Rosemount NGA 2000 Platform SW 2.2-Rev J Manuals & Guides

NGA 2000

P

LATFORM

Rosemount Analytical

748329-J

N

OTICE

The information contained in this document is subject to change without notice.
Rosemount Analytical's system of NGA 2000 Modular Gas Analyzers and Controllers are patented under U.S. Patent

5.787.015.

Excel™, Word™, Visual Basic™, Windows™ and Windows NT™ are trademarks of Microsoft Corporation.
MS-DOS
Echelon

®

is a U.S. registered trademark of Microsoft Corporation .

®

is a U.S. registered trademark of Echelon Corporation.
LONTALK™ and LonManager™ are trademarks of Echelon Corporation.
IBM® is a U.S. registered trademark of International Business Machines.

Manual Part Number 748329-J
October 1999
Printed in U.S.A.

Rosemount Analytical Inc.

4125 East La Palma Avenue
Anaheim, California 92807-1802

C

ONTENTS

P

REFACE

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

GLOSSARY ......................................................................................................P-3

SPECIFICATIONS - PLATFORM .......................................................................P-9

SPECIFICATIONS - I/O MODULE......................................................................P-9

SPECIFICATIONS - 30 A BULK POWER SUPPLY ...........................................P-10

CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE ............P-11

RETURNING PARTS TO THE FACTORY .........................................................P-11

TRAINING ......................................................................................................P-11

DOCUMENTATION............................................................................................P-11

COMPLIANCES..................................................................................................P-12

S

ECTION

1.1 INTRODUCTION TO THE NGA CONCEPT................................................1-1

1.2 THE DIGITAL COMMUNICATION SYSTEM - AN INTRODUCTION ..........1-2

1.3 PLATFORM OVERVIEW.............................................................................1-2

1.4 THE LON - THE NGA 2000 DIGITAL COMMUNICATIONS NETWORK ....1-4

1.5 PC INTERFACE...........................................................................................1-5

1.6 INSTRUCTION MANUALS..........................................................................1-5

1.7 PLATFORM COMPONENTS.......................................................................1-8

1. I

1.6.1 Platform Components Manual........................................................1-6

1.6.2 Analyzer Module Manuals..............................................................1-6

1.6.3 NGA Reference Manual.................................................................1-7

1.7.1 Operator Interface..........................................................................1-8

1.7.2 Platform Controller Board...............................................................1-9

1.7.3 Power Input Module/Power Supply................................................1-10

1.7.4 Distribution Assembly Components...............................................1-11

NTRODUCTION

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

i

C

ONTENTS

S

ECTION

1.8 SOFTWARE/DISPLAYS .............................................................................1-12

1.9 MULTIPLE MODULE COMPONENTS AND SYSTEM INTEGRATION......1-13

1.10 I/O MODULE OVERVIEW.........................................................................1-20

S

ECTION

2.1 SHIPPING CARTON INSPECTION............................................................2-1

2.2 LOCATION..................................................................................................2-1

2.3 ELECTRICAL REQUIREMENTS ................................................................2-2

2.4 GAS REQUIREMENTS...............................................................................2-3

2.5 I/O REQUIREMENTS..................................................................................2-3

2.6 I/O MODULE INSTALLATION PROCE.......................................................2-3

2.7 I/O MODULE REMOVAL PROCEDURE.....................................................2-4

1. (

CONTINUED

1.10.1 I/O Module General Description..................................................1-20

1.10.2 Analog Functions And I/O Connections.......................................1-23

1.10.3 Additional I/O Modules ................................................................1-25

2. I

NSTALLATION

)

2.8 I/O MODULE SOFTWARE CONFIGURATION...........................................2-4

2.9 I/O MODULE BINDING PROCEDURE .......................................................2-4

2.10 I/O MODULE BINDING PROCEDURE - SOFTWARE V2.3 AND

HIGHER........................................................................................2-6

2.11 SAMPLE HANDLING................................................................................2-8

S

ECTION

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

3.2 SOFTWARE MENU STRUCTURE.............................................................3-1

3.3 SECURITY..................................................................................................3-3

3.4 USING THE USER INTERFACE.................................................................3-3

3.5 START UP ..................................................................................................3-6

3.6 DISPLAY SETUP........................................................................................3-7

3.7 OPERATION...............................................................................................3-7

3. S

3.4.1 Using The Menus ..........................................................................3-4

3.4.2 Using The Help Screens................................................................3-5

TARTUP AND OPERATION

3.8 CORRECT OPERATION ............................................................................3-8

ii

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

C

ONTENTS

S

ECTION

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

4.2 FUSE REPLACEMENT ...............................................................................4-2

4.3 CONTROLLER BOARD REPLACEMENT...................................................4-2

4.4 POWER INPUT MODULE REPLACEMENT ...............................................4-3

4.5 POWER SUPPLY REPLACEMENT ............................................................4-3

4.6 FRONT PANEL ASSEMBLY REPLACEMENT............................................4-3

4.7 SYSTEM TROUBLESHOOTING.................................................................4-4

S

ECTION

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

5.2 MULTI-MODULE COMPONENT PARTS LIST.........................................5-1

S

ECTION

6.1 ANALOG I/O MODULE DESCRIPTION ......................................................6-1

4. M

5. R

6. A

AINTENANCE AND TROUBLESHOOTING

EPLACEMENT PARTS

NALOG

I/O M

ODULE

6.2 ANALOG I/O MODULE ALARM DESCRIPTION - V2.2 ..............................6-2

6.3 ANALOG I/O MODULE ALARM DESCRIPTION - V2.3 ..............................6-5

6.4 ANALOG I/O MODULE INSTALLATION .....................................................6-7

6.4.1 Analog I/O Module Initial Setup procedure.....................................6-7

6.4.2 Analog I/O Module Calibration Procedure......................................6-13

6.4.3 Analog Output Over/Under Limits..................................................6-15

6.5 ANALOG I/O MODULE TRACK AND HOLD FEATURE .............................6-15

6.6 ANALOG I/O MODULE: RELAY OPERATION CHECK PROCEDURE.......6-17

6.7 ANALOG I/O MODULE RANGE CONTROL DISCUSSION ........................6-18

6.8 ANALOG I/O MODULE OUTPUT CONNECTIONS.....................................6-19

S

ECTION

7.1 SINGLE ANALYZER ANALOG AUTOCAL DESCRIPTION ........................7-1

7.2 SINGLE ANALYZER ANALOG AUTOCAL I/O MODULE

7.3 SINGLE ANALYZER ANALOG AUTOCAL I/O MODULE OPERATION......7-8

7. S

INGLE ANALYZER ANALOG AUTOCAL

INSTALLATION.............................................................................7-3

I/O M

ODULE

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

iii

C

ONTENTS

S

ECTION

8.1 SYSTEM AUTO CALIBRATION I/O MODULE DESCRIPTION..................8-1

8.2 SYSTEM AUTO CALIBRATION I/O MODULE INSTALLATION.................8-3

S

ECTION

9.1 EXCEL-BASED PC INTERFACE DESCRIPTION ......................................9-1

9.2 EXCEL-BASED PC INTERFACE GENERAL REQUIREMENTS................9-1

9.3 EXCEL-BASED PC INTERFACE SOFTWARE REQUIREMENTS.............9-2

9.4 EXCEL-BASED PC INTERFACE HARDWARE REQUIREMENTS ............ 9-2

9.5 EXCEL-BASED PC INTERFACE SOFTWA RE PRODUCT

9.6 PC INTERFACE PACKAGE........................................................................9-3

9.7 EXCEL-BASED PC INTERFACE INSTALLATION .....................................9-3

9.8 NGA VARIABLE LIBRARY..........................................................................9-5

9.9 EXCEL-BASED PC INTERFACE MULTIPLE PLATFORM SYSTEMS.......9-6

8. S

9. E

YSTEM AUTO CALIBRATION

XCEL-BASED

SPECIFICATIONS........................................................................9-2

PV I

NTERFACE

I/O M

ODULE

SECTION

10.1 NGA MODBUS INTRODUCTION .............................................................10-1

10.2 NGA MODBUS IMPLEMENTATION......................................................... 10-1

10.3 MODBUS ADDRESSING..........................................................................10-3

10.4 MODBUS FUNCTION CODE DESCRIPTIONS........................................10-8

10.5 MODBUS CONFIGURATION....................................................................10-3

10. NGA M

10.3.1 ModBus Device Addressing (DA)................................................10-3

10.3.2 ModBus Register Addressing......................................................10-4

10.4.1 Function 03 (decimal) - Read Holding Registers.........................10-8

10.5.1 ModBus User Defined Addressing...............................................10-13

10.5.2 ModBus configuration - Front Panel Menu..................................10-17

ODBUS

iv

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

C

ONTENTS

S

ECTION

11.1 LOCAL I/O MODULE DESCRIPTION........................................................11-1

11.2 LOCAL I/O MODULE BINDING.................................................................11-2

11.3 LOCAL I/O MODULE INSTALLATION ......................................................11-2

11.4 LOCAL I/O MODULE SETUP....................................................................11-2

11.5 LOCAL I/O MODULE CALIBRATION PROCEDURE ................................11-5

11.6 LOCAL I/O MODULE TROUBLESHOOTING............................................11-6

11.7 LOCAL I/O MODULE CONNECTIONS......................................................11-7

A

PPENDIX

A

PPENDIX

A

PPENDIX

11. L

OCAL

A. NGA M
B. U
C. P

SER INTERFACE HELP

LATFORM IDENTIFICATION MATRIX

I/O M

ODULE

ENU STRUCTURE

ARRANTY

W

IELD SERVICE AND REPAIR FACILITIES

F

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

v

C

ONTENTS

F

IGURES

1-1. Single Analyzer Display..............................................................................1-8

1-2. Multiple Analyzer Display (Showing Two Analyzers)..................................1-9

1-3. Rear View Of Power Input Module.............................................................1-10

1-4. Measurement Screen Display....................................................................1-12

1-5. Dual Analyzer Enclosure............................................................................1-15

1-6. Dual Analyzer Enclosure With Two Analyzers...........................................1-16

1-7. Dual Analyzer Enclosure With One Analyz................................................1-16

1-6. Dual Analyzer Enclosure With Two Analyzers...........................................1-16

1-8. Wiring NGA Systems .................................................................................1-18

1-9. Supporting Multi Platform Integration.........................................................1-19

1-10. I/O Modules Location In Platform (Instrument Configuration)..................1-20

1-11. I/O Module Location In Platform – Rear Panel View

(Instrument Configuration)............................................................1-21

1-12. Analog I/O Module Component Location And Mounting Dimensions ......1-21

1-13. Analog I/O Module Backplane Connector Pin Assignments ....................1-22

1-14. Analog I/O Module Output Connector/Adapter Pin Assignments.............1-24

3-1. Main Menu .................................................................................................3-1

3.2 Typical Menu...............................................................................................3-4

3-3. First Help Menu..........................................................................................3-5

3-4. Single Analyzer Display..............................................................................3-7

6-1. Analog Output Module Setup Menu...........................................................6-7

6-2. Analog Output Parameter Menu ................................................................6-8

6-3. V2.2 Alarm Parameter Menu......................................................................6-9

6-4. V2.2 Concentration Alarm Parameters ......................................................6-9

6-5. Analog Output Module Setup Menu - V2.3 ................................................6-11

6-6. Alarm Condition Menu - V2.3....................................................................6-11

6-7. Concentration Alarm Parameters Menu - V2.3 ........................................6-12

6-8. Typical Concentration Alarm Parameter Menu - V2.3................................6-12

6-9. Voltage Output Calibration Menu...............................................................6-13

6-10. Current Output Calibration Menu.............................................................6-13

6-11. Output Parameters Menu.........................................................................6-15

6-12. First Relay State Menu.............................................................................6-17

6-13. Analog I/O Module Output Connector/Adapter Pin Assignments.............6-19

7-1. Autocalibration Module Setup Menu..........................................................7-4

7-2. Autocalibration Module Timing Parameters Menu .....................................7-4

7-3. Typical Gas Valve Control Menu................................................................7-6

7-4. General Valve Parameters Menu...............................................................7-7

7-5. Automatic Calibration Menu.......................................................................7-8

7-6 Manual Calibration Menu............................................................................7-8

7-7. Output Connector/Adapter Pin Assignments .............................................7-9

8-1. Output Connector/Adapter Pin Assignments .............................................8-4

9-1. Using The PC Interface With Multiple NGA Systems.................................9-6

11-1. Output Calibration Menu..........................................................................11-5

vi

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

T

ABLES

1-1. Node Count And Power Consumption For NGA 2000 System Integration.1-14

1-2. I/O Module Features...................................................................................1-22

1-3. Analog I/O Module Specifications...............................................................1-23

2-1 User Tag Numbers ......................................................................................2-5

6-1. Available Functions – Analog Output with 3 Alarms I/O Module V2.2........6-3

6-2. Alarm Relay Configuration Matrix V2.2.......................................................6-3

6-3. Available Functions – Analog Output with 3 Alarms I/O Module V2.3........6-5

6-4. Available Alarms – Analog Output with 3 Alarms I/O Module V2.3...........6-6

7-1. Autocalibration Module - Input Line Range Control....................................7-2

7-2. Available Functions – Single Analyzer Autocalibration I/O Module V2.2...7-3

8-1. Available Functions - System Autocalibration I/O Module V2.2..................8-2

9-1. Variables For Use In Excel Spreadsheets..................................................9-5

10-1. NGA Modbus Functions............................................................................10-2

10-2. Event Assignment....................................................................................10-4

10-3. Modbus “All Variable” Address Table.......................................................10-5

10-4. “Must Be Supported” Register Addresses................................................10-6

10-5. Modbus “User Defined” Register Address Example.................................10-6

10-6. Modbus Function 03 Message..................................................................10-8

10-7. Modbus Function 03 Response From The Slave Device..........................10-8

10-8. Modbus Function 04 Message..................................................................10-9

10-9. Modbus Function 04 Response From The Slave Device..........................10-9

10-10. Modbus Function 06 Message................................................................10-10

10-11. Modbus Function 06 Response From The Slave Device........................10-10

10-12. Modbus Function 08 Message................................................................10-11

10-13. Function 08 Response From The Slave Device.....................................10-11

10-14. Modbus Function 16 Message................................................................10-12

10-15. Modbus Function 16 Response From The Slave Device........................10-12

10-16. Modbus ASCII And RTU Comparison ....................................................10-13

10-17. Modbus Configuration Variables.............................................................10-14

10-18. Modbus Configuration Variable Addresses ............................................10-15

10-19. Modbus Address Assignment Example..................................................10-16

11-1. Local I/O Module Alarm Functionality.......................................................11-4

11-2. 25 Pin Sub-D Connector Pin Identification...............................................11-7

11-3. 9 Pin Sub-D Connector Pin Identification.................................................11-8

C

ONTENTS

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

vii

C

ONTENTS

N

OTES

viii

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

P

REFACE

P

URPOSE/SAFETY SUMMARY

The purpose of this manual is to provide the procedures for the installation, operation
and maintenance of the Platform and the System Accessories of the NGA 2000
System.

Read this instruction manual completely before attempting to install any components
into the NGA 200 System.

WARNING: AUTHORIZED PERSONNEL

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 the
NGA 2000 Platform 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

will

can

or

cause

cause

can

cause

severe

severe

minor

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

P-1

P

REFACE

WARNING: ELECTRICAL SHOCK HAZARD

Do not operate without doors and covers secure. Servicing requires access to
live parts which can cause death or serious injury. Refer servicing to qualified
personnel.

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

Platforms with two power supplies require disconnection of BOTH power cords
to remove power from the platform.

WARNING: POSSIBLE EXPLOSION HAZARD

This equipment may contain modules used in the analysis of sample gases
which may be flammable. If used for analysis of such gases, the module must
be protected by a continuous dilution purge system in accordance with
Standard ANSI/NFPA 496-1993, Chapter 6.

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.

WARNING: PARTS INTEGRITY

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

WARNING: STATIC SENSITIVE COMPONENTS

Circuit boards in this instrument are static-sensitive. Take all static precautions
when handling them.

Note: If this Platform is stored in an environment whose ambient temperature is
below 5
hours prior to powering up. If not, moisture may form inside the LCD display.

°°°°

C (41

°°°°

F), it must be moved into a room temperature environment for 24

P-2

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

G

LOSSARY

P

REFACE

30 A B

A power supply that is mounted in an en closure capable of supplying powe r (+24 VDC @
30 Amperes) to up to ten Analyzer Modules installed in the NGA 2000 System.

ULK POWER SUPPLY

AK

A serial interface protocol, popular in Europe in the automotive industry.

AMSN

Network variable name containing the module Serial number. This should be the
same as the number physically marked on the unit.

LARM

A

An indication (normally) of an out-of-normal circumstance. This covers status
indications, concentration limit violation, internal limit violations or an internal problem.
Alarms may be indicated to the user either visually or through a relay contact closure.

NALYZER MODULE

A

Self contained analysis modules that are designed to be installed into the NGA 2000
System. One Analyzer Module can be installed into a Single Enclosure containing the
Platform Module. Two Analyzer Modules can be installed into a Dual Enclosure. The
simplest NGA 2000 System consists of one Analyzer Module.

ACKPLANE

B

The Controller Board, Power Supply Board, I/O Board(s) and Expansion Board(s) are
plugged into the Backplane

ASIC CONTROLS

B

In the NGA menu system, refers to the controls appropriate for normal operator use.
These include such things as range changing, zeroing the analyzer, and lighting the
flame on a FID analyzer.

ENCH

B

The physical measuring device within the analyzer module. It comes from the term
Optical Bench, describing the specialized optical components used in the original
analyzers.

INDING

B

A process by which analyzer modules and I/O modules are instructed with whom to
communicate over the LON. Once bound, variable updates from one module are
automatically transferred to the other.

ALIBRATE

C

In Internal Combustion Exhaust Emissions monitoring, to zero, span and linearize an
analyzer. In other industries, to zero and span an analyzer.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

P-3

P

REFACE

ALIBRATION CYCLE

C

A procedure for making an analyzer read sample gases correctly. It involves flowing
zero gas, waiting for stabilization, causing the analyzer to adjust its zero offset, and
then doing the same for one or more span gases with adjustment of span factors as
required.

CLD

Chemiluminescence Detector - a term for the type of analyzer that measures nitrogen
oxides by measuring the light emitted when nitric oxide reacts with ozone.

ONTROL MODULE

C

A Platform containing a Controller computer, a display and a keyboard. Used to view
analyzer data, and configure and troubleshoot the entire NGA system.

ONTROLLER BOARD

C

The Controller Board in the Platform which runs the software program that operates
the Display, Keypad and Network Manager. The Controller Board plugs into the
Backplane from the Platform front.

DDE

Dynamic Data Exchange - a Microsoft Windows function that allows programs to talk
to other programs. It is rather slow and primitive, but is a recognized standard.

DDE

A program running under Windows that provides DDE communication to Windows
applications. The Rosemount DDE server allows such applications to communicate
seamlessly to NGA analyzers.

SERVER

DIO

Digital input/output board, a special I/O Module that works with the platform to provide
many digital I/O lines.

ISTRIBUTION ASSEMBLY

D

The Distribution Assembly consists of the Backplane and the card cages in the
Platform Module that contain I/O Board(s) and Expansion Board(s).

XPANSION BOARD

E

The Expansion Board performs special features not related to I/O functions. The Expansion
Board plugs into the Backplane from the Platform front.

P-4

XPERT

E

Refers to the controls and configuration capability appropriate for engineering personnel.

AILURE

F

A form of alarm: Failure indicates an unrecoverable hardware or software failure such
as some component not responding to network communications or a safety related
failure such as lack of purge air in a Flame Ionization Detection Analyzer Module.

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

P

REFACE

FID

Flame Ionization Detector - refers to the hydrocarbon analyzer. This ionizes hydrocarbons
in a flame, and measures the resultant current.

HOME

The main menu, the top menu of the NGA menu system. Pressing the HOME softkey
always returns to this point.

I/O B

The optional I/O Board(s) provide input/output functions. The I/O Board(s) plug into the
Backplane from the rear of the Platform.

I/O M

An auxiliary module that provides some sort of interface to the outside world. I/O modules
may include analog outputs, relay contacts, and digital interfaces. In general, they are
mounted in platforms as options.

I

Refers to the help screens in the menu system.

I

It is sometimes necessary to limit the current drawn by a piece of electronics when it is first
switched on. Special devices are available to do this. The NGA multi-module power supply
uses them.

OARD

ODULE

NFO

NRUSH CURRENT LIMITING

IR

Infra-red, also short for NDIR or Non -dispersive Infra-red a nalyzer. Uses t he absorption of
infra-red energy by certain gases as a means of measuring the concentration.

INEARIZATION

L

The application of a mathematical formula to the analyzer's signal with the intention of
compensating for the analyzer's inherent non-linear response. Normally a fourth order
polynomial is used.

LON

The LON is the Local Operating Network wh ich is used to provide a communications link
between the I/O Module(s), Analyzer Module(s) and the Controller Board in the Platform.

AIN MENU

M

The top menu in the NGA menu system. The "HOME" key in all other menus returns you to
this.

ENU

M

A screen full of information. Menus contain any or all of text, variables, function controls, or
jumps to other menus.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

P-5

P

REFACE

NDIR

Infra-red, also short for NDIR or Non -dispersive Infra-red a nalyzer. Uses t he absorption of
infra-red energy by certain gases as a means of measuring the concentration.

NGA

Next Generation Analyzer, a term describing Rosemount Analytical's digital analyzer
system.

ARAMAGNETISM

P

The quality of certain materials, particularly oxygen, of being attracted to a magnetic field,
like a very weak form of iron. Most gases are diamagnetic, meaning that they are very
weakly repelled by a magnetic field.

ARMS

P

Parameters, information that either tells you ho w the analyzer is operating, or how it has
been configured.

HYSICS

P

Refers to the physical measurement components within the analyze r. Also the study of the
natural world.

LATFORM

P

Any combination of the NGA case , the disp lay and comput er board, po wer supply, a nd I/O
modules. In general, it could be considered to be anything in the NGA s ystem other than
the analyzer modules.

LATFORM MODULE

4P

A module that provides operator command and control via a local network to one or more
Analyzer Modules connected to the NGA 2000 System.

PMD

Paramagnetic Detector, the name used for the NGA paramagnetic oxygen analyzer
module.

OLYNOMIAL

P

A mathematical term meaning an expression (a funct ion of a variable) containing several
terms, each of which contain s a power of the variable. A + B X x + C X (x X x) is a second
order polynomial in x. A,B and C are its zeroth, first and second coefficients. "X" means
multiply, as usual.

P-6

OWER SUPPLY BOARD

P

The Power Supply Board that plugs into the front of the Backplane capa ble of supplying
power (+24 VDC @ 5 Amperes) to the pla tform compo nents and ju st one ana l yzer modu le
mounted within the platform.

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

P

REFACE

RIMARY VARIABLE

P

The measured species concentration value from an Analyzer Module.

ANGE

R

The bounds of concentration over which the analyzer's read ing is accurate, o r possible.
Traditionally this is set by the analyze r circuitry or its physic s: in NGA, it is often merely a
mathematical fiction provided for operational convenience.

ESPONSE FACTOR

R

The relative response of the analyzer to different gases to which it is sensitive. I n the ca se
of the FID this refers to its response to various hydrocarbons, which is roughly in proportion
to the number of carbon atoms contained in the gas' molecule.

AFETY FAILURE

S

Indicates a failure of the analyzer safety system, with resultant shut down of the analyzer.

ECONDARY VARIABLE

S

The current status data placed on the network by an Analyzer Module. The includes sample
flow, source voltage and other diagnostic information.

ERIAL NUMBER

S

A number assigned to the module at time of manufacture. It is stored in the network
variable AMSN, and marked on a label on the module enclosure.

OFTKEYS

S

The five function keys located below the front panel disp lay. The menu function for each
softkey is displayed directly above it and is controlled by the software.

OLENOID VALVES

S

A gas switching element controlled by electrical current. It is used to control the flow of
sample or cal ibr ati on ga s to a n analy zer .

PAN

S

The range over which something works, or the act of standardizing the upper e nd of the
range.

YSTEM

S

A NGA 2000 System consistin g of one (or more) Analyzer Module s, an optional Platform,
one or more optional I/O Boards, an opt ional Expansion Board and an Op tional 30 A Bulk
Power Supply.

YSTEM I NTEGRATOR

S

An individual or organization who des igns and builds analytical systems. Typica lly these
are panels containing one or more ana lyze rs to gether with the samp le s ystem component s
and any other devices required for stand-alone operation.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

P-7

P

REFACE

TAG

The name of a module. This may be defined by the user. I t is used to identify the modu le
both in the menu system and through the PC interface. See also AMSN, or Serial number.

ECHNICAL LEVEL

T

In the NGA menu system, refers to the controls and configuration capability, and dia gnost ic
information appropriate for analyzer technicians.

THC

Total Hydrocarbons, a term for the total quantity of hydrocarbons present, regardless of
their type.

WEAK

T

A slang term meaning to adjust. Used in the NGA system specifically to describe a process
of modifying the linearity of an NGA analyzer.

ALIDITY

V

A concept used to describe a condition in which gas concentration values present on the
Operator Interface or output lines should be considered valid or invalid. The Analyzer
Module alerts the system that an error in gas concentration is present. Causes include
failure or lack of calibration, flame out in a FID, or a not-from-process gas applied by a
sample control module.

VBA

Visual Basic for Applications - Microsoft's version of Visual Basic that they supply built into
their main applications such as Excel or Word. It is similar but not iden tical to the stand­alone Visual Basic, and each variety has its own idiosyncrasies.

ARNING

W

A form of alarm: a warning indicates one or more software configured limits on any netwo rk
variable (other than gas concentration ) has been exceede d. Examples of these secondary
variables are flow rate and internal voltage. A warning indicates that the analyzer reading
may not be correct.

ERO

Z

To make the analyzer read zero on zero gas, by calibrating its of fset. Also the operation
that accomplishes this.

P-8

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

P

REFACE

S

PECIFICATIONS

P

OWER REQUIREMENTS

- P

LATFORM

85 to 264 VAC, 50/60 Hz; 24 VDC (optional); 150 W max.

E

NCLOSURE DIMENSIONS

Standard: 133 mm x 483 mm x 522 mm (5.2" x 19" x 20.5") H x W x D
Extended: 133 mm x 483 mm x 649 mm (5.2" x 19" x 25.5") H x W x D

W

EIGHT (FULLY CONFIGURED; NO ANALYZER

, I/O,

Standard: 10.0 kg (22 lbs.)
Extended: 10.5 kg (23 lbs.)

E

NCLOSURE MOUNTING

Horizontal rack or bench (kit is available for bench mounting)

E

NVIRONMENT

Location - Class B controlled, indoor, non-hazardous

A

LTITUDE

Up to 2000 m.

P

OLLUTION DEGREE

2

I

NSTALLATION CATEGORY (OVER-VOLTAGE CATEGORY

II

OR EXPANSION MODULES

)

)

O

PERATING TEMPERATURE

0 oC to 45 oC (32 oF to 113 oF)

O

PERATING HUMIDITY

20 to 90 % Relative Humidity, non-condensing

S

PECIFICATIONS

P

OWER REQUIREMENTS

24 VDC; 5 W max.

R

ELAY CONTACT RATING

1A, 24VDC; resistive load only.

R

ELAY CONTACTS

3 SPDT; 4 SPST

C

URRENT OUTPUT

-2 to +22 mA max.; 0 - 20 mA range or 4 - 20 mA range; 600 Ohms maximum
load.

V

OLTAGE OUTPUT

-9 to + 9 V max.; 0 - 5V range; 10K Ohm minimum load.

- I/O M

ODULE

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

P-9

P

REFACE

S

PECIFICATIONS

AC P

OWER INPUT

115/230 VAC (selectable), 47 to 440 Hz, 12/8 Amperes: Brown-out Voltage:
80/160VAC. Efficiency is 80% minimum.

F

USES

2 fuses each: 110V T12A; 230V T8A

L

INE REGULATION

1.2 % maximum.

L

OAD REGULATION

0.6 % maximum.

DC V

OLTAGE OUTPUT

+24 VDC.

DC C

URRENT OUTPUT

30 Amperes maximum.

R

IPPLE

& N

OISE

Less than 100 mV peak-to-peak maximum.

O

PERATING TEMPERATURE

0 to 45 °C.

- 30 A B

ULK POWER SUPPLY

S

TORAGE TEMPERATURE

-20 °C to 75 °C.

S

AFETY

The power supply unit within the enclosure is UL Recognized; CSA Certified.

W

EIGHT

8.7 kg (19.2 lbs.).

See the appropriate Analyzer Module manuals for specifications regarding the analyzer
(e.g., drift, noise, repeatability).

P-10

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

P

REFACE

C

USTOMER SERVICE

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

R

ETURNING PARTS TO THE FACTORY

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

Number.

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

When returnin g any pro duct o r compon ent t hat has be en exp osed to a toxic, corrosi ve
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 92840-1802

T

RAINING

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

D

OCUMENTATION

The following NGA 2000 Platform instruction materials are available. Contact
Customer Service or the local representative to order.

748329 Instruction Manual (this document)

Current Operator and Service Training Schedule

Rosemount Analytical Inc.

Phone: [phone]

FAX: [phone]

contact

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

P-11

P

REFACE

C

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

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

N96

P-12

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NTRODUCTION

1

1.1 INTRODUCTION TO THE NGA CONCEPT

NGA stands for "Next Generation Analyzer". It describes a new concept in gas
analyzer design. The basis for this concept is the division of the traditional analyzer
functions into modular parts, connected by a digital communication link called LON.

Traditional analyzers contain the "physics" - the mechanism for detecting the gas in
question - and a means of controlling the operation of and getting data from the
physics. This normally consists of a display with associated controls on the front of the
box, and "I/O" (input/output) consisting of an analog or sometimes RS232 output,
together with some relay contacts, on the back. Power is supplied by an AC
connection to the wall plug. Each analyzer in a system has to contain all of these
components.

In the NGA concept, the physics is separated from everything else into an "Analyzer
module", and a single "Control module" or "Platform" (so called) contains the control,
display, I/O and power supply components.

Communication between the Analyzer module and the Control module is by means of
a sophisticated digital communication system made by the Echelon corporation, called
LONWORKS™ or LON™. There are many subtleties involved in such systems, but
the NGA and the LON hide almost all of these from the user. A great deal of the
sophistication of the NGA concept is involved in making the communication system
extremely simple to use and in removing the complexity that, for example, your MIS
administrator has to deal with while managing the LAN (Local Area Network) you
probably have to use at work!

A typical NGA system then consists of a number of different types of Analyzer
modules connected to a single Platform, with some selection of I/O provided according
to the particular needs of the user. Control of the entire system takes place through
the single Platform, and any I/O to the system goes through it. (It is also possible for a
computer to talk directly to the Analyzer Modules without the need of a Platform, but
that is outside the scope of this document.)

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

1-1

I

NTRODUCTION

1.2 THE DIGITAL COMMUNICATION SYSTEM - AN
INTRODUCTION

The NGA uses a proprietary digital communication system made by Echelon
corporation, called LONWORKS™ or LON™ for short. It is a sophisticated system
that deals with most of the subtleties required without user intervention or knowledge,
but there are certain aspects of it of which you should be aware.

The LON sends data in packets called "Variables". These are named, so that, for
example, the main output of an analyzer is contained in a variable called "PVA". Its
range is contained in a variable called "CRANGE". These variables are emitted by
the source and read by other modules on the network that are interested in them.

I/O Modules contain input variables of the same name, and when the I/O is "bound" to
an Analyzer Module, the contents of the Analyzer's PVA are automatically
communicated to the I/O's PVA, so that it now knows what the analyzer's reading is. It
can convert it to a 4-20mA signal, or whatever it is configured to do. Obviously it is
important that the I/O Module knows which analyzer to listen to!

The way we tell the I/O Module which analyzer it should pay attention to is to "bind" it
to that analyzer. This process selects an analyzer, selects an I/O Module, and ties
them together so that the set of analyzer variables is bound to the equivalent set of I/O
variables, and the two act as if they are one unit. The process itself is described
below, and it is much easier in V2.3 than in V2.2 and earlier versions. It is the only
thing you have to do to configure the LON.

The other thing to realize is that the LON is extremely reliable. Any apparent problem
with it has always been proved to be from some obvious error, like a broken wire. It is
possible to overload it, and there is information in this and the reference manual about
this, but once a system has been setup the LON itself keeps working. If there is a
problem, look for other things besides the LON to be at fault!

1.3 PLATFORM OVERVIEW

This manual describes the Control and I/O capabilities of the Platform part of an NGA
system.

NGA system consists of three basic elements:

Platform components

•

1-2

Analyzer Modules

•

Input/Output (I/O) Modules

•

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NTRODUCTION

The Platform serves as a local operator interface for up to six (ten for V2.3 and higher)
Analyzer Modules. It consists of a group of components that can be assembled in
many different configurations depending on the user's needs. It can be composed of
any workable collection of the following:

Operator Interface - Front Panel, Display and Keypad

•

Power Input Module/ Power Supply Board

•

Platform Controller Computer

•

One or more of a number of I/O Modules

•

Enclosure.

•

The Platform is also available in a dual version, with two complete independent sets of
electronics in one enclosure. Such dual versions act as two separate Platforms and
allow two independent analyzer systems to be run from one place. The front panel in
this case consists of two half panels directly mounted on the chassis with no hinges.

The NGA 2000 family of gas Analyzer Modules utilizes proven methodologies such as:

Non-dispersive infrared (NDIR) to measure gases such as carbon monoxide

•

(CO), carbon dioxide (CO2) and sulfur dioxide (SO2)

Paramagnetic (PMD) for measurement of oxygen

•

Chemiluminescence (CLD) for measurement of nitrogen oxides (NO and NOX)

•

Flame ionization detection (FID) for measurement of total hydrocarbons (THC).

•

Further modules made in Europe and described in their own manuals. These

•

include the MLT (a multi-analy si s module) and th e NGA II series.

These gas detectors are packaged in standard sized modules that can be linked
together via the LON communications network. The modularity of NGA 2000 allows for
the use of multiple interchangeable Analyzer Modules with no change in overall
operational characteristics.

The I/O Modules provide signal input and ou tput capability outside of the NGA 2000
communications network and are designed for easy installation in the Platform. I/O
Module options provide analog and digital signals, dry contact closures for alarms and
calibration valve sequencing, and accept remote signals for range change and
calibration initiation. These I/O Modules contain a small computer that operates
autonomously providing I/O capability through the LON connection without burdening
the Analyzer module computers.

The SIO Board and DIO Board are extensions to the Platform Controller Board. They
plug into the back of the Platform just as do the I/O Moduleboards, but they do not
contain on board intelligence. The Platform will only accept one SIO board but it is
possible to add up to four DIO boards - but only if the software in the Platform is V3.3,
or higher. (At the time of writing, this software is not available in the USA.)

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

1-3

I

NTRODUCTION

The LON I/O Module boards allow for external LON connections to the Platform.
Components that comprise the Platform and the I/O Modules can be assembled in

other configurations depending on user needs.

NOTE
The Platform controller board software must be of a later major revision than

any Analyzer Module software. For example, a V2.2 Platform controller board
will work with V2.2.1 Analyzer Modules, but not with V2.3 Analyzer Modules. The
".1" after the V2.2 refers to a minor revision, which is compatible with the V2.2
Platform controller board software.

NOTE
It is strongly recommended that you note the actual software revisions that you

have. Service or support people will be able to diagnose any problem you may
have more easily if this information is immediately available. The revision is
marked on each component, as well as noted in their Manufacturing data menus.

1.4 THE LON - THE NGA 2000 DIGITAL COMMUNICATIONS
NETWORK

The NGA 2000 Digital Communications Network operates over a bi-directional, peer­to-peer, two-wire system at a rate of 78 kbps. Modules are connected with RJ-45
modular connectors and UL level 4, 100 Ohm LAN cable. This means that there is a
single wire connection between all the modules on the network. It plugs into each
module using a plug much like standard telephones use. (In fact the wiring is not
critical, plain wire connections will work well over reasonably short distances such as
100 feet.)

The network utilizes LONW
by the Echelon Corporation. This uses the L
the NGA 2000 modular architecture with the robust L
capability to “multi-drop” nodes to create a distribu ted network. This is to say that it is
possible to connect many devices onto the same network, and the network protocol
keeps everything working without conflicts.

Every Analyzer Modules or I/O Module node that communicates to the network
contains a N

EURON

® C

HIP

and EEPROM memories, timers, multifunctional I/O, and the network interface. From
the user perspective the inner complexities of the LON are thoroughly hidden from
view and can safely be ignored.

®, an open control networking technology developed

ORKS

ONTALK

™ protocol. The combination of

ONTALK

™ protocol allows the

. This chip integrates three microprocessors, ROM, RAM,

1-4

The network is self-installing upon startup. The control module acts as a Network
Manager, assigning addresses and generating its own database automatically.
Manual intervention is only needed to determine linkages (“binding”) between Analyzer
Modules and I/O Modules. This means that all you have to do is to connect everything

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NTRODUCTION

and power it up, and then tell it which I/O Module is connected to which analyzer.
Once this has been done once, it never needs to be done again unless modules are
exchanged or added.

Each NGA 2000 Analyzer Module transmits over two hundred pieces of data (called
variables) that are characteristic of its specific gas detection methodology. In addition
to the main reading - the primary or process variable (gas concentration), many other
parameters and pieces of diagnostic information are available. This data includes:

Manufacturing data such as serial number and software revision

•

Configuration setup for calibration control, component temperature and other

•

alarm set points, and linearization parameters

Operational status conditions such as faults and calibration

•

Secondary variables such as type of gas measured, flow, temperature, and

•

pressure readings

Historical data such as known good calibration values and factory configuration

•

settings

1.5 PC INTERFACE

There are several ways of using the NGA system with a PC. The Platform can support
RS232 or RS485 interfaces, using either AK or ModBus as the protocol. ModBus is
described in detail in this manual, and AK is touched on here and more extensively in
the NGA Reference manual.

It is also possible to setup a PC to communicate directly with the LON. The easiest
way is to use the Rosemount Analytical DDE Server, together with a set of suitable
hardware. This is described briefly in the NGA Reference manual, and in detail in the
DDE Server manual.

1.6 INSTRUCTION MANUALS

Each module has its own instruction manual that describes the functionality of that
specific module. The Rosemount Analytical part numbers for these manuals are as
follows:

Pre-V2.2 Software:

748270 - Platform & I/O
748271 - Analyzer Module, PMD
748272 - Analyzer Module, FID
748273 - Analyzer Module, NDIR
748274 - Analyzer Module, CLD
748275 - I/O Modules

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

1-5

I

NTRODUCTION

Software V2.2:

748329 - Platform Components (this document)
748330 - Analyzer Module, PMD
748331 - Analyzer Module, FID
748332 - Analyzer Module, NDIR
748333 - Analyzer Module, CLD
748313 - Analyzer Module, Wet NOx
748297 - Analyzer Module, Heated FID
748356 - Analyzer Module, McFID
748384 - NGA Reference Manual
748368 - DDE Server Manual

The manuals for any given collection of modules together constitute the single
instruction manual for that system. All manuals should be read and understood before
operation.

1.6.1 P

LATFORM COMPONENTS MANUAL

This manual describes:

The general characteristics and specifications of Platform components

•

Installation guidelines

•

Display and keypad functions

•

General operation procedures

•

I/O boards available

•

I/O Module specifications

•

Interconnections with internal and external devices

•

Display menus and keypad functions that are I/O specific

•

Recommended replacement parts.

•

1.6.2 A

NALYZER MODULE MANUALS

The Analyzer Module manuals describe:

1-6

Theory of technology and typical applications

•

Module specifications

•

Gas connection installation

•

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NTRODUCTION

Sample conditioning specifications

•

Start-up procedures

•

Calibration routines

•

Operational functions, including analyzer-specific displays and keypad

•

procedures

Troubleshooting and maintenance information, and

•

Recommended replacement parts.

•

1.6.3 NGA R

EFERENCE MANUAL

The NGA Reference Manual provides a detailed discussion of the inner workings of
the NGA software and its application to the NGA analyzers. It includes:

Discussion of typical calibration issues

•

In depth discussion of network issues

•

Troubleshooting information

•

Analyzer variable reference

•

This latter refers to the technical description of the pieces of data - "variables" ­available over the LON from each of the Analyzer Modules.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

1-7

I

NTRODUCTION

1.7 PLATFORM COMPONENTS

1.7.1 O

IGURE

F

PERATOR INTERFA CE

1-1. S

INGLE ANALYZER DISPLAY

The Front Panel Display is a 128- by 240-pixel liquid crystal graphics display with cold
cathode back lighting. During normal analysis operation (Single analyzer
measurement mode), the Display indicates:

The current conce ntration of the component of interest,

•

A single-line, horizontal bar graph indicating the component concentration in

•

percent of fullscale format,

Four secondary parameters (e.g., Sample flow), selectable from either the

•

Analyzer Module or its associated I/O Modules.

Current functions for the five "softkeys" located below the display.

•

It may also indicate the following data for each of up to five analyzers in the multiple
analyzer measurement mode (V2.3 software, four analyzers for V2.2):

The current conce ntration of the component of interest,

•

The name of the gas measured,

•

The Analyzer module TAG,

•

A single-line, horizontal bar graph indicating the component concentration in

•

percent of fullscale format.

1-8

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NTRODUCTION

IGURE

F

1-2. M

ULTIPLE ANALYZER DISPLAY (SHOWING TWO ANALYZERS

)

It is possible to page through multiple analyzer measurement screens if more than five
analyzers are present - with V2.3 software. Select an analyzer with the arrow keys or
SELECT softkey to drop to the Single analyzer display screen for that analyzer.

Ten push-button keys provide the user complete access to the functionality of NGA

2000. They are:

5 Softkeys

dependent for their function on the Display labels directly above them

4 Arrow Keys

(←,↑,→,↓) multi-functional; a fundamental function is scrolling input data

Enter Key

(↵) executes menu items and data input by the user.

1.7.2 P

LATFORM CONTROLLER BOARD

The Controller Circuit Board acts as a network manager and provides user interaction
with NGA 2000 components through the Display and Keypad.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

1-9

I

NTRODUCTION

V2.3 and higher Controller boards come with additional memory and can support up to
10 Analyzer Modules with their associated I/O Modules. This board can be re­programmed locally through a PC serial port if desired to upgrade its software.

If the Platform Controller Board malfunction s, the Operator Interface will be affected,
but the Analyzer Module will continue to produce an accurate Primary Variable and I/O
Modules can still send accurate data to external recording devices. If the controller
loses contact with an analyzer, it indicates this fact with the phrase “No Data” replacing
the normal analyzer reading.

LFM 01

!

Fan

115/230 VAC
Plug Socket

Fuseholder Door
(closed)

24 VDC
Plug Socket

IGURE

F

1.7.3 P

POWER
230 V
56/60 Hz
F1/F 2=T 1.25A
115 V
50/60 Hz
F1/F 2=T 2.5 A

24V DC IN

1-3. R

Unit
Extraction
Handle

EAR VIEW OF POWER INPUT MODULE

OWER INPUT MODULE/POWER SUPPLY

Power can be supplied to all NGA 2000 components through the Power Input Module,
which plugs into the Backplane. External line voltage (85 to 264 VAC, 50 to 60 Hz) is
supplied to the Power Input Module and conditioned for usage by other NGA 2000
components. See Figure 1-3 and Figure 1-10.

1-10

The Power Supply Board also plugs into the Backplane and conditions incoming
power for usage by all modules (only one Analyzer Module). The Power Supply Board
provides +24 VDC at 5A.

Alternatively, the user may supply regulated 24 VDC directly to the Platform through
the Power Input Module. If multiple Analyzer Modules are used, a larger 30 A power
supply is required to power the system.

If the user initially applies AC power and then applies DC power, the DC circuitry
assumes control, and all components may continue operating without interruption but
may reset depending on the current draw. If the user initially applies DC power,

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NTRODUCTION

application of AC power will have no effect. DC power will remain in control. If both AC
and DC power have been applied, removal of DC power will reset the system, and AC
circuitry will then assume control.

WARNING: IMPROPER CONNECTION

The internal LON connection is for use with internally mounted and powered
analyzers only. Using this connection for external analyzers or LON
components could result in short-circuiting the 24V Power Supply Module
through the cable, with resultant damage. Use the LON I/O board for external
Analyzer Module connections (see Section 1.10.3).

1.7.4 D

ISTRIBUTION ASSEMBLY COMPONENTS

The Backplane is the backbone of much of the NGA 2000 Series' modularity. The
Controller Board, Power Input Module, Power Supply and I/O Modules all plug into the
Backplane. Identifying ground pins allow I/O Modules to identify their slot position.

NOTE
Earlier I/O Modules did not support slot identification. If so they will indicate

slot 0 no matter where they are placed.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

1-11

I

NTRODUCTION

1.8 SOFTWARE/DISPLAYS

IGURE

F

1-4. M

EASUREMENT SCREEN DISPLAY

The User interface is an extensive menu structure. Three types of screens may appear
on the Front Panel Display:

1. Measurement (Single or multiple analyzer displays)

2. Menus

3. Info (Help)

The Measurement screen is the actual operational screen in which the measured
component concentration is shown. Up to four (five with V2.3 software and higher)
measurements can be shown on the multiple analyzer measurement screen at once. If
an Analyzer Module has lost communication with the network, the screen will display
"No Data."

From the Single analyzer measurement screen you can either select the menus by
pressing the “MENUS” softkey (or right arrow key), or you can select a couple of
screens that provide essential information about the analyzer. Access these by
pressing the “PARMS” (short for parameters) softkey.

1-12

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NTRODUCTION

The Menu screens include all of the data and functions necessary to interrogate and
operate the Analyzer and I/O Modules. The selected menu line is highlighted in
inverse video. Use the ↑ and ↓ keys to highlight the desired menu line. Press the Enter
(↵) key, and depending on the item selected, one of the following will occur:

If the highlighted item ends with a colon and a value on the right side of the display
screen, the item will become editable.

If the highlighted item includes an ellipsis (...), Another menu will appear.
If the line is not editable or executable (it is there for information only), nothing will

occur, and in fact you will not be able to select it.
If the first of the above possibilities occurs, only the right-hand portion of the menu line

will then be highlighted. Use the ↑ and ↓ keys to scroll the data. Under certain
circumstances, the cursor is movable with the → and ← keys. This allows you to edit
specific characters within a numerical or string (alphabetic) variable. Press → to start
individual character editing, and then → or ← to select the character to edit: edit it with
the ↑ or ↓ keys. Pre ss En ter (↵) when you are done, or press the ESCAPE softkey to
abort the editing and return to the original value.

To escape from a menu, either press the left arrow key (←), the ESCAPE soft key, or
to jump all the way back to the Main menu, press the HOME softkey.

Help screens contain comprehensive, context-sensitive information about all functions.
Press the softkey labeled INFO once and receive data concerning the current screen.
Press INFO twice and receive information about the overall system.

Each menu screen has at least one help screen. The user can move directly from one
help screen to another through an interrelated structure of functional titles.

1.9 MULTIPLE MODULE COMPONENTS AND SYSTEM
INTEGRATION

The Rosemount Analytical NGA 2000 architecture provides significant system
integration capabilities.

The compact 5.25" height and component modularity allow for space efficient
mounting, thus decreasing the required panel or rack space required by conventional
analyzers. The Analyzer Modules may be mounted virtually anywhere inside a panel;
they can be rack mounted, floor mounted, installed inside the Platform, or even
externally located.

Since a single Platform can accommodate up to ten Analyzer Modules and up to five
I/O Modules, the total number of "Nodes" allowed in any one Platform group is fifteen.
This combination of Nodes may consist of any number of Analyzer Modules and I/O

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

1-13

I

NTRODUCTION

Modules which total fifteen or less. Should addition I/O Modules be required, these
may be housed in an ancillary analyzer enclosure. Additionally, some Analyzer
Modules, such as the MCFID (Multi Component Flame Ionization Detector), or MLT
(Multi Method Multi Component) Analyzer Modules, actually provide discrete analysis
of more than a single component and thus are considered, by the Platform, to be more
than a single analyzer. Once a "Node Group" has been configured it may be
networked with additional Node Groups by means of a Router Assembly (see Figure
1-9) which provides a discrete address for that Node Group and isolates it from other
Node Groups.

Individual Analyzer Modules require 24 VDC power. As shown in Figure 1-8, this
power may be provided by individual power supplies located in the Platform or by the
Bulk Power Supply which can provide up to 30 amps of 24 VDC power. The Bulk
Power Supply can provide power for up to 10 NGA 2000 components.

Table 1-1 may be used to calculate the total number of Analyzer Modules and I/O
Modules which may be supported by a single Platform (Node count ≤ 15), and the total
power requirements for any single Node Group (Bulk Power Supply ≤ 30 Amps).

1

NDIR PMD FID CLD HFID WCLD MCFID MLT

Node Count 1111111 - 531 - 5

PLATFORM

4

Average Power22.4A 2.4A 3.4A 3.5A 3.9A 3.5A 4.0A 2-4A 2.0A
Average Power23.1A 3.0A 3.7A 4.2A 4.8A 3.7A 4.9A 3A - 5A 2.5A

1

Calculate MLT power consumption as follows:

MLT1 ≤3.0 A
MLT2 ≤3.0 A
MLT3 (without internal power supply) ≤5.0 A

2

Total power consumed may not exceed 30 Amps for interconnection to any single Bulk Power Supply.

3

MCFID must be counted as one to five nodes depending upon the number of components measured.

4

MLT must be counted as one to five nodes depending upon the number of measurement channels

ABLE

T

MLT4 ≤5.0 A.

specified.

1-1. N

ODE COUNT AND POWER CONSUMPTION FOR

NTEGRATION

I

NGA 2000 S

YSTEM

1

1-14

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

The following accessories can be used to design a NGA 2000 system:

I

NTRODUCTION

• DUAL ANALYZER ENCLOSURE

used to house two Analyzer Modules for

either standard or extended lengths

• SINGLE ANALYZER ENCLOSURE used to house one Analyzer Module and up

to 5 I/O Modules.

• DUAL PLATFORM ENCLOSURE

to allow control of two independent systems

from one location

• 5 A POWER INPUT MODULE

to be used in the single analyzer compartment

enclosure to power the housed Analyzer Module

• 30 A BULK POWER SUPPLY

which is capable of providing power for up to 10

NGA 2000 components

The number of I/O Modules that can be housed in a Platform or single analyzer
enclosure is limited to five.

IGURE

F

748329-J Rosemount Analytical October 1999

1-5. D

UAL ANALYZER ENCLOSURE

NGA 2000 Platform

1-15

I

NTRODUCTION

LON Cables

IGURE

F

IGURE

F

1-6. D

1-7. S

UAL ANALYZER ENCLOSURE WITH TWO ANALYZERS (FRONT VIEW

COVER REMOVED

24 VDC power connection

INGLE ANALYZER ENCLOSURE WITH ONE ANALYZER (FRONT VIEW

COVER REMOVED

24 VDC power connection

)

LON Cables

)

Connection to third analyzer

,

,

1-16

The

Dual Analyzer Enclosure

simply provides space for two Analyzer Modules as
well as rear panel power and network connections for both. The front is a blank panel.
Note the following about the Dual Analyzer Enclosure:

If two Analyzer Modules are installed, the network connection

•

analyzers

If only one Analyzer Module is installed, only one cable need be connected to

•

must

be made

between

the two

the network or Platform supporting the Analyzer Module

If a standard Platform is used in conjunction with multiple module components, power
should be connected to the Platform's 24 VDC connector on the Power Input Module
and the network cable should be connected to the Network Port (see Figure 1-3. Rear
view of power ent ry module).

Single Analyzer Enclosure

The

provides additional flexibility in system design. It is a

standard Platform (with room for one Analyzer Module) with no front panel display. It

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NTRODUCTION

can be ordered with or without a 5 A Power Supply Module, depending on whether the
user can provide 24 VDC power.

Bulk Power Supply

The

provides the additional 24 VDC energy necessary to power
an entire system (standard Platform, I/O Modules, and multiple Analyzer Modules)
where the standard integral 5A Power Supply Module housed inside the Platform is
not sufficient. The supplemental Bulk Power Supply is capable of powering up to 10
NGA components, but is limited to 30 Amps (refer to Table 1-1)

WARNING: OVERHEATING HAZARD

To prevent the Bulk Power Supply from overheating, ventilation openings on the
top, bottom and rear of the enclosure should not be blocked.

note
Early multi-module power supplies were supplied with 5A fuses installed, these

fuses were inadequate for the HFID (Heated FID) and WNX (Wet NOx) Analyzer
Modules. When powering these modules, 8A fuses are recommended. The
internal wiring is adequate for this current, early supplemental supplies are,
however, limited to 25 A total.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

1-17

I

NTRODUCTION

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10

J1 J2 J3 J4 J5 J6 J7 F8 F9 F10

STANDARD PLATFORM - FRONT STANDARD PLATFORM - REAR

MULTI MODULE PLATFORM - FRONT MULTI MODULE PLATFORM - REAR

MULTI MODULE PLATFORM - FRONT MULTI MODULE PLATFORM - REAR

IGURE

F

1-8. W

IRING

NGA S

YSTEMS

1-18

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

(

)

(

)

(

)

NTRODUCTION

PC Running

NGA 2000

DDE Server

Analyzer
Module

Analyzer
Module

Analyzer
Module

Router

Standard Platform

rear view

Analyzer
Module

Analyzer
Module

Analyzer
Module

Analyzer
Module

Analyzer
Module

Analyzer
Module

Standard Platform

rear view

Analyzer
Module

Analyzer
Module

Analyzer
Module

Analyzer
Module

Analyzer
Module

Analyzer
Module

RouterRouter

Standard Platform

rear view

Analyzer
Module

Analyzer
Module

Analyzer
Module

IGURE

F

748329-J Rosemount Analytical October 1999

1-9. S

UPPORTING MULTI PLATFORM INTEGRATION

NGA 2000 Platform

1-19

I

y

d

NTRODUCTION

1.10 I/O MODULE OVERVIEW

1.10.1 I/O M

ODULE GENERAL DESCRIPTION

The I/O Modules are plugged into the Backplane of the Platform. Up to five I/O
Modules can be installed into the Backplane of the Platform as shown in Figures 1-10
and 1-11.

Enclosure

Analyzer Modu le

Operator
Interface

Distribution
Assembly

I/O Modules

Fan Boar

Power Input
Module

Power Suppl

I/O MO DUL E

I/O MODULE CONNECTION

(Back View)

Output
Connector

I/O Module
Extractor

IGURE

F

DC Connector
(24 VDC)

IGURE

F

1-10. I/O M

ONFIGURATION

C

Power Input
Module

LFM 01

!

POWER

115 V

∼

230 V

∼

50/60 Hz

115 V/230V

F1/F2 = T 3.5 A/230V

-DC 24V IN-

1-11. I/O M

NSTRUMENT CONFIGURATION

(I

ODULES LOCATION IN PLATFORM (INSTRUMENT

)

I/O Module
Window (used)

AC Connector
(85 to 264 VAC)

LON I/O Board

LON 1

LON 2

I/O Module Wi ndows (unused)

ODULE LOCATION IN PLATFORM

Analyzer Module Window
(stand-alone configuration)

EAR PANEL VIEW

– R

)

1-20

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

[

]

NTRODUCTION

Each I/O Module contains a NEURON CHIP microprocessor which acts as a Node
on the Local Operating Network (LON). The NEURON CHIP also controls the
functions of the I/O Module in accordance with the installed software on the I/O
Module. These functions can be modified via the Operator Interface of the Platform.
The SIO and DIO boards are controlled by menus contained within the Platform
Controller board menus.

The I/O Modules can provide a variety of digital and analog inputs and outputs via the
connectors located on the rear panel of the I/O Module. A typical I/O Module Rear
Panel is shown on Figure 1-10 under the arrow on the right side of the figure.

Figure 1-12 provides the I/O Module component locations and mounting dimensions.
The available input and output functions include voltage outputs (0 to +5 VDC), current

outputs (0 to 20 mA and 4 to 20 mA), alarms (3), auto calibration, remote range
change and identification and gateway translations such as the ModBus protocol.

Figure 1-13 provides the I/O Module backplane (not the external!) connector pin
assignments. This data is provided for oem user reference only and is not required
information for normal customer use. This information is

the user interconnect

NOT

diagram. See Section 1.10.2 for user connection information.

5.05

[128.3]

IGURE

F

4.75

[120.7]

DIMENSIONS

INCH

[mm]

1-12. A

1.0

[25.4]

I/O MODULE

NALOG

IMENSIONS

D

Output
Connector

Module
Extractor

I/O M

7.0

177.8

3.5

[88.9]

4.0

[101.6]

Backplane
Connector

ODULE COMPONENT LOCATION AND MOUNTING

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

1-21

I

NTRODUCTION

Output Connector

IGURE

F

Rear of Plate

Backplane
Connector

1-13. A

NALOG

PCB

I/O M

FEATURE ANALOG I/O

Orientation

: PCB is located behind connector.

Pin Assignments

A1 +24 VDC
A2 +24 VDC Return
A7 Network
C1 +24 VDC
C2 +24 VDC Return
C7 Network

ODULE BACKPLANE CONNECTOR PIN ASSIGNMENTS

AUTOCALIBRATION

LON I/O SERIAL I/O

SINGLE SYSTEM

ABLE

T

A

NALOG OUTPUT

A

UTO RANGE

CHANGE

A

LARM OUTPUT

S

ERIAL OUTPUT

D

IGITAL INPUT

LON I/O
C

ALIBRATION

GAS CONTROL

1-2. I/O M

1 1 None None 2 (to 6)
Yes No No No No

Yes ­programmable

No No No Yes - fixed

No No No Yes - V2 Yes (optional)
Yes -

programmable

Yes - fixed Yes - fixed No No

No No No Yes No
No

ODULE FEATURES

Yes - single
analyzer

Yes - up to 4
analyzers

No No

1-22

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NTRODUCTION

1.10.2 A

NALOG FUNCTIONS AND

I/O C

ONNECTIONS

The I/O Modules that include analog functions provide seven relay contact (contacts
are rated 24 VDC at 1 Ampere resistive) outputs [three single-pole, double-throw
(SPDT) and four single-pole, single-throw (SPST)], one analog output and six digital
inputs. Figure 1-14. Provides the I/O Module output connector and adapter pin
assignments. Table 1-3 provides the I/O Module Input, Output and Power
Specifications. If the I/O Module is installed in a Platform, the 24 VDC power is
derived from the Platform and no external power is required.

Note that the connector on the I/O Module is a male 25 pin sub D shielded connector.
It is equipped with EMC protection devices, but it is essential that no more than 24V be
applied to any of its pins. This includes the analog output which is isolated from the
metallic shield, but which also has EMC devices which restrict the maximum common
mode voltage allowed.

I/O Modules can provide standard automatic range change between high and low
ranges. A user-adjustable time delay is available to prevent range switching caused by
a noisy environment.

FEATURE DESCRIPTION

O

UTPUT RELAYS

I

NPUT

S

TANDARD OUTPUT

P

OWER REQUIREMENTS

ABLE

T

1-3. A

NALOG

7 relay contacts (3 relays SPDT, 4 relays SPST)
Contacts rated at 24 VDC, 1 amp resistive.

6 digital inputs and 24 VDC return, 5 mA resistive.
0 to 5 VDC or 0/4 to 20 mA (isolated, software-selectable)
24 VDC, 3 Watts maximum

I/O M

ODULE SPECIFICATIONS

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

1-23

I

NTRODUCTION

13

1

I/O Module

Output Connector

25

13

14

1

Output Adapter

(Accessory)

25

14

PIN ASSIGNMENTS

1 Analog Current Output 14 SPST Relay 4 (NO)
2 Analog Voltage Output 15 SPST Relay 5 (NO)
3 Analog Return for Pins 1, 2 16 SPST Relay 6 (NO)
4 Analog Chassis Ground 17 SPST Common

IGURE

F

5 SPST Relay 1 (NC) 18 SPST Relay 7 (NO)
6 SPST Relay 1 (C) 19 Digital Input 1
7 SPST Relay 1 (NO) 20 Digital Input 2
8 SPST Relay 1 (NC) 21 Digital Input 3

9 SPST Relay 1 (C) 22 Digital Input 4
10 SPST Relay 1 (NO) 23 Digital Input 5
11 SPST Relay 1 (NC) 24 Digital Input 6
12 SPST Relay 1 (C) 25 Digital Common
13 SPST Relay 1 (NO)

1-14. A

SSIGNMENTS

A

NALOG

I/O M

ODULE OUTPUT CONNECTOR/ADAPTER PIN

1-24

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NTRODUCTION

1.10.3 A

DDITIONAL

I/O M

ODULES

There are several additional I/O options available. These include the SIO board, the
DIO board, and the LON I/O board.

The SIO is described in its own section of this manual. It can provide up to 8 channels
of analog output at once. It can also provide an RS-232 or RS-485 digital link.

The DIO can provide up to 24 channels of discrete digital signals via pull-down
transistors. It can provide specific alarm indication for V2.3 or later Analyzer Modules.

It cannot work with V2.2 analyzers or earlier than V3.3 Platforms.

The LON I/O board provides two LON connections, as well as ventilation holes for the
Platform. The LON connections are paralleled. They allow the internal LON of the
Platform to be connected to external analyzers.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

1-25

I

NTRODUCTION

N

OTES

1-26

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NSTALLATION

2

2.1 SHIPPING CARTON INSPECTION

Carefully examine the shipping carton and contents for signs of damage. Notify the
shipping carrier immediately if the carton or contents is damaged. Retain the carton
and packing material until the Platform components and associated modules are
operational.

2.2 LOCATION

Install Platform components in weather-proofed, non-hazardous, vibration-free
locations isolated from extreme temperature variations. For best results, install near
the sample stream to minimize sample transport time if the Platform contains an
Analyzer Module.

note
If this Platform is stored in an environment whose ambient temperature is below

5

°°°°

C (41

°°°°

F), it must be moved into a room temperature environment for 24 hours

before powering up. Otherwise, moisture may form inside the LCD display.

note
Unrestricted air flow in the rear of the Platform is critical to the component's

performance and reliability. The bulk power module requires unrestricted air
flow vertically through itself. It should therefore not be placed between other
modules which restrict this flow.

WARNING: POSSIBLE EXPLOSION HAZARD

This equipment may contain modules used in the analysis of sample gases
which may be flammable. If used for analysis of such gases, the module must
be protected by a continuous dilution purge system in accordance with
Standard ANSI/NFPA 496-1993, Chapter 6.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

2-1

I

NSTALLATION

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.

Although the NGA 2000 Flame Ionization Detectors (FID and HFID) contain Type Z
purge equipment due to the presence of an internal source of flammable gas, the
instruments are designed for non-hazardous locations. Type Z continuous dilution
purge is designed to provide protection in accordance with standard ANSI/NFPA 496
(1993), Chapter 6 when sampling non-flammable gases. Do not place this (or any
general purpose) analyzer in a hazardous environment.

2.3 ELECTRICAL REQUIREMENTS

The NGA 2000 Series Platform and Multi-Module Power Supplies can operate on any
AC line voltage between 85 and 134 VAC, and between 218 and 264 VAC and the
Platform and Analyzer Modules can also operate on any regulated 24 ±5% VDC
power source. Power consumption (wattage) is dependent on the number and type of
modules connected together as a system. Wiring used must meet the current draw
requirements of the analyzers concerned.

Earlier versions of the Power Input Module were factory-equipped with 115 VAC fuses
(2 required). In this case, if available line voltage is 230 VAC, replace the fuses with
the accessory fuses found in the shipping kit that accompanied the Platform. Current
Platforms are equipped with a Power Entry Module that does not require such a fuse
change.

24 Volt power wiring must be connected individually to each Analyzer Module in a star
configuration (i.e. an individual set of wires to each analyzer), using appropriate gauge
wire to tolerate the current draw. The ground connection must be made to each
Analyzer Module and returned to a high quality common ground point. This
connection should not be used as the power return wire.

The LON connection wiring may be made in a daisy chain fashion. If the total length
of the LON connection exceeds a few meters, the configuration should be restricted to
a daisy chain, with LON termination devices at each end of the connection. Distances
of less than about ten meters are not as critical, and such connections may be made
in a star formation. The wiring used must be level 4 LAN twisted pair wiring, (100 ohm
impedance), preferably shielded. Standard 8 pin RJ45 telephone plugs and jacks are
used, with pins 1 and 2 carrying the signal, all others being unused. Terminal block
connections are permissible for junction boxes, if desired.

2-2

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

A dual version of the Platform is available by special order. This contains two
complete sets of Platform electronics including AC input and power supply. Note that
both AC connections must be removed to disconnect power from this unit.

The 30 A Bulk Power Supply is factory-configured for 115 VAC input. A 230 VAC
version (PN 659310) is also available.

WARNING: ELECTRICAL SHOCK HAZARD

When using the Bulk Power Supply, use a power cord rated at 13 A, 125 V and
1625 W or better. A cord with a lower rating may overheat and cause a fire
hazard.

2.4 GAS REQUIREMENTS

Since gas requirements (e.g., flow rate, flow pressure and connections) vary between
the available Analyzer Modules, information concerning this can be found in each
Analyzer Module manual.

I

NSTALLATION

2.5 I/O REQUIREMENTS

Input/Output requirements (including connections) are dependent on Analyzer
Modules and applications. Information concerning these requirements can be found
in the I/O Module section of this manual.

Various adapters are available for use with the I/O Module DB25 connector. See the
spare parts list Contact the facto ry fo r availability.

2.6 I/O MODULE INSTALLATION PROCEDURE

Remove power from all the components of the NGA 2000 System before installing an
I/O Module.

To install an I/O Module into the Platform, perform the following steps:

1. Remove a blank panel from one of the unused I/O Module slots as shown in Figure
1-11. Retain the blank panel for future use.

2. Hold the I/O Module by the rear panel and insert it into the open slot making sure
that the printed circuit board is aligned with the card guides at both the top and the
bottom.

3. Push the I/O Module completely into the slot to insure that the module connector
mates with the Backplane connector.

4. Tighten the two captive screws on the I/O Module Rear Panel.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

2-3

I

NSTALLATION

2.7 I/O MODULE REMOVAL PROCEDURE

Remove power from all the components of the NGA 2000 System before removing an
I/O Module.

To remove an I/O Module from the Platform, perform the following steps:

1. Loosen the two captive screws on the I/O Module Rear Panel.

2. Push down on the extractor handle to extract the I/O Module from the backplane
connector. Carefully pull the module out of the slot.

3. Install a Blank Panel to cover the slot.

2.8 I/O MODULE SOFTWARE CONFIGURATION

Configuring the software for an I/O Module is performed using the Platform Display
and Keyboard. First, an I/O Module must be bound to the associated Analyzer
Module. If only one Analyzer Module is used, all installed I/O Modules are
automatically bound to the Analyzer Module. The second step consists of custom
configuration of the I/O Module and selection of desired options and parameters.

2.9 I/O MODULE BINDING PROCEDURE

In an NGA 2000 System that contains only one Analyzer Module, binding between
that module and any I/O Module(s) will occur automatically upon startup.

If the system contains multiple Analyzer Modules it will be necessary to bind each
Analyzer Module to the associated I/O Module(s). To bind a newly installed I/O
Module to an Analyzer Module perform the following steps:

1. From the Main Menu, make the following selections:

Configurations, Listing of All Modules

NGA 2000 components (Analyzer Modules, I/O Modules and Platform [Control
Module]) recognized during the initialization of the network. Any module connected
(or disconnected) after initialization will not be recognized until the system is
reinitialized. Ensure that the system recognizes all modules on the network. If it
does not, the problem must be isolated and corrected before continuing further.

2. On the
tag number. Later I/O modules will be able to add their slot ID to their TAG as
shown on this screen. If so, you do not need to otherwise identify them. It is this
tag number that is used to bind an I/O Module to an Analyzer Module. The user tag
number can be set as shown in the example below. For example, in a system
consisting of two NDIR modules, two FID modules and one CLD module, the tags
could be chosen from Table 2-1.

Listing of All Modules

screen, ensure that each module has a unique user

. The

Listing of All Modules

Technical Level

screen shows all

2-4

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

ANALYZER MODULE TAG NO. I/O MODULE TAG NO.

I

NSTALLATION

NDIR-CO

2

I/O -IR1-CO

2

NDIR-CO I/O - IR2-CO
FID-HIGH I/O - THC1-HIGH
FID-LOW I/O - THC2-LOW

ABLE

T

2-1 U

CLD-NO

SER TAG NUMBERS

X

I/O - NOx

The user tag numbers should be somewhat logical in their description to avoid
confusion. They should not contain a period (.) so as to avoid confusing PC software
that attempts to communicate with the NGA system.

Note
From the Listing of All Modules screen, the diagnostics of a selected module

can be selected. The I/O Module diagnostics displays the I/O Module tag number
and allows it to be changed if necessary. To change the Analyzer Module tag
number, however, access the Analyzer Manufacturing Data screen by making
the following selections: Technical Level Configuration, Service Menus,
Manufacturing Data, or Expert Menu, Analyzer Module Setup, Analyzer Module
Tag. The initial Analyzer Module tag number is set during production test and
may be meaningless from the user's standpoint. I/O Module tag numbers initially
will probably each read "Analog I/O, Autocal I/O, SCAL,", etc.

3. Once all Analyzer Modules and I/O Modules have unique tag numbers, binding can
begin. Note that earlier I/O Modules were not identified as to which slot each one
occupied in the Platform (later units had this function enabled). The slot number
would always read "0." To remedy this condition, remove all but one I/O Module,
reinitialize the system and note which I/O Module tag number remains on the List
of All Modules screen. Edit the tag numbers in some unique fashion to aid in
subsequent recognition. Reinsert each I/O Module one at a time and reinitialize the
system. Note or edit the tag numbers that appear each time.

4. Note the physical location of each I/O Module for future reference. A common
problem in multiple Analyzer Module systems is the assumption that a module is
not responding (no output response - voltage, current, alarms) when actually the
wrong I/O Module was being accessed.

5. Select the top level display that shows multiple module output. Select the Analyzer
Module to be bound to an I/O Module, ensuring that it is identified with the correct
tag number.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

2-5

I

NSTALLATION

6. From the

Main Menu

Configuration, System Setup, Module Binding, Select Modules

, make the following selections

: Technical Level

.

7. Ensure that the Analyzer Module selected is, in fact, the one to which an I/O
Module is to be bound. Select the I/O Module to be bound. The screen will
appear as “Proposed New Bind”. If the proposal is correct, press the “BIND”
softkey. If incorrect, return to the

Module Binding

screen and re-select the correct
I/O Module. When the “BIND” softkey is pressed, the system will reinitialize
automatically.

8. To achieve binding between other Analyzer Modules and I/O Modules, return to
the top level display screen, select the next Analyzer Module and repeat steps 5
through 7. As I/O Modules are bound, they disappear from the

Select I/O Module

screen because they are no longer available for binding. In a system with only one
Analyzer Module, no I/O Module would appear in the

Select Module

screen since

they are automatically bound upon initialization of the system.

Note
Do not press the “UNBIND” softkey, doing so would unbind all modules,

requiring the user to repeat the complete binding procedure. However, if a
binding mistake is made, the only way to correct the mistake is to press
“UNBIND” and repeat the binding procedure. Also, do not press the “RE-INIT”
softkey during any of the automatic re-initializations in the binding process. If
the “RE-INIT” softkey is pressed, this will abort the binding process and all prior
binds will be removed.

9. Verify all bindings by selecting

View Bindings

in the

Module Binding

screen. A
“miss-bound” module can lead to confusion and mis-diagnosis of system problems.
Use the NEXT softkey to move from one Analyzer Module to another in this
screen.

2.10 I/O MODULE BINDING PROCEDURE - SOFTWARE V2.3
AND HIGHER

In an NGA 2000 System that contains only one Analyzer Module, binding between
that Analyzer Module and any I/O Module(s) will occur automatically upon startup.

If the system contains multiple Analyzer Modules it will be necessary to bind each
Analyzer Module to the associated I/O Module(s). To bind a newly installed I/O
Module to an Analyzer Module perform the following steps:

1. From the Main Menu, make the following selections:

Configurations, Listing of All Modules

. The

Listing of All Modules

NGA 2000 components (Analyzer Modules, I/O Modules and Platform [Control
Module]) recognized during the initialization of the network. Any module connected
(or disconnected) after initialization will not be recognized until the system is

Technical Level

screen shows all

2-6

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

I

NSTALLATION

reinitialized. Ensure that the system recognizes all modules on the network. If it
does not, the problem must be isolated and corrected before continuing further.

2. On the

Listing of All Modules

screen, ensure that each module has a unique user
tag number. Later I/O modules will be able to add their slot ID to their TAG as
shown on this screen. If so, you do not need to otherwise identify them. It is this
tag number that is used to bind an I/O Module to an Analyzer Module. The user tag
number can be set as shown in the example below. For example, in a system
consisting of two NDIR modules, two FID modules and one CLD module, the tags
could be chosen from Table 2-1.

The user tag numbers should be somewhat logical in their description to avoid
confusion. They should not contain a period (.) so as to avoid confusing PC
software that attempts to communicate with the NGA system.

Note
From the Listing of All Modules screen, the diagnostics of a selected module

can be selected. The I/O Module diagnostics displays the I/O Module tag number
and allows it to be changed if necessary. To change the Analyzer Module tag
number, however, access the Analyzer Manufacturing Data screen by making
the following selections: Technical Level Configuration, Service Menus,
Manufacturing Data, or Expert Menu, Analyzer Module Setup, Analyzer Module
Tag. The initial Analyzer Module tag number is set during production test and
may be meaningless from the user's standpoint. I/O Module tag numbers initially
will probably each read "Analog I/O, Autocal I/O", etc.

3. Once all Analyzer Modules and I/O Modules have unique tag numbers, binding can
begin. Note that earlier I/O Modules were not identified as to which slot each one
occupied in the Platform (later units had this function enabled). The slot number
would always read "0." To remedy this condition, remove all but one I/O Module,
reinitialize the system and note which I/O Module tag number remains on the

of All Modules

screen. Edit the tag numbers in some unique fashion to aid in

List

subsequent recognition. Reinsert each I/O Module one at a time and reinitialize the
system. Note or edit the tag numbers that appear each time.

If not identified, note the physical location of each I/O Module for future reference.

4.

A common problem in multiple Analyzer Module systems is the assumption that a
module is not responding (no output response - voltage, current, alarms) when
actually the wrong I/O Module was being accessed.

5. From the

Main Menu

, make the following selections:

Technical Level

Configuration, System Setup, Module Binding.

6. The screen shows one or more analyzer modules. Select one, and press the

ADD

softkey (or the right arrow). The screen will now list available I/O modules.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

2-7

I

NSTALLATION

7. Select one, and press

Enter

(

). The menu listing analyzer modules will reappear,

↵↵↵↵

with the selected I/O module indented under the analyzer module.

8. Continue the process until all desired I/O modules have been selected for all
analyzers. Note that this screen scrolls to show further analyzer modules, simply
press the down arrow key to see more.

9. Press the

BIND

softkey. The system will re-initialize itself, binding all the modules

as instructed.

10. To abort the process, or correct a mistake, press the Left arrow (

←←←←)

or the

softkey.

2.11 SAMPLE HANDLING

Rosemount Analytical offers many different sample handling systems, either
assembled or as loose components. Sample handling is dependent on the
requirements of the particular application and the preferences of the individual user.

Typical sample handling systems incorporate such components as pumps, valves,
needle valves, flowmeters and filters in order to provide a clean, dry sample to the
Analyzer Module.

HOME

There are some general sample handling issues that must be addressed. It must be
possible to control the sample flow into the analyzers, and also this flow must in
general not be made to pass through analyzers in succession, but rather through them
in parallel. The analyzer reading is sensitive to sample pressure changes, so care
must be taken to make sure that such changes do not occur, and that the span gas
pressure is the same as the sample pressure.

Excessive sample flow can destroy the flow sensor within the Analyzer Module; bring
the flow up from zero, rather than down from wide open when starting them up.

Solenoid valves used for zero and span gas control are prone to leaking. If they do so
it will be impossible to get good readings from the system.

Sample systems must be designed to make it impossible for water to get into the
analyzer. Heated sample lines should be heated the entire length, and care must be
taken to make sure that any water dropped out is drained from the sample line.
Unheated lines must slope down to the analyzer - water will collect in the low points
and be subsequently entrained in the sample. The same is true of exhaust lines ­particularly for the FID analyzers. It must be impossible for condensate to freeze or
flow back into the analyzer, or provide a slug of water whose effect will be to provide
pressure changes as the bubbles go through it.

2-8

There are many such issues. Sample system design is rather an arcane skill, and it is
worth having an experienced person or company design such a system. Most
analyzer problems are in fact sample handling system problems.

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

S

TARTUP AND OPERATION

3

3.1 OVERVIEW

The Platform can perform a narrow set of active functions within the NGA 2000 Series
range of operations. That set of functions includes the following:

Supply power to a single internal Analyzer Module, and any integral I/O

•

Modules, if equipped with an integral power supply

Output data to the front panel display

•

Hold and maintain network configuration data

•

Most other functions are performed by other modules. For instance, the Analyzer
Module(s) performs all functions related to gas concentration measurement, and
therefore places on the network all related data. This data (which appears on the Run
Mode, Menu and Diagnostic display screens) is Analyzer Module-specific. Refer to the
respective Analyzer Module instruction manuals for descriptions of those operational
functions. Multiple Analyzer module systems require an additional source of 24 VDC
power.

3.2 SOFTWARE MENU STRUCTURE

19.7 ppm NDIR - CO2

Main Menu

Basic Controls

Expert controls and setup ...
(Operational configuration)

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

DISPLAY PARMS. NEXT LOCK INFO

F1 F2 F3 F4 F5

IGURE

F

3-1. M

AIN MENU

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

3-1

S

TARTUP AND OPERATION

The displayed menu structure is divided into three levels, based on which personnel is
likely to use it:

Basic Controls:

Range selection

•

Control mode (e.g., local/remote)

•

Zero and span

•

Expert Controls:

Detailed Analyzer Module controls such as calibration gases, calibration mode,

•

flow, pressure and temperature range limits

Setup and configuration screens

•

Technical Controls:

System setup (e.g., system reset, front panel controls such as Module binding,

•

LCD brightness, time and date)

Service menus (e.g., manufacturing and service history)

•

Diagnostic menus (e.g., network, I/O, and analysis diagnostic data)

•

Each menu also shows the current reading and the current Analyzer Module tag on
the top line. It also has a set of softkey labels on the bottom line. In the above
example, DISPLAY leads back to the single Analyzer Module display screen; PARMS.
Leads to a pair of screens showing the important secondary parameters, such as flow,
pressures, alarm status etc.; NEXT jumps to the menu structure for the next Analyzer
Module in a multi-analyzer system; LOCK disables access to menus whose security
function has been enabled; and INFO jumps into the Platform help menus.

See Appendix D for Platform-related screens in the menu structure.
For information specific to Analyzer Modules, refer to Section 3 of the Analyzer

Module manual(s). Analyzer Module screens are shown in the appropriate
Appendices A.

3-2

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

S

TARTUP AND OPERATION

3.3 SECURITY

In Software V2.2 and later, three levels of keypad lockout are available, corresponding
to the menu structure divisions.

To record a security code, select the following from the

Configuration..., System Set Up...
Codes

Security Code (where

menu, enable whichever level security is required, select Record

XXXXX

, and

Security Codes...

is Basic, Expert or Technical) and follow screen

Main Menu: Technical Level

. In the

Record Security

XXXXX

instructions.

Note
During routine operation of this component, the user will be prompted to enter a

security code only if that particular level of security has been

Record Security Codes

menu.

enabled

3.4 USING THE USER INTERFACE

The user interface consists of the screen, four arrow keys (←, ↑, →, ↓) an Enter key
(↵), and five "softkeys". These latter are the keys marked F1 through F5 under the
display. Their function depends on the menu currently showing, and is indicated by
the reverse video word immediately above the key on the bottom line of the screen.

The general concept of the menu system is that the menus deal with one Analyzer
Module at a time, together with any system components related to that Analyzer
Module. Since the control module is common to all Analyzer Modules in the system,
its menus are always available and in fact constitute the first layer of menus, such as
the

Main menu

above.

Level

in the

To reorganize the Analyzer Modules on the multiple display screen, once you have
selected one (the > caret appears next to the one you have selected), press the Enter
key (↵) and this Analyzer Module will move to the top of the Analyzer Module list.

Toggle the TAGs (showing the names of the Analyzer Modules) with the TAGS ON or
TAGS OFF softkey.

To enter the menus from the multiple Analyzer Module display, use the up and down
keys to select an Analyzer Module. Press the SELECT softkey (the one on the left) to
select the Analyzer Module, then SELECT again (or the right arrow key) to see the
single Analyzer Module display screen.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

3-3

S

TARTUP AND OPERATION

3.4.1 U

SING THE MENUS

Menus can contain any of the following elements: Text, data, editable data, functions
or jumps to another menu.

IGURE

F

3.2 T

19.7 ppm NDIR - CO2

Measurement range number:
Zero gas concentration:
Span gas concentration:
Sample flow:
Raw measurement signal:
Measurement gas:
NO/NOx toggle!
Status:
Result...
Calibration adjustment limits:

Home Factors Zero Span Info

F1

YPICAL MENU

Zero/span calibration

0RANGE
CURRENTZERO
CURRENTSPAN

FLOW IS

RAW SIGNAL

NO NOX

CALSTAT

CALCHKLIMITS

F2 F3 F4 F5

Data, either informational or editable, is described by a phrase ending with a colon, as
in "

Measurement range number:

". If the line can be selected with the up or down key,

it will highlight with inverse video when selected.

Measurement range number: 3

Pressing either the Enter key or the right arrow key at this point will allow you to edit
the variable whose data is showing, highlighting the variable only.

Measurement range number:

3

At this point you can scroll the variable through its possible values with the up (↑) and
own (↓) keys.

Certain variables such as string variables, only allow you to scroll each letter with the
up and down keys, moving within the variable with the left (←) or right (→) arrow keys.
Some numerical variables also allow you to scroll each number, by pressing the left or
right arrow key, and then the up and down key when a single element is highlighted.

Press the Enter key (↵) when you are done, or, if you are not scrolling particular letters
or numbers, press the left (←) arrow key.

Pressing the ESCAPE softkey will abort this editing session and return the variable to
the value it had before you started editing it.

Menus are identified by phrases containing three periods at the end, as in "

Result...

Selecting these with either the right (→) arrow key, or the Enter (↵) key, will jump you
into the appropriate menu.

".

3-4

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

S

TARTUP AND OPERATION

Functions cause the module to do something, such as zero itself. These are identified
with a final exclamation point, such as

"NO/NOX toggle!

". Highlight the function line
with the up and down keys, and start the function with the right (→) arrow key or the
Enter (↵) key.

Softkeys are identified in reverse video on the bottom line. As it happens, all the
softkeys in the example above are menu jumps, but they may also initiate a function.
If in the example shown you press the ZERO softkey, it will lead to an "Are you sure?"
menu, which itself has another ZERO softkey. This softkey, if pressed, will initiate the
zero function.

In the appendices showing menus, for simplicity, the softkeys are not shown in inverse
video, and the very top line showing the current reading and Analyzer Module tag is
also not shown. In fact these exist on all menus.

If alarms are enabled, and an alarm appears, the softkeys are replaced by a single
ACK key. At this point all you can do is acknowledge the alarm. Once you have done
this the normal softkeys will reappear.

3.4.2 U

IGURE

F

SING THE HELP SCREENS

19.7 ppm NDIR - CO2

The Main Menu for the analyzer system.
Note that this menu refers to the particular analyzer selected, scroll
through analyzer with NEXT.
The HOME key will always return you to this screen.

System initialization...
Finding your way in the menu system...
Help menu system...
Help on help...
Keyboard controls...
Editing controls...

Home Escape Notes Map

F1

3-3. F

IRST HELP MENU

Main Menu Help

F2 F3 F4 F5

There is an extensive set of help menus that can be accessed from each functional
menu. There is also an overall set of help menus headed by the example above
which provide an overview into the operation of the user interface itself. Feel free to
explore this, it contains a lot of useful information.

One of the features provided is accessed by pressing the MAP softkey in the example
above. It leads to a menu that shows the sequence of menus necessary to find about
twenty possible configuration or data elements commonly sought.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

3-5

S

TARTUP AND OPERATION

Pressing HOME will return you to the Main menu, pressing ESCAPE or the left arrow
key (←) will return you to the menu from which you entered the help system.

3.5 START UP

1. Check the sample system operation, and make sure that flows are correct. Be
careful not to destroy the analyzer flow sensor with excessive flow (maximum 2
l/min).

Note
Ensure that all flow and pressure settings are at or below their recommended

values before applying gas or power to the Analyzer Modules. Instrument
damage can occur if maximum values are exceeded.

2. Check the power connections, and LON connections, and power up the system.
Do not initiate any PC LON software yet.

3. The Platform should interrogate the system, and build its database. See the NGA
Reference manual for troubleshooting information if anything goes wrong.

4. Systems are normally provided already setup, but if not done, bind the I/O modules
to the Analyzer Modules using the procedure outlined in the NGA Reference
manual.

5. Check that the Platform has found all the Analyzer Modules and I/O modules, and
all have been correctly bound.

6. Go through each Analyzer Module checklist (Appendix D in the Analyzer Module
manuals), setting up each Analyzer Module as desired. Set up their I/O modules
as desired.

7. Set the clock in the Platform, and setup any display, security and editing options
desired. See Appendix B for path details.

8. Set up any calibration modules as desired.

9. Set up any PC interface components.

10. Verify the operation of the Analyzer Modules on zero and span gases, and then on
the sample itself.

11. Verify the Analyzer Module linearity on mid-scale span gases.

3-6

12. Verify the operation of the sample system.

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

3.6 DISPLAY SETUP

g

pp

NDIR - CO2

19.4 ppm CO2

S

TARTUP AND OPERATION

0 ppm

nal: 556320

Raw Si
PRESSURE: 14.7 psia
CASE TEMPERATURE: 45.3 C
NOISE LEVEL: 0.811

m

50

Display Parms. Menu Next Info

IGURE

F

3-4. S

F1

INGLE ANALYZER DISPLAY

F2 F3 F4 F5

The single Analyzer Module display screen shows four auxiliary lines below the main
reading bar graph. These lines are configurable. They can come from data in any
module bound to the Analyzer Module, including the Analyzer Module itself, and in
each module each line is itself selectable. Also the number of digits displayed on the
screen as the main reading is configurable.

For details on this see the NGA Reference manual.
As a default, the auxiliary lines are set to read the selections from the Analyzer

Module. To change these, enter

Expert controls and set up, Analyzer Module set up,

Analyzer parameters list.

3.7 OPERATION

Once an NGA system has been properly installed, it will need little attention. The
Analyzer Modules will need to be calibrated at intervals, and the sample system will
have to be maintained. Calibration gas information will have to be entered into the
Calibration gas menus for each Analyzer Module whenever gas bottles are changed.

Calibration information is given both in the Analyzer Modules manuals and in the NGA
reference manual.

Certain Analyzer Modules require periodic maintenance: CLD Analyzer Modules need
new converter material and occasional ozonator replacement; FIDs need their flame
towers cleaned; NDIR Analyzer Modules require periodic sample cell cleaning. See
their appropriate manuals for details.

It is possible to use several means of making digital communication between the NGA
system and a PC.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

3-7

S

TARTUP AND OPERATION

This communication can be via AK or ModBus over RS 232 or RS 485, or directly over
the LON. Using any of these the PC may be setup to control the operation of the
system, and to download calibration information as desired.

If an NGA component is changed out, the Platform and also the PC interface must be
told about it. The simplest way to tell the Platform is to power it down and back up
again. It will re-interrogate the network and load the new component into its database.
If it runs out of memory during this operation, it will hang, and you will have to reset it,
and then rebind everything. See the NGA Reference manual for details.

A PC LON interface will also have to be reset; AK and ModBus will have to be re­addressed also due to the change in the database.

3.8 CORRECT OPERATION

The following is a summary of what you should expect from an NGA system.
The response of the screen to user inputs - such as changing menus or editing

variables - should be immediate, with new menus appearing well within one second.
The main reading should show stable numbers on zero or span gas, except at its

lowest range where the 1% of range noise level may be noticeable. Analyzers should
hold their calibration to at least 1% of range per day (see their specifications for details
on this).

There may be a perceptible delay in indication of secondary values, such as flow and
pressure. Some of these may take as much as five seconds to be reported.

Analyzer flow rates should be stable and should be controlled similarly on zero, span
and sample. The Analyzer Module should respond to its span gases at its
specification (depending on its filter settings), but bear in mind the exponential time
response and allow ten time constants for real stability.

The main screen will wash out in direct sunlight, but it should be bright enough to read
in complete darkness or ordinary room light.

Analyzers should warm up within about an hour, and should show stability within one
day, other than Trace O2s or FIDs which have special considerations.

Analyzers should show no sign of wetness in their sample tubing. FIDs will show
water condensate in their exhaust.

3-8

Analyzers should not be too hot to touch, except possibly for heated FIDs.
There should be no perceptible stepping on the trace of a chart recorder from an I/O

module (as normally configured).

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

S

TARTUP AND OPERATION

The system should remember how it is configured no matter how it is powered up or
down, and it should always be possible to enter any module’s menus.

It is normal for a Platform to run out of memory if it is given too many Analyzer
Modules to deal with, or Analyzer Modules are replaced too often without resetting it.
V2.2 Platforms can deal with about 6 Analyzer Modules, and V2.3 or later with about
10 (when used with the increased RAM Platform Controller board). The symptom of
this is that the Platform hangs up while starting up, or continuously restarts itself. In
this case, you need a hardware upgrade, and should call Rosemount Service.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

3-9

S

TARTUP AND OPERATION

N

OTES

3-10

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

M

AINTENANCE AND TROUBLESHOOTING

4

4.1 MAINTENANCE OVERVIEW

WARNING: ELECTRICAL SHOCK HAZARD

Disconnect power to the module(s) prior to replacing components.

CAUTION: QUALIFIED PERSONNEL

This equipment should not be adjusted or repaired by anyone except properly
qualified service personnel..

WARNING: STATIC SENSITIVE COMPONENTS

Circuit boards in this instrument are static-sensitive. Take all static precautions
when handling them.

The components that may require removal or replacement during the life of the
Platform include:

Fuses (Power Input Module)

•

Power Supply Board (Backplane)

•

Platform Controller Board (Backplane)

•

Front Panel Assembly

•

I/O Modules

•

Analyzer Modules are covered under their own manuals.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

4-1

M

AINTENANCE AND TROUBLESHOOTING

4.2 FUSE REPLACEMENT

To replace the general protection fuses of the Platform, do the following:

1. Remove the power cord from the back of the Platform. (Remove both power cords
in the case of the dual Platform.)

2. Open the f use holder door located on the base of the AC power cord socket on the
Power Input Module.

3. Remove the current fuses by pressing each individual restraining tab toward its
holder and pulling. There are two individual fuse holders in the receptacle.

4. If the current fuses have blown, replace them with ones of the same type and
value (see Section 5 parts list). Note that both fuses are required for protection,
and both should be replaced.

5. If the operator, during initial installation, is switching to 230 VAC, and the Platform
module is an earlier unit with individual fuses for the two voltage ratings, use the
appropriate fuses and fuse holders found in the shipping kit. Note that two fuses
are required for protection, and both should be replaced. If the fuses are already
marked as 230V AC, they do not need to be replaced.

6. Secure the fuse holder door.

4.3 CONTROLLER BOARD REPLACEMENT

To replace the Controller Board, refer to Figure 1-10 and do the following:

1. Remove the six screws securing the Front Panel, and swing it completely open into
the locked position. (Dual Platforms have no hinge - simply remove the appropriate
side's front panel.)

WARNING: 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. Disconnect the display ribbon cable from the controller board by unhooking the
black hold down clips on top and bottom of the connector. Pushing the clip back
will aid in extracting the connector.

3. Remove the board by pushing down on the PCB Extractor (the red lever at the
bottom of the board)

4-2

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

M

AINTENANCE AND TROUBLESHOOTING

Note
The battery on the Controller board is a Lithium type. The battery is a

permanently attached component and should only be replaced by qualified
service personnel. If replaced, use appropriate hazardous material disposal
procedures.

4. Replace by reversing Steps 1 and 3.

4.4 POWER INPUT MODULE REPLACEMENT

To replace the Power Input Module, do the following:

1. Remove power cable from its socket on the Power Input Module.

2. Remove the four securing screws near the corners of the Power Input Module face
plate.

3. Using the extraction handle, gently pull the Power Input Module from the Platform.

4. Replace the unit by reversing steps 1 through 3, ensuring that Backplane
connections are seated properly.

4.5 POWER SUPPLY REPLACEMENT

To replace the Power Supply, do the following:

1. Remove power cable from its socket on the Power Input Module.

2. Loosen the six securing screws on the front panel of the Platform module.

3. Locate the Power Supply on the extreme right of the Backplane inside the f ront of
the Platform module. It is a black metal box mounted on a circuit card.

4. Press down on the red tab and gently pull the Power Supply from the Platform.

5. Replace the unit by reversing steps 1 through 4, ensuring that Backplane
connections are seated properly.

4.6 FRONT PANEL ASSEMBLY REPLACEMENT

To replace the Front Panel assembly, do the following:

1. Remove power from the Platform.

2. Remove the six screws securing the Front Panel, and swing it completely open into
the locked position. (Dual Platforms do not have such a hinge. In this case,
remove both halves of the front panel.)

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

4-3

M

AINTENANCE AND TROUBLESHOOTING

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.

3. Remove the ribbon cable connector from the Display Board.

4. Remove the four screws securing the Front Panel to the L-bracket attached to the
hinge.

5. Replace the Front Panel assembly by reversing steps 1 through 4.

4.7 SYSTEM TROUBLESHOOTING

Most Analyzer Module problems stem from sample system issues. A lot of these are
addressed in the NGA Reference Manual, and in the Analyzer Module manuals
themselves.

The NGA Reference Manual also contains operational details that should assist you to
diagnose faults not covered in this present section or the Analyzer manuals
themselves. Each section of the NGA Reference Manual contains specific
troubleshooting tips: this section will simply try to point out the area of concern for a
given symptom.

Control module hangs up on start up

Out of memory. Reset it. See System Setup in the NGA Reference Manual. Also,
not enough RAM for a large system. Use the Controller board with RAM expansion.

Also, an Analyzer Module may have lost power or connection during the initialization
process. Power down the system and try again. Check each Analyzer Module with
the Platform one at a time to see which one hangs up the system.

Can’t enter menus

Network error or module gone dead (or an earlier than V2.2 I/O Module). Check for
power failure for an absent module, bad connection, or failed module. Upgrade an
early I/O Module.

4-4

Also, excessive network traffic. Reduce update rate - see the NGA Reference Manual
section titled Response time.

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

M

AINTENANCE AND TROUBLESHOOTING

If the LON length is greater than about ten meters, make sure that you have LON
terminations in place.

Control module shows “No Data”

Analyzer module no longer responding. Check its LON connection, power connection,
power fuse.. Open it up and see if the red LED’s on its Analysis Computer Board are
on or blinking. If so, power it down and back up, and if it still doesn’t communicate,
replace the board or the entire Analyzer Module. Try connecting the bad Analyzer
Module by itself to the Platform using a new cable.

No analog output, or wrong output

Check the binding of the I/O module, and check that you are monitoring the correct
one. In its diagnostic menus, check the analog output of the I/O module. If it is
reported as being OK, the problem is in the wiring or in the recording device. See I/O
module section.

Calibration problems

See the calibration I/O module sections of this manual, and the zeroing and spanning
sections of the NGA Reference Manual.

Analyzer stability problems

Check the Analyzer Module power and grounding, the ambient temperature, and the
sample system. Check for ambient gas interference - CO2 in the atmosphere, etc.
Check the exhaust pressure stability. Generally make sure that the environment is
satisfactory before assuming that the Analyzer Module is at fault. See the NGA
Reference generally, and the Analyzer Module manuals in particular for further hints.

Analyzer Linearity Problems

See the appropriate sections in the NGA Reference manual.

User programmed data is lost after momentary power loss to
Platform

The Controller board in the Platform uses a long life lithium battery to maintain user
programmed data in the event of a power loss. The battery voltage must be 3.38 VDC
or greater for proper operation. If the battery voltage is less than 3.38 VDC it must be
replaced by qualified service personnel or the Controller board replaced by the user.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

4-5

M

AINTENANCE AND TROUBLESHOOTING

N

OTES

4-6

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

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

655407 Power Input Module
655420 Backplane Board
659954 Controller Board (v2.4 software)
658185 Controller Board with RAM Expansion
656237 Front Panel Assembly
902762 Power Supply Board
903217 Fuse, 115 VAC, 2.5 A, Time-Lag (T Type), UL/CSA Recognized
903218 Fuse, 230 VAC, 1.25 A, Time-Lag (T Type), SEMCO Recognized
656871 Fan Card Board

5.2 MULTI-MODULE COMPONENT PARTS LIST

656264 Dual Analyzer Platform - Standard
656265 Dual Analyzer Platform - Extended
656875 Single Analyzer Enclosure - Standard
656876 Single Analyzer Enclosure - Extended
659090 30 A Bulk Power Supply
656193 Analog/Alarm I/O Module
658085 Analog I/O Module v2.3
656194 Single Analyzer Autocalibration I/O Module
656586 System Autocalibration I/O Module
656318 25 Pin Adapter (Sub-D To Wires)
904362 25 Pin Adapter (Sub-D To Wires). Narrow Version.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

5-1

R

EPLACEMENT PARTS

904390 2-Channel SIO I/O Module
904393 2-Channel Analog Expansion Module
904391 RS-232 Adapter Module
904392 RS-485 Adapter Module
904394 DIO Digital I/O Module
656236 I/O Slot Cover
656103 LON I/O Module

5-2

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

A

NALOG

I/O M

ODULE

6

6.1 ANALOG I/O MODULE DESCRIPTION

Refer to Section 1 for instructions on how to install and bind the Basic Analog I/O
Module.

Software V2.0, V2.1 and V2.2 Analog I/O Modules provide an analog output signal, up
to three alarm contacts, four contacts that are used to indicate the current range of
operation of its associated analyzer, and six digital inputs, of which four are used to
determine which range to use. V2.3 and later allow the user to configure all of the
relay outputs and digital inputs to whatever functionality is desired.

In V2.3, special software allows the I/O module to track the special functions
supported by the analyzer, and to show on its control screens whatever the analyzer
can provide or accept in the way of digital indication or control. Any of the relay
outputs or digital inputs can be assigned to any function that the analyzer can support.

Note
V2.2 Platform software only supports V2.2 I/O Modules. V2.3 Platform software

supports both V2.2 and 2.3 I/O Module software, but only V2.3 I/O Module
software has the special features mentioned here.

The analog output signal is bound to the analyzer’s PVA variable, i.e. its main output
reading. The analog output is scaled to the current operating range (or to a specific
operating range if desired). It may be connected as either a voltage output (0-5V) or
as a current output (0 or 4 - 20mA). In any case both the zero and span are live,
which is to say that the output can go below the zero point or above the fullscale point.

There are three SPDT relay outputs which can be used as alarms. SPDT refers to a
type of relay which allows connection to the Common (C), Normally Open (NO) and
Normally Closed (NC) contacts. These designations refer to the state of the contacts
when the relay is un-powered.

In V2.2 and earlier, four more SPST relay outputs are used to indicate the active
range of the I/O module. This is normally the same as the range used by the
analyzer, unless the user has chosen to operate the I/O module on a constant range.
Only one of these relays will be energized at one time. These relays may retain this
function in V2.3, or they can be re-assigned to other functions.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

6-1

A

NALOG

I/O M

ODULE

There are also digital inputs that may be used to control which range the I/O module
or analyzer is on. In V2.3 they may be made to control any specific functionality
supported by the bound analyzer, such as to light the flame in the case of the FID.

Note
Use the path Expert controls and setup..., Auxiliary module setup... to access

the I/O module setup menus. The section called Local I/O setup... accesses only
the SIO card controls, and will not affect any other I/O module.

6.2 ANALOG I/O MODULE ALARM DESCRIPTION - V2.2

This section describes the alarm capability in V2.2. V2.3 added some significant
features which are described in the next section.

There are three alarm relays each of which may be programmed to respond to any of
the following categories.

Concentration

•

Warning

•

Failure

•

Control Status

•

Validity

•

Concentration alarms respond to the analyzer primary reading, its measured gas
concentration. The alarm can be set to trigger above or below a set point, and the
relay can be set to operate in normal or fail-safe (powered when in the normal state)
operation. The set point may be expressed either as an absolute value, or as a
percent of the current range, in which case the concentration at which it alarms will
depend on the range.

The alarm deadband may also be programmed with an upper limit of 20% of fullscale.

6-2

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

ITEM FUNCTION NOTES

Supports auto-range

Output Analog, 0 to 5 V, 0/4 to 20 mA

changing, or independent
range selection from that of

the analyzer.
Alarm relay 1 Programmable function SPDT
Alarm relay 2 Programmable function SPDT
Alarm relay 3 Programmable function SPDT
Alarm relay 4 Powered when output on range 1 SPST
Alarm relay 5 Powered when output on range 2 SPST
Alarm relay 6 Powered when output on range 3 SPST
Alarm relay 7 Powered when output on range 4 SPST
Input line 1 High sets range to 1
Input line 2 High sets range to 2
Input line 3 High sets range to 3
Input line 4 High sets range to 4
Input line 5 No action
Input line 6 No action

A

NALOG

I/O M

ODULE

ABLE

T

ABLE

T

6-1. A

M

VAILABLE FUNCTIONS
ODULE

V2.2

NALOG OUTPUT WITH

– A

3 A

LARMS

I/O

ALARM TYPE COMMENTS

Concentration Programmable high/low, fail-safe/normal.
Warning Tied to analyzer WARNING alarms, if analyzer alarm

reporting is enabled.

Failure Tied to analyzer FAILURE alarms, if analyzer alarm reporting

is enabled.
System Failure Loss of communication with any module in the system.
Control Status Shows that remote control of range inputs is enabled.
Validity Valid if: Analyzer operational state is normal; last span and

zero did not fail, the analyzer is looking at the sample gas

(not a calibration gas), no internal analyzer alarms are

reported, the sample flow is greater than the lower limit, and

the detector temperatures are within limits (except for the

CLD). There are other analyzer specific problems which may

affect validity also, such as flame out in a FID.

6-2. A

LARM RELAY CONFIGURATION MATRIX

V2.2

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

6-3

A

NALOG

I/O M

ODULE

Concentration

C

an be expressed as a percentage of the current range or as an absolute value of gas
concentration measured. Alarms can be set to alert the user of low concentration, high
concentration and percent of range values.

Warning

Indicates one or more software-configured limits on any network variable (other than
gas concentration) has been exceeded. Examples of these secondary variables are
flow rate and internal voltage. A software reset or other resolved software failure
would also be reported.

In the event of a Warning alarm, gas concentration values displayed on the Operator
Interface or present on output lines may not be accurate.

Failure

I

ndicates an unrecoverable hardware or software failure such as some component not
responding to network communications or a safety related failure such as lack of
purge air in a Flame Ionization Detection Analyzer Module.

In the event of a Failure alarm, gas concentration values displayed on the Operator
Interface or present on output lines will not remain accurate .

Control Status

Indicates that the analyzer control has been set to remote, in which case the input
lines on the I/O module are enabled.

Validity

Describes a condition in which gas concentration values present on the Operator
Interface or output lines should be considered invalid. The Analyzer Module alerts the
system that an error in gas concentration is present. Causes include failure or lack of
calibration, flame out in a FID, or a not-from-process gas applied by a sample control
module.

The Analog I/O Module has the capability of tracking a set range regardless of which
range the Analyzer Module is on. It is therefore possible to use several Analog
modules bound to one analyzer to provide multiple outputs at the same time.

6-4

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

A

NALOG

6.3 ANALOG I/O MODULE ALARM DESCRIPTION - V2.3

V2.3 of the Analog I/O Module software added the ability to define the operation of
each of the seven relays, and to include analyzer-specific alarm indication. Each
analyzer module has a list of possible specific alarm indications, such as flow failure or
flame-out. Software in the 2.3 or later control module allows the menu for the I/O
module to include these alarm descriptions as if they were known to the I/O module in
advance, providing a transparent means of controlling these alarms.

Possible alarm indications include low flow, high flow, under- and over-range, the
status alarms as above, and specific analyzer alarms such as flame out for a FID or
NO mode for a CLD. The specifics are determined by the relevant analyzer module.

The default setting of the alarms is identical to those in the V2.2 Alarm I/O Module
described in the previous setting, but it is possible to change them as desired.

I/O M

ODULE

1. Enter the
Select

2.

3.

Select

Expert controls and setup...
Auxiliary module setup...

Main

menu

4. Select the Analog I/O Module
Select

5.

Alarm conditions...

6. Select the relay to be configured

7. For each relay, use the up/down softkeys to select the signal to which it responds.

8. When the desired signal is shown, press ENTER softkey to set.

ITEM FUNCTION NOTES

Supports auto-range

Output Analog, 0 to 5 V, 0/4 to 20 mA

changing, or independent
range selection from that of
the analyzer.

Alarm relay 1 - 7 Programmable function SPDT
Input line 1 - 6 Programmable function

ABLE

T

748329-J Rosemount Analytical October 1999

6-3. A

VAILABLE FUNCTIONS
ODULE

M

V2.3

NALOG OUTPUT WITH

– A

Depends on analyzer
bound

LARMS

3 A

NGA 2000 Platform

I/O

6-5

A

NALOG

I/O M

ODULE

STANDARD ALARM FUNCTION

Normal Shows no other alarm
Maintenance request Indicates a warning alarm
Failure Indicates a failure alarm

Calibration in progress

Zero in progress

Span in progress

Indicates a bound Autocalibration module is in its
calibration sequence

Indicates the analyzer is performing a zero
calibration

Indicates the analyzer is performing a span

calibration
Zero failure Indicates the last zero calibration failed
Span failure Indicates the last span calibration failed

Range overflow

Range underflow

Indicates the reading is higher than the current

range

Indicates the reading is lower than the high limit of

the next lower range
Flow low Indicates the flow is less than its low limit
Flow high Indicates the flow is higher than its high limit
Concentration limit 1 - 4 Only supported on MLT modules
Range 1 - 4 Indicates analyzer is on range 1 to range 4

ABLE

T

6-6

Validity Shows invalid readings, see previous section
Failure Indicates analyzer hardware failure

System failure

Indicates loss of communication with one or more

LON modules
Control status Indicates remote or local control
CLD only - Ozonator out See CLD manual
CLD only - NO/NOx mode See CLD manual
FID only - Purge failure See FID manual
FID only - Flame out See FID manual

6-4. A

VAILABLE ALARMS

NALOG OUTPUT WITH

– A

3 A

LARMS

I/O M

V2.3

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

ODULE

A

NALOG

6.4 ANALOG I/O MODULE INSTALLATION

If the Analog I/O 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 are operational.

To install the Analog I/O Module, perform the General Procedure in Section 2. Bind
the Analog I/O Module to an Analyzer Module as detailed in Section 2.

Perform the procedures in Sections 6.4.1 and 6.4.2.

I/O M

ODULE

6.4.1 A

NALOG

I/O M

ODULE INITIAL SETUP PROCEDURE

1. Enter the menus.

2. Select

3. Select

Expert controls and setup...
Auxiliary module setup...

4. Select the analog I/O module

Analog output parameters. ..
Automatic range change parameters...
Input line control...
Alarm conditions...
Concentration alarm param eters...
Displayed parameters...

Slot position:
IO module ID:

HOME ESCAPE INFO

F1 F2 F3 F4 F5

Analog Output Module

SLOTPOSITION

TAG

IGURE

F

6-1. A

NALOG OUTPUT MODULE SETUP MENU

5. Select Analog output parameters...

6. Select Voltage or current:

7. Select Output value on analyzer failure — if the analyzer dies, do you want the
output to go to zero, fullscale, or hold its last value? This could have safety
implications.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

6-7

A

NALOG

I/O M

ODULE

Analog Output Parameters

Parameter reported:
Voltage or current:

Output value on analyzer failure:
Output hold on validity:

Output hold on maintenance:
Output hold on calibration:

IOMAINTHOLD

GAS

RNG1EI
AMFAIL

VAL_HOLD

IOHOLDCAL

HOME ESCAPE INFO

IGURE

F

6-2. A

F1

NALOG OUTPUT PARAMETER MENU

F2 F3 F4 F5

8. Select whether the output holds its value when any of the three alternatives shown
happens. If the reading becomes invalid, if a calibration is underway or if the
menus are entered (maintenance), you can make the output hold its last value.
This may be undesirable, so consider this carefully.

Setting up automatic range change parameters

Go back one menu (into the Analog I/O Module setup menu), then select Automatic
range change parameters...

You can setup how it calculates its range change points. These are calculated as a
percent of the lower of the two ranges, always.

Note
In V2.2, the range down calculation was incorrect. Do not use the automatic

range change feature with V2.2 I/O modules.

You can also select the hold off times. The first hold off time is the delay before it
changes range the first time, and the toggle hold off time is a further delay when it
tries to change back immediately. All of these settings are normally best left in their
default values.

You can also make the output track the analyzer range, or make it stay in one range
despite what range is being used by the analyzer. Set this on the “Output on range:”
line.

6-8

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

A

NALOG

I/O M

ODULE

There are six options to this setting:

Analyzer (Track the analyzer range)

•

Fixed on range 1

•

Fixed on range 2

•

Fixed on range 3

•

Fixed on range 4

•

Independent (i.e. may auto range change or respond to range inputs, but

•

without affecting the analyzer range)

Setting up alarm relays - V2.2

You can make the alarm relays respond to concentration values, or to certain status
values. You can express concentration values in absolute numbers, or as a
percentage of scale.

IGURE

F

6-3. V2.2 A

General concentration alarm parameters

Trips as % of range or absolute:
Hysteresis:
Delay till alarm activates:

GENPARMA
GENPARMB
GENPARMC

HOME ESCAPE INFO

F1

F2 F3 F4 F5

LARM PARAMETER MENU

Relay 1 concentration alarm parameters

Alarm trip point - absol ut e ppm:
Alarm trip point - % range:
Alarm type:
Alarm operation:

ALLVL1
ALLVL2

ALTYPE1

ALOP1

HOME ESCAPE NEXT LAST INFO

F1 F2 F3 F4 F5

IGURE

F

748329-J Rosemount Analytical October 1999

6-4. V2.2 C

ONCENTRATION ALARM PARAMETERS

NGA 2000 Platform

6-9

A

NALOG

I/O M

ODULE

In

Auxiliary module setup

, with the analog I/O module selected:

1. Select Alarm conditions...

2. Select a condition for each alarm relay. In V2.2, Analyzer specific alarms do not

work (refer to Table 6-2 for available alarms).

3. Go back one screen, and if you have selected any concentration alarms, select

General concentration alarm parameters...

4. In this screen, select whether to alarm as percentage of range or on absolute

values. If the former, the alarm set point will change with each range. If the latter,
there will be a single alarm point, no matter what ra nge is selected.

5. Select the hysteresis. This is the difference between the “on” point and the “off”

point, expressed as a percentage of the on point. E.g., in the case of a high alarm,
if the alarm is set at 80ppm, it will trip when the reading goes above 80ppm. When
it comes back down if the hysteresis is set to 10%, the alarm won’t go back off
until the reading gets below 72 ppm. The 10% default is usually satisfactory.

6. Select the Delay till alarm actuates: This adds a time delay, preventing nuisance

alarms on short term spikes in the reading.

7. Go back up one screen, and select Relay 1 (or 2 or 3) concentration alarm

parameters....

8. Set the alarm level in either absolute or percentage of range. You can select both,

and then the alarm set point will perhaps change as you select whichever mode
you want.

9. Select the alarm type, as high or high high, or low or low low. High high goes off at

a higher value than high, but it doesn’t matter if you get it wrong.

10. Select the alarm operation, fail-safe or not. Fail-safe means that the relay is

powered when in non-alarm mode, which means that it generates an alarm signal
when the power goes off, or when the software is reset.

All alarms other than concentration alarms are automatically in fail-safe mode.

6-10

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

A

NALOG

I/O M

ODULE

Setting up alarm relays - V2.3

V2.3 allows you to set each relay individually to any of the possible alarm conditions.

Analog output module

Analog output parameters. ..
Automatic range change parameters...
Input line control...
Alarm conditions...
Concentration alarm param eters...
Displayed parameters...

IGURE

F

6-5. A

1. Select the

2. Select

Slot position:
IO module ID:

HOME ESCAPE INFO

F1 F2 F3 F4 F5

NALOG OUTPUT MODULE SETUP MENU

Analog output module

setup menu as above.

Alarm conditions...

Alarm Conditions

Relay 1 trips on:
Relay 2 trips on:
Relay 3 trips on:
Relay 4 trips on:
Relay 5 trips on:
Relay 6 trips on:
Relay 7 trips on:

(If used as an automot i ve remote control module, rel ay 3 must be
set to

SLOTPOSITION

TAG

- V2.3

ALVAR1
ALVAR2
ALVAR3
ALVAR4
ALVAR5
ALVAR6
ALVAR7

HOME ESCAPE INFO

IGURE

F

6-6. A

F1

LARM CONDITION MENU

F2 F3 F4 F5

- V2.3

3. Choose the operation of each relay

4. (If you have selected any concentration alarms) Go back one menu and select
Concentration alarm parameters...

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

6-11

A

NALOG

I/O M

ODULE

Relay 1 concentration alarm parameters...
Relay 2 concentration alarm parameters...
Relay 3 concentration alarm parameters...
Relay 4 concentration alarm parameters...
Relay 5 concentration alarm parameters...
Relay 6 concentration alarm parameters...
Relay 7 concentration alarm parameters...

Concentration alarm parameters

HOME ESCAPE INFO

F1 F2 F3 F4 F5

IGURE

F

6-7. C

ONCENTRATION ALARM PARAMETERS MENU

5. Select the appropriate relay whose parameters to set

Relay 1 concentration alarm parameters

Alarm trip point - absol ut e ppm:
Alarm trip point - % range:
Alarm type:
Alarm operation:
Trips as % of range or absolute:
Hysteresis:
Delay till alarm activates:

- V2.3

ALLVL1
ALLVL2

ALTYPE1

ALOP1

PERCENT_ABS1

HYSTERESIS1

DELAY_ON1

HOME ESCAPE NEXT LAST INFO

F1 F2 F3 F4 F5

IGURE

F

6-8. T

YPICAL CONCENTRATION ALARM PARAMETER MENU

6. Set parameters as desired

7. Press HOME to leave the I/O Module setup.

- V2.3

6-12

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

A

NALOG

I/O M

ODULE

6.4.2 A

NALOG

I/O M

ODULE CALIBRATION PROCEDURE

Perform the Output signal zero and span calibration procedures as follows:

Voltage output calibration

RNG1EI

IODIAG3

TESTMODE2

RNG1EI

IODIAG6

TESTMODE2

IGURE

F

6-9. V

Voltage/current mode:
Desired output voltage:
Measured output voltage:
Zero offset:
Gain factor:
Set to test for calibration:
Set desired output voltage: adj ust the
measured voltage with the zero and
gain factors. Then set t o aut o.

HOME ESCAPE INFO

F1 F2 F3 F4 F5

OLTAGE OUTPUT CALIBRATION MENU

Current output calibration

Voltage/current mode:
Desired output current:
Measured output current:
Zero offset:
Gain factor:
Set to test for calibration:
Set desired output current: adj ust the
measured voltage with the zero and
gain factors. Then set t o aut o.

HOME ESCAPE INFO

F1 F2 F3 F4 F5

IGURE

F

6-10. C

URRENT OUTPUT CALIBRATION MENU

1. Enter the Analog Output Parameters menu by making selections in the following

path:

Main Menu, Technical Level Configuration

Analog I/O [module],
Menu or

Current Output Calibration

Analog Output

Menu.

Menu and either

Menu

, Diagnostic

Menu, [choose]

Voltage Output Calibration

2. To perform both the zero and span calibration procedures, the operator must use

output values obtained from a calibrated digital voltmeter or other sensing device
connected to the I/O Module output. The Measured values shown by the I/O
module itself are not accurate enough to calibrate the output circuitry.

3. In the I/O Module Analog Output Diagnostics Menu, choose Voltage Output

Calibration or Current Output Calibration, depending on output requirements.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

6-13

A

NALOG

I/O M

ODULE

4. Choose Test on the Set to Test for Calibration line.

5. If the operator is performing a Voltage Output Calibration, do steps 6 through 9. If
the operator is performing a Current Output Calibration, do steps 10 through 13.

6. Voltage calibration: perform the zero calibration procedure first. Set the Desired
Output Voltage to 0.

7. Observe and record the output value.

8. Ad just, if necessary, the output value by scrolling the Zero Offset until the outpu t
value is 0.

9. Perform the span calibration. Change the Desired Output Voltage to 5, and scroll
the Gain Factor until the output value is 5. Skip the remaining steps.

10. Current calibration: perform the zero calibration first. Set the Desired Output
Current to 0 (no matter whether the module is set to operate on 0 - 20 mA or 4 ­20 mA).

11. Observe and record the output value.

12. A djust, if necessary, the output value by scrolling th e Zero Offset until the outp ut
value is the zero value (0 mA).

13. Perform the span calibration procedure. Change the Desired Output Current to 20,
and scroll the Gain Factor until the output value is 20.

After completing the span calibration procedure, the operator should recheck and
readjust, if necessary, the zero calibration values.

Note
The measured output current or voltage is not measured with enough precision

to do more than tell you whether the output circuit is working or not. Don’t try to
use it to calibrate the output. On the other hand, if it does show a value, but you
don’t detect one in your monitoring device, it means that either the output
connector, or EMC components on the I/O module are bad, or there is an error in
the wiring. The measured signal does in fact measure the output signal, it is not
merely calculated from the value the output is supposed to be putting out.

6-14

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

A

NALOG

I/O M

ODULE

6.4.3 A

NALOG OUTPUT OVER/UNDER LIMITS

The analog output can be configured with live zero/span or “clipped” zero/span by
setting the over limit and under limit of the voltage or current output signal.

In the

I/O Module Analog Output Diagnostics

menu, select

Diagnostic limits

Section 6.4.2). There will be various current and voltage limit selections to choose
from. Edit the appropriate set of over and under limit values that pertain to the analog
output you have selected.

The minimum current under limit is –2.0 and –6.0 while the maximum current over limit
is 25 mA. The minimum voltage under limit is –90 V and the maximum voltage over
limit is 10.0 V.

Setting the under limit and over limit values is essentially setting the minimum and
maximum signal output.

The analog I/O Module is now fully operable and read for use.

6.5 ANALOG I/O MODULE TRACK AND HOLD FEATURE

An I/O Module function critical to certain applications (such as CEMS) is the track and
hold feature.

(see

Analog output parameters

Parameter reported:
Voltage or current:

Output value on analyzer failure:
Output hold on validity:

Output hold on maintenance:
Output hold on calibration:

List range limits :

IOMAINTHOLD

GAS

RNG1EI

AMFAIL

VAL_HOLD

IOHOLDCAL

HOME ESCAPE INFO

F1 F2 F3 F4 F5

IGURE

F

6-11. O

UTPUT PARAMETERS MENU

The three "Output Hold..." selections on the Analog Output Parameters Menu refer to
the I/O Module capacity to maintain or hold the output of the gas concentration value
despite a change in the state of the Analyzer Module.

If

Output Hold on Validity

is enabled and the state of the Analyzer Module becomes

invalid, the last gas concentration value measured during the valid state is held and

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

6-15

A

NALOG

I/O M

ODULE

output from the I/O Module. When the Analyzer Module state returns to valid, the gas
concentration value is updated instead of held.

If

Output Hold on Maintenance

is enabled and the state of the Analyzer Module is
either maintenance or standby, the last gas concentration value measured during the
valid state is held and output from the I/O Module. When the Analyzer Module state
returns to valid, the gas concentration value is updated instead of held.

If

Output Hold on Calibration

is enabled, three selections are available; Disabled,

Enabled and CEMS. These selections operate as follows:

Disabled

If

, the gas concentration value is updated while the Analyzer Module is in

the calibration state.

Enabled

If

, and when the Analyzer Module is in the calibration state or the QC check
state, the last gas concentration value measured during the valid state is held and
output.

CEMS

If

, and when the Analyzer Module is in the calibration state, the gas
concentration value is updated throughout the zero and/or span cycles. The calibration
factors are held until the calibration cycle is over. Therefore the output responds to
the reading of the calibration gases using the factors from the previous calibration, as
if the analyzer were simply measuring them rather than calibrating itself. Only when
the calibration cycle is over does the analyzer use the new calibration factors. This
allows the user to determine how much drift has occurred.

6-16

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

A

NALOG

6.6 ANALOG I/O MODULE: RELAY OPERATION CHECK
PROCEDURE

For troubleshooting, it is convenient to check the measured state of the relays when
they don’t seem to be working.

The circuitry actually measures the unused contacts of the relays.

Relay status

I/O M

ODULE

Relay function:
(Set this to TEST to set relays below).

Relay 1 status:
Relay 1 measures:
Relay 2 status:
Relay 2 measures:
Relay 3 status:
Relay 3 measures:

TESTMODE1

RSTATUS1

RMEASURE1

RSTATUS2

RMEASURE2

RSTATUS3

RMEASURED3

HOME ESCAPE MORE INFO

F1 F2 F3 F4 F5

IGURE

F

6-12. F

IRST RELAY STATE MENU

You can see what their state is, and you can manually set them to a state:

1. Get into Technical level configuration...

2. Select Diagnostic menus...

3. Select the I/O module

4. Select Relay status...

5. Set Relay function: to TEST. This allows you to edit the relay states, but it will
automatically reset itself to auto after a minute.

6. Look at each relay, and if desired edit its status line to ON or OFF. After a moment
you should see its measure line change state too. Check to see if the reporting
device sees this. If not, you either have a wiring error, or there is a failure in the
EMC circuitry or output connector.

Note
V2.2 I/O modules report the state of relays 1, 2 and 3 reversed from reality - that

is to say they report the contact open when it is in fact closed, and vice versa.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

6-17

A

NALOG

I/O M

ODULE

6.7 ANALOG I/O MODULE RANGE CONTROL DISCUSSION

The whole question of ranges in the NGA system is rather complex. Analyzers
themselves support four ranges, but these are mostly software considerations only,
and mainly result in the application of different calibration and linearization parameters
to the same sensor signals. Certain analyzers do make hardware changes as a result
of range changes, and these are described in the appropriate manuals and the NGA
reference manual.

The Analog I/O module can be made to track the range of operation of the analyzer,
or to operate independently of it. It can also control the range of the analyzer, either
automatically or as a result of external input through the digital input lines.

If the module is made to control the operation of the analyzer, allowance must be
made for the delay associated with the LON communication system. It may take as
much as a second for the analyzer to respond to an external range change request.
During this time the reading may not relate to the requested range. Any control
system relying on an instantaneous range change will produce an error during this
time.

If this fact cannot be dealt with in the control system software, the Analog I/O module
should be set to operate independently of the analyzer. In this mode, the output
scaling corresponds to the range requested by the digital input line, but the analyzer's
range is not affected. As long as the analyzer's range is wider than those of the
Analog I/O module, the system will operate correctly, except that of course any
specific calibration or linearization performed on the other ranges by the analyzer will
not be used. In this case the response time to a requested range change by a 2.3 V
Analog I/O module will be variable but always less than 100mSec, typically 40mSec.

The preferred solution, of course, is to get the output of the analyzer directly from the
LON, where these considerations do not apply, and the analyzer can be operated on
one or several ranges as desired

6-18

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

6.8 ANALOG I/O MODULE OUTPUT CONNECTIONS

A

NALOG

I/O M

ODULE

13

1

I/O Module

Output Connector

25

13

14

1

Output Adapter

(Accessory)

25

14

PIN ASSIGNMENTS

1 Analog Current Output 14 SPST Relay 4 (NO)
2 Analog Voltage Output 15 SPST Relay 5 (NO)
3 Analog Return for Pins 1, 2 16 SPST Relay 6 (NO)
4 Analog Chassis Ground 17 SPST Common

IGURE

F

5 SPDT Relay 1 (NC) 18 SPST Relay 7 (NO)
6 SPDT Relay 1 (C) 19 Digital Input 1
7 SPDT Relay 1 (NO) 20 Digital Input 2
8 SPDT Relay 2 (NC) 21 Digital Input 3

9 SPDT Relay 2 (C) 22 Digital Input 4
10 SPDT Relay 2 (NO) 23 Digital Input 5
11 SPDT Relay 2 (NC) 24 Digital Input 6
12 SPDT Relay 2 (C) 25 Digital Common
13 SPDT Relay 2 (NO)

6-13. A

SSIGNMENTS

A

NALOG

I/O M

ODULE OUTPUT CONNECTOR/ADAPTER PIN

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

6-19

A

NALOG

N

OTES

I/O M

ODULE

6-20

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

S

INGLE ANALYZER ANALOG AUTOCAL

I/O M

ODULE

7

7.1 SINGLE ANALYZER ANALOG AUTOCAL DESCRIPTION

Refer to Section 2 to install and bind the Single Analyzer Analog Autocal I/O Module
(also known as the Single Analyzer Analog Autocal I/O Module).

The standard calibration procedure in the Analyzer Module Menu Structure (under
“Basic controls”) is not automatic. When you press “ZERO” or “SPAN”, the analyzer
assumes that you are flowing the appropriate gas. It does not itself change any gas
flow, nor does it communicate to the Autocal module described in this or the next
section.

The Single Analyzer Analog Autocal I/O Module allows the user to either manually or
automatically perform the calibration procedures for the Analyzer Module. The
calibration procedures can be either initiated manually or automatically.

The Single Analyzer Analog Autocal I/O Module also provides analog signal outputs.
Up to four span solenoid valves and one zero solenoid valve (customer supplied) can

be energized at set time intervals. The frequency and duration of the calibration cycle
is software programmable, allowing many varied sequences, a few of which follow:

zero

•

•

•

Four SPST and two SPDT relays are used to drive solenoid valves that control the
flow of zero and span calibration gases to the Analyzer Module. The seventh relay
indicates an in-calibration condition. Relay output definitions:

• Relay 1

• Relay 2

• Relay 3

• Relay 4

x times, then

zero

, then

zero, span,

through the Analyzer Module.

cycle is being executed.

span.

then check on a

- sample bypass: closed when the sample should

- zero gas: closed when the zero gas should be flowing.

- calibration in progress: closed when any zero, span or calibration

- span gas 1: closed when span gas 1 should be flowing.

span.

midpoint.

not

be flowing

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

7-1

S

INGLE ANALYZER ANALOG AUTOCAL

I/O M

ODULE

• Relay 5

• Relay 6

• Relay 7

- span gas 2: closed when span gas 2 should be flowing.

- span gas 3: closed when span gas 3 should be flowing

- span gas 4: closed when span gas 4 should be flowing

The Auto Calibration Module has six digital input lines for remotely initiated calibration.
The function of each line:

• Line 1

• Line 2

• Line 3

• Lines 4 & 5

- do zero calibration

- do span on the selected range

- do a zero and/or span, as programmed

- select the desired range in the following binary fashion (for Line 2

above ONLY):

RANGE LINE 4 LINE 5

1OFF OFF
2ON OFF
3OFF ON

ABLE

T

7-1. A

• Line 6

Note the following:

These remote functions will apply only if the remote controls are enabled

!

Lines 4 and 5 control only the desired range of the span function as described

!

If the digital lines described above are not connected, the Line 2-related span

!

After calibration, the Analyzer Module will be returned to the range it was

!

4ON ON

UTOCALIBRATION MODULE

NPUT LINE RANGE CONTROL

- I

- disables calibration instruction and allows only a check to occur

through this I/O Module.

in Line 2.

function will only select Range 1; it will not calibrate any othe r range. However,
the Line 3 function will span or check ranges as setup in the module's
programming.

operating on previous to calibration.

7-2

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

S

INGLE ANALYZER ANALOG AUTOCAL

ITEM FUNCTION NOTES

Supports independent

Output Analog, 0 to 5 V, 0/4 to 20 mA

range selection from that
of the analyzer (no auto-

range)
Alarm relay 1 Calibration in progress SPDT
Alarm relay 2 Calibration gas / samp le gas SPDT
Alarm relay 3 Zero gas valve SPDT
Alarm relay 4 Span gas valve 1 SPST
Alarm relay 5 Span gas valve 2 SPST
Alarm relay 6 Span gas valve 3 SPST
Alarm relay 7 Span gas valve 4 SPST
Input line 1 Perform a zero cycle
Input line 2 Perform a span cycle

Input line 3

Perform a complete calibration

cycle
Input line 4 Range selection
Input line 5 Range selection
Input line 6 Calibration / Check selection

I/O M

ODULE

ABLE

T

7-2. A

VAILABLE FUNCTIONS
ODULE

M

V2.2

INGLE ANALYZER AUTOCALIBRATION

– S

7.2 SINGLE ANALYZER ANALOG AUTOCAL I/O MODULE
INSTALLATION

If this I/O 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
are operational.

To install this I/O Module, follow general installation guidelines in Section 2 and then
do the following:

UTOCALIBRATION SEQUENCE SETUP

A

VERALL TIMING

O

The calibration sequence is; wait until the calibration time; indicate a calibration
sequence; purge with zero gas; tell the analyzer to zero itself; wait until it says it’s

I/O

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

7-3

S

INGLE ANALYZER ANALOG AUTOCAL

I/O M

ODULE

done; purge with the first span gas; tell the analyzer to change range (if necessary);
tell the analyzer to span this range; wait until it says it’s done; purge with the next span
gas and repeat up to a total of four spans; purge with sample gas; indicate the
calibration sequence is over.

Before setting these parameters, make sure the system clock is set correctly.

This is to be found in

time…

.

1. Enter the

2. Enter
Enter

3.

Expert controls and setup
Auxiliary module setup...

Main menu

Technical level configuration…, System setup…, Date and

...

4. Select the Autocalibration module

Auto Cal Module

Automatic calibration initiation...
Manual calibration initiation. ..
Timing parameters...
Valve control parameters...
General parameters...

Number of zeros before the next span:
Displayed parameters...
Analog output parameters. ..
Slot position:

HOME ESCAPE INFO

F1

F2 F3 F4 F5

MISC_INT2

MISC_INT3

IGURE

F

7-1. A

UTOCALIBRATION MODULE SETUP MENU

5. Enter Timing parameters...

IGURE

F

7-2. A

UTOCALIBRATION MODULE TIMING PARAMETERS MENU

Timing parameters

Start sequence at this time - Day of month:
Start sequence at this time - Hrs:
Start sequence time - mins:
Calibration cycle period:
Zero gas dwell time:
Span gas dwell time:
Sample dwell time:

This module's control status:

C_TIME3
C_TIME1
C_TIME2

TIME_PERIOD

DWELL_1
DWELL_2
DWELL_3

MSTR_SLV

HOME ESCAPE INFO

F1

F2 F3 F4 F5

7-4

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform

S

INGLE ANALYZER ANALOG AUTOCAL

I/O M

ODULE

6. Set the day of the month, and the time of day to start the calibration sequence. The
unit will automatically calibrate thereaf ter at a suitable period set below. Make sure
you have chosen a day and time in the future! Otherwise it will wait a month.

7. Set the calibration cycle period. This is the length of time it will wait between
calibrations. 24 hours is traditional, but it can be programmed to 255 hours. You can
set it to zero at this period, but to span only every so many zeros, see below.

8. Set the zero gas dwell time. It should be long enough that the analyzer reaches a
good stable zero point. If in doubt make it longer.

9. Set the span gas dwell time. This has to be long enough for the analyzer to become
stable at the span point. This time is normally shorter than the zero time.

10. Set the samp le gas dwell time. This is the time it will wait after its last span b efore
releasing the “In Calibration signal” (either the relay or the PROCESS variable). This
time should be long enough to allow the reading to get to within its error tolerance of
the actual reading, normally shorter than the other two times.

11. Set the control status. This module can be slaved to another Autocalibration module,
or it can be a master for a group of two or more such modules, or it can be
independent of them. If it is a master, it will make all the other slaves start a
calibration when this one does: if a slave it will wait until it is told to calibrate before
doing so. If independent it will ignore any other Autocalibration modules and calibrate
on its own sequence as setup above.

Note
Only the start time is common to master/slave groups. Because of the differing

times taken by the analyzer modules over their zero and span functions, the
spans and the end times will probably not occur simultaneously. This means
that in general you cannot use a single span gas valve for multiple analyzers
when using multiple single-Autocalibration modules. Use the system
Autocalibration module instead.

In the Timing parameters screen, the following should be considered: If Start
sequence at this time - Day of month is 0, calibration will occur every day and If
Calibration cycle period is 0, auto cal is disabled.

748329-J Rosemount Analytical October 1999

NGA 2000 Platform

7-5

S

INGLE ANALYZER ANALOG AUTOCAL

ERO AND SPAN OPTIONS

Z

I/O M

ODULE

1. Press the left arrow key to get back into the Autocalibration module setup screen.

2. Select Valve control parameters...

3. Select Zero gas valve...

IGURE

F

7-3. T

Edit

Operation performed:

Operates on ranges as select ed i n t he anal yzer.
Operation performed:
Current status:

HOME ESCAPE INFO

F1

F2 F3 F4 F5

YPICAL GAS VALVE CONTROL MENU

Zero gas valve

SV_OP_5

CALSTATA

; this may be CAL or QC Check. The former causes the
analyzer to do a zero, whereas the latter simply flows gas but does not cause the
analyzer to do a zero. Normally this is left as CAL!

The next line shows the current status of the system.

7-6

Press the left arrow key, and then select

Span valve 1...

Edit the analyzer range to be used on this span gas.
Edit the operation to be performed: Cal, QC check, or disabled (to skip this value)
Press the NEXT button to go directly to the Span valve 2 screen, and continue

until all are setup as desired.

October 1999 Rosemount Analytical 748329-JNGA 2000 Platform