Instruction manual

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Instruction Manual

760004-A

February 2002

http://www.processanalytic.com

Model NGA 2000 HFID

Heated Flame Ionization Detector Module

Summary of content (118 pages)

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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID Heated Flame Ionization Detector Module http://www.processanalytic.
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ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING! 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.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 TABLE OF CONTENTS PREFACE...........................................................................................................................................1 Definitions ...........................................................................................................................................1 Safety Summary .................................................................................................................
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Instruction Manual 760004-A February 2002 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 ii Model NGA 2000 HFID Burner Internal Components .................................................................................................4-8 a. Disassembly of Burner/Thermal Block............................................................................4-8 b. Replacing Burner Jets.....................................................................................................4-9 c. Burner Jet Installation ....
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 LIST OF ILLUSTRATIONS Figure 1-1. Flame Ionization Detection Technology ...........................................................................1-2 Figure 1-2. Heated Flame Ionization Detector Analyzer Module - Top View....................................1-3 Figure 2-1. Back Panel Connections ..................................................................................................2-2 Figure 2-2. Flow Diagram........................
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Instruction Manual 760004-A February 2002 iv Contents Model NGA 2000 HFID Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model 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.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID SAFETY SUMMARY If this equipment is used in a manner not specified in these instructions, protective systems may be impaired. 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 this equipment should be thoroughly familiar with and strictly follow the instructions in this manual. SAVE THESE INSTRUCTIONS. DANGER.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID WARNING. HIGH TEMPERATURE 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.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID WARNING. POSSIBLE EXPLOSION HAZARD Ensure that all gas connections are made as labeled and are leak free. Improper gas connections could result in explosion or death. CAUTION.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 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.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID DOCUMENTATION The following NGA 2000 HFID instruction materials are available. the local representative to order.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 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.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID Softkeys The five function softkeys located below the front panel display; they assume the function displayed directly above each on the display, a function dictated by software. System Any collection of Analyzer Module(s), Platform(s), I/O Module(s) and Expansion Module(s). P-8 Preface Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID SECTION 1 DESCRIPTION AND SPECIFICATIONS 1-1 OVERVIEW This manual describes the Heated Flame Ionization Detector (HFID) Analyzer Module of Rosemount Analytical's NGA 2000 Series of gas analysis components. See Figure 1-1 and Figure 1-2. The HFID Analyzer Module is designed to continuously determine the concentration of hydrocarbons in a flowing gaseous mixture at a user-selectable temperature setpoint between 93°C and 204°C (200°F and 400°F).
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID concentration of hydrocarbons in the sample. This measure of concentration is placed on the network, where it can be shown on a data acquisition device. Negative Ion Collection Plate +90V Signal Conditioning Positive Carbon Ions Air Sample Fuel C Figure 1-1. Flame Ionization Detection Technology 1-2 Description and Specifications Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model 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 Burner Air Solenoid Valve Power Supply Board Purge Air Regulator Burner Air & Fuel Regulators (Stacked Vertically) Network & Power Module Figure 1-2.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 1-5 SPECIFICATIONS a. General Measurement Species ....................Total hydrocarbons Ranges (H2/He Fuel) Low range .............................. 0 to 10 ppm, CH4, through 0 to 1%, CH4 at an oven setpoint between 113°C and 191°C High range ............................. 0 to 50 ppm, CH4, through 0 to <5%, CH4 at an oven setpoint between 113°C and 191°C Analysis Temperature .....................
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Instruction Manual 760004-A February 2002 Model 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 .......................... 110oC to 230oC (230oF to 446oF), <20oC variance/24 hours, <10oC variance/hr. Particulates ............................ filtered to <2 microns Dewpoint......................
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Instruction Manual 760004-A February 2002 d. Model 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.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID SECTION 2 INSTALLATION 2-1 UNPACKING If the HFID Analyzer Module is received as a separate unit, carefully examine the shipping carton and contents for signs of damage. Immediately notify the shipping carrier if the carton or contents is damaged. Retain the carton and packing material until all components associated with the Analyzer Module are operational.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID graph-grade tubing. Thoroughly clean before use (if a hydrocarbon-based cleaning solvent such as acetone is used, purge tubing with dry nitrogen or helium for several minutes before using.) the line and flood the burner. Depending on the percent of water vapor in the sample, the sample bypass out connection may have condensation. Proper drainage may be required. Gas line connections are compression fittings. Do not use pipe thread tape.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID b. Pneumatic Connections c. Specifications Fuel Gas WARNING HIGH TEMPERATURES The Sample In, Sample Bypass Out, and Burner Exhaust Out gases and fittings can reach temperatures of up to 250°C. Make connections to these fittings when the oven heater is disabled or the module is powered down.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID introduced through the sample inlet at the rear of the module. Burner Air Pressure should be : 1725 to 3450 hPa-gauge (25 to 50 psig) for cylinder regulator, 1035 hPa-gauge (15 psig) nominal for internal pressure. Zero Gas - Analysis is affected by the background gas of the sample. Therefore, it is recommended to use zero gas with as close to the background composition of the sample as possible. Normally less than 0.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID BULKHEAD 3/8T BRASS PURGE AIR IN REGULATED AIR IN HEATED SAMPLE SAMPLE BYPASS IN OUT BULKHEAD 1/4T - 1/8T SS MANIFOLD, SAMPLE CHECK VALVE 1/3 PSIG PLUG 1/8NPT PLUG 1/4NPT DIFFUSER BURNER AIR IN PURGE AIR OUT FILTER BULKHEAD FUEL 3/8T - 1/4MPT IN BRASS BULKHEAD CONNECTOR 1/4T - 1/8NPT SS FUEL RESTRICTOR SOLENOID VALVE RUN TEE 1/4T - 1/4FPT BRASS MALE CONNECTOR 1/8T - 1/8NPT SS PORT CONNECTOR 1/4 TUBING 1/4 OD VITON RESTRICTOR, B
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 2-6 ELECTRICAL CONNECTIONS Two electrical connections are required on the Analyzer Module: POWER and NETWORK (See Figure 2-3 and Figure 2-4). On the Analyzer Module, two NETWORK connectors are available, either of which is appropriate for: 1) interconnection with the control module or 2) "daisy-chaining" with other NGA 2000 components.
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Instruction Manual 760004-A February 2002 Model 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] SIDE VIEW 1.1 [28] 22.5 [571] .3 [7] 1.4 [34] .25 [6] DIA .7 [17] .2 [6] 7.2 [183] REAR VIEW 5.4 [137] 4.2 [107] 4.0 [103] 2.0 [52] 1.1 [27] 1.4 [35] 3.3 [83] .9 [23] 1.0 [25] 2.4 [60] 3.2 [81] 3.1 3.0 [78] [75] Dimensions: INCHES [MM] Rosemount Analytical Inc. Figure 2-5.
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2-8 Description and Specifications COMPUTER ANALYSIS BOARD J1 J2 J3 P1 P2 P3 EI P1 E2 J1 E3 PREAMP BOARD Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 2-7 INSTALLATION CONSIDERATIONS CHECKLIST Verify the following: • The Analyzer’s location should be: Clean A well ventilated area weatherproofed Non-hazardous 760004-A February 2002 • The bypass line connection must be slanted down a minimum of 6 degrees from horizontal for drainage of water condensation. • If required, thermal insulation around the bypass fitting to prevent condensation in the bypass restrictor.
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Instruction Manual 760004-A February 2002 2-10 Description and Specifications Model NGA 2000 HFID Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID SECTION 3 OPERATION 3. Connect the LON cable(s) and the +24VDC power cable. 3-1 OVERVIEW Prior to initial startup, the user should leak test the module as outlined in Section 2. 4. Turn power ON. For the remainder of this section, Analyzer Module interconnection with a control module or some interfacing component will be assumed operational. 5. Check the 4 LEDs. The power green LED should be illuminated.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID • Power supply test - Verifies that all internal DC voltages are within the required tolerances. • Network test - Checks the internal network interface. • • • 10. Wait for the Purge Air green LED to illuminate. 20 bit ADC test - Checks the 20-bit ADC on the Analysis Computer PCB by sending a DC signal through the Preamp PCB and reading the signal back with the 20-bit ADC.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID and the Purge Gas variable does not read "ON," contact factory. If the safety system is initiated successfully (Purge Gas variable is "ON"), continue with the remainder of the startup procedure. NOTE Do not restrict the PURGE OUT port and the pressure relief valve. They must be vented to atmospheric pressure. 13. Manual or Auto-ignite the flame. The Flame-On green LED should be illuminated.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID Technical Level Configuration, Service Menus, Manufacturing Data, Analyzer Module Data). 3-4 CALIBRATION Calibration gas setup is as follows: 4. Supply heated zero gas to sample inlet. Adjust external flow controller or throttle valve so that the sample inlet pressure is between 5 and 9 psig., 7 nominal. 5.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 1. Verify that correct zero and span calibration gases are being used properly. If so, attempt to recalibrate according to instructions at the beginning of Section 3-4, ensuring that the oven, sample and case temperatures and displayed measurement reading are stable before initiating the calibration routine. If incorrect gases were used in the initial, failed calibration, skip to Step 2. 2.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID than 0.5 inches of water. (Monitor display message, Purge Gas (ON) in Miscellaneous Control Parameters menu for correct state. Proper sealing hardware must be used in order to obtain the required purge air in flow rate and case pressure). • 3-6 Five case volumes of purge air have been achieved and the three above conditions are present. The time duration to achieve a safe system is a minimum of 6 min.
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Instruction Manual 760004-A February 2002 Model 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 0 5 344 10 688 15 1032 20 1376 25 1726 30 2064 psig FUEL PRESSURE hPa Figure 3-1. Typical Curves of Module Response vs. Pressure Setting on Fuel Pressure Regulator 1.0 FUEL: 30 psig (2064 hPa) H2 0.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID DISPLAY MESSAGE DESCRIPTION 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 TYPE FID Air FET current WARNING FID Air Pressure WARNING Burner Air Flow WARNING System Barometer WARNING Burner Fuel Flow WARNING Heater current WARNING Case Temperature WAR
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID SECTION 4 MAINTENANCE AND SERVICE 1. Remove power to the unit; shut off gases and disconnect lines. Allow module to cool. WARNING QUALIFIED PERSONNEL 2. Refer to Figure 4-1. Remove the six screws securing the front panel, then the six screws securing the cover to the rear panel. Slide cover towards rear panel to remove. Loosen four screws securing inner insulation shield to base, lift up to remove.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID Rear Panel Assembly 656954 Electronics Assembly 656943 DC Power Supply Module Assembly 657413 Oven Assembly 659551 Fan Assembly 657414 Fixed Flow Controller Assembly 657434 Front Panel Assembly 656949 Figure 4-2. Locations of Major Assemblies of the HFID 4-2 Maintenance and Service Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 4-2 OVEN NOTE DO NOT remove the fittings from the gas lines on the detector. Though the oven can be replaced as a complete unit, all internal components are field replaceable. a. Remove the two hex nuts securing the oven to the chassis and the two screws securing oven to the rear panel. Lift oven assembly from analyzer.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID b. 4. Refer to Figure 4-4B. Remove the two nuts and washers from the electrical preamp connectors on the inner oven front panel. Do not unsolder these connections. Disassembly 1. Refer to Figure 4-4A. Remove the four retaining screws on the oven cover, remove cover. 2. Remove the two screws and one nut securing the outer oven front panel to the outer oven, remove front panel. 3.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID A B Oven Cover 657105 (with insulation 657346) 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 (typ 2) Outer Oven Outer Oven Front Panel 657356 C Burner 657359 Spring, Heated Bridge 904294 Heated Bridge 659555 Heater/Cable Assembly 659643 Jam Nuts 659550 Insulating Washers 073737 For clarity, outer oven not shown in Figures B and C.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 4-3 BURNER 5. Insert replacement RTD detector into hole, snug down set screw. This section covers burner components which can be replaced without removal of oven from the chassis. 6. Re-attach wiring connector. 7. Install oven cover. a. Temperature Sensor c. 1. Refer to Figure 4-4A. Remove the four screws on the oven cover, remove cover. 1. Refer to Figure 4-4A. Remove the four screws on the oven cover, remove cover. 2.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID Retainer, Burner Cap Burner Cap O-Ring 903736 Igniter Assembly 657205 Temperature Sensor 657468 O-Ring 903737 Flameout Sensor 657199 RTD Detector 657063 Set Screw M3X0.5 x 10mm 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.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 4-4 BURNER INTERNAL COMPONENTS 2. Remove burner/thermal block from oven per Section 4-2b. WARNING 3. Refer to Figure 4-6. Disconnect sample capillary nut at base of burner. BURNER CONTAMINATION Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates. a. 4. Remove screw securing thermal block to burner. 5. Carefully pull burner away from thermal block.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID b. 1. Remove oven from analyzer module per Section 4-2a. Replacing Burner Jets Disassemble the burner only if contaminants are evident. Combustion products or other contaminates which accumulate inside the burner may form electrical leakage paths between the collector and the burner contact, resulting in noisy readings. 2. Remove burner/thermal block from oven per Section 4-2b. 3. Remove thermal block from burner per Section 4-4a. 4.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 7. Refer to Figure 4-8. Lift air baffle out of burner base. 9. Remove the jet nut. Grasp jet assembly and lift out (along with upper gasket) of burner base. Remove bottom gasket. 8. Remove the sample jet and gasket from the bottom of the burner base. Air Baffle (Ref) 102260 See Below Nut, Jet 657016 Gasket 102273 Jet Assembly 657012 Gasket 102256 Air Baffle End bent to raise it above the tab a distance equal to the height of the tab.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID c. Burner Jet Installation WARNING BURNER CONTAMINATION 4. Install air baffle per Figure 4-8. NOTE Incorrect installation of air baffle will cause ignition failure. Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates. 5. See Figure 4-7B. Insert new o-ring into burner base. 1. Install new lower gasket, jet assembly and upper gasket into burner base, finger-tight jet nut. 2.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 4-5 THERMAL BLOCK 2. Disconnect the sample RTD wiring connector, note location. 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. 3. Refer to Figure 4-9. Remove the two screws securing the sample RTD, pull sample RTD out. 4.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID b. Cartridge Heater 5. Install burner/thermal block into oven. 1. Remove oven from analyzer module per Section 4-2a. 6. Install oven into analyzer module. d. 2. Remove burner/thermal block from oven per Section 4-2b. 3. Refer to Figure 4-9. Loosen retaining set screw, pull out cartridge heater. 4. Install replacement cartridge heater, snug down set screw. Sample Capillary 1. Remove oven from analyzer module per Section 4-2a 2.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID Sensor Board Case Temperature Sensor Case Pressure Switch 4-6 ELECTRONICS ASSEMBLY The electronics assembly must be removed from the chassis if replacement of any of the following components is necessary: Power Supply Board Safety Board Computer Analysis Board Preamp Assembly 1. Remove the hex nut and screw as shown in Figure 4-11. 2. Lay electronics assembly on bench, do not disconnect cables or tubing.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID Preamp Assembly 656945 Case Pressure Purge Switch 903690 Computer Analysis Board 659149 Sensor Board 657060 Safety Board 657499 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: Per Section 4-6, remove securing hardware from electronics assembly and lay on bench.
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Instruction Manual 760004-A February 2002 b. Model NGA 2000 HFID Case Temperature Sensor 1. Per Section 4-6, remove securing hardware from electronics assembly and lay on bench. 2. Disconnect case temperature sensor cable. 4. Remove case temperature sensor from cable clamp holder. 5. Per Figure 4-13 insert replacement case temperature sensor into cable clamp holder. 6. Re-assemble to signal board mounting screw. 3. Remove screw securing cable clamp holder to signal board.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID c. Case Pressure Purge Switch 3. Disconnect tube at pressure switch. 1. Per Section 4-6, remove securing hardware from electronics assembly and lay on bench. 4. Remove mounting screws (2) and washers (2). 2. Disconnect the two electrical terminals, note location. 5. Reverse procedure for installation of replacement switch.
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Instruction Manual 760004-A February 2002 d. Model NGA 2000 HFID 4. Remove the lower bracket from the preamp assembly and install on replacement preamp assembly. Preamp Assembly 1. Per Section 4-6, remove securing hardware from electronics assembly and lay on bench. 5. Slide replacement preamp assembly into top bracket and secure with mounting hardware. 2. Disconnect and note location of cables. 6. Re-connect cables. 3.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 4-7 FAN ASSEMBLY 1. Disconnect and note location of cables. 2. Remove the two hex nuts securing the fan to the chassis, lift fan assembly out. Fan Assembly 657414 Figure 4-16. Fan Assembly Installation Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 4-8 FLOW CONTROLLER 1. Disconnect the all tubing and wiring connectors, note locations. 2. Remove the four hex nuts securing the flow controller assembly to the analyzer module chassis. Flow Controller Assembly 657434 Figure 4-17. Flow Controller Replacement 4-20 Maintenance and Service Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID Regulated Air In Regulator 250 psi 023382 Remove red cap after installation FLOW Regulated Air Out Sample Sensor 656418 Remove and discard bracket supplied with regulator, assembly as shown. Figure 4-18. Flow Controller Assembly Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 4-9 DC POWER SUPPLY MODULE 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 4-22 Maintenance and Service Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 4-10 FRONT PANEL COMPONENTS • The following components are mounted to the front panel: • • • • • LON/Power Module Manual Ignite Toggle Switch • • • Connector fitting • • • 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 656219 Air Measurement Restrictor 656
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID The front panel can now be pulled away from the chassis. Replacing Front Panel Components 1. To access components, remove the four front panel mounting screws (two on front, one on each side). NOTE The wiring from front panel components is still connected. Do not disconnect unless replacing that component. 2. Remove the burner air regulator and fuel regulator mounting nuts. 3. Remove the purge air regulator mounting bracket screws.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID a. LON/Power Module d. 1. Disconnect wiring connectors, note locations. 1. Disconnect wiring connector, note location. 2. Refer to Figure 4-20. From the outside of the front panel, remove the two mounting screws. 2. Using an open-end wrench to hold the sensor fitting while using another open-end wrench to remove the sensor. 3. Install replacement module in reverse order. b. Burner Air Sensor 3.
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Instruction Manual 760004-A February 2002 5. Inspect o-ring for damage, replace if necessary. Install o-ring onto regulator threaded shaft. Model NGA 2000 HFID i. Burner Air Solenoid Valve 1. Disconnect the tube at the top elbow fitting. 6. Insert regulator into front panel, secure with mounting nut. 2. Disconnect the tube at the tee fitting, remove valve analyzer module. 7. Re-attach the three tubes. g. Purge Air Regulator 3. Holding the air ignite restrictor, unscrew the solenoid valve. 1.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 4-11 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, Heated Sample Bypass Out –
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Instruction Manual 760004-A February 2002 a. Model NGA 2000 HFID into the bulkhead fitting to force out the filter disc. Fuel In 2-Way Solenoid Valve 1. Disconnect wiring solenoid valve wiring connector, note location. 3. Install the replacement filter in the same manner, through the rear of the bulkhead fitting. 2. Inside the analyzer module, disconnect the tube going to the connector on the “out” port of the solenoid valve. 3. On the rear of the analyzer module at the fuel in port: 4.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID SECTION 5 TROUBLESHOOTING 5-1 TROUBLESHOOTING CHECKLIST a. Safety System 1. Verify purge supply pressure at bulkhead is between 10 and 20 psig. b. Ignition 1. Verify that the fuel pressure/flow is correct. 2. Verify that the burner air pressure/flow is correct. 2. Check case for leaks. 3. Check burner for leaks. 3. Verify that the igniter is generating enough heat. 4. Verify purge pressure sensor tube connection. 4.
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Instruction Manual 760004-A February 2002 18. Verify that there is +10VDC to the reference thermistor. c. Model NGA 2000 HFID d. Noise Drift 1. Check that the burner exhaust is free from water condensation. 1. Verify that the sample, burner air, and fuel supply pressures are constant. 2. Verify connection to the collector is correct. 2. Check that the tubing, regulators, pumps, fittings, and valves are clean of hydrocarbons. 3. Verify connection to the polarizing voltage is correct. 3.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID SECTION 6 REPLACEMENT PARTS WARNING PARTS INTEGRITY Tampering with or unauthorized substitution of components may adversely affect safety of this product. Use only factory-approved components for repair. 6-1 MATRIX Each analyzer is configured per the customer sales order. Below is the HFID sales matrix which lists the various configurations available. To identify the configuration of an analyzer, locate the analyzer name-rating plate.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID 6-2 GENERAL 813344 903107 657029 656560 657413 657053 657414 656943 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 659149 Computer Board 656945 Preamp Assembly 657499 Safety Board 655764 Power Supply Board 657060 Sensor Board 656026 Case Temperature Sensor 6-3 PNEUMATICS 017154 902832 6
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 6-4 OVEN COMPONENTS 659551 Rosemount Analytical Inc. Oven Assembly 657359 Burner Assembly 657205 Igniter Assembly 903736 O-Ring (Igniter Assembly) 657063 RTD Detector 903125 Set Screw M3X0.
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Instruction Manual 760004-A February 2002 6-4 Replacement Parts Model NGA 2000 HFID Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID SECTION 7 RETURN OF MATERIAL 7-1 RETURN OF MATERIAL If factory repair of defective equipment is required, proceed as follows: 1. Secure a return authorization from a Rosemount Analytical Inc. Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted. Rosemount CSC will provide the shipping address for your instrument.
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Instruction Manual 760004-A February 2002 7-2 Return of Material Model NGA 2000 HFID Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID SECTION 8 APPENDIX A - MENU DISPLAYS Menu: 0 ANALOP Menu: 1 ANALSET MENU: 2 FLOCHEK Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 3 FLOCHEKI1 MENU: 4 ACALSET MENU: 5 APARLST 8-2 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 6 ANALSETI1 MENU: 7 CALLIST MENU: 8 CALLISTI1 Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 9 ACALSETI1 MENU: 10 APARLSTI1 MENU: 11 AMMAN 8-4 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 12 AMMANI1 MENU: 13 AMSVC MENU: 14 AMSVCI1 Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 15 ADIAG MENU: 16 AMPWR MENU: 17 AM1V 8-6 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 18 AMTEMP MENU: 19 AMMISC MENU: 20 AMTREND Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 21 ADIAGI1 MENU: 22 RANGESETAM MENU: 23 RANGESSETI1 8-8 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 24 LINRANGE1 MENU: 25 LINRANGE2 MENU: 26 LINRANGE3 Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 27 LINRANGE4 MENU: 28 LINRANGE0 MENU: 29 AMPWRI1 8-10 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 30 FLOCHEK1I1 MENU: 31 FILTER MENU: 32 AM1VI1 Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 33 AMTEMPI1 MENU: 34 AM2VA MENU: 35 PLIMITSA 8-12 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 36 TLIMITSA MENU: 37 AMMISCI1 MENU: 38 ANALSIMPLE Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 39 FILTERI1 MENU: 40 LINRANGE0I1 MENU: 41 PLIMITSAI1 8-14 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 42 CALFACTORS MENU: 43 R1FACTORS MENU: 44 RN2FACTORS Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 45 RN3FACTORS MENU: 46 RN4FACTORS MENU: 47 AMHELPINDEX 8-16 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 48 LINRANGE1I1 MENU: 49 CALFACTORSI1 MENU: 50 APARLST2 Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 51 APARLST4 MENU: 52 APARLST5 MENU: 53 APARLST6 8-18 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 54 IGNITION MENU: 55 LISTNOTES MENU: 56 LIGHTFLAMEI1 Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 57 AUTOFLAMEI1 MENU: 58 DISPLAY MENU: 59 MPARMS 8-20 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 60 AMTOPINFO MENU: 61 ANALSET2 MENU: 62 MPARMSI1 Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 63 TLIMITSAI1 MENU: 64 IGNITIONI1 MENU: 65 SELFTEST 8-22 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 66 AMHELPINDEX2 MENU: 67 SOFT_DIAG MENU: 68 CALI1 Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 69 AM2VC MENU: 70 AM2VD MENU: 71 OVENTEMP 8-24 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 72 LINFUNCT MENU: 73 POLYSETUP MENU: 74 MIDPOINT1 Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 75 POLYGAS1 MENU: 76 POLYSETI1 MENU: 77 POLYGAS2 8-26 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 78 POLYGAS3 MENU: 79 POLYGAS4 MENU: 80 POLYGAS5 Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 81 POLYGAS6 MENU: 82 POLYGAS7 MENU: 83 POLYGAS8 8-28 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 84 POLYGAS9 MENU: 85 POLYGAS0 MENU: 86 MIDPOINT2 Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 87 MIDPOINT3 MENU: 88 MIDPOINT4 MENU: 89 LIGHTFLAME 8-30 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 90 EXP_CAL MENU: 91 ZEROI2 MENU: 92 EXP_CAL_DAT Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 93 EXP_CAL_DATI MENU: 94 UNITS MENU: 95 UNITSI1 8-32 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 96 POLYSETI2 MENU: 97 POLYSETI3 MENU: 98 RESET Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 99 STORE MENU: 100 ANALOPI1A MENU: 101 RFHIST1A 8-34 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 102 RFACTORSIA MENU: 103 RFHIST2A MENU: 104 RFHIST3A Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 105 RFHIST4A MENU: 106 SW_DIAGI1 MENU: 107 TWEAKI1 8-36 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 108 ANALSETI3 MENU: 109 STOREDPVA MENU: 110 ZEROI2A Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 111 ZEROI1A MENU: 112 ZERO_NOW2 MENU: 113 SPAN_NOW2 8-38 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 114 AMMISC2 MENU: 115 MPARMS2 MENU: 116 AUTOFLAME Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID MENU: 117 REBOOT MENU: 118 ABOUT MENU: 119 ABOUT1 8-40 Appendix A - Menu Displays Rosemount Analytical Inc.
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Instruction Manual Model NGA 2000 HFID 760004-A February 2002 MENU: 120 ALARM1 MENU: 121 MANDATA Rosemount Analytical Inc.
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Instruction Manual 760004-A February 2002 8-42 Appendix A - Menu Displays Model NGA 2000 HFID Rosemount Analytical Inc.
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WARRANTY Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by Seller.
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Instruction Manual 760004-A February 2002 Model NGA 2000 HFID Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com Fisher-Rosemount GmbH & Co. Industriestrasse 1 63594 Hasselroth Germany T 49-6055-884 0 F 49-6055-884209 ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd.