fluororesin membrane. Oxygen which barely diffuses through the membrane is electrochemically reduced on the gold electrode. The temperature compensating thermistor and adjusting resistance are connected between the cathode and anode. The current generated by oxygen reduction is converted into a voltage by these resistances. The value of the current flowing to the thermistor and resistance varies in proportion to the oxygen concentration of the measuring gases which contact the membrane. Therefore , the voltage at the terminal of the resistances is used for the sensor output to measure the oxygen concentration.

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OXYGEN MEASUREMENT

Instruction Manual

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(Red) (Black)

Thermistor (5)

(-)

Gold-

Cathode (2)

O2 + 4 H+ + 4 e- → 2 H2O

Summary reaktion O

(11)

Resistor (6)

Electrolyte (3)

(ph 6)

+ 2 Pb → 2 PbO

(+)

Lead-

Anode (1)

2 Pb + 2 H2O → 2 PbO + 4 H+ + 4 e

Fig. 2-6: Reaction of galvanic cell

In consequence of it‘s design the sensor‘s lifetime is limited and depends on theoretical designed life and oxygen concentration. The sensor output can be taken as a rough criterion for end of lifetime: The sensor is weared when the output in atmosphere is below 70 % of the initial output. The period till this can be calculated by

Lifetime =

designed life (hours) O2 concentration (%)

The sensor‘s designed life under constant conditions of 20 °C is approx. 900,000 hr s. The lifetime at 21 % o xygen is then calculated to approx. 42,857 hrs, corresponding to appro x.

5 years.

The given values are for reference only! The expected lifetime is greatly affected by the temperature of the environment in which the sensor is used or stored. Increases or decreases in atmospheric pressure have the same effect as that by increases or decreases in oxygen concentration (Operation at 40 °C halves lifetime).

Notes for analyzers with electrochemical EO2 cell!

This sensor is not suitable for anorganic gases containing chlorene or flourene! In addition is not suitable for sample gases containing ozone, H2S (> 100 ppm) or NH

(> 20 ppm).

Due to the measuring principle the electrochemical oxygen cell requires a minimum internal consumption of oxygen (residual humidity av oids drying of the cell). Supplying cells contin uously with dry sample gas of low grade oxygen concentration or with sample gas free of o xygen could result in a rev ersible detuning of O

sensitivity. The output signal will become instab le, b ut response time remains constant.

For correct measurement the cell needs continuously to be supplied with concentrations of at least 0.1 Vol.% O

. We recommend to use the cells if need be in alternating mode, means to purge cells with conditioned

(not dried, but dust removed) ambient air when measurement pauses. If it is necessary to interrupt oxygen supply for sev er al hours or da ys, the cell has to regenerate (supply cell for about one day with ambient air). Temporary flushing with nitrogen (N analyzer zeroing purpose) has no influence on measuring characteristics.

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) for less than 1 h (e.g. for

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Instruction Manual

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NGA 2000 MLT Hardware

MEASURING PRINCIPLE

OXYGEN MEASUREMENT

2.3.3 Trace Electrochemical Measurement (TEO2)

The ML T uses an electrochemical sensor technology to achieve the trace measurement of oxygen. The principle structure of the oxygen sensor is shown in Fig. 2-7. The sensor is a self contained disposable unit which requires no maintenance. The sensor utilizes the principle of electrochemical reaction to generate a signal proportional to the oxygen concentration in the sample.

The sensor consists of a cathode and anode which are in contact via a suitable electrolyte. The sensor has a gas permeable membrane which covers the cathode allowing gas to pass into the sensor while preventing liquid electrolyte from leaking out. As the sample diffuses into the sensor, an y oxygen present will dissolve in the electrolyte solution and migrate to the surface of the cathode. The oxygen is reduced at the cathode. Simultaneously , an oxidation reaction is occurring at the anode generating four electrons. These electrons flow to the cathode to reduce the oxygen.

The representative half cell reactions are:

Cathode: Anode: 4e- + 2H2O + O2 → 4OH- 4OH- + 2Pb → 2PbO + 2H2O + 4e-

The resultant overall cell reaction is:

2Pb + O2 → 2PbO

This flow of electrons constitutes an electric current which is directly proportional to the concentration of oxygen present in the sample. In the absence of oxygen, no o xidation / reduction reaction occurs and therefore no current is generated. This allows the sensor to ha ve an absolute zero .

Fig. 2-7: Structure of electrochemical Trace Oxygen Sensor

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OXYGEN MEASUREMENT

Instruction Manual

Notes for analyzers with electrochemical TEO2 cell!

For TEO2 sensor please note that the gas inlet and outlet connections of the analyzer are sealed to prev ent exposure of the sensor to air . Prolonged exposure of the sensor to air can cause extended start up time, reduction of performance or damage to the sensor. Do not remo ve the sealing caps until all associated sample handling components are installed and the instrument is fully ready for installation.

After replacement purge gas paths with inert gas (nitrogen (N2)) or sample gas as soon as possible to avoid prolonged exposure of the sensor to high concentrations of o xygen. The longer the sensor is exposed to air, the longer it will tak e f or the sensor to recover to lo w ppm lev els. When installing a new sensor or starting the instrument for the first time, it may take as long as eight hours for the analyzer to purge down to the lo w est operating r ange . Prolonged exposure of the sensor to air can cause extended start up time, reduction of performance or damage to the sensor.

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After initial startup or startup following a prolonged shutdown, the analyzer ma y require extended time to recover to the range of measurement. Commonly , this is caused by the introduction of ambient air into the sample and/or vent lines to the sensor. The presence of higher than normal levels of oxygen at the sensor will cause the sensor electrolyte to become saturated with dissolved oxygen. When the instrument is placed in operation, the sensor must now consume all excess dissolved oxygen above the desired measuring level.

All analyzers with electrochemical TEO

cell have to be purged with inert gas (Nitrogen, N2) prior to

disconnect the gas lines ! Then the gas line fittings hav e to be closed for transport or depositing analyzer .

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Instruction Manual

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NGA 2000 MLT Hardware

MEASURING PRINCIPLE

THERMAL CONDUCTIVITY

2.4 Thermal Conductivity

To measure gases like Hydrogen (H2), Argon (Ar) or Helium (He), the measurement method of thermal conductivity (TC) will be used.

2.4.1 Sensor Design

A complete in glass encapulated temperature resistor is the basis of the measuring. Four of this resisitors are arranged in a Wheatstone Bridge which is mounted into a block. The block itself is thermostatted to supress influence of external temperature change.

2.4.2 Analysis Cell

Both the cell volume and the mass of its measurement resistor hav e been minimized in order to obtain short response time. The block contains two gas paths for sample and reference gas. Always two sensors are located in the sample and the reference gas path. Depending on application the reference side either is closed gastight and optional filled with reference gas or it is opened and can be purged with reference gas (corresponding to the respective measuring application). Materials in contact with sample gas are aluminum, Viton, glass and gold in the standard type. Measuring cells stand for corrosive applications, block and tubing are of SiO2 coated stainless steel or from Hastelloy according to the measuring application.

Fig. 2-8: Sensor block (thermal conductivity detector TCD)

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THERMAL CONDUCTIVITY

Instruction Manual

2.4.3 Measurement Method

The entire measurement cell is thermostated to a temperature of up to 75 °C. The four integral temperature sensors are electrically heated to a higher temperature. Their temperatures, and thus their electrical resistance, are dependent upon heat losses, which, in turn, result from heat transport in the surrounding gas to colder chamber walls. For otherwise stable conditions, this heat transport will be proportional to the thermal conductivity of the gas present between the sensor and the chamber wall. Interconnecting the f our sensors into Wheatstone bridge circuit (Fig. 2-9) provides an electronic signal proportional to gas density . Electronic circuitry processes this signal to obtain standardized signal amplitudes, and transmits these to both an indicator instrument and to the signal output connector.

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The internal gas paths are constructed to get a minimimized response time at minimized dependence of the analytical signal upon sample gas flow rate.

reference

measure

DC voltage supply

measure

Display

(Vol.-%)

reference

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Fig. 2-9: Measuring principle Thermal Conductivity Sensor (Wheatstone bridge)

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Instruction Manual

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NGA 2000 MLT Hardware

5. Installation

This chapter describes in detail how to install the different analyzer v ariations.

5.1 General

Carefully examine the shipping carton and contents for signs of damage. Immediately notify the shipping carrier if the carton or its contents are damaged. Retain the carton and packing material until the instrument is operational.

INSTALLATION

GENERAL

ELECTRICAL SHOCK HAZARD!

Prior to connecting the analyzer to mains ensure all safety instructions as given in the appropriate chapter at the beginning of this manual and in the following analyzer refered sections are read and unterstood!

EXPLOSION HAZARD !

Do not operate nor install these instruments in hazardous areas without additional measures!

Installation area has to be clean, free from moisture, excessive vibration and frostprotected. Take care to meet the permissible ambient temperatures as given in the technical data section!

Instruments must not be exposed to direct sunlight, fluorescent lamps nor sources of heat.

For suppressed ranges of MLT 3 for gas purity measurment we recommend installation between 20 °C and 30 °C ( 68 to 86 °F).

For outdoor installation it is recommended to mount the instruments into a cabinet. At least sheltering against rain is required.

Do not cover v enting openings and take care to mount the instrument in a distance to walls not affecting venting.

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INSTALLATION

GENERAL

Instruction Manual

T o stay in compliance with regulations regarding electromagnetic compatibility it is recommended to use only shielded cables, as optionally available from Emerson Process Management or equivalent. Customer has to take care that the shield is connected in proper way . Shield and signal connector enclosure need to be conductively connected, submin-d-plugs and sockets must be screwed on the analyzer.

Using external submin-d-to-terminal adaptor elements (option) affects electromagnetic compatibility. In this case the customer has to take measures to sta y in compliance and has to declare conformity, when required by legislation (e.g. European EMC Directiv e).

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The mains socket has to be nearby the power supply unit and easily accessible! Disconnecting from mains requires unplugging the power plug!

To comply with the CE mark requirements, analzyers requiring DC power supply must be supplied by a power supply unit of type UPS 01 T, DP 157, SL5, SL10 (DP 157 rack installation only) or equivalent units. Equivalent units must provide SELV output voltages!

Verify proper polarity when connecting DC 24 V operated analyzers !

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Instruction Manual

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TRANSFER SAFETY LOCK OF MLT 1/ULCO OR MLT 2

5.1.1 Transfer Safety Lock of MLT 1/ULCO or MLT 2

TRANSFER SAFETY LOCK ! First of all operations unscrew transfer safety lock of ML T 1/ULCO or MLT 2 ! MLT 1/ULCO: Unscrew both knurled-head screws on bottom side of the housing

(Fig. 5-1a) ! For protection against loss screw the knurled-head screws into the respective holders at housing rear side (Fig. 5-1b) !

MLT 2: Unscrew transfer safety lock of photometer sliding carriage (Fig. 51c)!

For transport of MLT the transfer safety lock absolutely have to be locked !

NGA 2000 MLT Hardware

INSTALLATION

Transfer safety lock (two knurled-head screws)

Fig. 5-1a: Transfer safety lock MLT-ULCO

(housing side view, detail sketch)

Fig. 5-1b: MLT 1, Rear panel

(holder for safety lock)

Front panel

Emerson Process Management GmbH & Co. OHG

Fig. 5-1c: MLT 2, Photometer safety lock

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NGA 2000 MLT Hardware

INSTALLATION

GAS CONDITIONING (SAMPLE HANDLING)

Instruction Manual

5.2 Gas Conditioning (Sample Handling)

T o ensure trouble-free analyzer operation one has to attach great importance to gas conditioning:

All gases must be conditioned before supplying! When supplying corrosive gases ensure that gas path components are not

affected!!

Flammable gases must not supplied without additional pr otective measures! It is prohibited to supply e xplosive gases!

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Furthermore the gases must be

❏ dry ❏ free of dust ❏ free of aggressive components aff ecting gas path materials (e.g. by corrosion).

If moisture can not be avoided tak e care that the gas‘ de w point is at least 10 °C below ambient temperature to avoid condensation within the gas path. Pressure and flow hav e to be within the limits giv en in the technical data section. For suppressed ranges a constant pressure (+- 1 psig at 20 - 25 psig) and constant temperature (20 - 30 °C, 68 - 86 °F) are very important.

Suitable gas conditionning hardware may be supplied or recommended for specific analytical problems and operating conditions.

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Rosemount MLT Series Analyzer Hardware including CAT 200-11th Ed. Manuals & Guides

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