Instruction Manual HAS64E-IM-HW September 2008 Instruction Manual HFID Heated Flame Ionization Detector NGA 2000 Hardware Manual for HFID Analyzer Module (combined with NGA 2000 Platform, MLT, CAT 200 or TFID Analyzer) 1st Edition 09/2008 www.EmersonProcess.
ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING! Emerson Process Management (Rosemount Analytical) designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Table of Contents PREFACE ........................................................................................................................... P - 1 DEFINITIONS...................................................................................................................... P - 1 SAFETY INSTRUCTIONS WIRING AND INSTALLATION OF THIS APPARATUS ........ P - 2 OPERATING AND MAINTAINING THIS APPARATUS .......................................
Instruction Manual NGA 2000 HFID HAS64E-IM-HW September 2008 SECTION 2 INSTALLATION .............................................................................................. 2 - 1 2-1 UNPACKING ............................................................................................................... 2 - 1 2-2 ASSEMBLY ................................................................................................................. 2 - 1 2-3 LOCATION ..............................................
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 3-5 ROUTINE OPERATION .............................................................................................. 3 - 9 a) Operation ................................................................................................................ 3 - 9 b) Sensitivity ............................................................................................................... 3 - 9 c) Shutdown .................................................
Instruction Manual NGA 2000 HFID HAS64E-IM-HW September 2008 4-6 THERMAL BLOCK .................................................................................................... 4 - 12 a. Sample RTD ......................................................................................................... 4 - 12 b. Cartridge Heater ................................................................................................... 4 - 12 c. Thermostat ......................................................
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 5 TROUBLESHOOTING .................................................................................... 5 - 1 5-1 TROUBLESHOOTING CHECKLIST ........................................................................... 5 - 1 a. Safety System ........................................................................................................ 5 - 1 b. Ignition ................................................................................
Instruction Manual NGA 2000 HFID VI Table of Contents HAS64E-IM-HW September 2008 Emerson Process Management GmbH & Co.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID PREFACE The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the NGA 2000 HFID and the System Accessories of the NGA 2000 System. Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID IMPORTANT SAFETY INSTRUCTIONS WIRING AND INSTALLATION OF THIS APPARATUS The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or National Standards. 1. Suitable grounding connections should be made at all connectors provided for this purpose. 2.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID OPERATING AND MAINTAINING THIS APPARATUS On leaving our factory, this instrument conformed to all applicable safety directives. In order to preserve this state of affairs, the operator must take care to strictly follow all the instructions and notes given in this manual and on the unit. Before switching on the instrument, ensure that the local nominal mains voltage corresponds to the factory-set operational voltage of this unit.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID GENERAL SAFETY NOTICE / RESIDUAL RISK If this equipment is used in a manner not specified in these instructions, protective systems may be impaired.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID WARNING ELECTRICAL SHOCK HAZARD Do not operate without covers secure. Do not open while energized. Installation and/or servicing requires access to live parts which can cause death or serious injury. Refer servicing to qualified personnel. For safety and proper performace this instrument must be connected to a properly grounded threewire source of power.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID WARNING HIGH TEMPERATURES This equipment is used in the analysis of sample gases at temperatures of up to 250°C. All components and material in contact with the sample, the oven and the burner can reach this temperature level. Operate this equipment only when covers are secured. Servicing requires access to "hot" parts which can cause serious injury. Refer servicing to qualified personnel.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID CAUTION POSSIBLE INSTRUMENT DAMAGE Do not interchange gas inlets and outlet! All gases must be conditioned before supplying! When supplying corrosive gases ensure that gas path components are not affected! Exhaust lines must be installed in a descending way, need to be pressureless, frost-protected and in compliance with applicable legislative requirements! WARNING HAZARDS BY SAMPLE GAS COMPONENTS! Before opening gas paths they must be purged w
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID GASES AND GAS CONDITIONING (SAMPLE HANDLING) WARNING GAS SAFETY Take care of the safety instructions applicable for the gases (sample gases, test gases and fuel gas)! CAUTION PRESSURIZED GAS This module requires periodic use of pressurized gas. See General Precautions for Handling and Storing High Pressure Gas Cylindes, page P-11. WARNING POSSIBLE EXPLOSION HAZARD Do not use 100% hydrogen fuel in a 40% H2 / 60% He configured Analyzer Module.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID POWER SUPPLY CAUTION ELECTRICAL HAZARD Verify the power voltage at site of installation corresponds to the analyzer module´s rated voltage as given on the nameplate label! Verify the safety instruction given by power supply unit manufacturer ! CAUTION ELECTRICAL HAZARD The mains socket has to be nearby the power supply unit and easily accessible! Disconnecting from power requires unplugging the power connector! To comply with the CE mark require
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID ELECTROSTATIC DISCHARGE CAUTION ELECTROSTATIC DISCHARGE The electronic parts of the Analyzer Module can be irreparably damaged if exposed to electrostatic discharge (ESD). The instrument is ESD protected when the covers have been secured and safety precautions observed.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS CYLINDERS Edited from selected paragraphs of the Compressed Gas Association´s „Handbook of Compressed Gases“ published in 1981. Compressed Gas Association 1235 Jefferson Davis Highway Arlington, Virginia 22202 Used by Permission 1. Never drop cylinders or permit them to strike each other violently. 2.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID DOCUMENTATION The following HFID instruction materials are available. Contact Customer Service Center or the local representative to order.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID GLOSSARY OF TERMS Analyzer Module The module that contains all sensor/detector components for development of a Primary Variable signal; includes all signal conditioning and temperature control circuitry. Backplane The interconnect circuit board which the Controller Board, Power Supply, Analyzer Module power and network cables, I/O Modules and Expansion Modules plug into. Control Module The Operator Interface plus the Controller Board.
Instruction Manual NGA 2000 HFID HAS64E-IM-HW September 2008 Primary Variable The measured species concentration value from an Analyzer Module. Secondary Variable Data placed on the network by a module regarding current status, e.g., sample flow, temperature and pressure. Softkeys The five function softkeys located below the front panel display; they assume the function displayed directly above each on the display, a function dictated by software.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID ANALYZER SYSTEM ARCHITECTURE The platform/MLT´s front panel can act as operator interface for a stand-alone analyzer or as the a central interface for multiple Analyzer Modules. In multi analyzer systems, this feature eliminates duplication of the display/operator interface. In addition to the obvious operational benefits there are significant cost and system packaging advantages not possible with conventional analyser configurations.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID The modular configurable bi-directional network offers the following options: ❏ ❏ Stand-alone analyzers (Single devices) • analyzer modules in a platform including optional inputs and outputs (SIO/DIO). Simple interconnection of analyzer modules to an analyzer system based on one of the three structures - see below.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Based on a platform, MLT or TFID analyzer the schematic on Figure A-3 illustrates the simplicity of a networked system which incorporates AM’s, such as Chemiluminesence Detectors, MLT's (NDIR/UV/VIS plus Oxygen or TCD) and Flame Ionisation Detectors. Other system functionality includes links to associated sample handling (PLC) and Data Acquisition Systems such as WinControl.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID System unit CLD/FID/HFID analyzer module (AM): SIO/DIO-Configuration • No local CLD/FID/HFID I/O’s • without front panel, i.e.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 1 DESCRIPTION AND SPECIFICATIONS 1-1 OVERVIEW This manual describes the Heated Flame Ionization Detector (HFID) Analyzer Module of Emerson Process Mangement´s NGA 2000 Series of gas analysis components (See Figure 1-2 and 1-3).
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 1-4 THEORY OF TECHNOLOGY This Analyzer Module uses the flame ionization method of detection. The sensor is a burner in which a regulated flow of sample gas passes through a flame sustained by regulated flows of a fuel gas (hydrogen or a hydrogen/ diluent mixture) and air. With a flame, the hydrocarbon components of the sample stream undergo a complex ionization that produces electrons and positive ions.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID BULKHEAD RESTRICTOR 1/4T - 1/4T SS PURGE AIR IN REGULATED AIR IN BULKHEAD 3/8T BRASS BURNER EXHAUST BULKHEAD 1/4T - 1/4T BRASS BULKHEAD 1/4T - 1/8T SS MANIFOLD, SAMPLE PLUG 1/8NPT CHECK VALVE 1/3 PSIG PLUG 1/4NPT DIFFUSER BULKHEAD PURGE 3/8T - 1/4MPT AIR OUT BRASS FILTER BULKHEAD REDUCER 1/4T - 1/8T BRASS RESTRICTOR, BYPASS ELBOW 1/4T - 1/4FPT BRASS SWITCH, PURGE FLOW PRESSURE RELIEF BURNER VALVE AIR IN FUEL IN BULKHEAD CONN
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Gas Lines (See Figure 2-2) Purge Air Outlet Fuel Shutoff Solenoid Valve Detector (Burner) Oven Preamp Board (in Shield) Case pressure switch Air circulation fan Computer Board Case Heater Sensor Board Sample Flow Controller Safety Board Purge Air Flow Switch DC-DC-Module Power Supply Board Burner Air Solenoid Valve Purge Air Regulator Burner Air & Fuel Regulators (Stacked Vertically) Network & Power Module Figure 1-3: HFID Analyzer Modul
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 1-5 SPECIFICATIONS a. General Measurement Species: ........................ Total hydrocarbons Ranges (H2/Fuel): Low Range ............................ 0 to 10 ppm CH4 through 1 to 1 % CH4 at an oven setpoint between 113 °C and 191 °C (235 °F and 376 °F) High range ............................. 0 to 50 ppm CH4 through 0 to < 5 % CH4 at an oven setpoint between 113 °C and 191 °C (235 °F and 376 °F) Analysis temperature ........................
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID c. Gas requirements Sample .............................................. Non-flammable, below 100 % of LEL Flow Rate: ............................. 1.0 to 2.5 l/min Supply Pressure .................... 345 to 620 hPa-gauge (5 to 9 psig) Temperature: ......................... 110 °C to 230 °C (230 °F to 446 °F), < 20 K variance / 24 hours, < 10 K variance / hour Particles: ................................ Filtered to < 2 microns Dewpoint: ......
Instruction Manual HAS64E-IM-HW September 2008 d. NGA 2000 HFID Gas Connections Sample In: ........................................... 1/4" O.D. tube fitting, stainless steel Regulated Air In: .................................. 1/4" O.D. tube fitting, brass Burner Air In: ....................................... 1/4" O.D. tube fitting, brass Fuel In: ................................................ 1/4" O.D. tube fitting, stainless steel Purge Air In: ........................................ 3/8" O.D.
Instruction Manual NGA 2000 HFID 1-8 Description and Specifications HAS64E-IM-HW September 2008 Emerson Process Management GmbH & Co.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 2 INSTALLATION 2-2 WARNING GENERAL HAZARD Before starting to install this equipment, read the "Essential instructions" on the inside cover and the Safety Summary beginning on page P-2. Failure to follow the safety instructions could result in serious injury or death. If the HFID Analyzer Module requires assembly with other components (e.g., the Platform and associated I/O Modules), do so at this time.
Instruction Manual NGA 2000 HFID 2-3 HAS64E-IM-HW September 2008 LOCATION Install the Analyzer Module in a clean, weather-proofed, non-hazardous, vibration-free location free from extreme temperature variations. For best results, install the Analyzer Module near the sample stream to minimize sample transport time. WARNING INSTALLATION RESTRICTIONS For safety, the Analyzer Module should be installed in a non-confined, ventilated space.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID ! WARNING Possible electric shock, explosion or toxic gas hazard.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID c. Calibration Gases Specifications Fuel Gas Standard analysis usually requires mixed fuel, i.e., 40 % (± 2 %) hydrogen and 60 % helium. H2/He mixed fuel is recommended over H2/N2 fuel because of better linearity in concentration output. Such blends are supplied by many gas vendors specifically for this use, with a guaranteed maximum total hydrocarbon content of 0.5 ppm, measured as methane.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Pressure / Filtration 2-5 SAMPLE PRESSURE at the SAMPLE inlet should be within The Analyzer Module is completely tested at the factory for gas leakage (leakage rate - 7.5 hPa/min. (- 0.11 psig/ min.) with He or - 2.5 hPa/min. (- 0.036 psig/min.) with N2). The user is responsible for leakage testing at the inlet and outlet fittings on the rear panel minimum twice a year (see Section 4-13).
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 2-6 ELECTRICAL CONNECTIONS Network Connection “1” NOTE Electrical installation must be in compliance with the requirements of NAMUR and DIN VDE and/or any applicable national or local codes (like local electricity supply enterprises (ESE)). Network Connection “2” Refer to figure 2-3 and 2-4. Two electrical connections are required on the Analyzer Module: POWER and NETWORK.
Brief Description J1 J2 J3 P1 P2 P3 9.7 cc/min. @ 3.5 psig 659551 2.5 cc/min. @ 3.5 psig 658338 COMPUTER ANALYSIS BOARD 1 Emerson Process Management GmbH & Co.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID FRONT VIEW 8.2 [208] 6.8 [174] 3.6 .7 [91] [18] 1.9 [48] .6 [15] 1.1 [28] 4.3 [110] 2.8 [71] 2.0 [51] 6.0 [152] 1.1 [28] SIDE VIEW 22.5 [571] .3 [7] 1.4 [34] .25 [6] DIA .7 [17] .2 [6] 7.2 [183] 5.4 [137] REAR VIEW 4.2 [107] 4.0 [103] 2.0 [52] 1.1 [27] 1.4 [35] 3.3 [83] 1.0 [25] .9 [23] 2.4 [60] 3.2 [81] 3.1 3.
Instruction Manual HAS64E-IM-HW September 2008 2-7 INSTALLATION CONSIDERATIONS CHECKLIST Verify the following: • The Analyzer´s location should be: • • • • • • • • Clean A well ventilated area NGA 2000 HFID • The heated line is at the correct temperature. • The sample, zero, and span gases are at the correct temperature. • The heated line to have over temperature protection.
Instruction Manual NGA 2000 HFID 2 - 10 Installation HAS64E-IM-HW September 2008 Emerson Process Management GmbH & Co.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 3 OPERATION 3-1 OVERVIEW 3-2 STARTUP & INITIALIZATION Once the HFID has been correctly assembled and installed, the analyzer module is ready for operation. CAUTION Before operating the system, verify that the Leak Checks have been performed in accordance with Section 2-5. PRESSURIZED ENCLOSURE In this section, all operations for starting up the analyzer are explained.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID If the user´s system contains only one Analyzer Module, all system components, the Controller Board and the network "self-install" (bind together) during initial startup. If the system contains more than one Analyzer Module, the startup sequence will interrogate the network to locate and identify all components on the network. The user will have to bind appropriate combinations of components after the startup sequence.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID • Case temperature test - Compares the temperature read between Preamp temperature sensor and the case temperature sensor. They must be within 10°C of each other. This test sometimes fails if the case is opened. The sensor in the Preamp will take longer to cool off since it is in an enclosure. Re-running the self-test after thermal equilibrium will produce a positive result if the sensors are working properly.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID c) 1. Ignition of the Flame 4. Manual or Auto-Ignite the flame. The Flame-On green LED should be illuminated. Two methods of burner ignition are possible: auto-ignition and manual ignition Note the four LEDs on the front panel of the Analyzer Module. They provide necessary information for either ignition procedure. The LEDs, when illuminated, denote the following information: • Green - unit powered on • Amber .
Instruction Manual HAS64E-IM-HW September 2008 3-4 NGA 2000 HFID Common HC factors are: CALIBRATION PROCEDURE The HFID analyzer module may require periodic calibration with known zero and span gases in order to maintain a desire level of analytical accurancy. It is recommended, after initial startup, that the HFID Analyzer Module is calibrated at least once every eight hours.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Calibration Parameters Purge time: This menu provides various parameter settings for all calibration performed from Basic or Expert modes. Sets how long the analyzer will wait befor performing an adjustment. Main (Menu)... Analyzer and I/O expert controls & setup... Analyzer module setup... Calibration parameters... Line#1 0.
Instruction Manual HAS64E-IM-HW September 2008 b. NGA 2000 HFID Execution Zero Adjustment Calibration execution is as follows: 1. 2. 3. Set oven temperature setpoint according to Analyzer Module specific Test Data Sheet Test Data Sheet (Figure 3-12). Apply regulated air at a pressure between 689 to 1,723 hPa-gauge (10 to 25 psig) according to Analyzer Module specific Test Data Sheet Test Data Sheet (Figure 3-12). Allow case, oven, and sample temperatures to stabilize.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Span Adjustment c) After that, perform a Span adjust in the same measuring range: If the user is unable to calibrate the Analyzer Module (i.e., when ZERO or SPAN is initiated, nothing happens), several possible solutions present themselves. One solution relates to the use of an incorrect gas for zeroing or spanning (e.g., using a high concentration gas to zero or a zero gas to span the Analyzer Module).
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 3-5 ROUTINE OPERATION a) Operation After case, oven, and sample temperature stabilization, calibration, and binding, proceed as follows: Supply heated sample gas to SAMPLE INLET. Adjust external flow controller or throttle valve so that the sample inlet pressure is between 345 to 620 hPa-gauge (5 to 9 psig.), 485 hPa-gauge (7 psig.) nominal.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID External physical parameters are adjusted as follows Supply Pressure Fuel Gas Supply Pressure Burner Air Supply Pressure Sample Gas Supply Pressure Regulated Air (N2) Supply Pressure Purge Gas Min.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID • 3-6 SAFETY SYSTEM The HFID Analyzer Module safety system will not allow ignition or continous burner function unless the following conditions are present: • The internal purge gas pressure is at least 380 hPa-gauge (5.5 psig). Monitor message "Purge Gas Pressure" in "Physical Measurements" menu (Figure 3-11) for proper setting. • Flow rate for purge air in is at least 16 l/min and case pressure is greater than 0.5 inches of water.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 1.0 0.8 RESPONSE (100 ppm CH4 fullscale) 0.6 AIR 30 psig (2064 hPa) AIR 20 psig (1376 hPa) AIR 10 psig (688 hPa) 0.4 SAMPLE: 100 ppm CH4 in N2 at 3.5 psig (241 hPa) 0.2 0 _5_ 344 _10_ 688 _15_ 1032 FUEL PRESSURE _20_ 1376 _25_ 1726 _30_ 2064 psig hPa Figure 3-14: Typical Curve of Module Response vs. Pressure Setting on Fuel Pressure Regulator 1.0 FUEL 30 psig (2064 hPa) 0.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID DISPLAY MESSAGE AIR FET AIR PRESS BAIR FLOW BAROMETER BFUEL FLOW BLOCK FET CASE TEMP CRUDE NOISE CURRENTRNGHI CURRENTRNGLO CURRENTSFAC FLAME TEMP FUEL PRES LIN ERROR N15 VOLTS P10 VOLTS P15 VOLTS POL VOLTS SAMP PRES CALRESULT PURGE AIR SW ERROR DESCRIPTION FID Air FET current FID Air Pressure Burner Air Flow System Barometer Burner Fuel Flow Heater current Case Temperature Calculated Noise Current, High Range Current, Low Range Current Range Fl
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 3-7 SYSTEM & NETWORK I/O MODULE CONTROLS (SETUP) - SYSTEM SIO Output number: Choose the desired analog output (1-8) to set the parameters. The number of outputs depends on the analyzer configuration as 2, 4, 6 or 8. To adjust SIO functions, select Main (Menu)... Analyzer and I/O, expert controls & setup... System & network I/O module controls... System SIO module... Line#1 Choose signal source module... 0.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID -- Signals -- Burner air press.: Air sense: Burner air: Burner fuel flow: Burner fuel press.: Sample press.: Sample flow: Purge control status: Measure <<< Back... >>> >>> 0.000 ppm Line#1 -- Signals -- Case temp.: Preamp temp.: Flame status: AutoIgnition: t-90 time: Delay time: Linearizer: Calibration: Measure <<< Back...
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Output(s) value on analyzer failure: Choose the desired signal level to cause a failure condition. The choices are: • • • • • Acutal BeginOfRange EndOfRange BeginOfRange-10% BeginOfRange+10% Output number: Choose the output number (1-8) for setting the fine adjustment. Operation mode: Source module: The name of the module chosen in the "Choose signal source module" menu. Pressing the F5 (More...
Instruction Manual HAS64E-IM-HW September 2008 b. NGA 2000 HFID Serial interface Setup 0.000 ppm Line#1 The submenu "Serial interface Setup" is used to set the parameters for data transfer between the analyzer and external devices. The choices in this menu depend on the configuration of the analyzer. The full specification of the serial interface is described in its own manual.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID c. Relay Outputs Setup Choose signal... There are three relays on the SIO board. The contact logic can be set with a jumper on the SIO board to select NO (normally open) or NC (normally closed). Full details of the SIO board are contained in its own manual. Line#1 0.000 ppm -- Choose Signal -1 Function control Maintenance request Failure Cal.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 4 MAINTENANCE AND SERVICE CAUTION WARNING GENERAL HAZARD PRESSURIZED ENCLOSURE Before starting of maintenance and service to this equipment, read the "Essential instructions" on the inside cover and the Safety Summary beginning on page P-2.Failure to follow the safety instructions could result in serious injury or death.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Cover Insulation Shield WARNING FUEL IN PURGE AIR OUT BURNER AIR IN REGULATED AIR IN PURGE AIR IN BURNER EXHAUST OUT WARNING ATTENTION PRESSURE RELIEF VALVE HEATED SAMPLE IN HEATED SAMPLE BYPASS Cover/Rear Panel Securing Screws (6) Securing Screws (4) Front Panel Securing Screws (6) Figure 4-1: Removal of Cover and Insulation Shield 4-2 Maintenance and Service Emerson Process Management GmbH & Co.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Rear Panel Assembly 656954 Electronic Assembly 656943 DC Power Supply Module Assembly 657413 Oven Assembly Brief Description Part Number 9.7 cc/min. @ 3.5 psig 659551 2.5 cc/min. @ 3.5 psig 658338 Fan Assembly 657414 Fixed Flow Controller Assembly 657434 Front Panel Assembly 656949 Figure 4-2: Location of Major Assemblies of the HFID Module 4-2 FUSES The main power fuse may require replacement.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-3 OVEN b. Though the oven can be replaced as a complete unit, all internal components are field replaceable. a. 1. 2. Removal Refer to Figure 4-3, disconnect the oven´s three gas lines and seven electrical cables, noting location of mating connectors for re-installation. 3. Disassembly Refer to Figure 4-4A. Remove the tour retaining screws on the oven cover, remove cover.
Instruction Manual HAS64E-IM-HW September 2008 A NGA 2000 HFID Oven Cover 657105 (with insulation 657346) B Exhaust Nuts and Ferrules (2 ea.) Inner Oven Retaining Screw (2) and Washer (2) Inner Oven Inner Oven Front Panel 657352 Preamp Connector Nut, Washer (type 2) Outer Oven Outer Oven Front Panel 657356 Burner 657359 C Spring, Heated Bridge 904294 Heated Bridge 659955 Heater/Cable Assembly 659643 Jam Nuts 659550 Insulating Washers 073737 For clarity, outer oven not shown in Figures B and C.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-4 BURNER c. This section covers burner components which can be replaced without removal of oven from the chassis. a. 1. 2. 3. 4. 5. Temperature Sensor Refer to Figure 4-4A. Remove the four screws on the oven cover, remove cover. Refer to figure 4-5. Remove the burner cap retainer. Disconnect the temperature sensor wiring connector, note location. Remove the temperature sensor. Insert replacement sensor.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Retainer, Burner Cap Temperature Sensor 657468 O-Ring 903736 O-Ring 903737 Flameout Sensor 657199 Igniter Assembly 657205 RTD Detector 657063 Set Screw M3X0.5x10 mm 903125 The components shown can be replaced without removing burner/thermal block from oven. Oven not shown for clarity. Thermal block shown in phantom for clarity. Figure 4-5: Burner-Sensor, Flameout Detector, RTD Detector and Igniter Emerson Process Management GmbH & Co.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-5 BURNER INTERNAL COMPONENTS a. 1. CAUTION BURNER CONTAMINATION Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates. 2. 3. 4. 5. Disassembly of Burner / Thermal Block Remove oven from analyzer module per Section 4-3a. Remove burner / thermal block from oven per Section 4-3b. Refer to Figure 4-6. Disconnect sample capillary nut at base of burner.
Instruction Manual HAS64E-IM-HW September 2008 b. NGA 2000 HFID Replacing Burner Jets For best performance, replace the burner jet as follows: Disassemble the burner only if contaminants are evident. Combustion products or other contaminates which accumulate inside the burner may form electrical leakage paths between the collector and the burner contact, resulting in noisy readings.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 7. 8. Refer to Figure 4-8. Lift air baffle out of burner base. Remove the sample jet and gasket from the bottom of the burner base. 9. Remove the jet nut. Grasp jet assembly and lift out (along with upper gasket) of burner base. Remove bottom gasket. Air Baffle (Ref) 102260 (see below) Nut, Jet 016005 Gasket 102273 Sample Jet 657005 Gasket 102256 Air Baffle End bent to raise it above the tab a distance equal to the height of the tab.
Instruction Manual HAS64E-IM-HW September 2008 c. NGA 2000 HFID Burner Jet Installation 3. 4. CAUTION BURNER CONTAMINATION Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates. 1. 2. Install new lower gasket, jet assembly and upper gasket into burner base, finger-tight jet nut. Install new sample jet (with gasket) and tighten. Emerson Process Management GmbH & Co.OHG Tighten jet nut. Install air baffle per Figure 4-8.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-6 THERMAL BLOCK b. The sample RTD can be replaced with the thermal block attached to burner and mounted in oven. The cartridge heater and thermostat are also replaceable with thermal block secured to burner, but must be removed from the oven. a. 1. 2. 3. 4. 5. 6. Sample RTD 1. 2. 3. 4. Refer to Figure 4-4A. Remove the four screws securing the oven cover, remove cover. Disconnect the sample RTD wiring connector, note location.
Instruction Manual HAS64E-IM-HW September 2008 c. 1. 2. 3. 4. 5. 6. NGA 2000 HFID Thermostat d. Remove oven from analyzer module per Section 4-3a. Remove burner / thermal block from oven per Section 4-3b. Refer to Figure 4-9. Remove the two retaining screws, pull thermostat out. Install replacement thermostat, attach with the two retaining screws. Install burner / thermal block into oven. Install oven into analyzer module. 1. 2. 3. 4. 5. 6. 7. 8.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-7 ELECTRONICS ASSEMBLY CAUTION The electronics assembly must be removed from the chassis of replacement of any of the following components is necessary: Power Supply Board Safety Board ELECTROSTATIC DISCHARGE Computer Analysis Board The electronic parts of the Analyzer Module can be irreparably damaged if exposed to electrostatic discharge (ESD).
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Preamp Assembly 656945 Case Pressure Purge Switch 903690 Computer Analysis Board 658350 Sensor Board 657060 Safety Board 43500271 Power Supply Board 655764 Case Temperature Sensor 656026 Figure 4-12: Electronics Assembly - Exploded View a. Printed Circuit Boards When replacing a circuit board, the following procedure is recommended: One at a time, remove the wiring connectors and attach to replacement board.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID b. 1. 2. 3. Case Temperature Sensor Per Section 4-7, remove securing hardware from electronics assembly and lay on bench. Disconnect case temperature sensor cable. Remove screw securing cable clamp holder to signal board. 4. 5. 6. Remove case temperature sensor from cable clamp holder. Per Figure 4-13 insert replacement case temperature sensor into cable clamp holder. Re-assemble to signal board mounting screw.
Instruction Manual HAS64E-IM-HW September 2008 d. 1. 2. 3. NGA 2000 HFID Preamp Assembly Per Section 4-7, remove securing hardware from electronics assembly and lay on bench. Disconnect and note location of cables. Remove the two screws and washers from the top bracket and slide the preamp assembly out. 4. 5. 6. Remove the lower bracket from the preamp assembly and install on replacement preamp assembly. Slide replacement preamp assembly into top bracket and secure with mounting hardware.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-8 1. 2. FAN ASSEMBLY Disconnect and note location of cables. Remove the two hex nuts securing the fan to the chassis, lift fan assembly out. Fan Assembly 657414 Figure 4-16: Fan Assembly Installation 4 - 18 Maintenance and Service Emerson Process Management GmbH & Co.
Instruction Manual HAS64E-IM-HW September 2008 4-9 1. 2. NGA 2000 HFID FLOW CONTROLLER Disconnect the all tubing and wiring connectors, note locations. Remove the four hex nuts securing the flow controller assembly to the analyzer module chassis.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-10 DC POWER SUPPLY MODULE 1. 2. Disconnect and note location of all wiring to DC power supply module. Remove the two hex nuts securing module to chassis, remove module. DC Power Supply Module Figure 4-19: DC Power Supply Module Replacement 4 - 20 Maintenance and Service Emerson Process Management GmbH & Co.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-11 FRONT PANEL COMPONENTS The following components are mounted to the front panel: • • LON/Power Module Manual Ignite Toggle Switch Connector fitting Air Measurement Restirctor 656888 • • • • • • • • • • LED Indicator Assembly Purge Air Regulator Purge Air Flow Switch Burner Air Solenoid Valve Burner Air Regulator Fuel Regulator Burner Air Sensor Fuel Sensor Air Ignite Restrictor Air Measurement Restrictor Burner Air Solenoid Valve 65621
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Replacing Front Panel Components 1. 2. To access components, remove the four front panel mounting screws (two on front, one on each side). Remove the burner air regulator and fuel regulator mounting nuts. 3. Remove the purge air regulator mounting bracket screws. The front panel can now be pulled away from the chassis. NOTE The wiring from front panel components is still connected. Do not disconnect unless replacing that component.
Instruction Manual HAS64E-IM-HW September 2008 a. 1. 2. 3. LON/Power Module Disconnect wiring connectors, note locations. Refer to Figure 4-20. From the outside of the front panel, remove the two mounting screws. Install replacement module in reverse order. NGA 2000 HFID e. 1. 2. 3. b. 1. 2. 3. 4. c. 1. 2. 3. 4. 5. 6. d. 1. 2. 3. 4. 5. LED Indicator Assembly Disconnect wiring connector, note location. Refer to Figure 4-20.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID h. 1. 2. 3. 4. 5. 6. i. 1. 2. 3. 4. 5. 6. 7. 8. 9. 4 - 24 Purge Air Flow Switch and Diffuser j. Air Ignite Restrictor Unscrew flow switch from tee fitting. Replace Teflon pipe thread tape on tee fitting. Remove diffuser from flow switch and install into replacement flow switch. Install replacement flow switch. Install purge switch onto tee fitting. Re-connect tubes. 1. Burner Air Solenoid Valve 2.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-12 REAR PANEL COMPONENTS The following components are mounted to the rear panel: • • Fuel In 2-Way Solenoid Valve Regulated Air In Check Valve • • • Burner Air In Filter Heated Sample Bypass Out Restrictor Heated Sample In Restrictor VIEW FROM INSIDE ANALYZER MODULE Check Valve, Regulated Air IN 903728 Solenoid Valve, Fuel IN 656218 VIEW FROM OUTSIDE ANALYZER MODULE Filter, Burner Air IN 017154 Restrictor, Bypass OUT 10 Micron 619615
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID a. 1. 2. 3. 4. 5. 6. b. 1. 2. 3. 4. 4 - 26 Fuel In 2-Way Solenoid Valve Disconnect wiring solenoid valve wiring connector, note location. Inside the analyzer module, disconnect the tube going to the connector on the "out" port of the solenoid valve. On the rear of the analyzer module at the fuel in port: a. Disconnect the fuel in tube. b. Remove nuts and washers c.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-13 LEAKAGE TEST The gas path system should be leak tested at least twice a year and after maintenance, replacement or repair of gas path parts. a) 4. 5. 6.
Instruction Manual NGA 2000 HFID HAS64E-IM-HW September 2008 If there is a leakage, then proceed as follows: a) Using Helium (He) for test medium • Supply Analyzer Module with the test medium with a pressure of max. 250 hPa (3.63 psig). • Look for the leak with a helium leak detector. b) Using Nitrogen (N2) for test medium • Supply Analyzer Module with the test medium with a pressure of max. 250 hPa (3.63 psig).
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 5 TROUBLESHOOTING WARNING GENERAL HAZARD Before starting troubleshooting to this equipment, read the "Essential instructions" on the inside cover and the Safety Summary beginning on page P-2. Failure to follow the safety instructions could result in serious injury or death. 5-1 TROUBLESHOOTING CHECKLIST b. Ignition a. Safety System 1. Verify that the fuel pressure/flow is correct. 1.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID c. Drift d. Noise 1. Verify that the sample, burner air, and fuel supply pressures are constant. 1. Check that the burner exhaust is free from water condensation. 2. Check that the sample, burner air, and fuel supply pressures are constant. 2. Verify connection to the collector is correct. 3. 3. Verify that the oxygen level in the burner air and sample are constant. Verify connection to the polarizing voltage is correct. 4. 4.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 6 REPLACEMENT PARTS WARNING UNAUTHORIZED SUBSTITUTION OF COMPONENTS Tampering with or unauthorized substitution of components may adversely affect the safety of this instrument. Use only factory documented/approved components for repair. Because of the danger of introducing additional hazards, do not perform any unauthorized modification to this instrument! 6-1 MATRIX Each analyzer is configured per the customer sales order.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 6-2 GENERAL 813344 903107 657029 656560 657413 657053 657414 656943 6-3 PNEUMATICS 017154 902832 657434 871672 655794 656888 656443 656444 656418 656219 656218 903690 6-2 Fuse, 6A Fuse, Thermal Cutoff 72° (2 Required - Safety and Power Supply PCB's) LED Indicator Assembly LON/Power Module DC Power Supply Module Manual Ignite Switch Assembly Fan Assembly Electronics Assembly 658350 Computer Board 656945 Preamp Assembly 43500721 Safety Boar
Instruction Manual HAS64E-IM-HW September 2008 656533 903728 903647 6-4 NGA 2000 HFID Purge Air Flow Switch Regulated Air In Check Valve Case Pressure Relief Valve OVEN COMPONENTS 659551 658338 Oven Assembly 9.7 cc/min @ 3.5 psig Oven Assembly 2.5 cc/min @ 3.5 psig 657359 Burner Assembly 657205 Igniter Assembly 903736 O-Ring (Igniter Assembly) 657063 RTD Detector 903125 Set Screw M3x0.
Instruction Manual NGA 2000 HFID 6-4 Replacement Parts HAS64E-IM-HW September 2008 Emerson Process Management GmbH & Co.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 7 RETURN OF MATERIAL 7-1 RETURN OF MATERIAL If factory repair of defective equipment is required, proceed as follows: 1. 2. 3. Secure a return authorization from a Emerson Processs Management Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Emerson instructions or it will not be accepted.
Instruction Manual NGA 2000 HFID 7-2 HAS64E-IM-HW September 2008 CUSTOMER SERVICE For order administration, replacement parts, application assistance, on-site or factory repair, service or maintenance contract information, contact: EMERSON Process Management Process Analytic Division Customer Service Center USA: +1 (800) 433-6076 EU: +49 (6055) 884-470 7-3 TRAINING A comprehensive Factory Training Program of operator and service classes is available.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID LIST OF FIGURES AND TABLES 1 LIST OF FIGURES Figure A-1: From separate analyzers to analyzer system ............................................................... A - 1 Figure A-2: Example of NGA cabling ............................................................................................... A - 2 Figure A-3: Example/Possibilities of NGA Analyzer System ............................................................
Instruction Manual NGA 2000 HFID HAS64E-IM-HW September 2008 Figure 3-23: Serial Interface Setup Menu ........................................................................................ 3 - 17 Figure 3-24: AK Protocol Definitions Menu ...................................................................................... 3 - 17 Figure 3-25: Relay Outputs Setup Menu ..........................................................................................
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SUPPLEMENT 1 EC DECLARATION OF CONFORMITY Emerson Process Management GmbH & Co.
Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 2 DECLARATION OF CONTAMINATION Because of legal regulations and for the safety of Emerson Process Management employees and operating equipment, we need this „Declaration of Contamination“, signed by an authorized person, prior to processing your order. Ensure to include it with the shipping documents, or (recommended) attach it to the outside of the packaging. Instrument details Process details Analyzer model serial no.
Instruction Manual HAS64E-IM-HW September 2008 Emerson Process Management GmbH & Co.
Instruction Manual NGA 2000 HFID EUROPE Emerson Process Management GmbH & Co. OHG Industriestrasse 1 D-63594 Hasselroth Germany T +49 (6055) 884-0 F +49 (6055) 884-209 Internet: www.emersonprocess.de EUROPE, MIDDLE EAST, AFRICA Emerson Process Management Shared Services Limited Heath Place Bognor Regis West Sussex PO22 9SH England T +44-1243-863121 F +44-1243-845354 Internet: www.emersonprocess.co.uk NORTH AMERICA Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St.
