NGA 2000
F
LAME IONIZATION
A
NALYZER
D
ETECTION
M
ODULE
Rosemount Analytical
N
OTICE
HE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE
T
.
OSEMOUNT ANALYTICAL'S
R
UNDER
Teflon® is a registered trademark of E.I. duPont de Nemours and Co., Inc.
Kynar® is a registered trademark of Pennwalt, Inc.
U.S. P
ATENT
NGA 2000
5.787.015.
SYSTEM OF MODULAR GAS ANALYZERS AND CONTROLLERS ARE PATENTED
,
Manual Part Number 748331-E
November 1998
Printed in U.S.A.
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
C
ONTENTS
P
REFACE
PURPOSE/SAFETY SUMMARY........................................................................P-1
GLOSSARY ......................................................................................................P-4
SPECIFICATIONS - GENERAL..........................................................................P-7
SPECIFICATIONS - GAS REQUIREMENTS .....................................................P-8
SPECIFICATIONS - PHYSICAL.........................................................................P-9
SPECIFICATIONS - GAS CONNECTIONS........................................................P-9
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE ....P-10
RETURNING PARTS TO THE FACTORY .........................................................P-10
TRAINING ......................................................................................................P-10
DOCUMENTATION............................................................................................P-10
COMPLIANCES..................................................................................................P-11
S
ECTION
1.1 OVERVIEW ..............................................................................................1-1
1.2 TYPICAL APPLICATIONS........................................................................1-1
1.3 THEORY OF TECHNOLOGY...................................................................1-1
1.4 GAS SAFETY FEATURES.......................................................................1-3
1.5 FUEL GAS OPTION .................................................................................1-3
S
ECTION
2.1 UNPACKING.............................................................................................2-1
2.2 ASSEMBLY...............................................................................................2-1
2.3 LOCATION ...............................................................................................2-2
2.4 GASES .....................................................................................................2-3
1. I
2. I
2.4.1 Overview.....................................................................................2-3
NTRODUCTION
NSTALLATION
748331-E Rosemount Analytical November 1998
NGA 2000 Flame Ionization Detection Module
i
C
ONTENTS
2.4.2 Connections................................................................................2-4
2.4.3 Specifications .............................................................................2-5
2.4.4 Leak Test....................................................................................2-7
2.5 ELECTRICAL CONNECTIONS................................................................2-7
S
ECTION
3.1 OVERVIEW..............................................................................................3-1
3.2 DISPLAYS................................................................................................3-1
3.3 RUN MODE DISPLAY..............................................................................3-1
3.4 MENU DISPLAYS....................................................................................3-1
3.5 HELP DISPLAYS .....................................................................................3-2
3.6 STARTUP PROCEDURE.........................................................................3-6
3.7 BINDING ..................................................................................................3-9
3.8 CALIBRATION .........................................................................................3-9
3.9 ROUTINE OPERATION...........................................................................3-10
3.10 SAFETY SYSTEM....................................................................................3-11
S
ECTION
4.1 BURNER DISASSEMBLY AND CLEANING.............................................4-1
4.2 COMPONENT REPLACEMENT...............................................................4-3
3. S
4. M
TARTUP AND OPERATION
AINTENANCE AND TROUBLESHOOTING
4.3 BURNER STARTUP TROUBLESHOOTING ...........................................4-3
S
ECTION
5.1 REPLACEMENT PARTS ..........................................................................5-1
A
PPENDIX
ENERAL PRECAUTIONS FOR HANDLING
G
ARRANTY
W
IELD SERVICE AND REPAIR FACILITIES
F
5. R
5.1.1 Electronics..................................................................................5-1
5.1.2 Electro-Mechanical.....................................................................5-1
5.1.3 O-Rings and Gaskets.................................................................5-1
5.1.4 Burner Assembly and Components............................................5-2
5.1.5 Pneumatics.................................................................................5-2
EPLACEMENT PARTS
A. FID I
DENTIFICATION MATRIX
TORING HIGH PRESSURE CYLINDERS
& S
ii
November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
F
IGURES
1-1 Flame Ionization Detection Technology....................................................1-1
1-2 NGA 2000 Flame Ionization Detection Module - Top View.......................1-2
2-1 Analyzer Module Installation Into Platform ...............................................2-1
2-2 Back Panel Connections...........................................................................2-2
2-3 FID Module Flow Diagram........................................................................2-4
2-4 Front Panel Connections, Controls and Indicators...................................2-5
2-5 Outline and Mounting Dimensions............................................................2-8
2-6 FID Wiring Diagram..................................................................................2-9
3-1 Run Mode Display....................................................................................3-2
3-2 Main Menu Display...................................................................................3-2
3-3 Basic Controls Menu Display....................................................................3-3
3-4 Expert Controls and Setup Menu Display.................................................3-3
3-5 Technical Configuration Menu Display.....................................................3-3
3-6 Typical Help Screen..................................................................................3-4
3-7 Typical Curves of Module Response vs. Pressure Setting on Sample
Pressure Regulator........................................................................3-5
3-8 Typical Curves of Module Response vs. Pressure Setting on Fuel
Pressure Regulator........................................................................3-5
3-9 Typical Curves of Module Response vs. Pressure Setting on Air
Pressure Regulator........................................................................3-6
3-10 Front Panel Torquing Sequence...............................................................3-12
3-11 Display Screens (1 of 5)...........................................................................3-13
3-12 Display Screens (2 of 5)...........................................................................3-14
3-13 Display Screens (3 of 5)...........................................................................3-15
3-14 Display Screens (4 of 5)...........................................................................3-16
3-15 Display Screens (5 of 5)...........................................................................3-17
4-1 FID Burner Assembly................................................................................4-2
C
ONTENTS
T
ABLES
1-1 Analyzer Characteristics Relative to Fuel Gas...........................................1-5
3-1 FID Analyzer Module Alarms....................................................................3-4
748331-E Rosemount Analytical November 1998
NGA 2000 Flame Ionization Detection Module
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C
ONTENTS
N
OTES
iv
November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
P
REFACE
P
URPOSE/SAFETY SUMMARY
The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of this particular NGA 2000 module.
Some sections may describe equipment not used in your configuration. The user
should become thoroughly familiar with the operation of this module before operating
it. Read this instruction manual completely.
To avoid explosion, loss of life, personal injury and damage to this equipment
and on-site property, all personnel authorized to install, operate and service this
equipment should be thoroughly familiar with and strictly follow the instructions
in this manual. Save these instructions.
If this equipment is used in a manner not specified in these instructions,
protective systems may be impaired.
DANGER
personal injury, death, or substantial property damage if the warning is ignored.
WARNING
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION
personal injury or property damage if the warning is ignored.
NOTE
important but not hazard-related.
is used to indicate the presence of a hazard which
is used to indicate the presence of a hazard which
is used to indicate the presence of a hazard which
is used to indicate installation, operation or maintenance information which is
will
cause
can
cause
will or can
cause
severe
severe
minor
WARNING: ELECTRICAL SHOCK HAZARD
Operate this equipment only when covers are secured. Servicing requires
access to live parts which can cause death or serious injury. Refer servicing to
qualified personnel.
For safety and proper performance, this module must be connected to a
properly grounded three-wire source of electrical power.
748331-E Rosemount Analytical November 1998
NGA 2000 Flame Ionization Detection Module
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REFACE
WARNING: POSSIBLE EXPLOSION HAZARD
This equipment is used in the analysis of sample gases which may be
flammable, and the burner fuel used in the ionization process is flammable. A
continuous dilution purge system is factory-installed (in accordance with
Standard ANSI/NFPA 496-1993, Chapter 6, and it must be functional at all times
during operation. DO NOT DISABLE THIS PURGE SYSTEM.
WARNING: FLAMMABLE SAMPLES
Consult the factory if flammable samples will be measured.
WARNING: PARTS INTEGRITY
Tampering with or unauthorized substitution of components may adversely
affect safety of this product. Use only factory-approved components for repair.
WARNING: POSSIBLE EXPLOSION HAZARD
Ensure that all gas connections are made as labeled and are leak free. Improper
gas connections could result in explosion and death.
CAUTION: PRESSURIZED GAS
This module requires calibration with a known standard gas. See General
Precautions for Handling and Storing High Pressure Gas Cylinders at the rear of
this manual.
CAUTION: OVERBALANCE HAZARD
This Analyzer Module may tip instrument over if it is pulled out too far and the
Platform is not properly supported.
P-2
November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
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REFACE
CAUTION: HAND INJURY HAZARD
Dropping the front panel of the Platform while hand or fingers are inside either
case handle can cause serious injury.
CAUTION: PURGE AIR REQUIREMENT
This Analyzer Module must be used in conjunction with a device (Platform or PC
Interface) that can actively monitor network variables related to pressure or flow
of the continuous dilution purge, or the front panel LEDs of the Analyzer
Module, as installed, must be visible. The purpose of this requirement is to
maintain adherence to ANSI/NFPA 496 standard which assures the continued
viability of the purge system. Under no circumstances should any pressure or
flow indicator be connected to the PURGE AIR OUT outlet of the Analyzer
Module because this may affect the sealing performance of the module.
CAUTION: OVER-VOLTAGE SPIKING
If this Analyzer Module is used with a non-Rosemount Analytical power supply,
adding Rosemount P/N 903341 Current Protector in series with the 24 V positive
power line will prevent over-voltage spiking and resultant fuse blowing when
powering up the instrument.
Note
This Analyzer Module is completely leak-tested at the factory for gas leakage.
The user is responsible for testing for leakage at the inlet and outlet fittings on
the rear panel (with a test procedure chosen by the user). The user is also
responsible for leak-testing periodically and if any internal pneumatic
components are adjusted or replaced. See leak test instructions in section 2.4.4.
748331-E Rosemount Analytical November 1998
NGA 2000 Flame Ionization Detection Module
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P
REFACE
G
LOSSARY
NALYZER MODULE
A
The module that contains all sensor/detector components for development of a
Primary Variable signal; includes all signal conditioning and temperature control
circuitry.
ACKPLANE
B
The interconnect circuit board which the Controller Board, Power Supply, Analyzer
Module power and network cables, I/O Modules and Expansion Modules plug into.
ONTROL MODULE
C
The Operator Interface plus the Controller Board.
ONTROLLER BOARD
C
The computer board that serves as the Network Manager and operates the Display
and Keypad.
ISTRIBUTION ASSEMBLY
D
The Backplane and the card cages that hold I/O and Expansion Modules.
XPANSION MODULE
E
A circuit board that plugs into the Backplane from the front of the Platform and
performs special features not related to I/O functions.
I/O M
A circuit board that plugs into the Backplane from the rear of the Platform. Has a
connector terminal for communication with external data acquisition devices and
provides an input/output function.
O
The Display and Keyboard.
P
Any workable collection of the following: Controller Board, Power Supply, Distribution
Assembly, Enclosure and Operator Interface.
P
ODULE
PERATOR INTERFACE
LATFORM
OWER SUPPLY
Any of a variety of components that provides conditioned power to other NGA 2000
components, from the Power Supply Board that plugs into the front of the Backplane
in a stand-alone instrument to several larger ones that can power larger collections of
modules and components.
P-4
November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
P
REFACE
RIMARY VARIABLE
P
The measured species concentration value from an Analyzer Module.
ECONDARY VARIABLE
S
Data placed on the network by a module regarding current status, e.g., sample flow,
source voltage and other diagnostic information.
OFTKEYS
S
The five function keys located below the front panel display; they assume the function
displayed directly above each on the display, a function dictated by software.
YSTEM
S
Any collection of Analyzer Module(s), Platform(s), I/O Module(s) and Expansion
Module(s).
748331-E Rosemount Analytical November 1998
NGA 2000 Flame Ionization Detection Module
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REFACE
N
OTES
P-6
November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
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REFACE
S
PECIFICATIONS
M
EASUREMENT SPECIES
R
ANGES
H2/H
E FUEL
H2
FUEL OPTION
R
EPEATABILITY
M
INIMUM DETECTABLE LEVEL
N
OISE
L
INEARITY
R
ESPONSE TIME
CEMS
ICEE
Z
ERO DRIFT
S
PAN DRIFT
E
FFECT OF TEMPERATURE
O
PERATING TEMPERATURE
P
OWER REQUIREMENTS
- G
ENERAL
Total hydrocarbons
0 to 100 ppm (output scalable down to 0-2 ppm fullscale)
low range: 0 to 4 ppm CH4, through 0 to 1% CH
high range:: 0 to 50 ppm CH4, through 0 to <5% CH
low range: 0 to 1 ppm CH4, through 0 to 2500 ppm CH
high range:: 0 to 10 ppm CH4, through 0 to 2% CH
1% of fullscale at a constant temperature, sample flow and fuel, burner
≤
4
4
4
4
air and sample pressure
0.04 ppm H2/He fuel
0.01 ppm H2 fuel
1% of fullscale, peak to peak
≤
1% of fullscale for H2/He fuel and He fuel
≤ ±
30 sec. For 10% to 90% of fullscale, with sample bypass flow at 0.5
≤
L/min. (non-flammable sample)
1 sec. For 10% to 90% of fullscale, with sample bypass flow at 0.5
≤
L/min. (non-flammable sample)
1% of fullscale/24 hours at constant temperature, hydrocarbon
≤ ±
concentration of supply gases, sample flow and fuel, burner air and
sample pressure
1% of fullscale/24 hours at constant temperature, hydrocarbon
≤ ±
concentration of supply gases, sample flow and fuel, burner air and
sample pressure
2% of fullscale for any temperature change of 10°C and rate of
≤ ±
change less than 10°C/hour
32°F to 113°F (0°C to 45°C)
+24 VDC ±5%, 120 W max.. direct to analyzer module;
Ripple and Noise: <100 mV peak to peak
Line and Load Regulations: <±1%
748331-E Rosemount Analytical November 1998
NGA 2000 Flame Ionization Detection Module
P-7
P
REFACE
S
PECIFICATIONS
B
URNER AIR
F
LOW RATE
THC
S
UPPLY PRESSURE
F
UEL GAS (STANDARD
F
LOW RATE
THC
S
UPPLY PRESSURE
Unless this Analyzer Module is factory- or field-configured specifically for
using 100% hydrogen fuel, DO NOT USE PURE HYDROGEN FUEL. An
explosion resulting in severe personal injury or death could occur. Also,
each Analyzer Module is factory-configured for either mixed or pure
hydrogen fuel, and cannot use the fuel for which it was not configured
unless field reconfiguration is done.
- G
AS REQUIREMENTS
Zero-grade air
350 to 400 ml/min
ppm, CH
≤
4
1725 to 3450 hPa-gauge (25 to 50 psig)
)
Premixed 40% hydrogen and 60% helium
75 to 80 ml/min.
0.5 ppm, CH
≤
4
2415 to 3450 hPa-gauge (35 to 50 psig)
WARNING: POSSIBLE EXPLOSION HAZARD
F
UEL GAS
S
AMPLE
P
URGE AIR
(H
OPTION
2
F
LOW RATE
THC
S
UPPLY PRESSURE
F
LOW RATE
THC
S
UPPLY PRESSURE
T
EMPERATURE
P
ARTICULATES
D
EWPOINT
F
LOW RATE
S
UPPLY PRESSURE
)
Zero-grade hydrogen
35 to 40 ml/min.
0.5 ppm, CH
≤
4
2415 to 3450 hPa-gauge (35 to 50 psig)
Non-flammable (below 100% of LEL)
0.5 to 40 ml/min.
0.5 ppm, CH
≤
4
483 to 1035 hPa-gauge (7 to 15 psig)
32°F to 132°F (0°C to 55°C), <20°C variance/24 hours,
<10°C variance/hour
Filtered to <2 microns
<45°C
Instrument air, nitrogen or other non-flammable gas (refer
to ANSI/NFPA 496 for the requirements for the Protective
Gas System)
16 to 18 L/min.
689 to 1378 hPa-gauge (10 to 20 psig)
P-8
November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
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REFACE
S
PECIFICATIONS
M
ATERIALS IN CONTACT
WITH SAMPLE
D
IMENSIONS
W
EIGHT
M
OUNTING
C
ASE CLASSIFICATION
MAX. S
FROM PLATFORM
S
PECIFICATIONS
S
B
F
UEL IN
P
P
B
B
P
V
EPARATION
AMPLE IN
URNER AIR IN
URGE AIR IN
URGE AIR OUT
YPASS OUT
URNER EXHAUST OUT
RESSURE RELIEF
ALVE
- P
HYSICAL
Stainless steel, Teflon, glass-filled Teflon, brass, neoprene,
Kynar
See Figure 2-5, Outline and Mounting Dimensions
10.43 kg (23 lbs.)
Horizontal, inside a Platform or custom installed in a panel
General Purpose for installation in weather protected area
1600 m (1 mile)
- G
AS CONNECTIONS
1/4 inch O.D. tube fitting
1/4 inch O.D. tube fitting
1/4 inch O.D. tube fitting
3/8 inch O.D. tube fitting
3/8 inch O.D. tube fitting
1/4 inch O.D. tube fitting
1/2 inch O.D. tube connection, tygon or equivalent (this
connection shall slope downward 6° minimum from
horizontal)
CAUTION: PRESSURE RELIEF
See the Preface Section of the Platform manual for specifications regarding Platform
related components.
748331-E Rosemount Analytical November 1998
VALVE RESTRICTION
No connection shall be made to this fitting. If this
caution is ignored, damage to the case seals may occur,
and the instrument will not operate properly.
NGA 2000 Flame Ionization Detection Module
P-9
P
REFACE
C
USTOMER SERVICE
For order administration, replacement Parts, application assistance, on-site or factory
repair, service or maintenance contract information, contact:
R
ETURNING PARTS TO THE FACTORY
Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when
you call:
Number.
Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sender, freight collect.
When returning any product or component that has been exposed to a toxic, corrosive
or other hazardous material or used in such a hazardous environment, the user must
attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification
that the material has been decontaminated, disinfected and/or detoxified.
Model Number, Serial Number, and Purchase Order Number or Sales Order
, T
ECHNICAL ASSIST ANCE AND FIELD SERVICE
Rosemount Analytical Inc.
Process Analytical Division
Customer Service Center
1-800-433-6076
Return to:
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
T
RAINING
A comprehensive Factory Training Program of operator and service classes is
available. For a copy of the
the Technical Services Department at:
D
OCUMENTATION
The following NGA 2000 Flame Ionization Detection Module instruction materials are
available. Contact Customer Service or the local representative to order.
748331 Instruction Manual (this document)
Current Operator and Service Training Schedule
Rosemount Analytical Inc.
Phone: 1-714-986-7600
FAX: 1-714-577-8006
contact
P-10
November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
C
9
6
OMPLIANCES
This product may carry approvals from several certifying agencies, including Factory
Mutual and the Canadian Standards Association (which is also an OSHA accredited,
Nationally Recognized Testing Laboratory), for use in non-hazardous, indoor locations
P
REFACE
FM
APPROVED
Rosemount Analytical Inc. has satisfied all obligations from the European
Legislation to harmonize the product requirements in Europe.
This product complies with the standard level of NAMUR EMC.
Recommendation (May 1993).
This product satisfies all obligations of all relevant standards of the EMC framework in
Australia and New Zealand.
®
97-C219
NAMUR
N
748331-E Rosemount Analytical November 1998
NGA 2000 Flame Ionization Detection Module
P-11
P
REFACE
N
OTES
P-12
November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
I
NTRODUCTION
1
1.1 OVERVIEW
This manual describes the Flame Ionization Detector (FID) Analyzer Module of
Rosemount Analytical's NGA 2000 Series of gas analysis components. See Figures
1-1 and 1-2.
The FID Analyzer Module is designed to continuously determine the concentration of
hydrocarbons in a flowing gaseous mixture. The concentration is expressed in
parts-per-million or percent of volume.
The entire FID Analyzer Module is designed as a slide-in module (if configured in
stand-alone instrument fashion), removable from the front of the Platform, with gas
connections made from the rear. All electronics relative to sample detection and
conditioning are included in this module.
1.2 TYPICAL APPLICATIONS
The monitoring of atmospheric air for low-level hydrocarbon contaminants and
determining the hydrocarbon content of exhaust emissions from internal combustion
engines are examples of typical applications for the FID Analyzer Module.
1.3 THEORY OF TECHNOLOGY
This Analyzer Module uses the flame
ionization method of detection. The sensor is
a burner in which a regulated flow of sample
gas passes through a flame sustained by
regulated flows of a fuel gas (hydrogen or a
hydrogen/diluent mixture) and air.
Within the flame, the hydrocarbon
components of the sample stream undergo a
complex ionization that produces electrons
and positive ions. Polarized electrodes
collect these ions, causing current to flow
through an electronic measuring circuit.
Negative Ion
Collection
Ring
+90V
Sample
F
IGURE
1-1. F
D
LAME IONIZATION
ETECTION
Signal
Conditioning
Positive
Carbon
Ions
Air
Fuel
748331-E Rosemount Analytical November 1998
NGA 2000 Flame Ionization Detection Module
1-1
NTRODUCTION
I
The ionization current is proportional to the rate at which carbon atoms enter the
burner, and is therefore a measure of the concentration of hydrocarbons in the
sample. This measure of concentration is placed on the network, where it is can be
shown on the Platform Display or on other data acquisition devices.
Gas Lines
(See Figure 2-2)
Purge Air
Fuel Shutoff
Solenoid Valve
Pressure Regulator
Capillary
Case Heater Silicon
Pad (On Base)
Purge Air Flow Switc h
Fuel Pressure Sensor
Air Pressure Sensor
Ignite/Operate Mode
Burner-Air Flow
Solenoid Valve
Air Circulation Fan
Purge Air
Heater Cartridge
Sample Press u re
Sensor
Purge Air Outlet
Pressure Switch
Preamp Board
(In Shield)
Detector (Burner)
Computer Board
Sample Bypass
Flow Sensor
DC-DC Converter
Safety Board
Burner Air
and Fuel
Regulators
(Stacked Vertically)
Sample Back Pressure Regulators
F
IGURE
1-2. NGA 2000 F
1-2
Manual Ignite Switch
LAME IONIZATION DETECTION MODULE
November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
Power Supply Board
Network & Power Module
- T
OP VIEW
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