Rosemount NGA 2000 NDIR Analyzer Module SW 2.2-Rev D Manuals & Guides

NGA 2000

N

ON

-D

ISPERSIVE INFRARED

A

NALYZER

Rosemount Analytical

M

ODULE

N

OTICE

T

HE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE

Pyrex® is a registered trademark of Corning Glass Works

®

Irtran

is a registered trademark of Eastman Kodak Co.

®

Teflon

Ty-Rap

and Viton® is a registered trademark of E.I. duPont de Nemours and Co., Inc.

®

is a registered trademark of Thomas & Betts Corp.

.

Manual Part Number 748332-D
June 1997
Printed in U.S.A.

Rosemount Analytical Inc.

4125 East La Palma Avenue
Anaheim, California 92807-1802

C

P

REFACE

PURPOSE/SAFETY SUMMARY........................................................................P-1

GLOSSARY ......................................................................................................P-4

SPECIFICATIONS..............................................................................................P-6

CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE ....P-8

RETURNING PARTS TO THE FACTORY .........................................................P-8

TRAINING ......................................................................................................P-8

DOCUMENTATION............................................................................................P-8

COMPLIANCES..................................................................................................P-9

ONTENTS

S

ECTION

1.1 OVERVIEW ...............................................................................................1-1

1.2 TYPICAL APPLICATIONS.........................................................................1-1

1.3 THEORY OF TECHNOLOGY....................................................................1-2

1.4 SAMPLE REQUIREMENTS ......................................................................1-4

1-5 PURGE KITS.............................................................................................1-5

1.6 FEATURES................................................................................................1-5

S

ECTION

2.1 UNPACKING..............................................................................................2-1

2.2 ASSEMBLY................................................................................................2-1

2.3 LOCATION ................................................................................................2-2

2.4 GASES ......................................................................................................2-2

2.5 ELECTRICAL CONNECTIONS .................................................................2-5

1. I

2. I

2.4.1 Specifications...............................................................................2-2

2.4.2 Connections.................................................................................2-3

NTRODUCTION

NSTALLATION

748332-D Rosemount Analytical June 1997

NGA Non-Dispersive Infrared Analyzer

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C

ONTENTS

S

ECTION

3.1 OVERVIEW............................................................................................... 3-1

3.2 DISPLAY SCREENS.................................................................................3-1

3.2.1 RUN MODE DISPLAY............................................................................3-1

3.3 STARTUP PROCEDURE..........................................................................3-2

3.4 BINDING ...................................................................................................3-5

3.5 CALIBRATION ..........................................................................................3-5

3.6 LINEARIZATION.......................................................................................3-8

3.7 ROUTINE OPERATION............................................................................3-9

S

ECTION

4.1 OVERVIEW............................................................................................... 4-1

4.2 PCB REPLACEMENT...............................................................................4-2

4.3 POWER FUSE REPLACEMENT ..............................................................4-2

3. S

3.2.2 Menu Displays.............................................................................3-1

3.2.3 Help Displays...............................................................................3-2

4. M

TARTUP AND OPERATION

AINTENANCE AND TROUBLESHOOTING

4.4 MODULE FAN REPLACEMENT...............................................................4-2

4.5 CHOPPER MOTOR REPLACEMENT ......................................................4-3

4.6 SOURCE REPLACEMENT.......................................................................4-3

4.7 DETECTOR REMOVAL............................................................................4-3

4.8 FLOW SENSOR REPLACEMENT............................................................4-3

4.9 CASE TEMPERATURE SENSOR REPLACEMENT ................................4-4

4.10 THERMAL FUSE REPLACEMENT...........................................................4-4

4.11 OSCILLATOR TUNE/SOURCE BALANCE SHUTTER ADJUSTMENT....4-4

4-12 CLEANING CELLS ...................................................................................4-8

4-13 CELL DESICCANT ...................................................................................4-10

4.14 MODULATION CHECK.............................................................................4-10

S

ECTION

5.1 REPLACEMENT PARTS ..........................................................................5-1

5.

REPLACEMENT PARTS

A

PPENDIX

ii

A. I

DENTIFICATION MATRIX

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer

NFRARED ANALYZER DATA SHEET

I

ENERAL PRECAUTIONS FOR HANDLING

G

ARRANTY

W

IELD SERVICE AND REPAIR FACILITIES

F

F

IGURES

1-1 NGA 2000 NDIR Analyzer Module (Typical - Actual configuration May

Vary)..............................................................................................1-3

1-2 NDIR Technology ......................................................................................1-4

2-1 Analyzer Module Installation Into Instrument Platform...............................2-1

2-2 Outline and Mounting Dimensions.............................................................2-4

2-3 NDIR Back Panel.......................................................................................2-5

2-4 NDIR Front Panel Electrical Connections..................................................2-5

2-5 NDIR Wiring Diagram................................................................................2-6

3-1 Run Mode Display.....................................................................................3-3

3-2 Main Menu Display....................................................................................3-3

3-3 Basic Controls Menu..................................................................................3-3

3-4 Expert Controls and Setup Menu...............................................................3-4

3-5 Technical Level Configuration Menu .........................................................3-4

3-6 Typical Help Screen...................................................................................3-4

3-7 Typical Linearization Curve, Linearizer OFF..............................................3-7

3-8 Operator-Determined Linearization Curve (Normalized)............................3-7

3-9 Display Screens (1 of 5)............................................................................3-10

3-10 Display Screens (2 of 5)............................................................................3-11

3-11 Display Screens (3 of 5)............................................................................3-12

3-12 Display Screens (4 of 5)............................................................................3-13

3-13 Display Screens (5 of 5)............................................................................3-14

4-1 Printed Circuit Board Fold-Out Panel Views..............................................4-2

4-2 Module Fan Assembly...............................................................................4-3

4-3 Motor/Source Assembly.............................................................................4-4

4-4 Cell, PCB Assembly (Exploded View)........................................................4-6

4-5 Oscillator Tune, Source Balance Shutter Adjustments..............................4-7

4-6 Detector Block (Exploded View) ................................................................4-7

4-7 Cell Disassembly.......................................................................................4-9

TORING HIGH PRESSURE CYLINDERS

& S

C

ONTENTS

T

ABLES

2-1. Cell Purging Times at Atmospheric Sample Pressure...............................2-2

3-1 NDIR Analyzer Module Alarms..................................................................3-6

4-1 Cell Desiccant............................................................................................4-10

748332-D Rosemount Analytical June 1997

NGA Non-Dispersive Infrared Analyzer

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C

ONTENTS

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OTES

iv

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer

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REFACE

P

URPOSE/SAFETY SUMMARY

The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of this particular NGA 2000 module.

Some sections may describe equipment not used in your configuration. The user
should become thoroughly familiar with the operation of this module before operating
it. Read this instruction manual completely.

To avoid explosion, loss of life, personal injury and damage to this equipment
and on-site property, all personnel authorized to install, operate and service this
equipment should be thoroughly familiar with and strictly follow the instructions
in this manual. SAVE THESE INSTRUCTIONS.

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

DANGER

personal injury, death, or substantial property damage if the warning is ignored.

WARNING

personal injury, death, or substantial property damage if the warning is ignored.

CAUTION

personal injury or property damage if the warning is ignored.

NOTE

important but not hazard-related.

is used to indicate the presence of a hazard which

is used to indicate the presence of a hazard which

is used to indicate the presence of a hazard which

is used to indicate installation, operation or maintenance information which is

will

cause

can

cause

will or can

cause

severe

severe

minor

WARNING: ELECTRICAL SHOCK HAZARD

Operate this equipment only when covers are secured. Servicing requires
access to live parts which can cause death or serious injury. Refer servicing to
qualified personnel.

For safety and proper performance, this module must be connected to a
properly grounded three-wire source of electrical power.

748332-D Rosemount Analytical June 1997

NGA Non-Dispersive Infrared Analyzer

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WARNING: POSSIBLE EXPLOSION HAZARD

This equipment is not designed for and should not be used in the analysis of
flammable samples. Use of this equipment in this way could result in explosion
and death.

WARNING: POSSIBLE EXPLOSION HAZARD

Ensure that all gas connectors are made as labeled and are leak free. Improper
gas connections could result in explosion or death.

CAUTION: PRESSURIZED GAS

This module requires periodic calibration with a known standard gas. See
General Precautions for Handling and Storing High Pressure Gas Cylinders at
the rear of this manual.

CAUTION: HAND INJURY HAZARD

Dropping the front panel of the Platform while hand or fingers are inside either
case handle can cause serious injury.

P-2

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer

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REFACE

CAUTION: PARTS INTEGRITY

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

CAUTION: OVERBALANCE HAZARD

This Analyzer Module may tip instrument over if it is pulled out too far and the
Platform is not properly supported.

WARNING: OVER-VOLTAGE SPIKING

If this Analyzer Module is used with a non-Rosemount Analytical power supply,
adding Rosemount Analytical PN 903341 Current Protector in series with the
24V positive power line will prevent over-voltage spiking and resultant fuse
blowing when powering up the instrument.

Note
Apply leak test liquid to cell or detectors only as a last resort.

748332-D Rosemount Analytical June 1997

NGA Non-Dispersive Infrared Analyzer

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REFACE

G

LOSSARY

NALYZER MODULE

A

The module that contains all sensor/detector components for development of a
Primary Variable signal; includes all signal conditioning and temperature control
circuitry.

ACKPLANE

B

The interconnect circuit board which the Controller Board, Power Supply, Analyzer
Module power and network cables, I/O Modules and Expansion Modules plug into.

ONTROL MODULE

C

The Operator Interface plus the Controller Board.

ONTROLLER BOARD

C

The computer board that serves as the Network Manager and operates the Display
and Keypad.

ISTRIBUTION ASSEMBLY

D

The Backplane and the card cages that hold I/O and Expansion Modules.

XPANSION MODULE

E

A circuit board that plugs into the Backplane from the front of the Platform and
performs special features not related to I/O functions.

I/O M

A circuit board that plugs into the Backplane from the rear of the Platform. Has a
connector terminal for communication with external data acquisition devices and
provides an input/output function.

ODULE

P-4

PERATOR INTERFACE

O

The Display and Keyboard.

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer

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REFACE

LATFORM

P

Any workable collection of the following: Controller Board, Power Supply, Distribution
Assembly, Enclosure and Operator Interface.

OWER SUPPLY

P

Any of a variety of components that provides conditioned power to other NGA 2000
components, from the Power Supply Board that plugs into the front of the Backplane
in a stand-alone instrument to several larger ones that can power larger collections of
modules and components.

RIMARY VARIABLE

P

The measured species concentration value from an Analyzer Module.

ECONDARY VARIABLE

S

Data placed on the network by a module regarding current status, e.g., sample flow,
source voltage and other diagnostic information.

OFTKEYS

S

The five function keys located below the front panel display; they assume the function
displayed directly above each on the display, a function dictated by software.

YSTEM

S

Any collection of Analyzer M odule(s), Platform(s) , I/O Module(s) and Expansion Modul e(s).

748332-D Rosemount Analytical June 1997

NGA Non-Dispersive Infrared Analyzer

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P

REFACE

S

PECIFICATIONS

M

EASUREMENT SPECIES

R

ANGES

R

EPEATABILITY

M

INIMUM DETECTABLE

L

EVEL

N

OISE

L

INEARITY

R

ESPONSE TIME

D

RIFT (ZERO AND SPAN

E

FFECT OF

T

EMPERATURE

E

NVIRONMENT

A

MBIENT TEMPERATURE

E

FFECT OF FLOW

P

OWER REQUIREMENTS

:

:

:

:

:

:

:

:

- G

ENERAL

Heteroatomic gases such as ammonia (NH3), carbon dioxide

:

(CO2), carbon monoxide (CO), carbon monoxide + carbon
dioxide ethylene (C2H4), hexane (C6H14), methane (CH4), nitric
oxide (NO) and sulfur dioxide (SO2)

10 ppm fullscale to 100% fullscale (application-dependent); 4
fullscale selections, including suppressed zero ranges

1% of fullscale (at constant temperature)

±

0.1% CO2 (at 1 atm. sample pressure; application dependent)

<1% of fullscale, peak-to-peak

1% of fullscale with 4th order polynomial

±

.05 to 30 seconds (selectable) for 0 to 90% of fullscale
<±1% of fullscale/24 hours at constant temperature

):

(application dependent);
<±2% of fullscale/week at constant temperature (application

dependent)
<±1% of fullscale over any 10°C interval for rate of change no

greater than 10°C per hour (application dependent)
Location - Class B controlled, indoor, non-hazardous

0 to 45°C (32 to 113°F)

:

:

<1% of range when sample flow rate is changed by ≤250
ml/min. (No effect if flow rate is between 0 and 500 ml/min.)

24 VDC ±5%, 100 W max.; ripple and noise: <100 mV peak-to-

:

peak; line and load regulations: <±1%

S

PECIFICATIONS

T

EMPERATURE

F

LOW RATE

P

RESSURE

P

ARTICULATES

D

EWPOINT

M

ATERIALS IN CONTACT

WITH SAMPLE

:

:

:

:

:

P-6

- S

AMPLE

Non-flammable;: 0°C to 55°C (32°F to 138°F)
500 to 1400 ml/min.
Maximum 690 hPa-gauge (10 psig), higher pressure in

pressurized cell applications

:

filtered to <2 microns
<40°C (104°F), no entrained liquid
Gold plated Pyrex, sapphire, quartz, Irtran, FEP Teflon, Viton-

A, 316 stainless steel

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer

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REFACE

S

PECIFICATIONS

C

ASE CLASSIFICATION

D

IMENSIONS

W

EIGHT

M

OUNTING

M

AXIMUM LENGTH OF

LON C

:

:

ABLE

:

:

- P

HYSICAL

General purpose for installation in weather-protected areas

:

See Outline and Mounting Dimensions, Figure 2-3
Standard: 11 kg (24.2 lbs.); extended: 12.5 kg (27.5 lbs.)
Inside a Platform or custom-installed in a panel
1600 m (1 mile) between Analyzer Module and Platform

See the Preface Section of the Platform manual for specifications regarding Platform
related components.

748332-D Rosemount Analytical June 1997

NGA Non-Dispersive Infrared Analyzer

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C

USTOMER SERVICE

For order administration, replacement Parts, application assistance, on-site or factory
repair, service or maintenance contract information, contact:

R

ETURNING PARTS TO THE FACTORY

Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when
you call:

Number.

Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sender, freight collect.

When returning any product or component that has been exposed to a toxic, corrosive
or other hazardous material or used in such a hazardous environment, the user must
attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification
that the material has been decontaminated, disinfected and/or detoxified.

Model Number, Serial Number, and Purchase Order Number or Sales Order

, T

ECHNICAL ASSIST ANCE AND FIELD SERVICE

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

Return to:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

T

RAINING

A comprehensive Factory Training Program of operator and service classes is
available. For a copy of the
the Technical Services Department at:

D

OCUMENTATION

The following NGA 2000 Non-Dispersive Infrared Analyzer instruction materials are
available. Contact Customer Service or the local representative to order.

748332 Instruction Manual (this document)

Current Operator and Service Training Schedule

Rosemount Analytical Inc.

Phone: [phone]

FAX: [phone]

contact

P-8

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer

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9

6

OMPLIANCES

This product may carry approvals from several certifying agencies, including Factory
Mutual and the Canadian Standards Association (which is also an OSHA accredited,
Nationally Recognized Testing Laboratory), for use in non-hazardous, indoor locations

P

REFACE

FM

APPROVED

Rosemount Analytical Inc. has satisfied all obligations from the European
Legislation to harmonize the product requirements in Europe.

This product complies with the standard level of NAMUR EMC.
Recommendation (May 1993).

This product satisfies all obligations of all relevant standards of the EMC framework in
Australia and New Zealand.

®

97-C219

NAMUR

N

748332-D Rosemount Analytical June 1997

NGA Non-Dispersive Infrared Analyzer

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N

OTES

P-10

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer

I

NTRODUCTION

1

1.1 OVERVIEW

This manual describes the Non-Dispersive Infrared (NDIR) Analyzer Module of
Rosemount Analytical's NGA 200 Series of gas analysis components. See Figure 1-1.

The NDIR Analyzer Module is designed to continuously determine the concentration
of oxygen in a flowing gaseous mixture. The concentration is expressed in one of
three fashions:

parts-per-million

•

percent of composition

•

percent of fullscale

•

The user can obtain an output that is linear with concentration by initiating a linearizer,
which is based on a fourth-order polynomial. The linearizer is incorporated in the
Analyzer Module's electronic circuitry and is adjustable through interconnection with
the network.

The entire Analyzer Module is designed as a slide-in module (if configured in stand­alone instrument fashion), removable from the front of the Platform, with gas
connections made from the rear. All electronics relative to sample detection and
conditioning are included in this module.

1.2 TYPICAL APPLICATIONS

The NDIR Analyzer Module is designed to cover a wide range of process, stack and
automotive applications. Typical measurements include:

HEMICAL AND PETROLEUM

C

Carbon dioxide: Manufacture of ethylene oxide, phthalic anhydride and

•

ammonia; nitrogen generation; and producer gas monitoring

Carbon Monoxide: Stack monitoring

•

Methane: Ammonia manufacture

•

Acetylene: Manufacture of acetylene, acrylonitrile, and vinyl chloride

•

Sulfur Dioxide: Sulf uric acid stack gas

•

748332-D Rosemount Analytical June 1997

NGA Non-Dispersive Infraraed Analyzer

1-1

I

NTRODUCTION

OOD AND AGRICULT URE

F

EROSPACE AND OCEANOGRAPHY

A

ETALS AND CERAMICS

M

Carbon Dioxide and Water Vapor: Blanketing of perishables, fermentation

•

processes, photosynthesis studies, personnel protection

Carbon Dioxide, Carbon Monoxide, and Water Vapor: Diving and space

•

chambers

Carbon Dioxide: Monitoring of producer gas, steel converting, manufacture of

•

cement, soaking pit, heat treating

Carbon Monoxide: Inert gas generation, producer gas monitoring, rotary kiln

•

roasting, tin plate annealing, steel converting, aluminum power processing,
porcelain kilns, tunnels

Water Vapor: Heat treating, hydrogen brazing, nickel and chrome plating

•

Sulfur Dioxide: Flash smelting

•

Ammonia: Ammonia dissociation

•

1.3 THEORY OF TECHNOLOGY

Inside of the Analyzer Module, two equal-energy infrared beams are directed through
two parallel optical cells, a flow-through sample cell and a reference cell. The
reference cell may be sealed or may contain a continuously flowing reference gas.
(See Figure 1-2.)

The infrared radiation is interrupted by a chopper at a frequency of 5 Hz.
During analysis, a portion of the infrared radiation is absorbed by the component of

interest in the sample. The quantity of infrared radiation that is absorbed is
proportional to the component concentration.

1-2

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infraraed Analyzer





REFERENCE OUT

(

)

REFERENCE IN

PURGE GAS IN

CHOPPER MOTOR

FAN

SAMPLE OUT
(BOTTOM)

SAMPLE IN

POWER SUPPLY
BOARD

I

NTRODUCTION

SOURCE

CELLS

DETECTOR

THERMAL FUSE

DETECTOR COVER

CASE
TEMPERATURE
SENSOR

PRESSURE
COMPENSATION
BOARD

FLOW SENSOR

MICRO BOARD

DETECTOR
TEMPERATURE
CONTROL RTD

SIGNAL BOARD

OPTION

IGURE

F

748332-D Rosemount Analytical June 1997

1-1. NGA 2000 NDIR A

SHUTTER ADJUST
ACCESS HOLES

NALYZER MODULE (TYPICAL

ONFIGURATION MAY VARY

C

OSCILLATOR
TUNE ADJUST

)

OSCILLATOR
BOARD

NETWORK INPUT
MODULE

CTUAL

- A

NGA Non-Dispersive Infraraed Analyzer

1-3

I

NTRODUCTION

The detector is a "gas microphone" based on the Luft principle. The detector is
generally filled with the same gas being analyzed. The infrared energy is therefore
absorbed at the same wavelengths in the detector as that in the sample cell, making
the detector specific for the analyzed component. The detector converts the
difference in energy between sample and reference cells to a capacitance change.
This change, which is proportional to component concentration, is processed and
expressed as the primary variable on the network.

Other modules comprising the NGA 2000 unit then use this variable for a variety of
purposes (e.g., expressing the gas concentration on the Front Panel Display or
sending it to external data acquisition devices).

For a general understanding of the electrical interconnections in the NDIR Analyzer
Module, see Figure 2-5.

IGURE

F

INFRARED

SOURCE

REFERENCE

CELL

DETECTOR

STATIONARY

PLATE

1-2. NDIR T

DIAPHRAGM,
DARK STATE

ECHNOLOGY

CHOPPER

SAMPLE IN

SAMPLE
CELL

SAMPLE

DIAPHRAGM,
DISTENDED

COMPONENT OF INTEREST

NON-INTERFERING COMPOUNDS

1.4 SAMPLE REQUIREMENTS

Maximum allowable sample pressure is 690 hPa-gauge (10 psig) for a standard
configuration NDIR that has a flow restrictor which sets the flow at between 0.5 L/min.
to 1 L/min. Special high pressure cells (up to 10,350 hPa-gauge, 150 psig) are
available. Sample temperature range is 0°C to 55°C, and maximum dewpoint is 40°C.
The sample must be filtered to exclude particulates larger than 2 microns in size.
Consult factory for special configurations with specifications outside of those listed
above.

1-4

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infraraed Analyzer

1.5 PURGE KITS

A purge kit for the motor source or motor source/flowing reference cell accompanies
some NDIR modules. The purpose of these kits is to improve performance and
accuracy through the reduction of ambient CO2 interference.

protection from explosion hazard.

The purge gas vents into the case, which has no

They do not provide

outlet fitting for these types of purge gases.

1.6 FEATURES

Among the features available in the NDIR Analyzer Module are:

Pressure compensation for barometric fluctuations (optional)

•

Flow sensing

•

I

NTRODUCTION

748332-D Rosemount Analytical June 1997

NGA Non-Dispersive Infraraed Analyzer

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I

NTRODUCTION

N

OTES

1-6

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infraraed Analyzer

I

NSTALLATION

2

2.1 UNPACKING

If the NDIR 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 Analyzer Module are operational.

2.2 ASSEMBLY

If the NDIR Analyzer Module requires assembly with other components (e.g., the
Platform and associated I/O Modules), do so at this time. Following the guides on the
bottom left and bottom center of the Platform, carefully slide the Analyzer Module
halfway into place.

CAUTION: HAND INJURY HAZARD

Do not place hands or fingers in the Platform front handles when front panel is
open. Dropping the front panel of the Platform while hand or fingers are inside
either handle can cause serious injury.

ANALYZER MODULE GUIDES

PIN SEATS

DISENGAGED FRONT PANEL

IGURE

F

2-1. A

NALYZER MODULE INSTALLATION INTO INSTRUMENT PLATFORM

748332-D Rosemount Analytical June 1997

NGA Non-Dispersive Infrared Analyzer

2-1

I

NSTALLATION

Lift the spring-loaded pins on the front of the Analyzer Module, and carefully slide it
the rest of the distance. 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). 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.

Install I/O Module(s) according to guidelines in the I/O manual. After startup and
calibration have been performed, secure the front panel with the six screws provided.

2.3 LOCATION

Install the NDIR Analyzer Module in a clean, non-hazardous, weather protected,
vibration free location free from extreme temperature variations. For best results,
install the instrument near the sample stream to minimize sample transport time.
Operating ambient temperature is 0oC to 45oC (32oF to 113oF). Sample dewpoint is
40°C or less.

Note
Unrestricted air flow in the rear of the Analyzer Module is critical to its

performance and reliability.

CELL LENGTH CELL VOLUME

mm inch without inlet tube cell with inlet tube at 750 mm Hg

3 0.118 0.85 12 2 sec.
4 0.157 1.14 12 2 sec.

8 0.315 2.28 13 2 sec.
16 0.630 3.56 16 2 sec.
32 1.25 9.12 20 2 sec.
64 2.52 18.24 25 3 sec.

128 4.03 35.48 44 3 sec.
232 9.13 65.12 73 6 sec.
343 13.50 97.76 105 13 sec.
381 15.00 108.60 116 14 sec.

ABLE

T

2-1. C

2.4 GASES

2.4.1 S

PECIFICATIONS

TOTAL VOLUME INCCTIME FOR 2 VOLUMES AT

IN CC

ELL PURGING TIMES AT ATMOSPHERIC SAMPLE PRESSURE

2 SCFH (1L/MIN)

2-2

ALIBRATION GASES

C

All applications require a zero standard gas to set the zero point on the display and
external data acquisition devices. if the factory provided Calibration and Data Sheet

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer

I

NSTALLATION

(in the rear of the manual) specifies a background gas, use this as a zero gas. If a
background gas is not specified, use dry nitrogen.

Span gas should be between 75% and 100% of fullscale span. Flowing reference (if
used) should be dry nitrogen.

LOW RATE

F

Recommended sample flow rate is 1 to 2 SCFH (500 TO 1000 cc/min). A lower flow
rate will not affect readings but may result in an undesirable time lag. Excessive flow
can produce increases cell pressurization and reading error.

At higher cell pressures, the nonlinearity of the calibration curve increases. Therefore,
the calibration curve should be redrawn for higher flow rates. Also, the effect of
increased cell pressurization can be negated if the same flow rate is used for sample,
zero and span gases. But, if flow is high enough to cause elevated pressure, careful
control (tighter tolerance) of flow rate is required to avoid errors.

If low is kept at or below 2 SCFH (1 L/min), sample and instrument temperatures
reach equilibrium regardless of strea m temperature (within sp ecifications; 0 to 55°C).
At extremely high flow rates, this may not be true, although no such effect has been
noted up to 18 SCFH (9 L/min).

See Table 2-1 for cell purging times at atmospheric sample pressure.

AMPLE PRESSURE/FILTRATION

S

Sample should be introduced to the Analyzer Module at a maximum 690 hPa-gauge
(10 psig). Pressurized applications are available, which require pressurized cells and
careful control of flow rates, consult factory for these applications. Sample should be
filtered for particulates down to two microns.

EAK TEST

L

The Analyzer Module is completely tested at the factory for gas leakage. The user is
responsible for testing for leakage only at the inlet and outlet fittings on the rear panel.
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).

2.4.2 C

ONNECTIONS

(See Figure 2-3) Connect inlet and outlet lines for sample/zero/span and flowing
reference (if applicable) to appropriately labeled fittings on the rear panel. All four
connections are 1/4 inch ferrule-type compression fittings.

748332-D Rosemount Analytical June 1997

NGA Non-Dispersive Infrared Analyzer

2-3

I

[

]

[28]

NSTALLATION

4.3

[109]

8.4

[213]

6.2

[157]

8.2

[208]

[15]

.6

2.8

[71]

[13]

.5

.6

[15]

1.1

1.1

[27]

1.1

[28]

20.0

[508.0]

STANDARD

24.8

[628.7]

EXTENDED

6.0

[152]

STANDARD

8.4

213

17.41

[142.2]

22.41

[569.2]

EXTENDED

1.6

[40]

G. POWER CABLE TO NETWORK.
F. NETWORK CABLE CONNECTIONS TO PLATFORM.
E. PURGE GAS IN: 1/4" O.D. TUBE FITTING.
D. REFERENCE IN: 1/4" O.D. TUBE FITTING.
C. REFERENCE OUT: 1/4" O.D. TUBE FITTING.
B. SAMPLE OUT: 1/4" O.D. TUBE FITTING.
A. SAMPLE IN: 1/4" O.D. TUBE FITTING.

5.6

[143]

1.0

[25]

DIMENSIONS

5. MODULE TO BE IN STALLED WITHIN ±15° OF HORIZONTAL.

4. POWER REQUIREMENTS: 24 VDC 3.5 A.

3. ELECTRICAL INSTALLATION MUST BE IN COMPLIANCE WITH NATIONAL ELECTRICAL
CODE (ANSI/NFPA 70) AND/O R ANY APPLICABLE NATIONAL OR LOCAL CODES.

2. MODULE IS NOT WEATHERPROOF.

1. APPROXIMATE WEIGHT: 24.2 LB (11.0 kg).

IGURE

F

2-2 O

2-4

UTLINE AND MOUNTING DIMENSIONS

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer

INCH

[mm]

2.5 ELECTRICAL CONNECTIONS

Note
Electrical connections must be in compliance with National Electrical Code

(ANSI/NFPA 70) and/or any applicable national or electrical codes.

Two electrical connections are required on the Analyzer Module; POWER and
NETWORK. See Figure 2-4. On the Analyzer Module, two NETWORK connections
are available, either of which is appropriate for : 1) interconnection with Backplane of
the Platform (see Platform instruction manual) or 2) "daisy chaining" with other NGA
2000 components.

Connect Analyzer Module POWER 24 VDC power source, either the Platform or
external power source.

FAN

I

NSTALLATION

IGURE

F

OUT

SAMPLE

IN

10 PSI M AX

(69 kPa MAX)

Note: Reference and purge gas connections are applicable only to certain applications.

2-3. NDIR B

ACK PANEL

OUT

REFERENCE

IN

10 PSI M AX

(69 kPa MAX)

PURGE IN

15 PSI (103 kP a) MAX

NETWORK 1

NETWORK 2

POWER

IGURE

F

748332-D Rosemount Analytical June 1997

2-4. NDIR F

RONT PANEL ELECTRICAL CONNECTIONS

FUSE

NGA Non-Dispersive Infrared Analyzer

2-5

I

NSTALLATION

SAMPLE J2-1
SOURCE J2-2
REFERENCE J2- 3
SOURCE J2-4

FLOW SENSOR

FAN ASSEMBLY

MODULATION CHECK

HEATSINK/SOURCE

MOTOR ASSEMBLY

REF S O URCE

SAMPLE SOURCE

J2

J1

J15

J14

RESISTOR

DRIVER

SOURCE ASSY

J4

POWER
SUPPLY
BOARD

J6 J10

J9

PRESSURE

COMPEN SATION

BOARD

J7

1 2 3 4

J5

1 2

CHASSIS
GROUND

J3

J11

J8

FUSE, THERMAL
CUTOFF

RTD, TEMP CTRL

J4 J5 J6

J1

COMPUTER BOARD

J2

J3

CASE TEMPERATURE

SENSOR

HEATER

SENSOR °C

DETECTOR BASE

RECORDER

J5

J7

SIGNAL

J4

BOARD

BOARD

J6

J3 J1

J2

J7

°°°°

C

OSCILLATOR

J1

OUTPUT

J5

LON/POWER

BOARD

IGURE

F

2-5. NDIR W

IRING DIAGRAM

2-6

June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer

S

TARTUP AND OPERATION

3

3.1 OVERVIEW

Prior to initial startup, the user should leak test the module as outlined in Section 2.
For the remainder of this section, Analyzer Module interconnection with a Platform or

some interfacing component will be assumed. Display and Keypad information shall
refer to that which the user can expect to see and do with regard to the Front Panel of
the Platform.

(For a complete description of Platform Front Panel controls and indicators, see
Section 1 of the Platform Components instruction manual.)

3.2 DISPLAYS SCREENS

Three kinds of Display Screens are available to the user (see Figures 3-1 through
3-6.):

Run Mode

•

Menu

•

Help

•

3.2.1 R

3.2.2 M

UN MODE DISPLAY

The Run Mode is the normal mode of operation. In this mode, the Display will show
current gas measurement, the component of interest, the current operations of the
softkeys, a graphic bar representing the displayed concentration as a percent of
fullscale, and up to 4 user-selectable secondary variables and associated bargraphs.

If more than one Analyzer Module is connected to the system, the Run Mode display
will show as many as four gas measurements on a single screen. Alarm messages
may also appear on the display (See Table 3-1).

ENU DISPLAYS

The Menu structure enables the user to access data and functions, and put
information onto the network.

The Main Menu (see Figure 3-2) is subdivided into three levels of control based

748332-D Rosemount Analytical June 1997

NGA 2000 Non-Dispersive Infrared Analyzer

3-1

S

TARTUP AND OPERATION

generally on which personnel is likely to use it: Basic Controls, Expert Controls and
Setup, and Technical Controls. (See Figures 3-3 through 3-5.) Many layers of the
menu structure are described at appropriate places throughout this manual.

See Figures 3-9 through 3-13 for flow charts depicting Menu screens related to this
Analyzer Module.

From the Run Mode display, press the MENUS softkey to gain access to the Main
Menu. (See Figure 3-2.)

3.2.3 H

ELP DISPLAYS

The Help structure is on-line "tutorial," context-sensitive and topic-interconnected, so
that the user can practically operate NGA 2000 without need of an instruction manual.

3.3 STARTUP PROCEDURE

Introduce zero gas into SAMPLE INLET and reference and source purge gas, if
applicable, into their respective inlets. Ensure that gas pressures are set to
requirements listed on the Specifications page of the Preface section of this manual.

Apply power to the NDIR 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
switch. Once power has been supplied to the Platform, the NDIR Analyzer Module will
be energized.

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 procedure 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.

3-2

After the warm-up period (about one hour for the NDIR Analyzer Module), all modules
are completely functional.

Check the tune and detector signal values against the factory settings listed in the
Diagnostic Service menus. If both settings are within ±5% tolerance of factory setting,
go to section 3.4 for binding and 3.5 for calibration. If not, refer first to section 4.11 for
instructions about oscillator tune/source balance shutter adjustments

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

Analyzer PQ 322-14

y

y

y

y

23.2 % CO

S

TARTUP AND OPERATION

IGURE

F

3-1. R

0 ppm

Secondar
Secondar
Secondar
Secondar

Variable: XXXX
Variable: XXX
Variable: XXXX
Variable: XXXX

Display Parms. Menu Dual Info

F1 F2 F3 F4 F5

UN MODE DISPLAY

23.2 % CO Analyzer XXXXXXXX

Basic Controls

Expert controls and setup ...
(Operational configuration)

Technical level configuration ...
(Diagnostic and manufacturing/service)

Delete alarm message!

Display Parms. Info

50

Main Menu

IGURE

F

IGURE

F

3-2. M

3-3. B

F1

F2 F3 F4 F5

AIN MENU DISPLAY

23.2 % CO Analyzer XXXXXXXX

Measurement range Numbers:

Range upper limit: 25%
Range and functional control: Local
Calibration…

Status: Ready

Home Escape Zero Span Info

F1

F2 F3 F4 F5

ASIC CONTROLS MENU

Basic Controls

748332-D Rosemount Analytical June 1997

NGA 2000 Non-Dispersive Infrared Analyzer

3-3

S

g

p

p

p

TARTUP AND OPERATION

23.2 % CO Analyzer XXXXXXXX
ert controls and setu

Ex

Expert analyzer controls ...

Auxiliary module controls ...
System set up ...
Analyzer module set up ...
Auxiliary module set up ...

Home Escape Info

IGURE

F

IGURE

F

3-4. E

3-5. T

F1

F2 F3 F4 F5

XPERT CONTROLS AND SETUP MENU

23.2 % CO Analyzer XXXXXXXX
Technical confi

System set up ...

Service menus...
Diagnostic menus...
Other module diagnostic menus...
listing of all modules...

Status: normal

uration menu

Home Info

F1

F2 F3 F4 F5

ECHNICAL LEVEL CONFIGURATION MENU

IGURE

F

3-4

3-6. T

23.2 % CO Analyzer XXXXXXXX
Main Menu Hel

The Main Menu for the analyzer system.
Note that this menu refers to the particular
analyzer selected from t he run screen, when
used in a system. The s oftkey marked “HOME”
will always return you to this screen.
Help menu system...
Help on help...
Keyboard controls...
Editing controls.. .

Home Escape Map

F1 F2 F3 F4 F5

YPICAL HELP SCREEN

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

S

TARTUP AND OPERATION

3.4 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. (See Figure 3-12 of this manual and

Section 1.5 of the I/O Modules manual for binding instructions.)

3.5 CALIBRATION

Calibration can be executed from the
be entered only through

the Expert Controls and Setup

3-11 for display screen paths.
To calibrate the Analyzer Module, introduce zero gas into the SAMPLE INLET, and do

the following:

1. If the multi-Analyzer Module, split Run Mode display is shown, press the DISPLAY
softkey until the desired Analyzer's Run Mode display is acquired.

Basic Controls

menu. Calibration gas data can

menu. See Figures 3-9 and

2. Press the MENUS softkey to enter the
selections from the

Main Menu

: Expert Controls and Setup, Analyzer Module

Main Menu

and make the following

Setup, Calibration Gases.

3. Input appropriate data in the

4. Press the HOME softkey to return to the

Calibration Gas List

Main Menu.

menu.

5. Use the ↓ arrow key to select Basic Controls.

6. Press the ZERO softkey to enter the

Analyzer Zero

menu, press ZERO again and

wait.

7. Introduce span gas into the SAMPLE INLET, press SPAN softkey to enter the

Analyzer Span

8. Press HOME to re-enter the

menu, press SPAN again and wait.

Main Menu.

9. Press DISPLAY softkey for the Run Mode display.

If the user is unable to calibrate the Analyzer Module (i.e., when ZERO or SPAN is
initiated, nothing happens), a possible 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. Select the following from the
Module Set Up, and Calibration Parameters.

748332-D Rosemount Analytical June 1997

Main Menu

: Expert Controls and Setup, Analyzer

NGA 2000 Non-Dispersive Infrared Analyzer

3-5

S

TARTUP AND OPERATION

2. Using the ↓ arrow, select Zero Ranges, press ENTER and, using the up/down
arrows, toggle to SEPARATE. Do the same for the Calibrate Ranges selection. Do
not press ESCAPE at any time unless retention of prior settings is desired.

3. Return to the

Main Menu

and make the following selections: Expert Controls and

Setup, Expert Controls, CAL DATA softkey, FACTORS softkey, and Range 1 (2, 3,

4) Factors (do Steps 4 and 5 for each range).

4. Select Zero Offset, press ENTER, adjust the value to 500000 with the ↑ and
arrow keys, and press ENTER. Do not press ESCAPE at any time unless retention
of prior settings is desired.

5. Refer to the Data Sheet in the rear of this manual for Span Factors as originally set
at the factory. Select Span Factor, press ENTER, adjust the value to match the
values on the Data Sheet with the ↑ and ↓ arrow keys, and press ENTER. If Data
Sheet is not available, enter 0.000015 with the ↑ and ↓ arrow keys, and press
ENTER. Do not press ESCAPE unless retention of prior settings is desired.

6. Attempt to recalibrate the Analyzer Module according to the procedure outlined at
the beginning of Section 3.4. If recalibration fails, return to the

Range Factors

menu, readjust factors and try calibrating again.

Another cause of failure to calibrate is the following: The value for "Maximum range"
is lower than the upper limit value for the range in use. See the

Range Settings

menu for this information (See Figure 3-11).

DISPLAY MESSAGE DESCRIPTION TYPE

BAROMETER System Barometer WARNING
CASE TEMP Case Temperature WARNING
CHOP SPEED Chopper Speed WARNING
CRUDE NOISE Calculated Noise WARNING
DET SIG Detector Signal WARNING
DET TEMP Detector Temperature WARNING
LIN ERROR Linearizer Error WARNING
N15 VOLTS Power Supply, -15V WARNING
P12 VOLTS Power Supply, +12V WARNING
P15 VOLTS Power Supply, +15V WARNING
P24 VOLTS Power Supply, +24V WARNING
P5 VOLTS Power Supply, +5V WARNING
PERCENT MOD Percent Modulation WARNING
RAW SIGNAL Raw Signal WARNING
SVFLOW Sample Bypass Flow WARNING
SW ERROR Software Error FAILURE

↓

ABLE

T

3-6

3-1. NDIR A

NALYZER MODULE ALARMS

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

READING

% FULLSCALE

S

100 %

50 %

0 %

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

TARTUP AND OPERATION

IGURE

F

3-7. T

CONCENTRATION

NORMALIZED

YPICAL LINEARIZATION CURVE

Display ppm

1

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

CONCENTRATION

ppm

INEARIZER

, L

OFF

0

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

IGURE

F

748332-D Rosemount Analytical June 1997

3-8. O

PERATOR-DETERMINED LINEARIZATION CURVE (NORMALIZED

READINGS, NORMALIZED

(Axis Reversed)

NGA 2000 Non-Dispersive Infrared Analyzer

)

3-7

S

TARTUP AND OPERATION

3.6 LINEARIZATION

The NDIR Analyzer Module can be operated in linear and non-linear mode.
Linearization can be toggled ON/OFF in
In the OFF position, linearization is disabled for all ranges, and the component of
interest is measured in percent of fullscale. In the ON position, measurement is in
engineering units: Either ppm or percent of concentration.

The NDIR Analyzer Module is linearized with the following fourth-order polynomial:

the Expert Controls

menu (see Figure 3-10).

Y = AO + A1X + A2X

2

+ A3X3 + A4X

4

Where:

X = the normalized non-linear input
AO, A1, A2, A3, A4 = linearization coefficients
Y = the normalized linear output

Linearization coefficients can be developed and stored for each range through the

Expert Controls

menu. The operating range is selected by entering RANGE = 1, 2, 3

or 4 in the Range Mode section that that menu.
Coefficients for each selected range are automatically used when the module is in

Linearization Mode. The user instructs the Analyzer Module as to which set of
coefficients are to be used for each range. Maximum dynamic range is 3:1.

When ordered, special linearization coefficients for non-standard fullscale ranges are
entered in the appropriate range(s) at the factory. If a range is not specified, the set of
coefficients will be for Range 4.

3-8

The operator may want the module to output measurement in engineering units (ppm).
This response is linear over the operating range. The following coefficients will make
no correction to the non-linear response, but will cause the NDIR Analyzer Module to
output gas measurement in engineering units:

A0 = 0.00000
A1 = 1.00000
A2 = 0.00000
A3 = 0.00000
A4 = 0.00000

To calculate linearization coefficients other than those installed at the factory, take a

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

S

TARTUP AND OPERATION

minimum of 11 data points. (A more accurate curve can be obtained as the user
approaches 21 data points. If urgent, a curve can be created with as few as four
points, but this is only a temporary fix. A more accurate curve should be created as
soon as possible.)

These data points can be obtained with an accurate gas divider or other flow mixing
device. Before calculating coefficients, the data must be normalized to ranges of 0 to
1 units for both percent and concentration readings. Then, the axis must be reversed
as illustrated in Figures 3-7 and 3-8. A multiple linear regression is then used to
calculate coefficients. (For example: If the range is 0 to 5000 ppm and readings are 0
to 100%, then divide all of the concentrations by 5000 and the readings by 100. Put
the normalized concentrations on the Y-axis and the normalized readings on the X­axis.)

These data points can be entered into any program capable of computing a fourth­order polynomial curve. This curve will be the mirror image of the curve on the
Calibration and Data Sheet provided in the rear of this manual; however, the
linearization coefficients will be different. Use the coefficients calculated with the
curve in the polynomial shown on the previous page.

After taking the data points, the operator may determine coefficients for user-specific
gas by either using any program capable of calculating a fourth-order curve fit or
calling the factory to have the specific coefficients ca lculated.

When entering the operator-determined coefficients, note that the microprocessor only
recognizes five significant digits to the right of the decimal point (e.g., 0.12345).

3.7 ROUTINE OPERATION

Set the NDIR Analyzer Module for desired operating range. Zero and span the
module, and then supply sample gas to the SAMPLE INLET at the rear of the module.
The NDIR Analyzer Module will now automatically and continuously analyze the
sample stream.

As a check of instrument performance, the operator should keep a log of zero/span
status.

Maximum permissible interval between calibrations depends on the analytical
accuracy required. A frequency of once every 24 hours is recommended initially, and
that practice should be continued unless experience indicates that some other interval
is more appropriate.

Readout accuracy is directly proportional to change in barometric pressure (i.e., a
change in cell pressure of 7.6mm of mercury will result in a readout error of about 1%
of reading). Therefore, if barometric pressure changes significantly, a recheck of
calibration against a span gas is advised. Also, an optional Pressure Compensation
Board is available that electronically compensates.

748332-D Rosemount Analytical June 1997

NGA 2000 Non-Dispersive Infrared Analyzer

3-9

S

TARTUP AND OPERATION

The Analyzer Module will not allow the user to increase the upper limit of a range
beyond the "maximum range" software setting. To change the "maximum range"
value, select the following from the Main Menu: Technical Configuration Menu,
Service Menu, Manufacturing Data, Analyzer Manufacturing Data. Select Maximum
Range, and use the arrow keys to scroll the indicated value. The same applies for
"minimum range" setting.

Basic controls...

Main Menu

Expert controls and setup...
(Operational configuration)
Technical level configuration...
(Diagnostic and manufacturing/service)

Basic level security

(expert, technical)
Enter your security code with softkeys.
Security codes are set in the system setup
menu in the Technical level menus.
Press five characters when Security code
says READY. Press six to return to “READY”.
Security code: 54321

Basic controls

Measurement range number: 1
Range upper limit: 10 ppm
Range and functional control: LOCAL
Zero gas concentration: 0 ppm
Span gas concentration: 9.89 ppm
Ranges with valid calibration: 1&2

Calibration status: Ready
If it won’t calibrate...

Status: Ready

ZERO

Current measurement parameters

Measurement range number: 1

Range change control: Local

PARMS

Expert analyzer controls...
Auxiliary module controls...
System set up...
Analyzer module set up...
Auxiliary module set up...
Local I/O set up...

Measured Gas: CO2

Linearization mode: ON

Gas Measurement Setup: ON
Analyzer operational state: Normal
Analyzer alarm state: Normal
Alarms report: Failure

Expert controls and setup

SPAN

MORE

Technical configuration menu

System set up...
Service menus...
Diagnostic menus...
Other module diagnostic menus...
Listing of all modules...

Expert and Technical menus follow in
succeeding flow charts.

Current measurement parameters

Response time: 2.0 Secs
Sample flow: 1000 ml/min.
Sample pressure: 12.3 kPa
Case Temperature: 55.3°C

IGURE

F

3-10

Are you sure?
You must have zero gas flowing
through the analyzer.
This control does NOT control any
auto-cal. Module bound to this
analyzer!
If you are sure, press ZERO again now.
Press left arrow key when you are
done.

Calibration status: Ready
Error message for last zero: 24-08-94

Analyzer Zero

3-9. D

ISPLAY SCREENS

Are you sure?
You must have zero gas flowing
through the analyzer.
This control does NOT control any
auto-cal. Module bound to this
analyzer!
If you are sure, press SPAN again now.
Press left arrow key when you are
done.

Calibration status: Ready
Error message for last zero: 24-08-94

Analyzer Span

OF

(1

5)

Check that you are flowing the correct gas, and

If it won’t calibrate...

the gas concentration is what it is supposed to be.
Make sure that the reading is stable before
starting. If you have changed the range fullscale
value or any linearizer coefficients, or enabled or
disabled it, or done anything else that would affect
how it measures the gas, you may have made it
hard for the analyzer to calibrate. If so, manually
adjust the coefficients until the readings are close
to correct, and try again.

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

From MAIN MENU

⇒⇒⇒⇒

Expert controls and setup

Expert analyzer controls...
Auxiliary module controls...
System set up...
Analyzer Module set up...
Auxiliary Module set up...
Local I/O set up...

S

TARTUP AND OPERATION

Analyzer module set up...
and Auxiliary module set up... Outlined in the
next flow chart. Local I/O set up information is
included in the I/O Modules manual.

Measurement range number: 1
Range lower limit: 0 ppm
Range upper limit: 10 ppm
Linearizer: ON
Range and functional control: LOCAL
Zero/Span calibration...
Ranges with valid calibration: 1&2
Physical measurements...

CAL DATA

#1

Zero/Span diagnostic data

Date of last zero: 24-08­94
Error message for last zero: 24-08-94
Error percentage for last zero: 5%
Raw signal at last zero: 500000
Last zero gas would read: -0.83 ppm
Date of last span: 24-08-94
Error message for last span: Great!
Error percentage for last span 5%
Raw signal at last span: 500000
The last span gas would read: 11.3 ppm

FACTORS

#3

Calibration Factors

Range 1 factors...
Range 2 factors...
Range 3 factors...
Range 4 factors...
Zero compensation factor: 1
Span compensation factor: 1

Expert controls

CAL

Auxiliary module controls

This screen selects any module with a
control screen. This includes any auto
calibration or sample module bound to
this analyzer.
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag

Dependent on which auxiliary module is present
on the network. See I/O Modules manual.

#2

Zero offset: 500000
Span factor: 0.000015
Fullscale range at calibration: 10 ppm
Measurement range number: 1
Hardware zero offset: 0.0235 V
Raw measurement signal: 0.5250 V

Zero/Span Calibration

Measurement range number: 1
Zero gas concentration: 0 ppm
Span gas concentration: 9.89 ppm
Sample flow: 1000 ml/min.
Raw measurement signal: 0.3256 V
Ranges with valid calibration: 1&2
Status: Ready
Result...
Calibration adjustment limits: Enabled

FACTORS

Range 1 (2,3,4) Factors

System Set Up

Front panel control...
Display resolution...
Auxiliary lines...

See Platform manual for a flow chart
of these displays.

Physical Measurements

Sample flow: 1000 ml/min
Flow lower limit: 150 cc/min.
Flow upper limit: 250 cc/min.
Barometric pressure: 12.3 kPa
Case temperature: 54.3°C

See #1 on this flow chart

Range 1 (2,3,4) Factors

Manufacturer’s settings

HISTORY

Zero offset: 0
Span factor: 1000

Stored settings
Zero offset 500000
Span factor: 500000

IGURE

F

3-10. D

ISPLAY SCREENS

748332-D Rosemount Analytical June 1997

(2

OF

5)

NGA 2000 Non-Dispersive Infrared Analyzer

3-11

S

TARTUP AND OPERATION

From MAIN MENU

⇓

Expert controls and setup

Expert analyzer controls...
Auxiliary module controls...
System set up...
Analyzer Module set up...
Auxiliary Module set up...
Local I/O set up...

For Expert analyzer

controls, Auxiliary module

controls, and System set

up menus, see preceding

flow chard. Local I/O set

up information is included

in the I/O Modules manual.

Analyzer module set up

Calibration gas list...
Calibration param eters...
Gas measurement paramet er s...
Analyzer parameter list...
Physical measurement par ameters...
Displayed physical param eters...
Analyzer tag: IR

Auxiliary module set up

Select an auxiliary module for set up
Local I/O set up...
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag

Dependent on which auxiliary module is
present on the network.
See I/O Modules manual.

Calibration gas list

Zero gas - range 1: 0 ppm
Span gas - range 1: 9.3 ppm
Zero gas - range 2: 0 ppm
Span gas - range 2: 19.3 ppm
Zero gas - range 3: 0 ppm
Span gas - range 3: 101.1 ppm
Zero gas - range 4: 0 ppm
Span gas - range 4: 247.1 ppm
Calibration...

#4

Calibration Parameters

Calibration adjustment limi ts: enabled
Calibration averaging time: 5 S ec s
Calibration failure alarm: Yes
Cal failure error allowed: 5%

Calibration time out: 60 Secs

Zero ranges: TOGETHER

Span ranges: SEPARATE

Measurement parameters

Linearization parameters...
Response time/delay param eters...
Range setting...
Units...
Linearization functions...

Zero/Span Calibration

See #2 in Figure 3-10

Linearization paramete rs

Range 1 linearizer: Enabled
if enabled, uses curve no.: 1
Range 2 linearizer: Enabled
if enabled, uses curve no.: 2
Range 3 linearizer: Enabled
if enabled, uses curve no.: 3
Range 4 linearizer: Enabled
if enabled, uses curve no.: 4
Case temperature for coefficient s: 45°C
Set coeffi c ients…

Response time/delay parameters

Range 1 t90 time: 10 Secs
Range 2 t90 time: 1 Secs
Range 3 t90 time: 1 Secs
Range 4 t90 time: 1 Secs
LON update rate: 1 per Sec
Output delay time: 0 Secs

Range Settings

Minimum range: 10 ppm
Maximum r ange: 5000 ppm
Range 1 lower limit: 0 ppm
Range 1 upper limit: 10 ppm
Range 2 lower limit: 0 ppm
Range 2 upper limit: 100 ppm
Range 3 lower limit: 0 ppm
Range 3 upper limit: 250 ppm
Range 4 lower limit: 0 ppm
Range 4 upper limit: 1000 ppm

Gas measurement units: ppm
Pressure measurement units: psig
Temperature measurement units: F

Variables are still s e nt as the basic SI unit.

Units

#5

Linearity coefficients

Curve 1 (2,3,4)
AO coeffi c ient: 1.34523E-4
A1 coefficient: 0.983751
A2 coefficient: 0.115751

A3 coefficient: 1.11575E-6
A4 coefficient: 7.3421E-12

Curve upper limit: 10 ppm
Curve over- r ange: 10%

Curve under-range: 5%

Status: Enabled

Polynomial set up

Range to be linearized: 1

Current span gas: 9.69 ppm

Calculated polynom ial order : 4

Gas values shown as: Percent

Gas concentrations...

Analyzer function: Ready

Gas concentrations

Gas value: 0

Raw reading: 0 ppm

Linearized values: 0 ppm
Gas value: 10

Raw reading: 11 ppm

Linearized values: 10 ppm

Point to be measured: Point 1

Analyzer function: Ready

Point 1

Point 2

Midpoint correction set up

Range 1 (2,3,4)

Correction: Disabled
Point being measured: Pt 1
Point 1 gas concentration: 100 ppm
Point 2 gas concentration: 120 ppm
Point 3 gas concentration: 150 ppm

Point 1 reading: 100 ppm
Point 2 reading: 120 ppm
Point 3 reading: 150 ppm

Span gas value: 100 ppm
Analyzer function: Ready

Analyzer Parameter List

Analyzer tag: IR-CO2
First line’s parameter: Flow

Second line’s parameter: Flow
Third line’s parameter: Flow
Fourth line’s parameter: Flow
Linearization parameters...

#6

Physical Measurements

Barometric pressure: 10.13 hPa
Sample flow: 500 cc /min.
Case temperature: 45°C
Detector temperature: 52°C
Pressure limits...
Temperature limits...

Displayed Parameters

First line’s parameter: Flow
Second line’s parameter: Flow
Third line’s parameter: Flow
Fourth line’s parameter: Flow
May be displayed on the appropriat e
line of the singl e analyzer display
screen.

Linearization functions

Polynomial set up...
Midpoint correction set up...
Use the polynomial set up t o gener ate a
linearizing pol y nomial from up to 20
gases.

Linearity coefficients

See #5 above

NEXT

Pressure Limits

Sample pressure upper limit: 15 kPa
Sample pressure lower limit: 10 kPa

Temperature Limits

Case upper limit: 60 C
Case lower limit: 20 C
Detector upper limit: 69 C
Detector lower limit: 55 C

Analyzer Parameter List

Primary Vari able Parameters
Control mode: LOCAL
Output delay time: 0 Secs
Range 1 upper limit: 10 ppm

Range 2 upper limit: 100 ppm
Range 3 upper limit: 250 ppm

Range 4 upper limit: 1000 ppm
Range 1 lower limit: 0 ppm
Range 2 lower limit: 0 ppm
Range 3 lower limit: 0 ppm
Range 4 lower limit: 0 ppm

Analyzer Parameter List

Primary Vari able Parameters
Range 1 t90 time: 10 Secs
Range 2 t90 time: 1 Secs
Range 3 t90 time: 1 Secs
Range 4 t90 time: 1 Secs
Linearizer on range 1: Enabl ed
Linearizer on range 2: Enabl ed
Linearizer on range 3: Enabl ed
Linearizer on range 4: Enabl ed

Analyzer Parameter List

Calibration Parameters
Calibration averaging time: 5 S ec s
Calibration failure alarm: Yes
Cal failure error allowed: 5%
Calibration time out: 60 Secs
Ranges zeroed: TOGETHER
Calibrate ranges: SEPARATE
Calibration adjustment limi ts: ENABLED

Analyzer Parameter List

Calibration Gases
Zero gas - range 1: 0 ppm
Zero gas - range 2: 0 ppm
Zero gas - range 3: 0 ppm
Zero gas - range 4: 0 ppm

Span gas - range 1: 9.3 ppm
Span gas - range 2: 19.3 ppm

Span gas - range 3: 101.1 ppm
Span gas - range 4: 247.1 ppm

IGURE

F

3-12

3-11. D

ISPLAY SCREENS

(3

OF

5)

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

From MAIN MENU

⇓

Technical configuration menu

System set up...
Service m enus...
Diagnostic menus...
Other module diagnostic menus...
Listing of all modules...

For Diagnostic menus,

Other module diagnostic
menus, and Listing of all

modules, see Figure 3-11.

System Set Up

Main display configuration...
Front panel control...
Date and time...
Module binding...
System Reset...
Security codes...
System tag: Rosemount

Main display configuration, Front
panel control, and Date and time
displays can be found in the Platform
manual.

Module Binding

Analyzer module selec ted: IR-CO2
Select modules...
Proposed bind:
View bindings...
Bind selections!
Unbind everythi ng!

System Reset

Are you sure?
Re-initializing will destroy all the binds!!!
System reset!
Re-initialize network!

Record security codes

Basic level secur ity: Enabled
Expert level security: Enabled
Technical level security: Enabled
Record basic level security code...
Record expert level security code...
Record technical level security code...

Manufacturing data

Control module data. ..
Analyzer module data...
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag

Select IO modules

Select the modules you wish to bind to the
current analyzer.
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag

Modules Bound

Analyzer module selec ted: IR-CO2
Auxiliary module: Auto 1023
Auxiliary module: Acal 2322
Auxiliary module: HART 1092
Auxiliary module: None
Auxiliary module None
Auxiliary module: None

Proposed new bind:

#7

Record basic level security codes

(expert, technical)
Press the softkeys in any order to define the
code. The actual code is represented by the
order in which they are pressed, and shown
numerically below. Press the left arrow key
when you are done.
Actual code number: 54321

Control Unit Manufacturing Data

Control unit serial number: 800002356
Manufacturing date code: 12-08-93
Hardware revision number: 1.00
Software revision number: 1.09
Revision notes...
User tag number: PV1c

Analyzer Manufacturing Data

Analyzer module s/n: 900189342
Manufacturing data code: 17-08-93
Bench configurati on c ode: 17
Hardware revision number: 1.13
Software revision number: 1.03
Minimum range: 10 ppm
Maximum r ange: 5000 ppm
Measured gas: CO2
User tag number: IR-CO2

S

TARTUP AND OPERATION

IGURE

F

Service Menus

Manufacturing data. ..
Service history...
In maintenance since: N/A
Record security codes...

3-12. D

ISPLAY SCREENS

Service History

Control module data. ..
Analyzer module data...
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag

Record security codes

Basic level secur ity: Enabled
Expert level security: Enabled
Technical level security: Enabled
Record basic level security code...
Record expert level security code...
Record technical level security code...

See #7 above

OF

(4

5)

STORE

RESET

Store historical data

Are you sure?
STORE will copy current diagnostic data into
the historical ("was") variables, overwriting
what is currently there.

Reset

Are you sure?
RESET will erase ALL configuration and
manufacturing data, including serial
numbers.

Control Module Service History

Manufacturing date: 12-08-93
In service date: 01-23-94
Last service date: 01-23-94
List notes...
Add service date!

Analyzer module Service History

Manufacturing date: 17-08-93
In service date: 21-06-94
Last zero calibration date: 24-08-94
Last span calibration date: 24- 08- 94
Last service date: 21-06-94
List notes...
Add service date!

This function not applicable.
Slot position: 1

I/O module

748332-D Rosemount Analytical June 1997

NGA 2000 Non-Dispersive Infrared Analyzer

3-13

S

TARTUP AND OPERATION

From MAIN MENU

Technical configuration menu

System set up...
Service m enus...
Diagnostic menus...
Other module diagnostic menus...
Listing of all modules...

Diagnostic menus

Control module diagnostics...
Analyzer module di agnost ics...
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag

⇓

For Service set up and
Service m enus, see
preceding flow charts.

Control Unit Diagnostics

See Platform manual.

#8

Analyzer Diagnostics

Power supply voltages...
Primary variable parameters. ..
Physical measurement s...
Temperature control parameters...
Miscellaneous control parameters...
Barometric pressure param eters...
Software diagnostics...

Analyzer diagnostics

Power supply voltages

+15V analog is: 14.98V

+15V analog was: 14.92V

-15V analog is: -14.85V

-15V analog was: -14.92V
+5V digital is: 5.02V

+5V digital was: 4.98V
+24V power is: 2.38V
+24V power was: 2.42V
+12V analog is: 11.88V

+12V analog was: 12.0V

Primary variable parameters

Raw measurement signal: 0.3258
Signal gain setting: 4%
Oscillator tune: 85%

Chopper speed: 5 Hz
Source current: 1.212 A
Modulation check.. .
Percent modulati on: 20%
Calibration time out: 60 Secs
Calibration f ac tors...
Pk-pk noise: 0 ppm

Modulation check

Measurement range number: 1
Detector signal: 7.0
Signal gain setting: 4%
Status Ready
Instructions: Flow zero
Then: Watt

Percent modulati on: 20%
(updated only at the end of this test)

Calibration Factors

See #3 in Figure 3-12

HISTORY

Other module diagnostics

This screen reserved for other modules
if present.
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag

Listing of all modules

Lists all modules detected on the
network.
Jumps to the module’s diagnostic
screen.
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag
Module Tag

For I/O Module diagnostics,
see I/O Modules manual

Analyzer Diagnostics

See #8 above.

Physical measurements

See #6 in Figure 3-12

Temperature control

Fan lower setpoint: 60°C
Fan upper setpoint : 20°C
Minimum fan duty cycle: 30%
Case temperature: 45°C
Detector setpoint: 62°C
Detector P gain: 32.52
Detector I gain: 1.34
Detector bias: 283°C
Detector temperature: 62°C

Miscellaneous control parameters

Fan current: 35 mA
Fan duty cycle: 50%
Heater current: 1.7A
Heater duty cycle: 50%
Source current pot setting: 50%
Actual source current: 1. 212A
Alarm messages val id for: FAILURE

Barometric pressure parameters

Pressure transducer: Present
Barometric pres. Compensation: Enabled
Measured pressure: 12.3 kPa
Transducer offset: 1013 hP a
Transducer slope: 1.0
Transducer PGA gain: 1.0

Software diagnostics

Last message: No error
And: No error
And: No error
And: No error
And: No error
And: No error
And: No error
And: No error
Edit to reset: Report
Software error code (1 = no error): 1

Primary variable parameters

Signal gain settings: 4%
Oscillator tune: 85%
Source current: 1.212 A
Percent modulati on: 85%

IGURE

F

3-14

3-13. D

ISPLAY SCREENS

(5

OF

5)

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

M

AINTENANCE AND TROUBLESHOOTING

4

WARNING: ELECTRICAL SHOCK HAZARD

Servicing requires access to live parts which can cause death or serious injury.
Refer servicing to qualified personnel.

4.1 OVERVIEW

NDIR Analyzer Module components that may require cleaning or replacement include:

all printed circuit boards

•

power fuse

•

the module fan

•

the chopper motor

•

the source

•

the detector

•

flow sensor

•

case temperature sensor

•

Analysis cells and optical components

•

RTD - detector temp. controller

•

thermal fuse

•

The only components that may require adjustment are the oscillator tune and shutter
balance adjustments. These are factory-set, and should be adjusted only in the
following cases:

if the operator has changed sources, oscillator board or detector

•

if the operator disassembles the bench to any degree.

•

Also available for maintenance adjustment through the Front Panel display and
keypad are the source current, preamplifier gain (referred to as Signal Gain on the
sub-menu) and the modulation check.

748332-D Rosemount Analytical June 1997

NGA 2000 Non-Dispersive Infrared Analyzer

4-1

M

AINTENANCE AND TROUBLESHOOTING

4.2 PCB REPLACEMENT

Refer to Figure 4-1 for locations of the Signal, Micro, Power Supply, Oscillator and
optional Pressure Compensation boards.

All PCBs, except the Oscillator Board and the LON Power Board, are secured to a
side of the analyzer module that folds out while interconnect wiring is still in place.
Remove the securing screws and fold out the entire panel.

TOP VIEW

IGURE

F

SIDE VIEW

4-1. P

Power Supply
Board

RINTED CIRCUIT BOARD FOLD-OUT PANEL VIEWS

Pressure
Compensation Board

Micro Board Signal Board

To remove a particular board on the fold-out panel, label and unplug all interconnect
wiring, and remove securing hardware. (See Figure 4-1.) Do the reverse to install a
new board. Use caution when installing connectors by observing correct position
(polarity) and alignment of pins.

4.3 POWER FUSE REPLACEMENT

Remove power to the Analyzer Module prior to fuse replacement. To replace the
Power Fuse, view the front panel of the Analyzer Module, as shown in Figure 2-4, and
push and turn the fuseholder cap 1/4 turn counterclockwise. Remove and replace the
fuse as required.

4.4 MODULE FAN REPLACEMENT

The Analyzer Module fan assembly is disassembled as shown in Figure 4-2. Before
doing so, though, the entire optical bench must be removed. See Figure 4-4.

4-2

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

Air

Flow

M

AINTENANCE AND TROUBLESHOOTING

IGURE

F

4-2. M

ODULE FAN ASSEMBLY

4.5 CHOPPER MOTOR REPLACEMENT

See Figure 4-3 for a breakdown of the Motor/Source Assembly. The entire optical
bench must be removed to perform this replacement.

4.6 SOURCE REPLACEMENT

See Figure 4-3 for a breakdown of the Motor/Source Assembly. The entire optical
bench must be removed to perform this replacement.

4.7 DETECTOR REMOVAL

See Figures 4-4 and 4-6 for breakdowns of the optical bench. The entire optical bench
must be removed in order to perform this disassembly.

4.8 FLOW SENSOR REPLACEMENT

See Figure 4-4 for Flow Sensor location. To replace Flow Sensor, remove all
connecting hardware and undo connections to the sample line.

748332-D Rosemount Analytical June 1997

NGA 2000 Non-Dispersive Infrared Analyzer

4-3

M

AINTENANCE AND TROUBLESHOOTING

IGURE

F

Source Assemblies
(see detail below)

Screw

Lock Washer

Insulator

4-3. M

OTOR/SOURCE ASSEMBLY

Source

Housing Assembly

Ref - Source
Assemblies

Source Case

Insulator

Ref - Housing
Assembly

Motor Plate

Motor

Chopper
Blade

O-Ring

Retaining
Ring

Screw

Nylon
Washer

Source Buffer

Dual Cap
Assembly

Screen Filter
(optional)

Source Gasket

4.9 CASE TEMPERATURE SENSOR REPLACEMENT

Case Temperature Sensor is attached to the motor source assembly. To replace this
sensor, cut the Ty-Rap binder and disconnect the sensor connector. Reverse these
instructions by reconnecting the new sensor and attaching with a new Ty-Rap.

4.10 THERMAL FUSE REPLACEMENT

Disassemble and reassemble the Detector block according to Figure 4-6 to replace
the Detector Thermal Fuse.

4.11 OSCILLATOR TUNE/SOURCE BALANCE SHUTTER
ADJUSTMENT

The Analyzer Module is calibrated, tuned and balanced at the factory. If the diagnostic
values for oscillator tune and detector signals are within ±5 % of the factory settings
(see Figure 3-13, in Primary Variable Parameters and Modulation Check menus), no
adjustment is necessary. If not, see Figure 4-4 and 4-5 for Oscillator T une and Source
Balance Shutter adjustments, and do the following:

4-4

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

M

AINTENANCE AND TROUBLESHOOTING

1. Open Platform front panel, if present.

CAUTION: HAND INJURY HAZARD

Do not place hands or fingers in Platform front handles when the front panel is
open. Dropping front panel while hand or fingers are inside either handle can
cause serious injury.

2. Open Analyzer Module front panel

3. Access the oscillator tune value in the Primary Variable Parameters menu.

4. Adjust oscillator tune knob to its maximum setting and then turn it
counterclockwise to 80 % of that maximum setting.

5. Access the detector signal value in the Modulation Check menu.

6. Flow zero gas (nitrogen) through the sample cell until the display reading
stabilizes.

CAUTION: DELICATE COMPONENTS

The shutter is a delicate component with only a six-degree rotation. Take care
when making the required adjustments.

7. Using an appropriate screwdriver that will fit through the Source Balance

Adjustment Screw Holes (see Figure 4-5), rotate the sample shutter adjust screw
until a minimum reading on the display is obtained. (A typical reading is 0.2
through 0.5.)

8. Add 0.5 V to the value obtained in Step 7 by adjusting the sample shutter adjust

screw clockwise. (If this reading exceeds 1.2 V, then a cell cleaning is necessary;
see Section 4.12.)

9. Rotate the shutter adjust screw clockwise until the display reads the value obtained

in Step 8.

10. Reassemble the Analyzer Module and, if appropriate, the Platform.

748332-D Rosemount Analytical June 1997

NGA 2000 Non-Dispersive Infrared Analyzer

4-5

M

AINTENANCE AND TROUBLESHOOTING

Oscillator Tune
Adjust

Detector Assembly

Motor/Source
Assembly

Shutter Shaft

Power
Transistor/Heatsink

IGURE

F

4-6

4-4. C

ELL

, PCB A

Flow Sensor

SSEMBLY (EXPLODED VIEW

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

)



DETECTOR ASSEMBLY COVER

(Front View)

M

AINTENANCE AND TROUBLESHOOTING

IGURE

F

4-5. O

Oscillator Tune Adjustment

SCILLATOR TUNE



SHUTTER

Sample

OPEN

CLOSE

Source Balance Shutter
Adjustment Screw Hole

OURCE BALANCE SHUTTER ADJUSTMENTS

, S

Detector

IGURE

F

748332-D Rosemount Analytical June 1997

4-6. D

ETECTOR BLOCK (EXPLODED VIEW

Oscillator Board

Resistive Temperature
Detector

Thermal Fuse

Detector Heater

)

NGA 2000 Non-Dispersive Infrared Analyzer

4-7

M

AINTENANCE AND TROUBLESHOOTING

4.12 CLEANING CELLS

1. When zero gas is introduced in the SAMPLE IN inlet and the Detector signal is
greater 1.2V, the cells and windows require cleaning. To do this, follow this
procedure:

2. See Figure 4-7 to identify which detail drawing best matches the configuration in
question.

3. Fold out the PCB panel.

4. Disassemble the optical bench according to Figure 4-4 and the cells according to
Figure 4-7.

5. Rinse the cell with acetone. If this does not remove all foreign matter, use a soft
brush. Do not use an y metallic o bject in side the ce ll be cause it will scratch th e gold
plating. Loss of gold plating may require cell replacement.

6. After all matter has been remo ved, rinse the cell with distilled water and allow to air
dry. Do not use towels.

7. Inspect the cell inside by holding it up to a bright light. If particles are seen, repeat
Steps 5 and 6 as often as necessary.

8. After cleaning cell, examine O-rings at the source, detector and end caps. If
damaged, replace with new O-rings.

9. Remove any contaminants from windows with a lint-free cloth soaked in acetone.
Do not use alcohol or other solvents. Allow to air dry.

10. Reverse disassemble instructions to reassemble the unit.

11. Perform a leak check.

12. Replace desiccant if required. (See Section 4.13.)

13. After cleaning cells, the Analyzer Module must be optically aligned if the diagnostic
values for oscillator tune and detector signals are not within ±5% of the factory
settings (see Figure 3-13, in Primary Variable Parameters and Modulation Check
menus). If they are not within that range, follow Steps 7 through 10 of Section 4.11.

4-8

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

SHORT PATH CELLS

4mm TO 2.5 INCHES

Spacer

Desiccant Holder

M

AINTENANCE AND TROUBLESHOOTING

Detector
Assembly

Shutter Block
Assembly

Desiccant
Holders

LONG PATH CELLS

Motor/Source
Assembly

Sample Cell

Sample Cell

Detector
Assembly

Shutter Block
Assembly

Motor/Source
Assembly

IGURE

F

748332-D Rosemount Analytical June 1997

4.7. C

ELL DISASSEMBLY

NGA 2000 Non-Dispersive Infrared Analyzer

4-9

M

AINTENANCE AND TROUBLESHOOTING

4.13 CELL DESICCANT

The reference cell may use a flowing reference. If so, desiccant is required. A
desiccant holder is used on the inlet and outlets to keep moisture from entering the
reference cell (see Figure 4-7). The desiccant should be replaced each time the cell is
opened, refer to Table 4-1. Before inserting desiccant, purge cell with dry inert gas
(i.e., N2).

GAS DESICCANT PART NUMBER

CO

2

CO Mg (C104)
H20Mg (C10
SOS Mg (C104)
CH

4

Hexane Mg (C104)
CO + CO

2

Cardoxide + Mg (C104)

Cardoxide 096218

096217
096217
096217
096217
096217
096217/09621

4)2

Mg (C104)

2

2
2
2

2

ABLE

T

4-1. C

ELL DESICCANT

4.14 MODULATION CHECK

The modulation check is a measure of the energy absorption capacity of a gas
mixture, where total absorbency is 100% modulation and zero absorbency is 0%
modulation. The modulation check can be used as a tool for tracking the sensitivity of
the Analyzer Module and for discovering potential detector/source problems.

To perform a modulation check, do the following:

1. Access the Primary Variable Parameters menu (see Figure 3-13).

2. Select Modulation Check.

3. Follow the

Instructions

a. Flow zero gas, press START softkey and wait.
b. Flow span gas when prompted, press START softkey and wait.

4. When the

Instructions

check is finished.

5. Note the value on the

Find the Percent Modulation value on the Data Sheet in the rear of this manual. Some
standard Analyzer Modules will not have a value. If a value is present, compare this to
the new value.

and

line commands, which are the following:

Then

line again prompts the user to flow zero gas, the modulation

Percent Modulation

line.

4-10

If 100% span gas was used during the modulation check, the new value should be
within ±10% of value on the Data Sheet. If it is out of this range, call the factory for
further interpretation. If modulation checks are used for trending, variance from check
to check should not exceed ±20% per month.

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

R

EPLACEMENT PARTS

5

WARNING: PARTS INTEGRITY

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

5.1 REPLACEMENT PARTS

While the following sections list parts which are common to all NDIR Analyzer
Modules, the
specific to an individual application. The configuration number is on the Data Sheet in
the rear of this manual.

NL623998 Oscillator Board

configuration number

is required when ordering parts which are

NL657466 LON/Power Board
NL655729 Detector Heater
NL622917 Temperature Sensor, Detector
NL898733 Thermal Fuse with Q Pad
NL902931 Flow Sensor
NL655943 Case Temperature Sensor
NL655630 Power Supply Board
NL655670 Pressure Compensation Board
NL655588 Computer Analysis Board
NL655610 Signal Board
NL655893 Fan
NL655891 Chopper Motor
NL655925 Source (Matched Pair)

748332-D Rosemount Analytical June 1997

NGA 2000 Non-Dispersive Infrared Analyzer

5-1

R

EPLACEMENT PARTS

N

OTES

5-2

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

A

PPENDIX

A. NDIR I

DENTIFICATION MATRIX

A

Each analyzer is configured per the customer sales order. Below is the NDIR sales matrix
which lists the various configurations available.

To identify the configuration of an analyzer, locate the analyzer name-rating plate. The 12­position sales matrix identifier number appears on the analyzer name-rating plate.

I SINGLE CHANNEL NON-DISPERSIVE INFRARED ANALYZER MODULE

Code Language

A English
X Special

Code Configuration Identifier

A09, A10, A12, A20, B22, B23, B2B30, B36, B38
A06, A07, A08, A11, B21, B24, B26, B76, F63
A16, A28, B19, B25, B27, C31, C37, C39, D41, D44
A14, A15, B46, E54, F64, F65, F66, F67, H73
E56, H74, H75, J83, H84, J85, J88
L99 SPECIAL Extended Length
S99 SPECIAL Standard Length

Code

ZOO No Selection

Code Linearized Non-Standard Range Selection

A Four Standard Ranges

B One Non-Standard Range
C Two Non-Standard Ranges
D Three Non-Standard Ranges

F Four Non-Standard Ranges

X Special

Code

ZNo

IAA10Z00AZZ Example

748332-D Rosemount Analytical June 1997

Selection

Code

Z No Selection

NGA 2000 Non-Dispersive Infrared Analyzer

A-1

A

PPENDIX

N

OTES

A. NDIR I

DENTIFICATION MATRIX

A-2

June 1997 Rosemount Analytical 748332-DNGA 2000 Non-Dispersive Infrared Analyzer

ENERAL PRECAUTIONS FOR HANDLING AND

G

TORING HIGH PRESSURE GAS CYLINDERS

S

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 125°F (52°C). 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.

4125 E

AST LA PALMA AVENUE

Rosemount Analytical Inc.

• A
J

, C

NAHEIM

ULY

ALIFORNIA

1997 • 748525-C • P

92807-1802 • 714-986-7600 • FAX [phone]

RINTED IN

USA

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ARRANTY

W

Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from
defects in workmanship and material under normal use and service for a period of twelve (12)
months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid
junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and
material under normal use and service for a period of ninety (90) days from date of shipment by
Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or
material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods,
part(s) or consumables are returned to Seller's designated factory, transportation charges prepaid,
within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of
consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for
replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day warranty in
the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall
not operate to condemn such commercial unit when such goods, part(s) and consumables are
capable of being renewed, repaired or replaced.

The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly or
indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from any
other cause. All other warranties, expressed or implied are hereby excluded.

IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS, SELLER
GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER W ARRANTIES ARE
GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN
PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL
BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD W ARRANTY CLAUSE. IN
NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S
LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY
SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT
SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL
DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT ARE NOT LIMITED TO, LOSS
OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND
DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT. IN NO EVENT SHALL SELLER BE
OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR
PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE
AND/OR INDEMNITY COVERAGE PROVIDED TO BUYER, ITS ASSIGNS, AND EACH
SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER.

Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyond
Seller's direct control.

Rosemount Analytical

4125 E

AST LA PALMA AVENUE

Rosemount Analytical Inc.

• A

F

EBRUARY 1997 • 7485189-C • PRINTED IN USA

NAHEIM

, C

ALIFORNIA

92807-1802 • 714-986-7600 • FAX [phone]

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IELD SERVICE AND REPAIR FACILITIES

F

Field service and repair facilities are located worldwide.

U.S.A.

To obtain field service on-site or assistance with a service problem, contact (24 hours, 7
days a week):

National Response Center

1-800-654-7768

INTERNATIONAL

Contact your local Rosemount Sales and Service office for service support.

FACTORY

For order administration, replacement Parts, application assistance, on-site or factory repair,
service or maintenance contract information, contact:

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

RETURNING PARTS TO THE FACTORY

Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when you call:

Model Number, Serial Number, and Purchase Order Number or Sales Order Number.

Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sende r, f re ight collect.

When return ing any product or compon ent that has been expo sed to a toxic, co rrosive or
other hazardous material or used in such a hazardous environment, the user must attach an
appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification that the material
has been decontaminated, disinfected and/or detoxified.

Return to:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

4125 E

AST LA PALMA AVENUE

Rosemount Analytical Inc.

• A

ULY 1997 • 748190-G • PRINTED IN USA

J

NAHEIM

, C

ALIFORNIA

92807-1802 • 714-986-7600 • FAX [phone]

(blank)