Instruction Manual
HAS64E-IM-HW
September 2008
Instruction Manual HFID
Heated Flame Ionization Detector
NGA 2000 Hardware Manual for
HFID Analyzer Module
(combined with NGA 2000 Platform,
MLT, CAT 200 or TFID Analyzer)
1st Edition 09/2008
www.EmersonProcess.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management (Rosemount Analytical) designs, manufactures and tests its
products to meet many national and international standards. Because these instruments are
sophisticated technical products, you MUST properly install, use, and maintain them to ensure
they continue to operate within their normal specifications. The following instructions MUST be
adhered to and integrated into your safety program when installing, using and maintaining
Emerson Process Management (Rosemount Analytical) products. Failure to follow the proper
instructions may cause any one of the following situations to occur: Loss of life; personal injury;
property damage; damage to this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Emerson Process Management
(Rosemount Analytical) representative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and maintenance
of the product.
• Install your equipment as specified in the Installation Instructions of the appropriate
Instruction Manual and per applicable local and national codes. Connect all products to the
proper electrical and pressure sources.
• To ensure proper performance, use qualified personnel to install, operate, update, program,
and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement parts
specified by Emerson Process Management (Rosemount Analytical). Unauthorized parts and
procedures can affect the product’s performance, place the safe operation of your process at
risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical
hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place, except
when maintenance is being performed by qualified persons, to prevent electrical shock
and personal injury.
The information contained in this document is subject to change without notice. Misprints reserved.
1st Edition: 09/2008
Emerson Process Management
GmbH & Co. OHG
Industriestrasse 1
D-63594 Hasselroth
Germany
T +49 (0) 6055 884-0
F +49 (0) 6055 884-209
Internet: www.EmersonProcess.com
Teflon® and Viton® are registered trademarks of E. I. duPont de Nemours and Co., Inc.
Kynar® is a registered trademark of Atochem North America, Inc.
SNOOP® is a registered trademark of NUPRO Co.
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
Table of Contents
PREFACE ...........................................................................................................................P - 1
DEFINITIONS......................................................................................................................P - 1
SAFETY INSTRUCTIONS WIRING AND INSTALLATION OF THIS APPARATUS ........P - 2
OPERATING AND MAINTAINING THIS APPARATUS ........................................................P - 3
GENERAL SAFETY NOTICE / RESIDUAL RISK ................................................................P - 4
AUTHORIZED PERSONNEL ..............................................................................................P - 4
GASES AND GAS CONDITIONING (SAMPLE HANDLING) ..............................................P - 8
POWER SUPPLY ................................................................................................................P - 9
ELECTROSTATIC DISCHARGE .......................................................................................P - 10
GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS
CYLINDERS ................................................................................................................. P - 11
DOCUMENTATION ...........................................................................................................P - 12
COMPLIANCES ................................................................................................................P - 12
GLOSSARY OF TERMS ...................................................................................................P - 13
ANALYZER SYSTEM ARCHITECTURE ............................................................................A - 1
SECTION 1 DESCRIPTION AND SPECIFICATIONS ....................................................... 1 - 1
1-1 OVERVIEW ................................................................................................................ 1 - 1
1-2 TYPICAL APPLICATIONS .......................................................................................... 1 - 1
1-3 SAFETY GAS FEATURES.......................................................................................... 1 - 1
1-4 THEORY OF TECHNOLOGY ..................................................................................... 1 - 2
1-5 SPECIFICATIONS ...................................................................................................... 1 - 5
a. General ................................................................................................................... 1 - 5
b. Physical .................................................................................................................. 1 - 5
c. Gas requirements ................................................................................................... 1 - 6
d. Gas Connections .................................................................................................... 1 - 7
ITable of ContentsEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
SECTION 2 INSTALLATION .............................................................................................. 2 - 1
2-1 UNPACKING ............................................................................................................... 2 - 1
2-2 ASSEMBLY................................................................................................................. 2 - 1
2-3 LOCATION.................................................................................................................. 2 - 2
2-4 GASES ....................................................................................................................... 2 - 2
a. Overview................................................................................................................. 2 - 2
b. Pneumatic Connections .......................................................................................... 2 - 3
c. Specifications.......................................................................................................... 2 - 4
Fuel Gas...............................................................................................................................2 - 4
Burner Air .............................................................................................................................2 - 4
Purge Air ..............................................................................................................................2 - 4
Regulated Air........................................................................................................................ 2 - 4
Calibration Gases.................................................................................................................2 - 4
Sample Gas .........................................................................................................................2 - 4
Flow Rate .............................................................................................................................2 - 4
Pressure / Filtration ..............................................................................................................2 - 5
2-5 LEAK TEST................................................................................................................. 2 - 5
2-6 ELECTRICAL CONNECTIONS .................................................................................. 2 - 6
2-7 INSTALLATION CONSIDERATIONS CHECKLIST ..................................................... 2 - 9
SECTION 3 OPERATION .................................................................................................. 3 - 1
3-1 OVERVIEW ................................................................................................................ 3 - 1
3-2 STARTUP & INITIALIZATION ..................................................................................... 3 - 1
a) Startup .................................................................................................................... 3 - 1
b) Temperature/Pressure Settings and Check ............................................................ 3 - 3
c) Ignition of the Flame ............................................................................................... 3 - 4
Auto-Ignition of the Flame ....................................................................................................3 - 4
Manual Ignition of the Flame ................................................................................................3 - 4
3-3 BINDING ..................................................................................................................... 3 - 4
3-4 CALIBRATION PROCEDURE .................................................................................... 3 - 5
a. Calibration Setup .................................................................................................... 3 - 5
Calibration Gas List ..............................................................................................................3 - 5
Calibration Parameters ........................................................................................................ 3 - 6
Check of capillary type .........................................................................................................3 - 6
b. Execution ................................................................................................................ 3 - 7
Zero Adjustment ...................................................................................................................3 - 7
Span Adjustment ..................................................................................................................3 - 8
c) Problems with Calibration ....................................................................................... 3 - 8
II Table of Contents Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
3-5 ROUTINE OPERATION .............................................................................................. 3 - 9
a) Operation ................................................................................................................ 3 - 9
b) Sensitivity ............................................................................................................... 3 - 9
c) Shutdown................................................................................................................ 3 - 9
3-6 SAFETY SYSTEM ...................................................................................................... 3 - 11
3-7 SYSTEM & NETWORK I/O MODULE CONTROLS (SETUP) - SYSTEM SIO ......... 3 - 14
a. Analog Output Setup ............................................................................................ 3 - 14
Output number: ..................................................................................................................3 - 14
Choose signal source module... .........................................................................................3 - 14
Choose Signal... .................................................................................................................3 - 14
Signal value for 0% (100%) output:.................................................................................... 3 - 15
Output current: ...................................................................................................................3 - 15
Hold output during calibration: ........................................................................................... 3 - 15
b. Serial interface Setup ........................................................................................... 3 - 17
c. Relay Outputs Setup............................................................................................. 3 - 18
Output number: ..................................................................................................................3 - 18
Invert signal: .......................................................................................................................3 - 18
Choose source module... ................................................................................................... 3 - 18
Choose signal... ................................................................................................................. 3 - 18
SECTION 4 MAINTENANCE AND SERVICE.................................................................... 4 - 1
4-1 OVERVIEW ................................................................................................................ 4 - 1
4-2 FUSES ........................................................................................................................ 4 - 3
4-3 OVEN.......................................................................................................................... 4 - 4
a. Removal ................................................................................................................. 4 - 4
b. Disassembly ........................................................................................................... 4 - 4
4-4 BURNER..................................................................................................................... 4 - 6
a. Temperature Sensor ............................................................................................... 4 - 6
b. RTD Detector.......................................................................................................... 4 - 6
c. Igniter ...................................................................................................................... 4 - 6
d. Flameout Sensor .................................................................................................... 4 - 6
4-5 BURNER INTERNAL COMPONENTS ....................................................................... 4 - 8
a. Disassembly of Burner / Thermal Block.................................................................. 4 - 8
b. Replacing Burner Jets ............................................................................................ 4 - 9
c. Burner Jet Installation ........................................................................................... 4 - 11
IIITable of ContentsEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
4-6 THERMAL BLOCK.................................................................................................... 4 - 12
a. Sample RTD ......................................................................................................... 4 - 12
b. Cartridge Heater ................................................................................................... 4 - 12
c. Thermostat ........................................................................................................... 4 - 13
d. Sample Capillary .................................................................................................. 4 - 13
4-7 ELECTRONICS ASSEMBLY .................................................................................... 4 - 14
a. Printed Circuit Boards........................................................................................... 4 - 15
b. Case Temperature Sensor .................................................................................... 4 - 16
c. Case Pressure Purge Switch ................................................................................ 4 - 16
d. Preamp Assembly................................................................................................. 4 - 17
4-8 FAN ASSEMBLY ....................................................................................................... 4 - 18
4-9 FLOW CONTROLLER .............................................................................................. 4 - 19
4-10 DC POWER SUPPLY MODULE ............................................................................... 4 - 20
4-11 FRONT PANEL COMPONENTS .............................................................................. 4 - 21
Replacing Front Panel Components ......................................................................... 4 - 22
a. LON/Power Module .......................................................................................................4 - 23
b. LED Indicator Assembly ................................................................................................4 - 23
c. Manual Ignite Toggle Switch ..........................................................................................4 - 23
d. Burner Air Sensor .......................................................................................................... 4 - 23
e. Fuel Sensor ...................................................................................................................4 - 23
f. Burner Air and Fuel Regulator .......................................................................................4 - 23
g. Purge Air Regulator ....................................................................................................... 4 - 23
h. Purge Air Flow Switch and Diffuser ...............................................................................4 - 24
i. Burner Air Solenoid Valve ..............................................................................................4 - 24
j. Air Ignite Restrictor ........................................................................................................4 - 24
4-12 REAR PANEL COMPONENTS................................................................................. 4 - 25
a. Fuel In 2-Way Solenoid Valve ............................................................................... 4 - 26
b. Burner Air In Filter................................................................................................. 4 - 26
c. Heated Bypass Sample Out and Heated Sample In Restrictors ........................... 4 - 26
d. Regulated Air In Check Valve ............................................................................... 4 - 26
4-13 LEAKAGE TEST ....................................................................................................... 4 - 27
a) Required Tools...................................................................................................... 4 - 27
b) Procedure ............................................................................................................. 4 - 27
IV Table of Contents Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
SECTION 5 TROUBLESHOOTING .................................................................................... 5 - 1
5-1 TROUBLESHOOTING CHECKLIST........................................................................... 5 - 1
a. Safety System ........................................................................................................ 5 - 1
b. Ignition .................................................................................................................... 5 - 1
c. Drift ......................................................................................................................... 5 - 2
d. Noise ...................................................................................................................... 5 - 2
SECTION 6 REPLACEMENT PARTS ................................................................................ 6 - 1
6-1 MATRIX ...................................................................................................................... 6 - 1
6-2 GENERAL................................................................................................................... 6 - 2
6-3 PNEUMATICS............................................................................................................. 6 - 2
6-4 OVEN COMPONENTS ............................................................................................... 6 - 3
SECTION 7 RETURN OF MATERIAL ............................................................................... 7 - 1
7-1 RETURN OF MATERIAL ............................................................................................ 7 - 1
7-2 CUSTOMER SERVICE............................................................................................... 7 - 2
7-3 TRAINING................................................................................................................... 7 - 2
LIST OF FIGURES AND TABLES....................................................................................... L -1
1 LIST OF FIGURES ...................................................................................................... L -1
2 LIST OF TABLES ......................................................................................................... L -2
SUPPLEMENT .....................................................................................................................S -1
1 EC DECLARATION OF CONFORMITY.......................................................................S -1
2 DECLARATION OF CONTAMINATION .......................................................................S -2
VTable of ContentsEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
VI Table of Contents Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
PREFACE
The purpose of this manual is to provide information concerning the components, functions, installation and
maintenance of the NGA 2000 HFID and the System Accessories of the NGA 2000 System.
Some sections may describe equipment not used in your configuration. The user should become thoroughly
familiar with the operation of this module before operating it. Read this instruction manual completely.
DEFINITIONS
The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication.
WARNING
Highlights on operation or maintenance procedure, practice, condition, statement, etc.
If not strictly observed, could result in injury, death, or long-term health hazards of personnel.
CAUTION
Highlights on operation or maintenance procedure, practice, condition, statement, etc.
If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.
NOTE
Highlights an essential operating procedure, condition or statement.
P - 1PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
IMPORTANT
SAFETY INSTRUCTIONS
WIRING AND INSTALLATION OF THIS APPARATUS
The following safety instructions apply specifically to all EU member states. They should be strictly adhered to
in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the
following unless superseded by local or National Standards.
1. Suitable grounding connections should be made at all connectors provided for this purpose.
2. All safety covers and grounding connections must be properly reinstated after maintenance work or trouble-
shooting. The integrity of all earth terminals must be maintained at all times.
3. To ensure safe operation of this equipment, connection to the mains supply should only be made through
a circuit breaker which will disconnect
breaker may also include a mechanically operated isolating switch. Circuit breakers or switches must
comply with a recognized standard such as IEC947. All wiring must conform with any local standards.
all circuits carrying conductors during a fault situation. The circuit
4. Where equipment or covers are marked with the symbol to the right, hazardous voltages
are likely to be present beneath. These covers should only be removed when power is
removed from the equipment — and then by trained service personnel only.
5. Where equipment or covers are marked with the symbol to the right, there is a danger
from hot surfaces beneath. These covers should only be removed by trained service
personnel when power is removed from the equipment. Certain surfaces may remain hot
to the touch.
6. Where equipment or covers are marked with the symbol to the right, refer to the Instruc-
tion Manual for instructions.
7. Further graphical symbols used in this product:
Elektrostatic discharge (ESD)
Harmful (to Health)!
Explosion Hazard!
Toxic!
Flammable!
Disconnect from Mains!
All graphical symbols used in this product are from one or more of the following standards:
EN61010-1, IEC417, and ISO3864.
P - 2 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
OPERATING AND MAINTAINING THIS APPARATUS
On leaving our factory, this instrument conformed to all applicable safety directives.
In order to preserve this state of affairs, the operator must take care to strictly follow all the instructions and
notes given in this manual and on the unit.
Before switching on the instrument, ensure that the local nominal mains voltage corresponds to the factory-set
operational voltage of this unit.
Any interruption of the protective earth connections, whether inside or outside of the unit, or removal or interruption of its ground line connection, may result in exposure to the risk of electricity. Deliberately disconnected
the protective earth is therefore strictly forbidden.
Removing covers and opening panels may expose components conducting electric current. Connectors may
also be energized. The unit therefore should be be disconnected from all electrical supplies before any kinds
of maintenance, repair or calibration work requiring access to the inside of the unit. Only trained personnel who
are aware of the risk involved may work on an open and energized unit!
Fuses may only be replaced by fuses of an identical type and with identical ratings. It is forbidden to use
repaired fuses or to bypass fuses.
Take note of all applicable regulations when using this unit with an autotransformer or a variable transformer.
Substances hazardous to health may escape from the unit‘s gas outlet.
Please pay attention to the safety of your operation personnel. Protective measures must be taken, if required.
NOTE
Software compatibility is necessary for all NGA 2000 components in your system to work together.
The version of your Platform’s software must be equal to or greater than the version of any other
module(s) for successful compatibility.
You can locate the version of each NGA 2000 component as follows:
Platform Controller Board
Turn power ON. The display should show „Control Module V3. ...“. This is the software version.
Analyzer Module
See note on the name plate label located on the right side of the Analyzer Module case.
P - 3PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
GENERAL SAFETY NOTICE / RESIDUAL RISK
If this equipment is used in a manner not specified in these instructions, protective systems may be
impaired.
Despite of incoming goods inspections, production control, routine tests and application of state-ofthe-art measuring and test methods, an element of risk remains when operating a gas analyzer!
Even when operated as intended and observing all applicable safety instructions some residual risks
remain, including, but not limited to, the following:
• An interruption of the protective earth line, e.g. in an extension cable, may result in risk to the
user.
• Live parts are accessible when operating the instrument with doors open or covers removed.
• The emission of gases hazardous to health may even be possible when all gas connections
have been correctly made.
Avoid exposure to the dangers of these residual risks by taking particular care when ins-talling, operating, maintaining and servicing the analyzer.
AUTHORIZED PERSONNEL
In-depth specialist knowledge is an absolutely necessary condition for working with and on the unit.
Authorized personnel for installing, operating, servicing and maintaining the analyzer are instructed
and trained qualified personnel of the operating company and the manufac-turer.
It is the responsibility of the operating company to
• train staff,
• observe safety regulations,
• follow the instruction manual.
Operators must
• have been trained,
• have read and understood all relevant sections of the instruction manual before commencing
work,
• know the safety mechanisms and regulations.
To avoid personal injury and loss of property, do not install, operate, maintain or service this instrument before reading and understanding this instruction manual and receiving appropriate training.
Save these instructions.
P - 4 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
WARNING
ELECTRICAL SHOCK HAZARD
Do not operate without covers secure. Do not open while energized. Installation and/or servicing
requires access to live parts which can cause death or serious injury.
Refer servicing to qualified personnel.
For safety and proper performace this instrument must be connected to a properly grounded threewire source of power.
WARNING
POSSIBLE EXPLOSION HAZARD
This equipment is used in the analysis of sample gases which may be flammable, and the burner
fuel used in the ionization process is flammable. A continous dilution purge system is factoryinstalled and it must be functional at all times during operation.
Do not disable this purge system.
WARNING
POSSIBLE EXPLOSION HAZARD
Protection against explosion depends upon a special fuel flow restrictor in the fuel inlet fitting. Do
not remove fuel inlet restrictor. Use the correct fuel flow restrictor for the fuel being used.
Replace only with factory applied fitting.
WARNING
POSSIBLE EXPLOSION HAZARD
Ensure that all gas connections are made as labeled and described within this manual and leak free.
Improper gas connections may cause explosion, serious injury or death.
WARNING
FLAMMABLE SAMPLES
The internal compartment of the oven is vented to the main enclosure by the top and bottom vents.
DO NOT RESTRICT THOSE VENTS.
Consult the factory if flammable samples will be measured.
P - 5PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
WARNING
HIGH TEMPERATURES
This equipment is used in the analysis of sample gases at temperatures of up to 250°C. All components and material in contact with the sample, the oven and the burner can reach this temperature
level.
Operate this equipment only when covers are secured. Servicing requires access to "hot" parts
which can cause serious injury. Refer servicing to qualified personnel.
WARNING
HIGH TEMPERATURES
The Sample In, Byass Out and Burner Exhaust Out connections can reach temperatures of up to
250 °C (480 °F). Severe burns could result from touching these connections.
WARNING
UNAUTHORIZED SUBSTITUTION OF COMPONENTS
Tampering with or unauthorized substitution of components may adversely affect the safety of this
instrument. Use only factory documented/approved components for repair.
Because of the danger of introducing additional hazards, do not perform any unauthorized modification to this instrument!
NOTE
This Analyzer Module is completely leak-tested at the factory for gas leakage. The user is responsible for testing for leakage at the inlet and outlet fittings on the rear panel. The user is also responsible for leak-testing periodically and if any internal pneumatic components are adjusted or replaced.
WARNING
OVERBALANCE HAZARD
This analyzer module may tip instrument over if it is pulled out too far and the Platform is not
properly supported.
P - 6 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
CAUTION
POSSIBLE INSTRUMENT DAMAGE
Do not interchange gas inlets and outlet! All gases must be conditioned before supplying!
When supplying corrosive gases ensure that gas path components are not affected!
Exhaust lines must be installed in a descending way, need to be pressureless, frost-protected and
in compliance with applicable legislative requirements!
WARNING
HAZARDS BY SAMPLE GAS COMPONENTS!
Before opening gas paths they must be purged with ambient air or neutral
gas (N
) to avoid hazards caused by toxic, flammable, explosive or harmful to
2
health sample gas components!
CAUTION
PURGE AIR REQUIREMENT
This Analyzer Module must be used in conjuction with a device (Control Module or PC Interface)
that can actively monitor network variables related to pressure or flow of the continous dilution
purge, or the front panel LEDs of the Analyzer Module, as installed, must be visible. The purpose of
this requirement is to maintain adherence to ANSI/NFPA 496 standard which assures the continued
viability of the purge system. Under no circumstances should any pressure or flow indicator be
connected to the PURGE AIR OUT outlet of the Analyzer Module because this may affect the sealing
performance of the module.
CAUTION
PRESSURIZED ENCLOSURE
This enclosure shall not be opened unless the area is known to be free of flammable materials or
unless all devices within have been de-energized. Area classification for the protected enclosure:
Nonclassified.
Pressurization: Type Z
Temperature Identification Number: T4A
Power shall not be restored after enclosure has been opened (or loss of purge) until enclosure has
been purged for a minimum of 6 (six) minutes at the minimum pressure of 689 hPa (10 psig).
P - 7PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
GASES AND GAS CONDITIONING (SAMPLE HANDLING)
WARNING
GAS SAFETY
Take care of the safety instructions applicable for the gases
(sample gases, test gases and fuel gas)!
CAUTION
PRESSURIZED GAS
This module requires periodic use of pressurized gas. See General Precautions for Handling and
Storing High Pressure Gas Cylindes, page P-11.
WARNING
POSSIBLE EXPLOSION HAZARD
Do not use 100% hydrogen fuel in a 40% H
/ 60% He configured Analyzer Module.
2
An explosion resulting in severe personal injury or death could occur.
P - 8 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
POWER SUPPLY
CAUTION
ELECTRICAL HAZARD
Verify the power voltage at site of installation corresponds to the analyzer
module´s rated voltage as given on the nameplate label!
Verify the safety instruction given by power supply unit manufacturer !
CAUTION
ELECTRICAL HAZARD
The mains socket has to be nearby the power supply unit and easily accessible!
Disconnecting from power requires unplugging the power connector!
To comply with the CE mark requirements use only power supply units of type
SL5, SL10 or equivalent units. Equivalent units must provide SELV output
voltages!
Verify proper polarity when connecting DC 24 V operated analyzer modules !
P - 9PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
ELECTROSTATIC DISCHARGE
CAUTION
ELECTROSTATIC DISCHARGE
The electronic parts of the Analyzer Module can be irreparably damaged if exposed to
electrostatic discharge (ESD).
The instrument is ESD protected when the covers have been secured and safety precautions observed. When the housing is open, the internal components are not ESD
Although the electronic parts are reasonable safe to handle, you should be aware of the following considerations:
Best ESD example is when you walked across a carpet and then touched an electrical grounded metal
doorknob. The tiny spark which has jumped is the result of electrostatic discharge (ESD).
You prevent ESD by doing the following:
Remove the charge from your body before opening the housing and maintain during work with opened housing, that no electrostatic charge can be built up.
Ideally you are opening the housing and working at an ESD - protecting workstation. Here you can wear a wrist
trap.
However, if you do not have such a workstation, be sure to do the following procedure exactly:
Discharge the electric charge from your body. Do this by touching a device that is grounded electrically (any
device that has a three - prong plug is grounded electrically when it is plugged into a power receptacle).
This should be done several times during the operation with opened housing (especially after leaving the
service site because the movement on a low conducting floors or in the air might cause additional ESDs).
P - 10 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
GENERAL PRECAUTIONS FOR HANDLING AND STORING
HIGH PRESSURE GAS CYLINDERS
Edited from selected paragraphs of the Compressed Gas Association´s „Handbook of Compressed
Gases“ published in 1981.
Compressed Gas Association
1235 Jefferson Davis Highway
Arlington, Virginia 22202
Used by Permission
1. Never drop cylinders or permit them to strike each other violently.
2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather
and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when
located in areas where extreme temperatures are prevalent.
3. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench,
or placed in a cylinder stand, and is ready to be used.
4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a
suitable hand-truck.
5. Never tamper with safety devices in valves or cylinders.
6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is
attached to a pressurized system.
7. No part of cylinder should be subjected to a temperature higher than 52 °C (125 °F). A flame should never
be permitted to come in contact with any part of a compressed gas cylinder.
8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding,
precautions must be taken to prevent striking an arc against the cylinder.
P - 11PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
DOCUMENTATION
The following HFID instruction materials are available. Contact Customer Service Center or the local representative to order.
HAS64E-IM-HW Instruction Manual NGA 2000 HFID (this document)
90002496 Instruction Manual NGA 2000 Platform
COMPLIANCES
This product may carry approvals from several certifying agencies, including the Canadian Standards Association*
(which is also an OSHA accredited, Nationally Recognized Testing Laboratory), for use in non-hazardous, indoor
locations.
Emerson Process Management has satisfied all obligations from the European Legislation to harmonize the product
requirements in Europe.
This product complies with the standard level of NAMUR EMC. Recommendation (May 1993).
NAMUR
This product satisfies all obligations of all relevant standards of the EMC framework in Australia and New Zealand.
)
P - 12 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
GLOSSARY OF TERMS
Analyzer Module
The module that contains all sensor/detector components for development of a Primary Variable signal; includes all signal conditioning and temperature control circuitry.
Backplane
The interconnect circuit board which the Controller Board, Power Supply, Analyzer Module power and network
cables, I/O Modules and Expansion Modules plug into.
Control Module
The Operator Interface plus the Controller Board.
Controller Board
The computer board that serves as the Network Manager and operate the Display and Keypad.
Distribution Assembly
The Backplane and the card cages that hold I/O and Expansion Modules.
I/O Module
A circuit board that plugs into the Backplane from the rear of the Platform. Has a connector terminal for
communication with external data acquisition devices and provides an input/output function.
Power Supply
Any of a variety of components that provides conditioned power to other NGA 2000 components, from the
Power Supply Board that plugs into the front of the Backplane in a stand-alone instrument to several larger
ones that can power larger collections of modules and components.
P - 13PrefaceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
Primary Variable
The measured species concentration value from an Analyzer Module.
Secondary Variable
Data placed on the network by a module regarding current status, e.g., sample flow, temperature and pressure.
Softkeys
The five function softkeys located below the front panel display; they assume the function displayed directly
above each on the display, a function dictated by software.
System
Any collection of Analyzer Module(s), Platform(s) and I/O Module(s).
P - 14 Preface Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
ANALYZER SYSTEM ARCHITECTURE
The NGA 2000 HFID is available as a "stand-alone analyzer" or as a "blind" Analyzer Module (AM). The HFID
analyzer module can be part of the stand-alone analyzer or a component of an analyzers system (Fig. A-1).
The NGA 2000 system made it possible, to configure
the HFID as a flexible "stand-alone analyzer" consisting
of a HFID "Analyzer Module", a Platform (complete with
front panel display/operator interface), and input/output
(I/O) modules.
The “analyzer module” is a “blind” analysis unit but retains all the advanced design features. The AM variant
is designed for integration as part of a NGA 2000 analysis system or special customer developed networks.
The platform/MLT´s front panel can act as operator interface for a stand-alone analyzer or as the a central
interface for multiple Analyzer Modules. In multi analyzer systems, this feature eliminates duplication of the
display/operator interface. In addition to the obvious operational benefits there are significant cost and system
packaging advantages not possible with conventional
analyser configurations.
This flexible network communication architecture is
shown in the schematic of Fig. A-2.
½ 19" MLT
Analyzer
ROSEMOUNT NGA 2000NGA 2000
Platform with MLT AM
or
19" MLT Analyzer
CLD
HFID
PMD
NGA Network
½ 19" MLT
Analyzer
ROSEMOUNT NGA 2000NGA 2000
NGA Network
MLT MLT
ROSEMOUNT NGA 2000NGA 2000
CLD HFID
NGA Network
ROSEMOUNT NGA 2000NGA 2000
ROSEMOUNT NGA 2000NGA 2000
ROSEMOUNT NGA 2000NGA 2000
ROSEMOUNT NGA 2000NGA 2000
NGA NetworkNGA Network
HFID PS
Platform with MLT AM
19" MLT Analyzer
HFID PS
CLD
or
Figure A-1: From separate analyzers to analyzer system
NGA Network
PS
A - 1Analyzer System ArchitectureEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
The modular configurable bi-directional network offers
the following options:
❏ Stand-alone analyzers (Single devices)
• analyzer modules in a platform including
optional inputs and outputs (SIO/DIO).
Platform
❏ Simple interconnection of analyzer modules to an
analyzer system based on one of the three structures - see below.
These structures can be distinguished by acting
of the host
• with platform as host including system inputs
and outputs (SIO/DIO)
• with MLT/TFID/CAT 200 analyzer as control-
ler including system inputs and outputs (SIO/
DIO)
• with customer owned specific control units
(not described in this manual, consult factory)
For combination possibilities of NGA 2000 I/O´s see table
A-1.
Analyzer Module
AC DC
Network Cable
Analyzer Module
Analyzer Module
Network Cable
24VDC Cable
Figure A-2: Example of NGA cabling
Power supply
24VDC Cable
DC
AC
A - 2 Analyzer System Architecture Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
Based on a platform, MLT or TFID analyzer the schematic on Figure A-3 illustrates the simplicity of a networked system which incorporates AM’s, such as Chemiluminesence Detectors, MLT's (NDIR/UV/VIS plus Oxygen or TCD) and Flame Ionisation Detectors.
The system I/O modules (SIO, DIO) of the platform (or
MLT/TFID analyzer) support all integrated analyzer modules with analog, digital and serial interfaces as well as
relay outputs.
Analyzer Modules (AM’s)
Other system functionality includes links to associated
sample handling (PLC) and Data Acquisition Systems
such as WinControl.
Local I/O are existing to MLT, TFID and CAT 200 analyzers only and support the corresponding analyzer module only.
Local I/O’s via Internal System Bus
DIO SIO
DIO SIO
DIO SIO
O
PMD
2
HC
HFID
System I/O’s via Internal System Bus
DIO SIO
8
Digital
Inputs
24
Digital
Outputs
Solenoid
Valves
NO
WCLD
Printer
or PLC
x
3
Relay
Outputs
NO/NO
CLD
RS 232 /
Computer
x
19" MLT 3/4
Analyzer
RS 485
Personal
ppm O
2
TO2
Alternatively
19" Platform/
TFID Analyzer
Alternatively
HC
FID
½ 19" MLT
Analyzer
HC
TFID
NGA
Network
NGA 2000ROSEMOUNT
NGA 2000ROSEMOUN T
NGA 2000ROSEMOUNT
CO/NO/SO /
EO - MLT
Alternatively to Platform
or MLT/TFID Analyzer
2
2
MLT 2
Analyzer
PO
2
MLT
Field PC
Workstation
NGA 2000ROSEMOUNT
Figure A-3: Example/Possibilities of NGA Analyzer Systems
A - 3Analyzer System ArchitectureEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
System unit SIO/DIO-Configuration
Instruction Manual
HAS64E-IM-HW
September 2008
CLD/FID/HFID analyzer module (AM):
• without front panel,
i.e. without control unit (host)
• can be combined with
a platform,
a MLT analyzer,
a TFID analyzer;
a CAT 200 analyzer or
a customer developed control unit
Platform (Control Module Software):
• Control unit with front panel
• Without measurement channels
HFID analyzer
• HFID analyzer module into a platform with
front panel
• HFID analyzer module combined with
MLT/TFID/CAT 200 analyzer
• No local CLD/FID/HFID I/O’s
• 1 SIO and up to 4 DIO's (or 5 DIO's)
can be installed in the platform
(CM I/O’s)
• SIO and DIO’s can be configured
for all AM channels connected to the
platform
• 1 SIO and 4 DIO’s (or 5 DIO’s) can be
installed in the platform
• 1 SIO and 1 DIO (or 2 DIO’s) can be
installed in the MLT/TFID/CAT 200
analyzer (CM I/O)
• SIO and DIO can be configured
for all AM’s connected to the
MLT/TFID/CAT 200 analyzer
Table A-1: Possibilities of NGA 2000 I/O combinations
A - 4 Analyzer System Architecture Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
1-1 OVERVIEW
NGA 2000 HFID
SECTION 1
DESCRIPTION AND SPECIFICATIONS
This manual describes the Heated Flame Ionization Detector (HFID) Analyzer Module of Emerson Process
Mangement´s NGA 2000 Series of gas analysis components (See Figure 1-2 and 1-3).
The HFID Analyzer Module is designed to continously
determine the concentration of hydrocarbons in a flowing gaseous mixture at a user-selectable temperature
setpoint between 93 °C and 204 °C (200 °F and 400 °F).
The concentration is expressed in parts-per-million or
percent of volume..
The HFID Analyzer Module is designed as a slide-in module (if configured in stand-alone instrument fashion), removable from the front of the Platform, with gas connections made from the rear. All electronics relative to sample
detection and conditioning are included in this module.
1-2 TYPICAL APPLICATIONS
The monitoring of carbon bed scrubber for low-level hydrocarbon contaminants, determining of the hydrocarbon content of exhaust emissions from internal combustion engines and continuous emissions monitoring of fluegas emissions (e.g. incinerators) are examples of typical
applications for the HFID Analyzer Module
1-3 SAFETY GAS FEATURES
The HFID Analyzer Module is designed with a factoryinstalled continous dilution purge system in accordance
with standard ANSI/NFPA 496-1993, Chapter 6. Frontpanel LEDs indicate that the burner flame is lit and that
the purge system is enabled. In addition, fuel gas is automatically shut off when a flame-out condition occurs of
the safety system is disabled.
All tubing ahead of the burner is rigid metallic tubing assembled with ferrule/nut type compression fittings. However, should an internal fuel leak occur, a worst-case
leak would be dissipated below 25% of the LEL of hydrogen through the combination of an inlet fuel flow restrictor
and purge gas flow.
This module is designed to use 40% H2/60% He fuel at a
maximum inlet pressure of 3446 hPa-gauge (50 psig).
A standard HFID Analyzer Module is only equipped to
analyze a non-flammable sample, below 100% of the
LEL.
WARNING
POSSIBLE EXPLOSION HAZARD
Protection against explosion depends upon a special fuel flow restrictor in the fuel inlet fitting. Do
not remove fuel inlet restrictor. Use the correct fuel
flow restrictor for the fuel being used.
Replace only with factory applied fitting.
Do not use 100 % hydrogen fuel in a 40 % H2 /
60 % He configured Analyzer Module.
An explosion resulting in severe personal injury
or death could occur.
The purge system is enabled only if there is proper purge
gas flow in, purge gas pressure, and internal case pressure, and after five times the case volume has been exchanged.
1 - 1Description and SpecificationsEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
1-4 THEORY OF TECHNOLOGY
Instruction Manual
HAS64E-IM-HW
September 2008
This Analyzer Module uses the flame ionization method
of detection. The sensor is a burner in which a regulated
flow of sample gas passes through a flame sustained by
regulated flows of a fuel gas (hydrogen or a hydrogen/
diluent mixture) and air.
With a flame, the hydrocarbon components of the sample
stream undergo a complex ionization that produces electrons and positive ions. Polarized electrodes collect these
ions, causing current to flow through an electronic measuring circuit.
+ 90 V
The ionization current is proportional to the rate at which
carbon atoms enter the burner, and is therefore a measure of the concentration of hydrocarbons in the sample.
This measure of concentration is placed on the network,
where it is can be shown on the Platform Display or on
other data aquisition devices.
Negative Ion Collection Ring
Signal Conditioning
Positive Carbon Ions
Air
Sample
Figure 1-1: Function Principle of FID Measurement
1 - 2 Description and Specifications Emerson Process Management GmbH & Co.OHG
Fuel
Instruction Manual
HAS64E-IM-HW
September 2008
PURGE
3/8T
BRASS
PLUG
1/8NPT
ELBOW
PURGE AIR
RESTRICTOR
BRASS
TUBING 1/4 OD
VITON
TUBING 1/4 OD
COPPER
AIR IN
REGULATOR,
PURGE AIR
PLUG
1/4NPT
SWITCH,
PURGE
FLOW
DIFFUSER
PURGE
PRESSURE
SENSOR
BULKHEAD
REDUCER
3/8T - 1/4T
BRASS
REGULATED
CHECK
VALVE
1/3 PSIG
ELBOW
1/4T - 1/4NPT
BRASS
ADAPTER
1/4T - 1/4NPT
BRASS
BULKHEAD
RESTRICTOR
1/4T - 1/4T
AIR IN
BULKHEAD
1/4T - 1/4T
BRASS
MANIFOLD,
SAMPLE
ELBOW
1/4T - 1/4FPT
BRASS
UNION
1/4T
BRASS
PRESSURE SENSOR,
REGULATED AIR
0 - 15 PSIG
SS
HEATED
SAMPLE
IN
FUEL RESTRICTOR
1/8T - 1/8T
TUBING 1/4 OD
COPPER
SAMPLE
BYPASS
OUT
BURNER
DETECTOR
TUBING 1/8 OD
COPPER
BURNER
EXHAUST
BULKHEAD
1/4T - 1/8T
SS
ELBOW
1/8T - 1/8T
BRASS
PRESSURE
RELIEF
VALV E
BULKHEAD
REDUCER
1/4T - 1/8T
BRASS
RESTRICTOR,
BYPASS
SENSOR,
SAMPLE
TEMPERATURE
SAMPLE
CAPILLARY
(see table 1-1)
CONNECTOR
1/16T - 1/8NPT
SS
TUBING 1/8 OD
COPPER
RUN TEE
1/8T - 1/8MPT
BRASS
AIR RESTRICTOR
SENSOR,
BURNER AIR
PRESSURE
0 - 30 PSIG
TUBING 1/8 OD
COPPER
BURNER
AIR IN
FILTER
RUN TEE
1/4T - 1/4FPT
BRASS
PORT CONNECTOR
1/4
TUBING 1/8 OD
COPPER
TUBING 1/8 OD, SS
NGA 2000 HFID
BULKHEAD
PURGE
AIR OUT
TUBING 1/4 OD
GA
INOUT
3/8T - 1/4MPT
BRASS
BULKHEAD
CONNECTOR
1/4T - 1/8NPT, SS
VITON
PRESSURE
SWITCH
SENSOR,
FUEL PRESSURE
0 - 30 PSIG
FUEL
SOLENOID
VALVE
OUT
GA
INOUT
REGULATOR,
FUEL PRESSURE
0 - 30 PSIG
IN
FUEL
RESTRICTOR
TUBING 1/8 OD
SS
ELBOW
1/4T - 1/4MPT
BRASS
FIXED FLOW CONTROLLER,
REGULATED AIR
Sample Capillaries
Sample C apillary 9.7 cc/min. @ 3. 5 psig 6574 86
Sample C apillary 2.5 cc/min. @ 3. 5 psig 6575 50
Table 1-1: Sample Capillary depending on Module Configuration
IN
OUT
RUN TEE
1/4T - 1/4MPT
BRASS
AIR IGNITE
RESTRICTOR
ELBOW
1/8T - 1/8MPT
BRASS
Figure 1-2: HFID Analyzer Module - Flow Diagram
Brief Description
PRESSURE REGULATOR,
BURNER AIR
0 - 60 PSIG
Part Number
1 - 3Description and SpecificationsEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Gas Lines
(See Figure 2-2)
Fuel Shutoff Solenoid Valve
Instruction Manual
HAS64E-IM-HW
September 2008
Purge Air Outlet
Detector (Burner)
Oven
Air circulation fan
Case Heater
Sample Flow Controller
Purge Air Flow Switch
Preamp Board
(in Shield)
Case pressure switch
Computer Board
Sensor Board
Safety Board
DC-DC-Module
Power Supply Board
Burner Air Solenoid Valve
Purge Air Regulator
Burner Air & Fuel Regulators
(Stacked Vertically)
Figure 1-3: HFID Analyzer Module - Top View
1 - 4 Description and Specifications Emerson Process Management GmbH & Co.OHG
Network & Power Module
Instruction Manual
HAS64E-IM-HW
September 2008
1-5 SPECIFICATIONS
a. General
Measurement Species: ........................ Total hydrocarbons
Ranges (H2/Fuel):
Low Range ............................ 0 to 10 ppm CH4 through 1 to 1 % CH4 at an oven setpoint between 113 °C
High range ............................. 0 to 50 ppm CH4 through 0 to < 5 % CH4 at an oven setpoint between
Analysis temperature .......................... Adjustable from 93 °C to 204 °C (200 °F to 400 °F), maintained within
Repeatability: ...................................... < 1 % of fullscale for successive identical samples, at a constant
Min. Detectable Level: ......................... 0.10 ppm CH
Noise: .............................................. < ± 1 % of fullscale
Linearity: ............................................. < ± 1 % of fullscale, < ± 2 % of data point
Response Time: .................................. < 1.5 sec., 0 % to 90 % of fullscale
Drift:
Zero ....................................... < ± 1% of fullscale / 24 hours at constant temperature, hydrocarbon
Span ...................................... < ± 1 % of fullscale / 24 hours at constant temperature, hydrocarbon
Effect of Temperature: ......................... < ± 2 % of fullscale for any temperature change of 10 K and rate of change
Operating Temperature: ...................... 15 °C to 35 °C (59 °F to 95 °F)
Power Requirements: .......................... +24 VDC ±5%, 120W max.. direct to analyzer module:
NGA 2000 HFID
and 191 °C (235 °F and 376 °F)
113 °C and 191 °C (235 °F and 376 °F)
± 6 °C (± 11°F) from the setpoint
temperature, sample flow and fuel, burner air, regulated air and sample
pressures
4
(must be above the minimum detectable level)
concentration of supply gases, sample flow and fuel, burner air, regulated
air and sample pressures
concentration of supply gases, sample flow and fuel, burner air, regulated
air and sample pressures
less than 10 K/hour
Ripple and Noise: < 100 mV peak to peak
Line and Load Regulations: < ± 1 %
b. Physical
Case Classification: ............................. General purpose for installation in weather-protected area
Dimensions: ........................................ See Figure 2-6: Outline and Mounting Dimensions
Weight: .............................................. 15.9 kg (35 lbs.)
Material in Contact with Sample .......... Stainless steel and glass-filled Teflon
Mounting: ............................................ Horizontally, inside a Platform or custom-installed in a panel
Max. Length of LON Cable: ................. 1,600m (1 mile) between Analyzer Module and Platform
1 - 5Description and SpecificationsEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
c. Gas requirements
Sample .............................................. Non-flammable, below 100 % of LEL
Flow Rate: ............................. 1.0 to 2.5 l/min
Supply Pressure .................... 345 to 620 hPa-gauge (5 to 9 psig)
Temperature: ......................... 110 °C to 230 °C (230 °F to 446 °F), < 20 K variance / 24 hours,
Particles:................................ Filtered to < 2 microns
Dewpoint: .............................. <15 °C below the setpoint
Regulated Air:...................................... Instrument air or Nitrogen
Flow Rate: ............................. 1.0 to 4.0 l/min
THC ....................................... < 2 ppm CH
Supply Pressure .................... 689 to 1,723 hPa-gauge (10 to 25 psig)
Particles:................................ Filtered to < 2 microns
Purge Air: ............................................ Instrument air, Nitrogen or other non-flammable gas (refer to ANSI/NFPA
Flow Rate: ............................. 16.0 to 18.0 l/min
Supply Pressure .................... 689 to 1,378 hPa-gauge (10 to 20 psig)
Fuel Gas: ............................................ Premixed 40 % hydrogen (H
Flow Rate: ............................. 80 to 100 ml/min
THC ....................................... < 0.5 ppm CH
Supply Pressure .................... 3,101 to 3,446 hPa-gauge (45 to 50 psig)
Instruction Manual
< 10 K variance / hour
4
496 for the requirements for the Protective Gas System)
) and 60 % helium (He)
2
4
HAS64E-IM-HW
September 2008
WARNING
POSSIBLE EXPLOSION HAZARD
Do not use pure (100%) hydrogen (H2) fuel in a 40% H2 / 60% He configured Analyzer Module.
An explosion resulting in severe personal injury or death could occur.
Burner Air: ........................................... Zero-grade air
Flow Rate: ............................. 355 to 400 ml/min
THC ....................................... < 1.0 ppm CH
Supply Pressure .................... 1,723 to 3,446 hPa-gauge (25 to 50 psig)
4
1 - 6 Description and Specifications Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
d. Gas Connections
Sample In: ........................................... 1/4" O.D. tube fitting, stainless steel
Regulated Air In: .................................. 1/4" O.D. tube fitting, brass
Burner Air In: ....................................... 1/4" O.D. tube fitting, brass
Fuel In: ................................................ 1/4" O.D. tube fitting, stainless steel
Purge Air In: ........................................ 3/8" O.D. tube fitting, brass
Purge Air Out: ...................................... 3/8" O.D. tube fitting, brass
Bypass Out:......................................... 1/4" O.D. tube fitting, stainless steel
Burner Exhaust Out: ............................ 3/8" O.D. tube connection, stainless steel
(must slope downward 6 ° min. from horizontal)
NOTE
Burner Exhaust, Bypass Out and Purge Air Out to be vented to atmospheric pressure and to non-classified
location in accordance with ANSI/NFPA-496 guidelines.
Pressure Relief Valve: ......................... See Caution below
CAUTION
PRESSURE RELIEF VALVE
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.
WARNING
HIGH TEMPERATURES
The Sample In, Byass Out and Burner Exhaust Out connections can reach temperatures of up to 250°C
(480°F). Severe burns could result from touching these connections.
See the Preface section of the Platform manual for specifications regarding Platform-related components (e.g., case
dimensions) and the I/O Module manual for specifications regarding I/O (e.g., relay outputs).
1 - 7Description and SpecificationsEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
1 - 8 Description and Specifications Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
SECTION 2
INSTALLATION
WARNING
GENERAL HAZARD
Before starting to install this equipment, read the
"Essential instructions" on the inside cover and
the Safety Summary beginning on page P-2.
Failure to follow the safety instructions could result in serious injury or death.
2-1 UNPACKING
If the HFID Analyzer Module is received as a separate
unit, carefully examine the shipping carton and contents
for signs of damage. Immediately notify the shipping
carrier if the carton or contents is damaged. Retain the
carton and packing material until all components associated with the HFID Analyzer Module are operational.
NGA 2000 HFID
2-2 ASSEMBLY
If the HFID Analyzer Module requires assembly with other
components (e.g., the Platform and associated I/O Modules), do so at this time.
To install the HFID Analyzer Module into a Platform:
1. Loosen the six fastening screws for the front panel
of the Platform, hold the handles, and swing the
front panel to the farest right.
2. Following the guides on the bottom left and bottom center of the Platform, carefully slide the HFID
Analyzer Module halfway into place
3. Lift the spring-loaded pins on the front of the HFID
Analyzer Module, and carefully slide in the rest of
the distance.
If the module and Platform are difficult to assemble,
remove the module, ensure the top cover of the
module is firmly seated on the hold-down screws,
and repeat the assembly procedure.
4. Secure the module in position by releasing the pins,
which seat in the available holes in the bottom of
the case (see Figure 2-1, below).
5. Connect network cable and power cable to the
Analyzer Module (refer to Section 2-6 for electrical
connections).
6. After startup and calibration have been performed,
secure the front panel of the Platform with the six
screws provided.
Pin Seats
Analyzer Module Guides
Figure 2-1: Analyzer Module Installation into Instrument Platform (view without front panel)
2 - 1InstallationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
2-3 LOCATION
Instruction Manual
HAS64E-IM-HW
September 2008
Install the Analyzer Module in a clean, weather-proofed,
non-hazardous, vibration-free location free from extreme
temperature variations. For best results, install the Analyzer Module near the sample stream to minimize sample
transport time.
WARNING
INSTALLATION RESTRICTIONS
For safety, the Analyzer Module should be installed
in a non-confined, ventilated space. Do not block
any of the rear panel outlets as they are part of the
safety system.
Operating ambient temperature is 15 °C to 35 °C (59 °F
to 95 °F), limited to temperature changes of less than
10 K/hr. Acceptable dew point range is less than 95 %
relative humidity, but not in excess of 45 °C (113 °F) wet
bulb temperature.
The cylinders of fuel, air, and calibration gas(es) and the
source of purge and regulated air should be located in
an area of relatively constant ambient temperature.
2-4 GASES
Note that this type of drift occurs only when the flame is
burning. If drift occurs when the flame is extinguished,
the electronic circuitry is at fault. To minimze drift, use
clean fuel and air, keep the analyzer clean, and locate
the gas cylinders in an area of relatively constant ambient temperature.
The cylinders supplying all gases each should be
equipped with a clean, hydrocarbon free, two stage regulator and a shutoff valve.
All new external gas tubing (except for PURGE IN/OUT
and SAMPLE BYPASS) is strongly recommended, preferably precleaned, stainless steel, gas chromatograph
grade tubing. Thoroughly clean before use (if a hydrocarbon based cleaning solvent such as acetone is used,
purge tubing with dry nitrogen or helium for several minutes before using).
Gas line connections are compression fittings. Do not
use pipe thread tape.
Since the oxidation of hydrogen is accompanied by the
formation of water vapor, the Exhaust tubing always
should be slanted downward at least 6 degrees from
horizontal. Otherwise, water may accumulate in the line,
causing back pressure and noisy readings, or may back
up in the line and flood the burner. Depending on the
percent of vapor in the sample, the sample bypass out
connection may be required.
a. Overview
During normal operation, the Analyzer Module requires
fuel and air to maintain the burner flame as well as suitable standard gases for calibration and instrument air for
purge requirements. In addition, instrument air for regulated air in is required to control the sample pressure at
the sample capillary. Criteria for selection of these gases
follow in Section 2-4c.
After initial startup or after startup following a prolonged
shutdown, the analyzer may display baseline drift for a
considerable period of time, particularly on the most sensitive range. Commonly, the drift is caused by small
amounts of hydrocarbons in the inner walls of the tubing
in both the internal flow system and the external gas supply system. Drift results from any factor influencing the
equilibrium of these absorbed hydrocarbons, such as
temperature or pressure.
2 - 2 Installation Emerson Process Management GmbH & Co.OHG
If the sample is toxic or noxious, or is to be reclaimed,
connect the Bypass outlet to a suitable disposal system.
Do not use any device that may cause back pressure in
the line.
Purge air and burner air should be supplied from separate sources.
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
PURGE
AIR OUT
REGULATED
AIR IN
!
b. Pneumatic Connections
!
WARNING
BURNER
AIR IN
PURGE
AIR IN
ATTENTION
Possible electric shock, explosion or toxic gas hazard. See front of module
BURNER
EXHAUST
OUT
VENT TO SAFE AREA
SLOPE DOWNWARD 6
MINIMUM
WARNING
HOT !
ATTENTION
CHAUD !
HEATED
SAMPLE IN
HEATED
SAMPLE
BYPASS OUT
Danger d'electrocution, d'explosion ou d'emanation de gaz
toxique. Se refere aux details inscrits surla face du module.
Figure 2-2: HFID Rear Panel Connections
FUEL
IN
MAXIMUM
INPUT
PRESSURE
FUEL: 50 psig(3445 hPa)
BURNER AIR: 50 psig (3445 hPa)
SAMPLE: 8 psig (551 hPa)
PURGE AIR: 20 psig (1378 hPa)
REG AIR: 25 psig (1722 hPa)
PRESSURE
RELIEF
VALVE
WARNING
HIGH TEMPERATURES
The Sample In, Byass Out and Burner Exhaust Out
connections can reach temperatures of up to 250°C
(480 °F). Severe burns could result from touching
these connections.
Make connections to these fittings when the oven
heater is disabled ot the moduleis powered down.
(See Figure 2-2) Connect inlet and outlet lines for sample,
burner fuel and air, exhaust, bypass, regulated air, and
purge to appropriately labeled fittings on the rear panel.
All connections are 1/4 -inch ferrule-type compression
fittings except the PURGE AIR IN and OUT connections, which are 3/8-inch compression fittings. The
BURNER EXHAUST is a 3/8-inch connection.
It is recommended that no connection be made to the
PURGE AIR OUT port. If, however, the analyzer´s location requires interconnection with a venting system, the
3/8" O.D. line should be kept as short as possible, and
no longer than four feet.
CAUTION
POSSIBLE INSTRUMENT DAMAGE
No connection should be made to the PRESSURE
RELIEF VALVE fitting. Doing so may cause damage the instrument.
CAUTION
PURGE AIR REQUIREMENT
If the front panel LEDs of the Analyzer Module, as
installed, are not visible, the user should provide
an indicator for the safety system as per ANSI/NFPA
496 standard.
2 - 3InstallationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
c. Specifications
Fuel Gas
Standard analysis usually requires mixed fuel, i.e., 40 %
(± 2 %) hydrogen and 60 % helium. H2/He mixed fuel is
recommended over H2/N2 fuel because of better linearity in concentration output. Such blends are supplied by
many gas vendors specifically for this use, with a guaranteed maximum total hydrocarbon content of 0.5 ppm,
measured as methane. This specification should be used
when obtaining these mixtures.
NOTE
The fuel restrictor is marked with a red dot, and
the sample capillary is marked with a red or green
dot for mixed fuel applications.
Burner Air
In order to ensure a low background signal, burner air
should contain less than 1 ppm maximum total hydrocarbon content. An alternate source for burner air and
zero gas (see CALIBRATION GASES below) is a combination diaphragm pump and heated palladium catalyst. This process continuously removes moderate
amounts of hydrocarbons and carbon monoxide from
ambient air.
Purge Air
Calibration Gases
Calibration method and gases depend on the operating
range, and the desired measurement accurancy. In all
methods, zero and span gases are used, and are introduced through the sample inlet at the rear of the module.
ZERO GAS - Analysis is affected by the background gas
of the sample. Therefore, it is recommended to use zero
gas with as close to the background composition of the
sample as possible. Normally less than 0.5 THC as CH
is sufficient.
SPAN GAS - Span gas consists of a specified concentra-
tion of methane or other hydrocarbon in a background
gas such as nitrogen.
NOTE
Analysis is affected by the background gas of the
sample. Therefore, span gas containing the same
background gas as the sample is recommended.
Then, the background effect is canceled out.
Sample Gas
Sample gas should be nonflammable (below 100 % of
the sample´s LEL). For high sensitivity applications requiring background gas compensation, contact the factory.
4
Instrument quality air, nitrogen, or other nonflammable
Flow Rate
gas is required for the safety purge system.
The sample flow rate is 1.0 l/min to 2.5 l/min for a supply
Regulated Air
pressure between 5 and 9 psig. Flow rate for purge gas
should be 16 to 18 l/min. Flow rate for regulated air should
Instrument quality air or nitrogen is required. The air
be 2 to 4 l/min.
should contain less than 2 ppm maximum total hydrocarbon content.
2 - 4 Installation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
Pressure / Filtration
SAMPLE PRESSURE at the SAMPLE inlet should be within
the range 345 to 620 hPa-gauge (5 to 9 psig nominal),
and internally, should be between 206.7 and 275.6 hPagauge (3.0 and 4.0 psig).
BURNER FUEL PRESSURE should be:
3101 to 3450 hPa-gauge (45 to 50 psig) for cylinder regulator, 1723 hPa-gauge (25 psig) nominal for internal pressure.
BURNER AIR PRESSURE should be:
1725 to 3450 hPa-gauge (25 to 50 psig) for cylinder regulator, 1035 hPa-gauge (15 psig) nominal for internal pressure.
REGULATED AIR PRESSURE should be:
689 to 1725 hPa-gauge (10 to 25 psig) for cylinder regulator.
PURGE AIR PRESSURE should be:
689 to 1380 hPa-gauge (10 to 20 psig).
NOMINAL INTERNAL CASE PRESSURE is about 0.5 to 1.0
inch of water, and the pressure relief valve is set at 1/3
psig (nominal).
2-5 LEAK TEST
The Analyzer Module is completely tested at the factory
for gas leakage (leakage rate - 7.5 hPa/min. (- 0.11 psig/
min.) with He or - 2.5 hPa/min. (- 0.036 psig/min.) with
N2). The user is responsible for leakage testing at the
inlet and outlet fittings on the rear panel minimum twice
a year (see Section 4-13).
The user is also responsible for internal leak testing periodically and if any internal pneumatic components are
adjusted or replaced (with a test procedure chosen by
the user).
CAUTION
OVER PRESSURE DAMAGE
Noncompliance with these specifications,
particulary tose concerning purge air, could cause
over-pressure damage to the module.
2 - 5InstallationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
p
′
Instruction Manual
HAS64E-IM-HW
September 2008
2-6 ELECTRICAL CONNECTIONS
NOTE
Electrical installation must be in compliance with
the requirements of NAMUR and DIN VDE and/or
any applicable national or local codes (like local
electricity supply enterprises (ESE)).
Refer to figure 2-3 and 2-4. Two electrical connections
are required on the Analyzer Module: POWER and NETWORK. On the Analyzer Module, two NETWORK connectors are available, either of which is appropriate for:
1. Interconnection with the Backplane of the Platform. (See Instruction Manual for the NGA 2000
Platform).
2. "Daisy-chaining" with other NGA 2000 components.
Connect Analyzer Module POWER to a 24 VDC power
source with a voltage tolerance of ± 5 % and a minimum
power rating of 120 watts (either the Platform or external
power source).
Network
Connection “1”
Network
Connection “2”
Power
Connection
Fuse
[T 6A 250 V (6x32 mm)]
Figure 2-3: Front Panel Electrical Connections
Pressure Regulator
Burner Air
Pressure Regulator
Fuel
Front Panel LEDs
WARNING
BURNER
AIR
FUEL
!
POSSIBLE
EXPLOSION HAZARD
Hydrogen fuel gas is used in this instrument.
Do not remove fuel restrictor or operate at
greater than 50 psig. An explosion resulting
ersonal injury or death could occur.
in severe
ATTENTION
!
DANGER D′EXPLOSION
Cet instru ment contient du gaz hydrogene. Ne
retirez pas le limitateur d′de
combustible, et n′operez pas au plus de 50 psig
Ces conditions peuvent provoquer une explosion
entrainant des blessures graves mortelles.
POWER
OVEN
HEAT
FLAME
ON
PURGE
AIR
FUEL
OVERRIDE
IGNITE
24V
LON
1
LON
2
1 +
2 -
3 GND
T 6A
250 V
HFID
POSSIBLE
EXPLOSION
Do not operate flammable
sample without following
instructions in the Manual.
An explosion resulting in
severe personal injury or
death could occur.
DANGER
Ne pas utiliser l
inflammable avant d′avoir pris
connaissance des instructions
contenues dans le manuel. Le
non respec t de ces instruction s
peut entrainer une explosion
provoquant des blessure graves
ou mortell es.
Figure 2-4: Front Panel Controls, Indicators and Electrical Connections
WARNING
!
ATTENTION
!
echantillon
2 - 6 Installation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HARNESS, GLOWPLUG
J4P4J5
P5
6
J1
P1
,
AIR
HEAT
FLAMEON
U
G
R
SS
C
S
P2
1 23 4 567 8
C
SS
,
3
CO
U
J5 +10V REF
E
SHIELD
R38
GRY
PUR
HAS64E-IM-HW
September 2008
NGA 2000 HFID
P6
J6
J1
P1
POWER
SUPPLY
BOARD
FLAT 24 CO ND
J5
P4J4P5
CABLE ASSEMBLY
CABLE ASSEMBLY, FLAT 20 COND
ND
FLAT
EMBLY
ABLE A
1
Brief Description Part Number
9.7 cc/min. @ 3.5 psig 659551
2.5 cc/min. @ 3.5 psig 658338
CABLE ASSEMBLY,
FLAT 16 COND
P4
J4
SAFETY
BOARD
J3
CABLE ASSE MBLY,
FLAT 30 COND
P3
J6
P
COMPUTER
ANALYSIS
J1
P1
CABLE ASSEMBLY,
FLAT 3 COND
P9
J9
FUEL SOL.
+-+-+
P10
YEL
BRN
RED
ORN
BOARD
J2
P2
E AI
LON/POWER
MODULE
J5
P5
P3
J2
P2
J3
J8
P8
J11
OVEN HEATER
BLU
GRN
P15
P16
J2
P7
J7
J3
P3
P11
-
J7
P7
BLK
BLK
RED
RED
J15
AIR
3-WAY SOLENOID
EL IN
J16
POWER
MTG
STUD
2-WAY SOLEN OID
CABLE ASSY,
PRESSURE
E TEMP
F
A
SENSOR,
CASE
PRESS
SWITCH
SWITCH
FLOW
SW
FLOW
SW
FLOW
SWITCH
GND
STRAP
POL
VOL
E2 24VOLT
E1 RTN
E3
CABLE ASSEMBLY,
HARNESS,
CHASSIS
CHASSIS
GND
E3
FLAT 10 COND
THERMOSTAT
FAN ASSEMBLY
HEATER
SENSOR,
PRESSUR
P10
J10
CABLE ASSEMBLY,
SENSOR BD TO HAR NESS
P18
J18
OVEN
P17
J17
R37
CABLE ASSEMBLY, ANODE
CABLE ASSEMBL Y, CATHODE
CABLE ASSEMBL Y, THERMAL FUSE
BLK
RED
GRN
J14
P14
HARNE
P1
J1
E2
SHIELD
PREAMP
BOARD
POWEROVEN
J6
P1 J1
JP1
RTN
J3
P3
SENSOR,
SENSOR,
FUEL
PRESSURE
J10 P10
J11
J13
J16
J15
P4 J4
SAMPLE RTD
CABLE
ASSEMBLY,
IGNITOR
J1 P1
J10 P10
SAMPLE
PRESSURE
J9 P9
SENSOR
BOARD
P5 J5
SENSOR ASS EMBLY,
AIR
J11 P11
P11
P13
P16
P15
R
P
SWITCH
ASSEMBLY,
MANUA L
IGNITE
LED INDICATOR
ASSEMBLY
P2 J2
PWR
MOD
J1
J2
POWER
MODULE
ASSEMBLY
J12 P12
NC
J12 P12
J7 P7
NC
J14
P3 J3
CABLE ASSEMBLY,
FLAME OUT
CATHODE
DETECTOR
BLOCK
ASSEMBLY
THERMAL OV EN SAMPLE
SWITCH RTD RTD
J6
J1
J8 P8
OVEN HEATER
SENSOR ASSEMBL Y,
REF TEMP
OVEN
ANODE
HEATER
1
Figure 2-5: HFID Wiring Diagram
2 - 7InstallationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
[
]
[75]
[83]
[81]
[35].9[23]
FRONT VIEW
Instruction Manual
HAS64E-IM-HW
September 2008
8.2
[208]
6.8
[174]
1.1
[18]
3.6
[91]
1.9
.7
[48]
.6
[15]
SIDE VIEW
.3
[7]
.7
[17]
.2
[6]
REAR VIEW
1.1
[28]
2.8
[71]
1.4
[34]
4.3
2.0
110
[51]
6.0
[152]
22.5
[571]
.25
DIA
[6]
7.2
[183]
5.4
[137]
4.2
[107]
4.0
[103]
2.0
[52]
1.1
[27]
1.0
[25]
2.4
[60]
3.0
3.1
[78]
Dimensions:
3.3
1.4
3.2
INCHES
[MM]
Figure 2-6: Outline and Mounting Dimensions
2 - 8 Installation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
2-7 INSTALLATION CONSIDERATIONS
CHECKLIST
Verify the following:
• The Analyzer´s location should be:
• Clean
• A well ventilated area
• Weatherproofed
• Non-hazardous
• Vibration-free
• Have stable ambient temperature
• The gas cylinders should be equipped with a clean,
hydrocarbon free two stage regulator and shut off
valve.
• All external tubing, regulators, valves, pumps, fit-
tings, etc. are clean.
• The correct fuel type is being used.
• The heated line is at the correct temperature.
• The sample, zero, and span gases are at the cor-
rect temperature.
• The heated line to have over temperature protec-
tion.
• The sample, bypass, and burner exhaust tubing
material must handle high temperature and have
thermal insulation to protect from burns.
• The purge air out tubing to be 3/8 inch and less
than 4 feet in length.
• All external gas connections have been leak
checked.
• The dead volume for external sample and fuel lines
have been minimized.
• The stainless steel tubing used for the fuel and
sample lines is clean.
• The THC content of the supply gases are compat-
ible with the analysis range.
• The calibration background gases are similar to
the sample
• The purge air out, burner exhaust, and bypass are
vented to atmospheric pressure. The pressure
should be constant.
• The burner exhaust tube must be slanted downa
minimum of 6 degrees from horizontal.
• The bypass line connection must be slanted down
a minimum of 6 degrees from horizontal for drainage of water condensation.
• If required, thermal insulation around the bypass
fitting to prevent condensation to minimize the cold
spot.
2 - 9InstallationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
2 - 10 Installation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
SECTION 3
OPERATION
3-1 OVERVIEW
Once the HFID has been correctly assembled and installed, the analyzer module is ready for operation.
Before operating the system, verify that the Leak Checks
have been performed in accordance with Section 2-5.
In this section, all operations for starting up the analyzer
are explained. For more detailed information about software screens see associated Software Manual.
For the remainder of this section, Analyzer Module interconnection with a Platform or some interfacing component is assumed. Display and Keypad information
refers to that which the user can expect to see and do
with regard to the Front Panel of the Platform.
Depending from the software version that is installed,
menu layout can change, whereas the principle of operation always stays the same.
3-2 STARTUP & INITIALIZATION
CAUTION
PRESSURIZED ENCLOSURE
This enclosure shall not be opened unless the area
is known to be free of flammable materials or unless all devices within have been de-energized.
Area classification for the protected enclosure:
Nonclassified.
Pressurization: Type Z
Temperature Identification Number: T4A
Power shall not be restored after enclosure has
been opened (or loss of purge) until enclosure has
been purged for a minimum of 6 (six) minutes at
the minimum pressure of 689 hPa (10 psig).
For safety, the Analyzer Module should be installed
in a non-confined, ventilated space. Do not block
any of the rear panel outlets as they are part of the
safety system.
a) Startup
1. Connect supply gases and outlets to/from module.
2. Turn ON the purge gas only. Wait a minimum of 6
minutes (see Section 3-2b, too)
3. Apply LON connection and power to the HFID Analyzer Module. If it is associated with a Platform, do
this by plugging in the Platform to a power source.
The Platform has no ON/OFF power button. Once
power has been supplied to the Platform, the HFID
Analyzer Module will be energized.
After switching on the HFID, the analyzer will begin its booting procedure which is apparent on the
screen. The first part of the initialization procedure
is a self check of the software and analyzer components. Various displays will show the status of
the initialization.
3 - 1OperationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
If the user´s system contains only one Analyzer
Module, all system components, the Controller
Board and the network "self-install" (bind together)
during initial startup. If the system contains more
than one Analyzer Module, the startup sequence
will interrogate the network to locate and identify
all components on the network. The user will have
to bind appropriate combinations of components
after the startup sequence. See the Platform
manual for instructions on binding combinations
of modules.
Pressing the F1 key during initializing will reset
the HFID brightness and contrast to factory settings. Pressing the F3 softkey will abort the network initializing, aborting any connection to other
analyzers. In that case, only the menus of the local analyzer will be available.
At the end of the initializing routine the "measure"
screen will display. This screen is the access to all
other channels, menus and submenus. The actual display may differ from that shown depending on any custom configuration.
After the warm-up period (about one hour for the
HFID Analyzer Module), all modules are completely functional.
Line#1
Self Test Results
EEPROM Test:
EPROM Test:
RAM Test:
Power Supply Test:
Network Test:
20 bit ADC test:
12 bit ADC test:
Power Supply PCB Test:
Safety PCB Test:
Case Temperature Test:
Oven/Sample Temperature Test:
HOME ESCAPE TEST
0.000 ppm
Figure 3-1: Self Test Menu
Descriptions of the tests performed below:
• EEPROM test - Check the EEPROM on
the Analysis Computer PCB.
• EPROM test - Checks the EPROM on the
Analysis Computer PCB.
• RAM test - Checks the RAM on the Analysis
Computer PCB.
• Power supply test - Verifies that all internal DC
voltages are within the required tolerances.
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
3. Check the 4 LEDs. The power green LED should
be illuminated. The Oven amber LED should be
blinking or on. The other LEDs should be off.
4. Check the general health of the analyzer by reviewing the status of the Self Tests. All "Pass" conditions should be obtained. All tested parameters
should indicate "Pass".
Enter the menu "Self test" as follows, using the
softkeys F1 through F5:
Main (Menu)...
System Configurations and Diagnostics...
Diagnostic Menu...
Analyzer Module Diagnostic...
Self Test...
• Network test - Checks the internal network inter-
face.
• 20bit ADC test - Checks the 20-bit ADC on the
Analysis Computer PCB by sending a DC signal
through the Preamp PCB and reading the signal
back with the 20-bit ADC.
• 12bit ADC test - Checks the 12-bit ADC on the
Analysis Computer PCB by sending a DC signal
and reading the signal back with the 12-bit ADC.
• Power supply PCB test - Checks the presence
of the Power Supply PCB by activating the 3-way
air solenoid.
• Safety PCB test - Checks the presence of the
Safety PCB by sending a command and reading
it back.
3 - 2 Operation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
• Case temperature test - Compares the tempera-
ture read between Preamp temperature sensor
and the case temperature sensor. They must be
within 10°C of each other. This test sometimes
fails if the case is opened. The sensor in the
Preamp will take longer to cool off since it is in an
enclosure. Re-running the self-test after thermal
equilibrium will produce a positive result if the sensors are working properly.
• Oven/Sample Temperature test - Compares the
temperature read between the sample temperature sensor and the oven temperature sensor.
They must be within 50°C of each other.
5. Wait for the Purge Air green LED to illuminate.
b) Temperature/Pressure Settings and Check
1. Introduce the remaining supply gases. (See section 1-5 Specifications)
2. Set and verify the internal gas pressures.
Check pressure settings with the values defined
in your Test Data Sheet (Figure 3-12).
Internal Pressure
Regulator
Burner Air 965 to 1103 hPa-gauge (14 to 16 psig),
Fuel 1516 to 1723 hPa-gauge (22 to 25 psig),
Sample
(non-adjustable)
Typical Operating Pressures
nominal 1030 hPa (15 psig)
nominal 1640 hPa (23.8 psig)
206 to 290 hPa-gauge (3.0 to 4.0 psig),
nominal 260 hPa (3.8 psig)
Table 3-1: Typical Operation Pressures
Purge air of the following specifications must be
present:
Flow: 16 to 18 l/min
Supply Pressure: 689 to 1,378 hPa-gauge
(10 to 20 psig)
This, the user should set the external purge air
pressure initially at 689 hPa-gauge (10 psig).
Check the "Miscellaneous Control Parameters"
screen (Figure 3-2), and note whether the Purge
Gas (switch) variable is "ON". If it is "OFF", increase purge air supply by 69 hPa-gauge (1 psig),
and recheck the Purge Gas variable until it reads
"ON".
DO NOT EXCEED 1378 hPa-GAUGE (20 PSIG).
If the maximum setting is reached, and the Purge
Gas variable does not read "ON", contact factory.
If the safety system is initiated successfully (Purge
Gas variable is "ON"), continue with the remainder of the startup procedure.
NOTE
Do not restrict the PURGE OUT port and
the pressure relief valve. They must be
vented to atmospheric pressure.
Main (Menu)...
System Configurations and Diagnostics...
Diagnostic Menu...
Analyzer Module Diagnostic...
Miscellaneous Control Parameters...
Line#1
Miscellaneous Control Parameters
Case Heater Current:
Burner Air Valve Current:
Alarm Messages valid for:
Ignition Command Status:
Fuel Enrichment S
Flame Status:
Purge Gas Switch:
Ignition Status:
Fuel Type:
HOME ESCAPE TEST
tatus:
Figure 3-2: Miscellaneous Control Parameters
0.000 ppm
410 mA
0.3 mA
FAILURE
OFF
OFF
ON
OFF
OFF
H2-He
Noncompliance could case damage to the module. At the very least, the module´s safety system,
which requires a certain volume of purge air flowing through the case before allowing burner ignition, will not allow the instrument to operate. The
lowest purge air flow/pressure setting possible
during burner operation is preferable.
3 - 3OperationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
c) Ignition of the Flame
1. Manual or Auto-Ignite the flame. The Flame-On
green LED should be illuminated.
Two methods of burner ignition are possible:
auto-ignition and manual ignition
(Note: The burner is easier to ignite when the oven
has reached the desired setpoint temperature.)
Auto-Ignition of the Flame
Auto-ignition provides fuel override and three attempted ignitions (default setting), if necessary.
Before ignition and operation, Fuel Flow must be
set on "ON" in "Light Flame" display screen under
Basic Controls (Figure 3-7) and oven temperature must be at least 85°C.
Manual Ignition of the Flame
The manual iginition switch on the Analyzer Module front panel must be manipulated in the following ways:
• Press up and hold for one minute. This opens
burner fuel and air solenoids.
• Press down to ignite burner glow plug
for up to 10 seconds.
• Repeat as necessary (if fuel and air sources
are farther away than 10 feet, several more
attempts may be necessary).
• If the flame has been lit, but the flame tem-
perature increases slowly, perform the following steps:
1) After igniting flame, release switch for 2
seconds
2) Press switch down for 2 seconds
3) Repeat release switch and press down
steps as necessary.
4. Note the four LEDs on the front panel of the Analyzer Module. They provide necessary information for either ignition procedure. The LEDs, when
illuminated, denote the following information:
• Green - unit powered on
• Amber . continous illumination implies oven has
reached operating temp. within ± 6 °C of
setpoint.
• Green - flame on
• Green - purge air system intact (it has filled
five volumes of the module interior)
5. Check and re-adjust the internal pressures if
required .
The unit is ready for operation.
3-3 BINDING
To achieve full coordination between Analyzer Modules
and associated I/O Modules, the user must bind those
components together in the System Set Up portion of
the Technical Configuration Menu in software.
2. Allow the case and oven to warm up approximately
1 to 2 hours.
3. Verify that all 4 LEDs are illuminated.
3 - 4 Operation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
3-4 CALIBRATION PROCEDURE
The HFID analyzer module may require periodic calibration with known zero and span gases in order to maintain a desire level of analytical accurancy. It is recommended, after initial startup, that the HFID Analyzer Module is calibrated at least once every eight hours.
This practice should continue until evidence indicates
that some other interval is more appropriate depending
on the analytical accurancy required.
Calibration is the process of flowing known zero or span
calibration gas into the analyzer for a specified period
(averaging time), after which the analyzer will automatically set its zero or span factors so that the concentration measurement equals the calibration gas value. A
limit can be set, beyond which any attempt by the analyzer to reset its concentration measurement will cause
a warning alarm. In this case, user intervention would
be required to reset the alarm and attempt another calibration.
a. Calibration Setup
Calibration Gas List
This menu is used to set the concentration values of the
calibration gases for each range, the Operational Sample
Pressure and the Calibration Gas HC Response Factor.
Main (Menu)...
Analyzer and I/O expert controls & setup...
Analyzer module setup...
Calibration gas list...
Common HC factors are:
Methane (CH4): 1.0
Ethane (C2H6): 1.9
Propane (C3H8): 3.0
These factors are not used to compensate the reading,
but are used to select the proper preamp sense resistor.
In case that measuring ranges differ from ordering code,
put in the measuring ranges:
Main (Menu)...
Analyzer and I/O, expert controls & setup...
Analyzer module setup...
Gas measurement parameters...
Range settings...
Line#1
Range Settings
Minimum Range:
Maximum Range:
Range 1 lower limit:
Range 1 upper limit:
Range 2 lower limit:
Range 2 upper limit:
Range 3 lower limit:
Range 3 upper limit:
Range 4 lower limit:
Range 4 upper limit:
Pressure limits...
HOME ESCAPE INFO
0.000 ppm
10.0 ppm
1000.0 ppm
0.0 ppm
10.0 ppm
0.0 ppm
25.0 ppm
0.0 ppm
100.0 ppm
0.0 ppm
250.0 ppm
Figure 3-4: Range Settings Menu
Line#1
Calibration Gas List
Zero gas - range 1:
Span gas - range 1:
Zero gas - range 2:
Span gas - range 2:
Zero gas - range 3:
Span gas - range 3:
Zero gas - range 4:
Span gas - range 4:
Calibration gas HC response factor:
Operational sample pressure:
Calibration...
HOME ESCAPE INFO
0.000 ppm
0.00 ppm
10.00 ppm
0.00 ppm
25.00 ppm
0.00 ppm
100.00 ppm
0.00 ppm
250.00 ppm
344 hPa
Figure 3-3: Calibration Gas List
NOTE
In case that only one measuring range is in use,
we suggest to set all other measuring ranges to
the same value to prevent calibration failure. When
doing so, set also all test gas values to the same
value.
1.00
3 - 5OperationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
Calibration Parameters
This menu provides various parameter settings for all
calibration performed from Basic or Expert modes.
Main (Menu)...
Analyzer and I/O expert controls & setup...
Analyzer module setup...
Calibration parameters...
Line#1
Calibration adjustment limits:
Calibration averaging time:
Calibration failure alarm:
Cal failure error allowed:
Calibration time out:
Purge time
Zero ranges:
Span ranges:
HOME ESCAPE INFO
Calibration Parameters
CAL
0.000 ppm
Disabled
50 %
SEPARATELY
SEPARATELY
Figure 3-5: Calibration Parameters Display
Calibration adjustment limits:
Set to "Disable" to recover from a calibration failure.
Calibration averaging time:
9 s
Ye s
59 s
0 s
Purge time:
Sets how long the analyzer will wait befor performing an
adjustment.
Zero (Span) ranges:
Used to select wether to calibrate ranges "TOGETHER"
or "SEPARATELY". If together, zeroing or spanning will
go through each range one by one. If the change required is too great, it will fail and send an alarm if warning alarms are enabled. In this case, Disable Calibration Adjustment Limits and try again. First check that the
calibration gases are correct. If non-zero gases are used,
or the changes are great, zero and span may have to
be repeated a few times.
In case that a system calibration is used, set all ranges
to "SEPARATELY".
Please note that Software will accept only span gas values that are a factor of 10-110% of the measuring range.
From that, it is possible, that not all of the four measuring ranges can be calibrated altogether. In that case
you will have to set the option to "SEPARATELY".
In case that a calibration is not possible because the
difference of display to the true value is too great, switch
of the "CalCheck" option.
Set the time used by the analyzer to average its reading
during calibration. A longer time will give a better calibration.
When using a system calibration, take care that averaging time is long enough for the analyzer to reach a
settled reading. Otherwise, calibration may fail !
Calibration failure alarm:
When turned on ("yes"), issues a warning if the analyzer has to change its calibration by more than the Cal
Failure Error, if warning alarms are enabled.
Cal failure error allowed:
The percentage by which the calibration can change
before an alarm is triggered if the Calibration Failure
Alarm is enabled.
Calibration time out:
Sets how long the analyzer will wait for the signal to
stabilize before issuing a Warning.
Check of capillary type
Verify the capillary type in the "Analyzer Manufacturing
Data".
Main (Menu)...
"F5" (MFG Data)...
Analyzer module manufacturing data...
Line#1
More...
Minimum range:
Maximum range:
Measured Gas:
Capillary:
Flow sensor:
HOME ESCAPE INFO
Analyzer Manufacturing Data
9.7 ml/min @ 3.5 psig
0.000 ppm
10.00 ppm
10.00 ppm
10000.00 ppm
Present
Figure 3-6: Analyzer Module Factoring Data
THC
3 - 6 Operation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
b. Execution
Calibration execution is as follows:
1. Set oven temperature setpoint according to Analyzer Module specific Test Data Sheet Test Data
Sheet (Figure 3-12).
2. Apply regulated air at a pressure between 689 to
1,723 hPa-gauge (10 to 25 psig) according to
Analyzer Module specific Test Data Sheet Test
Data Sheet (Figure 3-12).
3. Allow case, oven, and sample temperatures to stabilize.
Main (Menu)...
Analyzer basic controls (calibration) & setup...
Line#1
Measurement range number:
Range upper limit:
Span gas concentration:
Automatic range change control:
Bypass Sample Flow:
Ranges with valid calibration:
Calibration status:
Flame Condition:
Light Flame...
HOME ESCAPE
Basic Controls
ZERO SPAN
0.000 ppm
24.9 ppm
10.0 ppm
Disabled
0.0 l/min.
1&2
READY
ON
Zero Adjustment
Supply heated zero gas to sample inlet. Adjust external
flow controller or throttle valve so that the sample inlet
pressure is between 345 to 620 hPa-gauge (5 to 9 psig.),
485 hPa-gauge (7 psig.) nominal.
In the Basic Controls menu (Fig. 3-7), push the F3 softkey
and enter the Analyzer Zero menu.
Line#1
Are you sure ?
You must have zero gas flowing through the analyzer.
Calibration time:
Measurement range number:
Zero ranges:
Calibration status:
Error message for last zero:
.
HOME ESCAPE INFO
1
Figure 3-8: Analyzer Zero Menu
Analyzer Zero
ZERO
0.000 ppm
24 s
1
SEPARATELY
READY
CAL OK
Push the F3 softkey again, to start the zeroing process.
Be sure to have zero gas flowing through your analyzer
and to have it purged from sample gas before.
When the zeroing process is finished, "Calibration status" will turn to "READY".
Figure 3-7: Basic Controls Menu
3 - 7OperationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
Span Adjustment
After that, perform a Span adjust in the same measuring range:
Supply heated span gas to sample input. The reading
of the sample pressure, oven, and sample temperatures
should be the same as that used during the adjustment
of the zero gas.
For that, push the F4 softkey in the Basic Controls menu,
so that the Analyzer Span menu turns up:
Line#1
Are you sure ?
You must have span gas flowing through the analyzer.
Calibration time:
Measurement range number:
Span ranges:
Calibration status:
Error message for last span:
HOME ESCAPE INFO
Analyzer Span
SPAN
0.000 ppm
SEPARATELY
READY
CAL OK
Figure 3-9: Analyzer Span Menu
24 s
c) Problems with Calibration
If the user is unable to calibrate the Analyzer Module
(i.e., when ZERO or SPAN is initiated, nothing happens),
several possible solutions present themselves. One
solution relates to the use of an incorrect gas for zeroing or spanning (e.g., using a high concentration gas to
zero or a zero gas to span the Analyzer Module). Simply recalibrating with the appropriate gas(es) will not
correct the problem because the ZERO OFFSET or
SPAN FACTOR has been set to an extreme value in the
process.
To remedy the problem, do the following:
1. Verify the correct zero and span calibration gases
are being used properly. If so, attempt to recalibrate
according to instructions at the beginning of Section 3-4, ensuring that the oven, sample and case
1
temperatures and displayed measurement reading are stable before initiating the calibration routine. If incorrect gases were used in the initial, failed
calibration, skip to step 2.
2. Disable Calibration Adjustment Limits
(Figure 3-5).
Push the softkey F4 again to start the spanning sequence. Be sure to have span gas flowing through your
analyzer and to have it purged before.
When the spanning sequence is finished, the "Calibration status" will turn to "READY".
If the user is unable to calibrate the Analyzer Module
(i.e., when ZERO or SPAN is initiated, nothing happens),
several possible solutions present themselves. One
solution relates to the use of an incorrect gas for zeroing or spanning (e.g., using a high concentration gas to
zero or a zero gas to span the Analyzer Module). Simply recalibrating with the appropriate gas(es) will not
correct the problem because the ZERO OFFSET or
SPAN FACTOR has been set to an extreme value in the
process.
3. Recalibrate the analyzer module according to instructions at the beginning of section 3-4, ensuring that oven, sample, and case temperatures and
displayed measurement reading are stable before
initiating the calibration routine.
4. Enable Calibration Adjustment Limits in the Calibration Parameters menu (Figure 3-5).
NOTE
If the range selections straddle 72 5ppm, CH4, the
zero and span calibration for each range must be
done separately.
3 - 8 Operation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
3-5 ROUTINE OPERATION
a) Operation
After case, oven, and sample temperature stabilization,
calibration, and binding, proceed as follows:
Supply heated sample gas to SAMPLE INLET. Adjust
external flow controller or throttle valve so that the sample
inlet pressure is between 345 to 620 hPa-gauge (5 to 9
psig.), 485 hPa-gauge (7 psig.) nominal. The reading
on the SAMPLE pressure gauge and sample and oven
temperatures should be the same as that used during
adjustment of the zero and span calibration gas control.
Adjust the Range Number setting. The Analyzer Module will now automatically and continously output the
measured hydrocarbon content of the sample. Output
is in terms of particular hydrocarbon present in the span
gas. Note that readings obtained during operation depend on the concentration of total hydrocarbons in the
sample.
The Analyzer Module will not allow the user to increase
the upper limit of a range beyond the "maximum range"
software setting.
To now check back physical parameters of the HFID
Analyzer Module with the values defined in your Test
Data Sheet, that you received with the analyzer, you
have to select the "Physical Measurements"-Menu.
You will find excerpt of a Test Data Sheeta as an example on the next page in figure 3-12.
Enter the diagnostics menu "Physical Measurements"
as follows, using the softkeys F1 through F5:
Main (Menu)...
Expert Controls and Setup...
Analyzer Module Controls...
Physical Measurements...
Line#1
Physical Measurements
Bypass Sample Flow:
Flow lower limit:
Flow upper limit:
Sample Pressure:
Fuel Supply Pressure:
Burner Air Pressure:
Purge Gas Pressure:
Case temperature:
0.000 ppm
1996 ml/min
400 ml/min
2000 ml/min
340 hPa
1600.3 hPa
1041 hPa
691 hPa
54.0 C
HFID
7.50
0.00 10.00Range 1
Sample pressure:
Case temperature:
Flame status:
Raw signal:
Display Status... Main... Channel BasicCal
340 hPa
51.4 C
524401
50.0
47.0
100000
ppm THC
490.0
61.0
ON
900000
Figure 3-10: Measure Mode Display
After starting up the Analyzer Module, the Measure Mode
Display is displayed as shown in figure 3-10.
After initial startup, or startup following a prolonged shutdown, the Analyzer Module requires about one day´s
continous operation to stabilize. For several days afterwards, calibrate daily. The frequency of subsequent
calibrations can be reduced as experience dictates,
consistent with the accurancy requirements of the particular application.
HOME ESCAPE INFO
Figure 3-11: Physical Measurements Display
The menu "Physical Measurements" lets you monitor
physical measurement parameters of the HFID analyzer.
b) Sensitivity
If maximum sensitivity is required from the HFID Analyzer Module, use an optimum combination of settings
on the FUEL, and AIR pressure regulators. Settings must
be determined experimentally, but the curves in Figures
3-14 and 3-15 may be used as guides.
c) Shutdown
During shutdown, always turn off fuel gas first, then the
air and sample gases. The flame can also be turned off
by setting Ignition System Enable to "Off" on the Light
Flame menu (under Basic Controls, Figure 3-7). Subsequently, remember to set Ignition System Enable to
"On" before attempting to ignite the flame.
3 - 9OperationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
External physical parameters are adjusted as follows
Instruction Manual
HAS64E-IM-HW
September 2008
Supply Pressure Fuel Gas
Supply Pressure Burner Air
Supply Pressure Sample Gas
Supply Pressure Regulated Air (N2)
Supply Pressure Purge Gas Min.
Sample Flow
The following parameters can be checked in menu "Physical Measurements"
Operation:
Internal physical parameters are adjusted as follows
Main Menu...
Expert Controls and Setup...
Analyzer Module Setup...
Physical Measurements...
Sample Pressure
Fuel Gas Pressure
Purge Gas Pressure
Burner Air Pressure
Case Temperature
Reference Temperature
Flame Temperature
Preamp Temperature
Sample Temperature
Oven Temperature
Bypass Flow
Burner Air Flow
Fuel Gas Flow
Capillary Flow Rate
2000,00
600,00
700,00
691,00
253,00
1642,00
691,00
1041,00
hPa
hPa
hPa
hPa
hPa
hPa
hPa
hPa
hPa
9,7 cc/min @ 3,5 psig
50,763500,00
29,01
8,70
10,15
10,02
no sensor
3,67
23,82
10,02
15,10
50,0
148,7
56,4
4560
472,5
75,2
226
190
191
psig
psig
psig
psig
psig
cc/min
psig
psig
psig
psig
°C
°C
°C
°C
°C
°C
cc/min
cc/min
cc/min
cc/min
Figure 3-12: Excerpt of a Test Data Sheet with values that are to be compaired with physical measurements
3 - 10 Operation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
3-6 SAFETY SYSTEM
The HFID Analyzer Module safety system will not allow
ignition or continous burner function unless the following conditions are present:
• The internal purge gas pressure is at least 380
hPa-gauge (5.5 psig).
Monitor message "Purge Gas Pressure" in "Physical Measurements" menu (Figure 3-11) for proper
setting.
• Flow rate for purge air in is at least 16 l/min and
case pressure is greater than 0.5 inches of water.
(Monitor display message "Purge Gas (ON)" in
"Miscellaneous Control Paramteres" menu (Figure 3-2) for correct state. Proper sealing hardware
must be used in order to obtain the required purge
air in flow rate and case pressure).
• Five case volumes of purge air have been
achieved and the three above conditions are
present. The time duration to achieve a safe system is a minimum of 6 min. (Monitor the Purge Air
Green LED (ON), Purge Control Status (ON), or
Purge Air Alarm for indication of the state of the
safety system.)
As stated above, proper sealing hardware is crucial
to the successful operation of the safety system.
Therefore, a specific torque sequence (shown in
Figure 3-13) must be followed when the front panel of
the module is being reinstalled after removal. All front
and rear panel screws must be installed.
NOTE
Do not over-torque rear panel screws.
6 1 4
2 3 5
Torque Sequence:
Screw #1, 4 to 5 turns
Screw #2, 4 to 5 turns
Screw #3, 4 to 5 turns
Screw #4, 4 to 5 turns
Screw #5, 4 to 5 turns
Screw #6, 4 to 5 turns
Repeat torque sequence until all screws are tight.
The gasket must fill in between the front panel plate
Figure 3-13: Front Panel Torque Sequence
3 - 11OperationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
1.0
0.8
Instruction Manual
HAS64E-IM-HW
September 2008
RESPONSE
(100 ppm CH4 fullscale)
0.6
0.4
0.2
SAMPLE: 100 ppm CH4 in N
at 3.5 psig (241 hPa)
0
_5_
344
_10_
688
_15_
1032
FUEL PRESSURE
_20_
1376
psig
hPa
AIR 30 psig (2064 hPa)
AIR 20 psig (1376 hPa)
AIR 10 psig (688 hPa)
2
_25_
1726
Figure 3-14: Typical Curve of Module Response vs. Pressure Setting on Fuel Pressure Regulator
1.0
FUEL 30 psig (2064 hPa)
0.8
FUEL 25 psig (1726 hPa)
_30_
2064
0.6
FUEL 20 psig (1376 hPa)
RESPONSE
(100 ppm CH4 fullscale)
0.4
0.2
SAMPLE: 100 ppm CH4 in N
at 3.5 psig (241 hPa)
0
_5_
344
_10_
688
_15_
1032
FUEL PRESSURE
_20_
1376
psig
hPa
2
_25_
1726
_30_
2064
Figure 3-15: Typical Curve of Module Response vs. Pressure Setting on Air Pressure Regulator
3 - 12 Operation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
DISPLAY MESSAGE DESCRIPTION TYPE
AIR FET
AIR PRESS
BAIR FLOW
BAROMETER
BFUEL FLOW
BLOCK FET
CASE TEMP
CRUDE NOISE
CURRENTRNGHI
CURRENTRNGLO
CURRENTSFAC
FLAME TEMP
FUEL PRES
LIN ERROR
N15 VOLTS
P10 VOLTS
P15 VOLTS
POL VO LTS
SAMP PRES
CALRESULT
PURGE AIR
SW ERROR
FID Air FET current WARNING
FID Air Pres sure WARNING
Burner Air Flow WARNING
System Barometer WARNING
Burner Fuel Flow WARNING
Heater current WARNING
Case Temperature WARNING
Calculated Noise WARNING
Current, High Range WARNING
Current, Low Range WARNING
Current Range WARNING
Flame Temperature WARNING
Fuel Pres sure WARNING
Linearizer Error WARNING
Power Supply -15V WARNING
Power Supply +10V REF WARNING
Power Supply +15V WARNING
Polarizing Volts WARNING
Sample Pressure WARNING
Calibration Error FAILURE
FID Purge Air FAILURE
Software Error FAILURE
Table 3-2: HFID Analyzer Module Alarms
3 - 13OperationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
3-7 SYSTEM & NETWORK I/O MODULE
CONTROLS (SETUP) - SYSTEM SIO
To adjust SIO functions, select
Main (Menu)...
Analyzer and I/O, expert controls & setup...
System & network I/O module controls...
System SIO module...
Line#1
Analog output setup...
Serial interface setup...
Relay outputs setup...
Module installed...
.
MEASURE
-- System SIO Module --
Back...
0.000 ppm
Figure 3-16: System SIO Module Menu
System SIO module menu allows you to adjust different
SIO functions, like analog outputs and serial interfaces.
YES
Output number:
Choose the desired analog output (1-8) to set the parameters. The number of outputs depends on the analyzer configuration as 2, 4, 6 or 8.
Choose signal source module...
Select the "Analyzer Modules" submenu by selecting
the "Choose signal source module..." line and pressing
the Return (↵) softkey.
Select the tag of the desired reference channel with the
↑ or ↓ softkeys and then press the ↵ or → softkey. The
display will return to the previous menu automatically
and the selected reference channel will be displayed in
the "Source module:" line.
The available selections may be different depending on
the installed modules.
Line#1
-- Analyzer Modules --
1000723 Line#1: 1.0
0.000 ppm
Control Module: 0.0
HFID: 2.0
MLT/CH3
1
a. Analog Output Setup
In the System SIO Module menu (Figure 3-16) select
"Analog output setup..."
Line#1
Output number:
Choose signal source module...
Choose signal...
Signal value for 0% output:
Signal value for 100% output:
Output current:
Hold output during calibration:
Signal name:
Current signal value:
Source module:
Measure More...
-- Analog Output Setup --
Back...
0.000 ppm
0.00
100.00
0...20 mA
????
-10.00
Line#1
Figure 3-17: Analog Output Setup Menu
No
HOME NO/NOx INFO
ZERO SPAN
Figure 3-18: Analyzer Modules Menu
Choose Signal...
1
Select the "Signals" submenu by selecting the "Choose
Signal..." line and pressing the ↵ softkey. (The list of
signals will depend on the module chosen.)
Press the F5 softkey to go to additional menus to choose
the Primary Variable signal for the analog output. The
Primary Variable is the actual NO or NOx concentration.
See Section 5.2.1.1 of HFID Software Manual for complete list of signals.
The signal chosen here will be applied to the analog
output (1-8) chosen above.
3 - 14 Operation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
Line#1
Measure >>>
-- Signals --
Purge control status:
<<< Back...
0.000 ppm
Burner air press.:
Air sense:
Burner air:
Burner fuel flow:
Burner fuel press.:
Sample press.:
Sample flow:
>>>
Line#1
Measure >>>
-- Signals --
<<< Back...
0.000 ppm
Case temp.:
Preamp temp.:
Flame status:
AutoIgnition:
t-90 time:
Delay time:
Linearizer:
Calibration:
Figure 3-19: Signals Menu
NOTE
If the measurement range is changed, the settings
done in this menu will revert back to the standard
values of the range. The output values can be
changed permanently in the menu "Range Settings."
NOTE
The signal range of the analog output should be
less than the smallest range of the channel. Otherwise the analog output may exhibit excessive
noise.
Output current:
Select the desired output range in the "Output current
range:" line. The options are 0...20 mA or 4...20 mA.
Hold output during calibration:
Enable this option to hold the analog output to the last
value during calibration.
Pressing the F5 (More...) softkey changes the to the
submenus "Output Signal if Assigned Module Fails" and
"Fine Adjustment."
Signal value for 0% (100%) output:
It is possible to set the signal value for 0 % output and
for 100% output so as to output only a portion of the
entire range.
Example:
• Range from 0 to 1,000 ppm
• 0% value to be 400 ppm,
100% value to be 700 ppm.
• Analog output normally:
0 V = 0 ppm, 10 V = 1,000 ppm
• After changing the output scaling:
0 V = 400 ppm, 10 V = 700 ppm.
Move the cursor to the "Signal value for 0 % output:"
line and adjust the value to 400. Then change to the
"Signal value for 100 % output:" line and adjust the value
to 700.
Line#1
Output(s) value on analyzer failure:
Output number:
Operation mode:
Fine adjustment for 0% output:
Fine adjustment for 100% output:
Measure More...
-- Output Signal If Assigned Module Fails --
BeginOfRange - 10%
-- Fine Adjustment --
Back...
0.000 ppm
Normal
4096
819
Figure 3-20: Output Signal If Assigned Module
Fails Menu
1
3 - 15OperationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
Output(s) value on analyzer failure:
Choose the desired signal level to cause a failure condition. The choices are:
• Acutal
• BeginOfRange
• EndOfRange
• BeginOfRange-10%
• BeginOfRange+10%
Output number:
Choose the output number (1-8) for setting the fine adjustment.
Operation mode:
Normal: The absolute measurement signal will be sent
to the analog output.
Adjust 0V: Used to set the display equal to the analog
output for 0 V and 0 mA. Life zero signals (4 - 20 mA
and 2 - 10 V) are set automatically and cannot be adjusted.
Adjust 10V: Used to set the display equal to the analog
output for 10V und 20mA.
Select the "Fine adjustment for 0% output" and/or "Fine
adjustment for 100 % output" lines with the ↵ or →
softkey. Adjust to the desired value with the ↑ or ↓ softkey
and confirm with the ↵ softkey.
The range of values are:
• 3,000 to 6,000 for 0 % (default 4096)
• 600 to 1,000 for 100 % (default 819)
Source module: The name of the module chosen in
the "Choose signal source module" menu.
Pressing the F5 (More...) softkey changes to the
submenu "Special Scaling for Concentration Signal"
Line#1
Output #1:
Output #2:
Output #3:
Output #4:
Output #5:
Output #6:
Output #7:
Output #8:
Measure More...
-- Special Scaling for Concentration Signal -(Scaling is the same as range limits)
Back...
0.000 ppm
Ye s
Ye s
Ye s
Ye s
Ye s
Ye s
Ye s
Ye s
Figure 3-21: Special Scaling for Concentration
Signal Menu
This menu allows for the setting of each of the 8 outputs
to be the same as the range limits "Yes" or as to set on
the previous menus.
Pressing the F5 (More...) softkey changes to the
submenu "Analog Output Updates per Second."
Line#1
-- Analog Output Updates Per Second --
Output #1:
Output #2:
Output #3:
Output #4:
Output #5:
Output #6:
Output #7:
Output #8:
0.000 ppm
1
0
0
0
0
0
0
0
0
The last three lines of the "Analog Output Setup" menu
are displayed only for configuration values of the analog output.
Signal name: The name of the signal chosen the
"Choose signal" menu.
Measure
Figure 3-22: Analog Output Updates per
Second Menu.
This menu allows for the setting of the update rate for
each of the 8 outputs.
Back...
Current signal value: The current value of the vari-
able.
3 - 16 Operation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
b. Serial interface Setup
The submenu "Serial interface Setup" is used to set the
parameters for data transfer between the analyzer and
external devices. The choices in this menu depend on
the configuration of the analyzer. The full specification
of the serial interface is described in its own manual.
In the System SIO Module menu (Figure 3-16) select
"Serial interface setup..."
Line#1
-- Serial Interface Setup --
Baud rate:
Data bits:
Stop bits:
Parity:
Echo mode:
Handshake:
Transmission delay:
Type of installed serial interface:
Communication protocol:
Special protocol definitions...
Pressure limits...
Measure
Back...
0.000 ppm
19200
Disabled
Xon/Xoff
RS232
Figure 3-23: Serial Interface Setup Menu
None
AK
Line#1
Device address (RS-485 only): 1
Measure More...
-- AK Protocol Deifinitions --
Back...
0.000 ppm
Figure 3-24: AK Protocol Definitions Menu
8
1
0
The value can range from 1 to 50.
Options:
• Baud rate:
300, 1200, 2400, 4800, 9600, 19200
• Data bits: 7, 8
• Stop bits: 1, 2
• Parity: None, Even, Odd
• Echo mode: Enabled, Disabled
• Handshake: None, Xon, Xoff
• Transmission delay: 0...100.
Type of installed serial interface: RS232, RS485/2w,
RS485/4w, RS485/4w bus, None.
Communication protocol: AK, MODBUS RTU, None (not
applicable to HFID)
NOTE
The "special protocol definitions..." line accesses
a submenu for setting the parameters of the AK
and MODBUS RTU (not available yet) communication protocols.
3 - 17OperationEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
c. Relay Outputs Setup
There are three relays on the SIO board. The contact
logic can be set with a jumper on the SIO board to select NO (normally open) or NC (normally closed). Full
details of the SIO board are contained in its own manual.
In the System SIO Module menu (Figure 3-16) select
"Relay outputs setup..."
Line#1
Output number:
Invert signal:
Choose source module...
Choose signal...
Signal comes from:
Signal name:
Actual status:
Measure
-- Relay Outputs Setup --
Back...
0.000 ppm
Disabled
Figure 3-25: Relay Outputs Setup Menu
Output number:
Corresponds to the relay number 1-3.
????
????
Off
Choose signal...
Line#1
1
Pressure limits...
Measure >>>
-- Choose Signal --
Maintenance request
<<< Back...
0.000 ppm
1
Function control
Failure
Cal. In progress
Zero in progress
Span in progress
Zero failed
Span failed
Figure 3-27: Choose Signal Menu
Choose desired signal for the relay output number (1-3)
being configured.
The list of signals will depend on the chosen module. If
available, press the >>> (F5) softkey for additional signals.
The three lines displayed at the bottom of the "Relay
Outputs Setup" menu show the current status of the
selected relay output.
Invert signal:
"Disabled" signal is normal, "Enabled" signal is inverted.
Choose source module...
Line#1
Measure >>>
-- Choose Source Module --
1000723 Line#1: 1.0
<<< Back...
0.000 ppm
Control Module: 0.0
Figure 3-26: Choose Source Module Menu
Choose desired source module for the relay output number (1-3) being configured.
The list of modules will depend on the installed modules.
Signal comes from: The module chosenfrom the
"Choose Source Module" menu.
Signal name: The signal chosen from the "Choose Signal" menu.
Actual status: The current status of the signal; Off or
On.
3 - 18 Operation Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
SECTION 4
MAINTENANCE AND SERVICE
WARNING
GENERAL HAZARD
Before starting of maintenance and service to this
equipment, read the "Essential instructions" on
the inside cover and the Safety Summary beginning on page P-2.Failure to follow the safety instructions could result in serious injury or death.
WARNING
ELECTRICAL SHOCK HAZARD
Do not operate without covers secure.
Do not open while energized.
Disconnect power to the module(s)
prior to replacing components.
This equipment should not be adjusted
or repaired by anyone except properly
qualified service personnel.
CAUTION
PRESSURIZED ENCLOSURE
This enclosure shall not be opened unless the area
is known to be free of flammable materials or unless all devices within have been de-energized.
This equipment should not be adjusted or repaired
by anyone except properly qualified service
personnal!
4-1 OVERVIEW
This section contains instructions and procedures for
troubleshooting and maintaining the HFID analyzer
module.
The HFID Analyzer Module requires very little maintenance during normal operation.
The gas path system should be leak tested at least twice
a year and after maintenance, replacement or repair of
gas path parts.
WARNING
UNAUTHORIZED SUBSTITUTION OF
COMPONENTS
Tampering with or unauthorized substitution of
components may adversely affect the safety of this
instrument. Use only factory documented/approved components for repair.
Because of the danger of introducing additional
hazards, do not perform any unauthorized modification to this instrument!
Several components may require replacement. These
are discussed in the following sections.
Tag each connector and its location before disconnecting any wiring. This helps in reassembly.
To access the internal components of the analyzer module, perform the following:
1. Remove power to the unit; shut off gases and disconnect lines. Allow module to cool.
2. Refer to Figure 4-1. Remove the six screws securing the front panel, then the six screws securing the cover to the rear panel. Slide cover towards rear panel to remove. Loosen four screws
securing inner insulation shield to base, lift up to
remove.
Figure 4-2 illustrates the locations of major components
of the HFID.
4 - 1Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
Cover
Insulation Shield
PURGE
AIR OUT
REGULATED
AIR IN
WARNING
BURNER
AIR IN
WARNING
ATTENTION
PURGE
AIR IN
HEATED
SAMPLE
BYPASS
FUEL
IN
BURNER
EXHAUST
OUT
PRESSURE
RELIEF
VALVE
HEATED
SAMPLE IN
Cover/Rear Panel
Securing Screws (6)
Securing Screws (4)
Front Panel
Securing Screws (6)
Figure 4-1: Removal of Cover and Insulation Shield
4 - 2 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
Rear Panel Assembly
656954
Oven Assembly
Brief Description Part Number
9.7 cc/min. @ 3.5 psig 659551
2.5 cc/min. @ 3.5 psig 658338
NGA 2000 HFID
Electronic Assembly
656943
DC Power Supply
Module Assembly
657413
Fan Assembly
657414
Fixed Flow Controller Assembly
657434
Figure 4-2: Location of Major Assemblies of the HFID Module
4-2 FUSES
The main power fuse may require replacement.
NOTE
Before replacing the fuse, remove power to the
Analyzer Module.
See figure 2-3 for the location of the main power fuse
[T 6A 250 V (6x32 mm)], which protects 24 VDC input to
the module.
NOTE
Use only fuses of the correct type and current ratings as replacements. Using repaired fuses and
short circuiting of fuse holders is prohibited.
Front Panel Assembly
656949
4 - 3Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
4-3 OVEN
Though the oven can be replaced as a complete unit,
all internal components are field replaceable.
a. Removal
Refer to Figure 4-3, disconnect the oven´s three gas
lines and seven electrical cables, noting location of
mating connectors for re-installation.
NOTE
DO NOT remove the fittings from the gas lines on
the detector.
Remove the two hex nuts securing the oven to
the chassis and the two screws securing oven to
the rear panel. Lift oven assembly from analyzer.
Oven Assembly
Brief Description Part Number
9.7 cc/min. @ 3.5 psig 659551
2.5 cc/min. @ 3.5 psig 658338
b. Disassembly
1. Refer to Figure 4-4A. Remove the tour retaining
screws on the oven cover, remove cover.
2. Removethe two screws and one nut securing the
outer oven front panel to the outer oven, remove
front panel.
3. Remove the nuts and ferrules from sample in and
sample bypass out.
CAUTION
PREAMP CONNECTORS !
The electrical preamp connectors are fragile, handle
with care to avoid breaking solder connection!
4. Refer to Figure 4-4B. Remove the two nuts and
washers form the electrical preamp connectors
on the inner oven front panel.
Do not unsolder these connections.
5. Unscrew the three screws from inner front panel
and remove it.
6. Refer to Figure 4-4C. Remove the two hex nuts
securing the burner to the bottom of the inner oven.
7. Disconnect the sample input and output bypass
fittings.
8. Lift the burner/thermal block up and out, while disconnecting exhaust.
Reverse Procedure for installation.
Figure 4-3: Removal of Oven from Chassis
4 - 4 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
A B
Nuts and
Ferrules (2 ea.)
Inner Oven
Outer Oven
Outer Oven Front Panel
657356
Oven Cover 657105
(with insulation 657346)
Inner Oven
Retaining Screw (2)
and Washer (2)
C
Exhaust
Inner Oven Front Panel
657352
Preamp Connector Nut,
Washer (type 2)
Burner
657359
Spring, Heated Bridge
904294
Heated Bridge
659955
Heater/Cable Assembly
659643
Jam Nuts
659550
For clarity, outer oven not shown in Figures B and C.
Figure 4-4: Oven Assembly
Insulating Washers
073737
4 - 5Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
4-4 BURNER
This section covers burner components which can be
replaced without removal of oven from the chassis.
a. Temperature Sensor
1. Refer to Figure 4-4A. Remove the four screws on
the oven cover, remove cover.
2. Refer to figure 4-5. Remove the burner cap retainer.
3. Disconnect the temperature sensor wiring connector, note location.
4. Remove the temperature sensor.
5. Insert replacement sensor.
NOTE
The leads of the temperature sensor must be leading away and down from the sensor to enable
proper fit of burner cap retainer.
6. Install the burner cap retainer. U-slot must be located above temperature sensor.
7. Re-attach wiring connector.
8. Install oven cover.
b. RTD Detector
1. Refer to Figure 4-4A. Remove the four screws on
the oven cover, remove cover.
2. Refer to Figure 4-5. Loosen the set screw securing RTD detector.
3. Disconnect RTD detector wiring connector, note
location.
4. Gently grasp RTD detector wires and pull out of
hole.
5. Insert replacement RTD detector into hole, snug
down set screw.
6. Re-attach wiring connector.
7. Install oven cover.
c. Igniter
1. Refer to Figure 4-4A. Remove the four screws on
the oven cover, remove cover.
2. Refer to Figure 4-5. Disconnect the Igniter wiring
connector, note location.
3. Using an open-end wrench, unscrew the igniter
assembly from the burner. Verify that o-ring is also
removed.
4. Install replacement igniter and new o-ring. Using
open-end wrench, snug down.
Do not over-tighten!
5. Re-attach wiring connector.
6. Install oven cover
d. Flameout Sensor
1. Refer to Figure 4-4A. Remove the four screws on
the oven cover, remove cover.
2. Refer to Figure 4-5. Disconnect the flameout detector wiring connector, note location.
3. Lift up the burner cap until flameout sensor is accessible. Using an open-end wrench, unscrew the
flameout detector from the burner. Verify that oring is also removed.
4. Install replacement flameout detector and new oring. Using open-end wrench, snug down.
Do not over-tighten!
5. Re-attach wiring connector.
6. Install oven cover.
4 - 6 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
Igniter Assembly
657205
O-Ring
903736
Retainer, Burner Cap
Temperature Sensor
657468
O-Ring
903737
NGA 2000 HFID
Flameout Sensor
657199
RTD Detector
657063
Set Screw
M3X0.5x10 mm
903125
The components shown can be replaced without removing burner/thermal block from oven.
Oven not shown for clarity.
Thermal block shown in phantom for clarity.
Figure 4-5: Burner-Sensor, Flameout Detector, RTD Detector and Igniter
4 - 7Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
4-5 BURNER INTERNAL COMPONENTS a. Disassembly of Burner / Thermal Block
1. Remove oven from analyzer module per Section
CAUTION
BURNER CONTAMINATION
Do not handle internal parts of the burner with bare
hands. All tools used for maintenance must be free
of contaminates.
4-3a.
2. Remove burner / thermal block from oven per
Section 4-3b.
3. Refer to Figure 4-6. Disconnect sample capillary
nut at base of burner.
4. Remove screw securing thermal block to burner.
5. Carefully pull burner away from thermal block.
Burner
Thermal Block
Sample Capillary input
Sample Capillary
Figure 4-6: Burner/Thermal Block Disassembly
4 - 8 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
b. Replacing Burner Jets
Disassemble the burner only if contaminants are evident. Combustion products or other contaminates which
accumulate inside the burner may form electrical leakage paths between the collector and the burner contact, resulting in noisy readings.
If the analyzer module is to be operated at the highest
sensitivity, traces of such contaminates can cause erroneous readings.
CAUTION
BURNER CONTAMINATION
Do not handle internal parts of the burner with bare
hands. All tools used for maintenance must be free
of contaminates.
A
Burner Cap Retainer
For best performance, replace the burner jet as follows:
1. Remove oven from analyzer module per Section
4-3a.
2. Remove burner / thermal block from oven per
Section 4-3b.
3. Remove thermal block from burner per Section
4-5a.
4. Refer to Figure 4-7A. Remove screws (2) holding
burner cap retainer, remove retainer.
5. Holding burner base, lift burner cap off assembly,
set aside, remove gasket.
6. Refer to Figure 4-7B. Holding burner base, lift
combustion chamber off, set aside.
O-Ring
03656580
Burner Cap
Burner Base
Combustion Chamber
B
O-Ring
ETC01463
Burner Base
Figure 4-7: Burner Disassembly
4 - 9Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
7. Refer to Figure 4-8. Lift air baffle out of burner
base.
8. Remove the sample jet and gasket from the bottom of the burner base.
Air Baffle (Ref)
102260
(see below)
9. Remove the jet nut. Grasp jet assembly and lift
out (along with upper gasket) of burner base. Remove bottom gasket.
Nut, Jet
016005
Gasket
102273
Sample Jet
657005
Sample Jet
657005
Gasket
102256
Figure 4-8: Burner Jets
Air Baffle
End bent to raise it above the tab a
distance equal to the height of the tab.
≈ .06
Position with tab over
the air hole
(approximately 1/16" to the right).
4 - 10 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
c. Burner Jet Installation
CAUTION
BURNER CONTAMINATION
Do not handle internal parts of the burner with bare
hands. All tools used for maintenance must be free
of contaminates.
1. Install new lower gasket, jet assembly and upper
gasket into burner base, finger-tight jet nut.
2. Install new sample jet (with gasket) and tighten.
3. Tighten jet nut.
4. Install air baffle per Figure 4-8.
NOTE
Incorrect installation of air baffle will cause ignition failure.
5. See Figure 4-7B. Insert new o-ring into burner
base.
6. Set combustion chamber into burner base being
careful not to move air baffle.
7. See Figure 4-7A. Insert new gasket on combustion chamber, install burner cap and burner cap
retainer, torque screws to 6 inch lbs.
4 - 11Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
4-6 THERMAL BLOCK
The sample RTD can be replaced with the thermal block
attached to burner and mounted in oven. The cartridge
heater and thermostat are also replaceable with thermal block secured to burner, but must be removed from
the oven.
a. Sample RTD
1. Refer to Figure 4-4A. Remove the four screws
securing the oven cover, remove cover.
2. Disconnect the sample RTD wiring connector, note
location.
3. Refer to Figure 4-9. Remove the two screws securing the sample RTD, pull sample RTD out.
4. Install replacement sample RTD, secure with
screws.
5. Attach sample RTD wiring connector.
6. Re-attach oven cover.
b. Cartridge Heater
1. Remove oven from analyzer module per Section
4-3a.
2. Remove burner / thermal block from oven per
Section 4-3b.
3. Refer to Figure 4-9. Loosen retaining set screw,
pull out cartridge heater.
4. Install replacement cartridge heater, snug down
set screw.
5. Install burner / thermal block into oven.
6. Install oven into analyzer module.
Sample RTD
657061
Cartridge Heater
659643
Thermostat
659068
Figure 4-9: Thermal Block- Sample RTD, Cartridge Heater and Thermostat
4 - 12 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
c. Thermostat
1. Remove oven from analyzer module per Section
4-3a.
2. Remove burner / thermal block from oven per
Section 4-3b.
3. Refer to Figure 4-9. Remove the two retaining
screws, pull thermostat out.
4. Install replacement thermostat, attach with the two
retaining screws.
5. Install burner / thermal block into oven.
6. Install oven into analyzer module.
d. Sample Capillary
1. Remove oven from analyzer module per Section
4-3a.
2. Remove burner / thermal block from oven per
Section 4-3b.
3. Remove burner from thermal block per Section
4-5a.
4. Refer to Figure 4-10. Remove the two screws
securing the capillary cover to thermal block,
remove cover.
5. Remove capillary nut, remove capillary.
6. Install replacement capillary.
7. Insert capillary into thermal block. The capillary
may require bending to fit.
8. Install cover.
Capillary
Figure 4-10: Thermal Block Assembly
Cover
4 - 13Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
4-7 ELECTRONICS ASSEMBLY The electronics assembly must be removed from the
chassis of replacement of any of the following components is necessary:
CAUTION
Power Supply Board
Safety Board
ELECTROSTATIC DISCHARGE
The electronic parts of the Analyzer Module can
be irreparably damaged if exposed to electrostatic
discharge (ESD).
Computer Analysis Board
Preamp Assembly
Sensor Board
Case Temperature Sensor
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.
Case Pressure Switch
1. Remove the hex nut and screw as shown in
Figure 4-11.
2. Lay electronics assembly on bench, do not disconnect cables or tubing.
Screw
Electronics Assembly
656943
Hex Nut
Figure 4-11: Removing Electronics Assembly from Chassis
4 - 14 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
Preamp Assembly
656945
Case Pressure Purge Switch
903690
Computer Analysis Board
658350
NGA 2000 HFID
Sensor Board
657060
Safety Board
43500271
Case Temperature Sensor
656026
Figure 4-12: Electronics Assembly - Exploded View
a. Printed Circuit Boards
When replacing a circuit board, the following procedure
is recommended:
Per Section 4-7, remove securing hardware from electronics assembly and lay on bench.
Remove securing hardware from printed circuit board
to be replaced, do not disconnect cable(s).
Power Supply Board
655764
One at a time, remove the wiring connectors and attach
to replacement board.
Mount replacement board to electronics assembly.
4 - 15Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
b. Case Temperature Sensor
Instruction Manual
HAS64E-IM-HW
September 2008
1. Per Section 4-7, remove securing hardware from
electronics assembly and lay on bench.
2. Disconnect case temperature sensor cable.
3. Remove screw securing cable clamp holder to signal board.
Figure 4-13: Case Temperature Sensor Installation
c. Case Pressure Purge Switch
1. Per Section 4-7, remove securing hardware from
electronics assembly and lay on bench.
2. Disconnect the two electrical terminals, note location.
4. Remove case temperature sensor from cable
clamp holder.
5. Per Figure 4-13 insert replacement case temperature sensor into cable clamp holder.
6. Re-assemble to signal board mounting screw.
Center Sensor
in Cable Clamp
3. Disconnect tube at pressure switch.
4. Remove mounting screws (2) and washers (2).
5. Reverse procedure for installation of replacement
switch.
Case Pressure Purge Switch
903690
The bracket does not have to be removed from
the electronics assembly for this procedure
Figure 4-14: Case Pressure Purge Switch Installation
4 - 16 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
d. Preamp Assembly
NGA 2000 HFID
1. Per Section 4-7, remove securing hardware from
electronics assembly and lay on bench.
2. Disconnect and note location of cables.
3. Remove the two screws and washers from the
top bracket and slide the preamp assembly out.
4. Remove the lower bracket from the preamp assembly and install on replacement preamp assembly.
5. Slide replacement preamp assembly into top
bracket and secure with mounting hardware.
6. Re-connect cables.
Preamp Assembly
656945
Bottom Bracket
Figure 4-15: Preamp Assembly Installation
4 - 17Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
4-8 FAN ASSEMBLY
1. Disconnect and note location of cables.
2. Remove the two hex nuts securing the fan to the
chassis, lift fan assembly out.
Fan Assembly
657414
Instruction Manual
HAS64E-IM-HW
September 2008
Figure 4-16: Fan Assembly Installation
4 - 18 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
4-9 FLOW CONTROLLER
1. Disconnect the all tubing and wiring connectors,
note locations.
2. Remove the four hex nuts securing the flow controller assembly to the analyzer module chassis.
NGA 2000 HFID
Flow Controller Assembly
657434
Figure 4-17: Flow Controller Replacement
Regulated Air IN
Remove red cap
after installation
Remove and discard bracket supplied with regulator, assembly as shown.
Regulator 250 psi
023382
Flow
Sample Sensor
656418
Figure 4-18: Flow Controller Assembly
Regulated Air OUT
4 - 19Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
4-10 DC POWER SUPPLY MODULE
1. Disconnect and note location of all wiring to DC
power supply module.
2. Remove the two hex nuts securing module to
chassis, remove module.
Instruction Manual
HAS64E-IM-HW
September 2008
DC Power Supply Module
Figure 4-19: DC Power Supply Module Replacement
4 - 20 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
4-11 FRONT PANEL COMPONENTS
The following components are mounted to the front
panel:
• LON/Power Module
• Manual Ignite Toggle Switch
Air Measurement
Restirctor
656888
Connector fitting
Air Ignite Restirctor
655794
Burner Air Sensor
656443
Burner Air Solenoid Valve
656219
Diffuser
657548
Purge Air Flow Switch
656533
Purge Air Regulator
871672
• LED Indicator Assembly
• Purge Air Regulator
• Purge Air Flow Switch
• Burner Air Solenoid Valve
• Burner Air Regulator
• Fuel Regulator
• Burner Air Sensor
• Fuel Sensor
• Air Ignite Restrictor
• Air Measurement Restrictor
Regulator Mounting Nut
Regulator Mounting Nut
LON/Power Module
656560
Fuel Sensor
656444
Sensor Fitings
657412
Burner Air Regulator
902832
Male Adapter
Fitting
Fuel Regulator
902832
O-Rings / Thrust Rings
008025 42716383
Plugs
Manual Ignite
Manual Ignite
Toggle Switch
Toggle Switch
655794
655794
O-Ring
011177
Figure 4-20: Front Panel - Exploded View
LED Indicator Assembly
657029
O-Ring
011167
Toggle Switch Seal
898980
4 - 21Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Replacing Front Panel Components
Instruction Manual
HAS64E-IM-HW
September 2008
1. To access components, remove the four front
panel mounting screws (two on front, one on each
side).
2. Remove the burner air regulator and fuel regulator mounting nuts.
3. Remove the purge air regulator mounting bracket
screws.
The front panel can now be pulled away from the chassis.
NOTE
The wiring from front panel components is still
connected. Do not disconnect unless replacing
that component.
Front panel mounting screw
(opposite side also)
Front panel
mounting screws
Figure 4-21: Accessing Front Panel Components
4 - 22 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
a. LON/Power Module
1. Disconnect wiring connectors, note locations.
2. Refer to Figure 4-20. From the outside of the front
panel, remove the two mounting screws.
3. Install replacement module in reverse order.
b. LED Indicator Assembly
1. Disconnect wiring connector, note location.
2. Refer to Figure 4-20. From the inside of the front
panel, remove the two hex nuts securing LED indicator assembly to front panel. Remove indicator assembly and o-rings (four).
3. Inspect o-rings for damage, replace if necessary.
Install o-rings on replacement indicator assembly, mount assembly on mounting studs with hex
nuts.
4. Re-connect wiring connector.
c. Manual Ignite Toggle Switch
1. Disconnect wiring connector, note location.
2. Refer to Figure 4-20. From the outside of the front
panel, remove the toggle switch seal.
3. Pull the switch and o-ring out from inside the front
panel.
4. Inspect o-ring for damage, replace if necessary.
Install o-ring on replacement switch, insert through
front panel from the inside.
5. Install switch seal.
6. Re-connect wiring connector.
d. Burner Air Sensor
1. Disconnect wiring connector, note location.
2. Using an open-end wrench to hold the sensor fitting while using another open-end wrench to remove the sensor.
3. Replace the Teflon pipe thread tape on the treads
of the sensor fitting.
4. Install sensor onto sensor fitting.
5. Re-connect wiring connector.
e. Fuel Sensor
1. Disconnect wiring connector, note location.
2. Using an open-end wrench to hold the sensor fitting while using another open-end wrench to remove the sensor.
3. Replace the Teflon pipe thread tape on the treads
of the sensor fitting.
4. Install sensor onto sensor fitting.
5. Re-connect wiring connector.
f. Burner Air and Fuel Regulator
1. Disconnect the two tubes and the sensor fitting
on the rear of the regulator, note locations.
2. Replace the Teflon pipe thread tape on the threads
of the sensor fitting.
3. Remove the regulator and o-ring.
4. The replacement regulator comes with two panel
mounting nuts, remove both and discard one of
them.
5. Inspect o-ring for damage, replace if necessary.
Install o-ring onto regulator threaded shaft.
6. Insert regulator into front panel, secure with mounting nut.
7. Re-attach the three tubes.
g. Purge Air Regulator
1. Remove the regulator mounting nut, remove
mounting bracket.
2. Loosen nut on tee fitting attached to purge air flow
switch.
3. Disconnect tube at elbow, remove regulator.
4. Remove the two plugs, elbow and male adapter
fittings from the regulator.
5. Replace the Teflon pipe thread tape on the two
plugs, the elbow and the male adapter and install
into replacement regulator.
6. Connect tube to elbow, insert male adapter into
tee fitting.
7. Install mounting bracket onto regulator, hand snug
mounting nut.
8. Attach mounting bracket to front panel, tighten
regulator mounting nut.
4 - 23Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
h. Purge Air Flow Switch and Diffuser
1. Unscrew flow switch from tee fitting.
2. Replace Teflon pipe thread tape on tee fitting.
3. Remove diffuser from flow switch and install into
replacement flow switch.
4. Install replacement flow switch.
5. Install purge switch onto tee fitting.
6. Re-connect tubes.
i. Burner Air Solenoid Valve
1. Disconnect the tube at the top elbow fitting.
2. Disconnect the tube at the tee fitting, remove valve
analyzer module.
3. Holding the air ignite restrictor, unscrew the solenoid valve.
4. On the solenoid valve, remove the connector fitting.
5. Replace the Teflon pipe thread tape on the elbow,
connector and restrictor.
6. Verify replacement solenoid valve wires (flat side
of body) are exiting on the same side as the COM
port as shown in Figure 4-20. If not, use an openend wrench to hold the N.O. hex port while rotating body.
7. Install air ignite restrictor into N.C. port.
8. Install elbow into COM port and connector fitting
into N.O. port.
9. Re-connecto tubes.
j. Air Ignite Restrictor
1. On the burner air solenoid valve:
a. Disconnect the tube at the top elbow
fitting.
b. Disconnect tube at tee fitting.
c. Lift solenoid valve from analyzer module.
d. Disconnect tube going to air ignite
restrictor.
e. Remove restrictor from solenoid valve.
2. Add Teflon pipe thread tape to replacement
restrictor, install into solenoid.
3. Re-connect tubes to restrictor, elbow and tee fitting.
4 - 24 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
4-12 REAR PANEL COMPONENTS
NGA 2000 HFID
The following components are mounted to the rear panel:
• Fuel In 2-Way Solenoid Valve
• Regulated Air In Check Valve
VIEW FROM INSIDE ANALYZER MODULE
• Burner Air In Filter
• Heated Sample Bypass Out Restrictor
• Heated Sample In Restrictor
Check Valve,
Regulated Air IN
903728
Solenoid Valve,
Fuel IN
656218
VIEW FROM OUTSIDE ANALYZER MODULE
Filter,
Burner Air IN
017154
Restrictor,
Bypass OUT
10 Micron
619615
Figure 4-22: Rear Panel Components
Restrictor,
Heated Sample IN
40 Micron
619616
4 - 25Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
a. Fuel In 2-Way Solenoid Valve
1. Disconnect wiring solenoid valve wiring connector, note location.
2. Inside the analyzer module, disconnect the tube
going to the connector on the "out" port of the solenoid valve.
3. On the rear of the analyzer module at the fuel in
port:
a. Disconnect the fuel in tube.
b. Remove nuts and washers
c. Remove solenoid valve from analyzer
module
4. Remove the fittings from the solenoid valve and
replace the Teflon pipe thread tape.
5. Verify that body of replacement solenoid valve is
oriented as shown in Figure 4-22. If not, rotate till
wires are in-line with "out" port.
6. Install fittings into replacement solenoid valve, reinstall in analyzer module.
b. Burner Air In Filter
c. Heated Bypass Sample Out and Heated
Sample In Restrictors
1. On the outside of the rear panel, disconnect tube
and remove nut.
2. Insert a small spade screwdriver into the bulkhead
and remove the restrictor.
3. Install in reverse order.
d. Regulated Air In Check Valve
1. Disconnect tube at elbow.
2. Remove check valve from female connector.
3. Remove elbow from check valve.
4. Add Teflon pipe thread tape to check valve threads.
5. Install elbow onto check valve.
6. Install check valve into female connector, verifying orientation of elbow fitting as shown in Figure
4-22.
1. Leaving the bulkhead fitting secured to the rear
panel, remove the tubes, nuts and ferrules from
the fitting.
2. Insert a clean, rigid piece of tube or rod (smaller
than .25 inch diameter) into the bulkhead fitting to
force out the filter disc.
3. Install the replacement filter in the same manner,
through the rear of the bulkhead fittings.
4. Re-connect tubes.
4 - 26 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
4-13 LEAKAGE TEST
The gas path system should be leak tested at least twice
a year and after maintenance, replacement or repair of
gas path parts.
a) Required Tools
• Test Medium
• external Manometer
• Swagelok® Blind Unions SS (2)
• Swagelok® Blind Unions brass (2)
• tube piece with rubber stopper
b) Procedure
To perform a leakage testing, proceed as follows (see
figure 4-23):
1. Close gas supplies and disconnect the gas connections
2. Close „Fuel IN“, „Burner Air IN“, „Bypass OUT“
and „Regulated Air IN“ with blind unions
3. Close „Exhaust“ with a tube piece with rubber stopper.
4. Connect a pressure meter to „Sample IN“ fitting
5. Connect test medium supply (N2 or He) to the pressure meter
6. Supply Analyzer Module with the test medium with
a pressure of max. 250 hPa (3.63 psig) and close
supply. Since HFID internal it comes to equalization of pressure, supply is to open and to close
repeatedly until manometer doesn’t show pressure changes.
CAUTION
POSSIBLE INSTRUMENT DAMAGE
The pressure of the test medium must
not exceed 250 hPa (3.63 psig) !
7. Watch the manometer.
Over a period of about 5 minutes the pressure
drop may not be higher than 7.5 hPa/min. (- 0.11
psig/min.) using Helium (He) or 2.5 hPa/min.
(- 0.036 psig/min.) using Nitrogen (N2).
If the specifications (see table 4-1) were adhered to,
then the test is finished.
N
2
or
He
test medium
Gas source with
Closed Gas Connections:
„Fuel IN“, „Burner Air IN“,
„Bypass OUT“, „Exhaust“,
„Regulated Air IN“
External Manometer:
3.63 psig = 250 hPa
HFID Analyzer Module
P
Sample In
Figure 4-23: Principle Leakage Test Assembly
Test Medium Nitrogen (N2) Helium (He)
Test Pressure
Test Time
permissible
Drop in Pressure
3.63 psig / 250 hPa / 0.25 bar 3.63 psig / 250 hPa / 0.25 bar
5 min 5 min
2.5 hPa (0.036 psig) / min 7.5 hPa (0.11 psig) / min
Table 4-1: Leakage Test Specifications
4 - 27Maintenance and ServiceEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
If there is a leakage, then proceed as follows:
a) Using Helium (He) for test medium
• Supply Analyzer Module with the test medium
with a pressure of max. 250 hPa (3.63 psig).
• Look for the leak with a helium leak detector.
b) Using Nitrogen (N2) for test medium
• Supply Analyzer Module with the test medium
with a pressure of max. 250 hPa (3.63 psig).
• Liberally cover all fittings, seals, and other possible sources of leakage with a suitable leak
test liquid such as SNOOP. Bubbling or foaming indicates leakage.
• Remove the source of leak.
• Perform a leakage test once more as decribed
obove.
Instruction Manual
HAS64E-IM-HW
September 2008
.
4 - 28 Maintenance and Service Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
SECTION 5
TROUBLESHOOTING
WARNING
GENERAL HAZARD
Before starting troubleshooting to this equipment, read the "Essential instructions" on the inside cover and
the Safety Summary beginning on page P-2.
Failure to follow the safety instructions could result in serious injury or death.
5-1 TROUBLESHOOTING CHECKLIST
a. Safety System
1. Verify purge supply pressure at bulkhead is
between 689 hPa and 1,378 hPa (10 psig and
20 psig).
2. Check case for leaks.
3. Check burner for leaks.
4. Verify purge pressure sensor tube connection.
5. Verify purge out port is vented to atmospheric
pressure.
6. Verify Safety PCB connector J2 is attached.
7. Check for a +24V power glitch.
8. Verify that there is no large vibration shock.
9. Check for external leak in purge line.
10. Verify case pressure is greater than 0.5" of
water.
11. Check case for over-pressurization.
12. Verify the purge flow/pressure switch harness is
routed away from the solenoid valves.
13. Verify the purge timer is counting.
14. Verify purge timer jumper is correctly installed.
b. Ignition
1. Verify that the fuel pressure/flow is correct.
2. Verify that the burner air pressure/flow is correct.
3. Verify that the igniter is generating enough heat.
4. Verify the burner exhaust is vented to atmosphere.
5. Verify safety system has been activated.
6. Verify the manual switch is operating correctly.
7. Verify auto-ignite parameters are properly set.
8. Verify burner is properly seated.
9. Verify quality of air supply is good.
10. Verify quality of fuel supply is good.
11. Check burner tip for damage.
12. Check air and fuel restrictor for correct flow.
13. Check burner tip alignment.
14. Verify burner cone is tight.
15. Check burner air and fuel lines for leaks.
16. Verify oven temperature is greater than 85°C
(185 °F).
17. Verify the reference thermistor is 100K ohm
±15% at 25°C (77 °F).
15. Verify Internal purge pressure is greater than
380 hPa (5.5 psig).
16. Verify the purge gas switch has been activated.
18. Verify that there is + 10 VDC to be the reference
thermistor.
5 - 1TroubleshootingEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
c. Drift
1. Verify that the sample, burner air, and fuel supply
pressures are constant.
2. Check that the sample, burner air, and fuel
supply pressures are constant.
3. Verify that the oxygen level in the burner air and
sample are constant.
4. Verify the THC level is correct for the burner air
and fuel supply.
5. Check that the ambient temperature is changing
< 10 K per hour.
6. Verify the burner is clean.
7. Verify temperature of the sample gas, case,
burner, and oven has stabilized.
8. Verify the Preamp PCB is clean.
9. Verify atmospheric pressure at burner exhaust is
constant.
10. Verify purge gas pressure is constant.
d. Noise
1. Check that the burner exhaust is free from water
condensation.
2. Verify connection to the collector is correct.
3. Verify connection to the polarizing voltage is
correct.
4. Check the ambient temperature is changing
< 10 K per hour.
5. Verify the + 24 VDC is clean and grounded
properly.
6. Verify there are no strong magnetic fields near.
7. Check for excessive vibration.
8. Verify burner exhaust is vented to a constant
atmospheric pressure.
9. Verify bypass line is vented to a constant
atmospheric pressure.
10. Verify purge out port vented to a constant
atmospheric pressure.
11. Verify burner has been on and stabilized.
12. Check for gas leaks.
11. Verify the collector wires are routed away from
the heater.
12. Verify the collector wires are clean and not
damaged.
5 - 2 Troubleshooting Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
SECTION 6
REPLACEMENT PARTS
WARNING
UNAUTHORIZED SUBSTITUTION OF COMPONENTS
Tampering with or unauthorized substitution of components may adversely affect the safety of this instrument. Use only factory documented/approved components for repair.
Because of the danger of introducing additional hazards, do not perform any unauthorized modification to
this instrument!
6-1 MATRIX
Each analyzer is configured per the customer sales order.
To identify the configuration of an analyzer, locate the
analyzer name plate label. The analyzer matrix appears
on the analyzer name plate label.
Measuring Range
(Fullsclae Range)
Serial Number
Analyzer Matrix
Figure 6-1: Name Plate Label
6 - 1Replacement PartsEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
6-2 GENERAL
813344 Fuse, 6A
903107 Fuse, Thermal Cutoff 72° (2 Required - Safety and Power Supply PCB's)
657029 LED Indicator Assembly
656560 LON/Power Module
657413 DC Power Supply Module
657053 Manual Ignite Switch Assembly
657414 Fan Assembly
656943 Electronics Assembly
658350 Computer Board
656945 Preamp Assembly
43500721 Safety Board
655764 Power Supply Board
657060 Sensor Board
656026 Case Temperature Sensor
657094 PROM SW-Version 2.3
659894-R1 PROM SW-Version 3.3.1
659894-R2 PROM SW-Version 3.3.3
659894-RB PROM SW-Version 3.3.4
659894-R3 PROM SW-Version 3.6
659894-R4 PROM SW-Version 3.7.0
659894-R5 PROM SW-Version 3.7.1
659894-R6 PROM SW-Version 3.7.2
659894-R7 PROM SW-Version 3.9.3
659894-R8 PROM SW-Version 3.9.4
Instruction Manual
HAS64E-IM-HW
September 2008
6-3 PNEUMATICS
017154 Filter, .25 DIA x .06 - .09 THK 50-100 Microns (Burner Air)
902832 Regulator 0-60 PSI (Fuel and Burner Air)
657434 Fixed Flow Controller Assembly
023382 Regulator 250 psi
656418 Sample Sensor
871672 Purge Air Regulator
655794 Air Ignite Restrictor
656888 Air Measurement Restrictor
656443 Burner Air Sensor
656444 Fuel Sensor
656418 Flow Control Sample Pressure Sensor
656219 Burner Air 3-Way Solenoid Valve
656218 Fuel In Solenoid Valve
903690 Case Pressure Purge Switch
6 - 2 Replacement Parts Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
656533 Purge Air Flow Switch
903728 Regulated Air In Check Valve
903647 Case Pressure Relief Valve
6-4 OVEN COMPONENTS
659551 Oven Assembly 9.7 cc/min @ 3.5 psig
658338 Oven Assembly 2.5 cc/min @ 3.5 psig
657359 Burner Assembly
657205 Igniter Assembly
903736 O-Ring (Igniter Assembly)
657063 RTD Detector
903125 Set Screw M3x0.5 x 10mm (RTD Detector)
657468 Temperature Sensor
657199 Flameout Sensor
903737 O-Ring (Flameout Sensor)
03656580 O-Ring
ETC01463 O-Ring
102260 Air Baffle
657016 Jet Nut
102273 Gasket
657012 Jet Assembly
102256 Gasket
657005 Sample Jet
NGA 2000 HFID
659614 Thermal Block Assembly
42716459 Spare Part Kit compl. (incl. ferrules) 9.7 cc/min @ 3.5 psig
657486 Capillary, Mixed Fuel (Lo) 9.7 cc/min @ 3.5 psig
42716460 Spare Part Kit compl. (incl. ferrules) 2.5 cc/min @ 3.5 psig
657550 Capillary, Mixed Fuel (Hi) 2.5 cc/min @ 3.5 psig
657061 Sample RTD
659618 Heated Bypass Sample Out Restrictor Assembly - 10 Microns
659615 Restrictor, Heated Bypass Sample Out - 10 Microns
659619 Heated Sample In Restrictor Assembly - 40 Microns
659616 Restrictor, Heated Sample In - 40 Microns
657065 Thermostat 232 °C (450 °F)
659643 Cartridge Heater
6 - 3Replacement PartsEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
Instruction Manual
HAS64E-IM-HW
September 2008
6 - 4 Replacement Parts Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
SECTION 7
RETURN OF MATERIAL
7-1 RETURN OF MATERIAL
If factory repair of defective equipment is required, proceed as follows:
1. Secure a return authorization from a Emerson
Processs Management Sales Office or Representative before returning the equipment. Equipment
must be returned with complete identification in
accordance with Emerson instructions or it will not
be accepted.
2. In no event will Emerson be responsible for equipment returned without proper authorization and
identification.
3. Carefully pack the defective unit in a sturdy box
with sufficient shock absorbing material to ensure
no additional damage occurs during shipping.
The completed and signed Declaration of Contamination (page S-2)
must be included with the instrument
(we recommend to attach it to the
packaging outside)!
4. In a cover letter, describe completely:
a. The symptoms that determined the equipment
is faulty.
b. The environment in which the equipment was
operating (housing, weather, vibration, dust,
etc.).
c. Site from where the equipment was removed.
d. Whether warranty or non-warranty service is
expected.
e. Complete shipping instructions for the return
of the equipment.
5. Enclose a cover letter and purchase order and
ship the defective equipment according to instructions provided in the Emerson Return Authorization, prepaid, to:
In US:
EMERSON Process Management
Rosemount Analytical Inc.
Customer Service Center
USA: 1-800-433-6076
1-440-914-1261
In Europe:
EMERSON Process Management
GmbH & Co. OHG
Service Department Deutschland
D-63594 Hasselroth, Germany
Industriestrasse 1
+49 6055 884-470/-472 Fax: -209
In Asia Pacific:
EMERSON Process Management
Asia Pacific Pte Limited
Singapore
+65-6-777-8211
If warranty service is expected, the defective unit will be
carefully inspected and tested at the factory. If the failure was due to the conditions listed in the standard Emerson warranty, the defective unit will be repaired or replaced at Emerson´s option, and an operating unit will
be returned to the customer in accordance with the shipping instructions furnished in the cover letter.
For equipment no longer under warranty, the equipment
will be repaired at the factory and returned as directed
by the purchase order and shipping instructions.
7 - 1Return of MaterialEmerson Process Management GmbH & Co.OHG
NGA 2000 HFID
7-2 CUSTOMER SERVICE
For order administration, replacement parts, application
assistance, on-site or factory repair, service or maintenance contract information, contact:
EMERSON Process Management
Process Analytic Division
Customer Service Center
USA: +1 (800) 433-6076
EU: +49 (6055) 884-470
7-3 TRAINING
A comprehensive Factory Training Program of operator
and service classes is available. For a copy of the Current Operator and Service Training Schedule, contact
the Technical Services Department at:
EMERSON Process Management
GmbH & Co. OHG
D-63594 Hasselroth, Germany
Industriestrasse 1
EU: +49 (6055) 884-470/-472 Fax: -469
Instruction Manual
HAS64E-IM-HW
September 2008
EMERSON Process Management
Rosemount Analytical Inc.
Customer Service Center
USA: +1 (800) 433-6076
7 - 2 Return of Materials Emerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
September 2008
NGA 2000 HFID
LIST OF FIGURES AND TABLES
1 LIST OF FIGURES
Figure A-1: From separate analyzers to analyzer system ............................................................... A - 1
Figure A-2: Example of NGA cabling ...............................................................................................A - 2
Figure A-3: Example/Possibilities of NGA Analyzer System ............................................................ A - 3
Figure 1-1: Function Principle of FID Measurement ........................................................................ 1 - 2
Figure 1-2: HFID Analyzer Module - Flow Diagram .........................................................................1 - 3
Figure 1-3: HFID Analyzer Module - Top View .................................................................................1 - 4
Figure 2-1: Analyzer Module Installation into Instrument Platform (view without front panel).......... 2 - 1
Figure 2-2: HFID Rear Panel Connections ...................................................................................... 2 - 3
Figure 2-3: Front Panel Electrical Connections................................................................................2 - 6
Figure 2-4: Front Panel Controls, Indicators and Electrical Connections.........................................2 - 6
Figure 2-5: HFID Wiring Diagram.....................................................................................................2 - 7
Figure 2-6: Outline and Mounting Dimensions .................................................................................2 - 8
Figure 3-1: Self Test Menu ...............................................................................................................3 - 2
Figure 3-2: Miscellaneous Control Parameters ................................................................................3 - 3
Figure 3-3: Calibration Gas List ....................................................................................................... 3 - 5
Figure 3-4: Range Settings Menu ....................................................................................................3 - 5
Figure 3-5: Calibration Parameters Display .....................................................................................3 - 6
Figure 3-6: Analyzer Module Factoring Data ................................................................................... 3 - 6
Figure 3-7: Basic Controls Menu......................................................................................................3 - 7
Figure 3-8: Analyzer Zero Menu ...................................................................................................... 3 - 7
Figure 3-9: Analyzer Span Menu......................................................................................................3 - 8
Figure 3-10: Measure Mode Display ..................................................................................................3 - 9
Figure 3-11: Physical Measurements Display ....................................................................................3 - 9
Figure 3-12: Excerpt of a Test Data Sheet with values that are to be compaired with ..............................
physical measurements. ..............................................................................................3 - 10
Figure 3-13: Front Panel Torque Sequence ..................................................................................... 3 - 11
Figure 3-14: Typical Curve of Module Response vs. Pressure Setting on Fuel Press. Regulator ...3 - 12
Figure 3-15: Typical Curve of Module Response vs. Pressure Setting on Air Press. Regulator ......3 - 12
Figure 3-16: System SIO Module Menu ...........................................................................................3 - 14
Figure 3-17: Analog Output Setup Menu .........................................................................................3 - 14
Figure 3-18: Analyzer Modules Menu .............................................................................................. 3 - 14
Figure 3-19: Signals Menu ...............................................................................................................3 - 15
Figure 3-20: Output Signal If Assigned Module Fails Menu .............................................................3 - 15
Figure 3-21: Special Scaling for Concentration Signal Menu........................................................... 3 - 16
Figure 3-22: Analog Output Updates per Second Menu. .................................................................3 - 16
L - 1List of Figures and TablesEmerson Process Management GmbH & Co.OHG
Instruction Manual
HAS64E-IM-HW
NGA 2000 HFID
September 2008
Figure 3-23: Serial Interface Setup Menu ........................................................................................3 - 17
Figure 3-24: AK Protocol Definitions Menu ......................................................................................3 - 17
Figure 3-25: Relay Outputs Setup Menu ..........................................................................................3 - 18
Figure 3-26: Choose Source Module Menu ..................................................................................... 3 - 18
Figure 3-27: Choose Signal Menu ...................................................................................................3 - 18
Figure 4-1: Removal of Cover and Insulation Shield........................................................................4 - 2
Figure 4-2: Location of Major Assemblies of the HFID Module ........................................................4 - 3
Figure 4-3: Removal of Oven from Chassis .....................................................................................4 - 4
Figure 4-4: Oven Assembly ..............................................................................................................4 - 5
Figure 4-5: Burner-Sensor, Flameout Detector, RTD Detector and Igniter ...................................... 4 - 7
Figure 4-6: Burner/Thermal Block Disassembly............................................................................... 4 - 8
Figure 4-7: Burner Disassembly.......................................................................................................4 - 9
Figure 4-8: Burner Jets .................................................................................................................. 4 - 10
Figure 4-9: Thermal Block- Sample RTD, Cartridge Heater and Thermostat ................................ 4 - 12
Figure 4-10: Thermal Block Assembly .............................................................................................4 - 13
Figure 4-11: Removing Electronics Assembly from Chassis............................................................ 4 - 14
Figure 4-12: Electronics Assembly - Exploded View ........................................................................4 - 15
Figure 4-13: Case Temperature Sensor Installation .........................................................................4 - 16
Figure 4-14: Case Pressure Purge Switch Installation ..................................................................... 4 - 16
Figure 4-15: Preamp Assembly Installation......................................................................................4 - 17
Figure 4-16: Fan Assembly Installation ............................................................................................4 - 18
Figure 4-17: Flow Controller Replacement ...................................................................................... 4 - 19
Figure 4-18: Flow Controller Assembly ............................................................................................4 - 19
Figure 4-19: DC Power Supply Module Replacement .....................................................................4 - 20
Figure 4-20: Front Panel - Exploded View ....................................................................................... 4 - 21
Figure 4-21: Accessing Front Panel Components ...........................................................................4 - 22
Figure 4-22: Rear Panel Components .............................................................................................4 - 25
Figure 4-23: Principle Leakage Test Assembly ................................................................................4 - 27
Figure 6-1: Name Plate Label ..........................................................................................................6 - 1
2 LIST OF TABLES
Table A-1: Possibilities of NGA 2000 I/O combinations ................................................................. A - 4
Table 1-1: Sample Capillary depending on Module Configuration ..................................................1 - 3
Table 3-1: Typical Operation Pressures..........................................................................................3 - 3
Table 3-2: HFID Analyzer Module Alarms .....................................................................................3 - 13
Table 4-1: Leakage Test Specifications ........................................................................................ 4 - 27
L - 2 List of Figures and Tables Emerson Process Management GmbH & Co.OHG
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