ROSEMOUNT ANALYTICAL NGA2000 HEATED FLAME IONIZATION DETECTOR ANALYZER MODULE 748414-A
NOTICE The information contained in this document is subject to change without notice. This manual is based on the production version of the Heated Flame Ionization Detector Analyzer Module. Hardware and/or software changes may have occurred since this printing. Rosemount Analytical's NGA 2000 system of Modular Gas Analyzers and Controllers are patented, under U.S. Patent 5.787.015. Teflon® is a registered trademark of E.I. duPont de Nemours and Co., Inc.
CONTENTS PREFACE Purpose/Safety Summary.................................................................................P1 Glossary ....................................................................................................P4 Specifications - General ...................................................................................P6 Specifications - Gas Requirements ..................................................................P7 Specifications - Physical...................................
CONTENTS SECTION 2. INSTALLATION 2.1 Unpacking ................................................................................................. 5 2.2 Assembly .................................................................................................. 5 2.3 Location ................................................................................................... 5 2.4 Gases ................................................................................................... 6 2.4.1 Overview ......
CONTENTS SECTION 4. MAINTENANCE AND TROUBLESHOOTING 4.1 Overview....................................................................................................27 4.2 Component replacement ...........................................................................28 4.2.1 Oven ......................................................................................28 4.2.1.1 Oven Removal ...............................................................28 4.2.1.2 Oven Disassembly ............................
CONTENTS SECTION 5. REPLACEMENT PARTS 5.1 Replacement Parts ................................................................................... 61 5.1.1 General ..................................................................................... 61 5.1.2 Pneumatics ................................................................................... 61 5.1.3 Oven Components ........................................................................ 62 APPENDIX A.
CONTENTS FIGURES Figure 1-1. Figure 1-2. Figure 2-1. Figure 2-2. Figure 2-3. Figure 2-4. Figure 2-5. Figure 2-6. Figure 3-1. Figure 3-2. Figure 3-3. Figure 4-1. Figure 4-2. Figure 4-3. Figure 4-4. Figure 4-5. Figure 4-6. Figure4-7. Figure 4-8. Figure 4-9. Figure 4-10. Figure 4-11. Figure 4-12. Figure 4-13. Figure 4-14. Figure 4-15. Figure 4-16. Figure 4-17. Figure 4-18. Figure 4-19. Figure 4-20. Figure 4-21. Figure 4-22. 748414-A August 1999 Flame Ionization Detection Technology .........................
CONTENTS TABLES Table 3-1. HFID Analyzer Module Alarms........................................................
PREFACE PURPOSE/SAFETY SUMMARY The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of this particular NGA 2000 module. Some sections may describe equipment not used in your configuration. The user should become thoroughly familiar with the operation of this module before operating it. Read this instruction manual completely.
PREFACE WARNING: POSSIBLE EXPLOSION HAZARD This equipment is used in the analysis of sample gases which may be flammable, and the burner fuel used in the ionization process is flammable. A continuous dilution purge system is factory-installed (in accordance with Standard ANSI/NFPA 496-1993, Chapter 6, and it must be functional at all times during operation. Do not disable this purge system.
PREFACE CAUTION: PURGE AIR REQUIREMENT This Analyzer Module must be used in conjunction with a device (Control Module or PC Interface) that can actively monitor network variables related to pressure or flow of the continuous dilution purge, or the front panel LEDs of the Analyzer Module, as installed, must be visible. The purpose of this requirement is to maintain adherence to ANSI/NFPA 496 standard which assures the continued viability of the purge system.
PREFACE GLOSSARY 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.
PREFACE Power Supply Any of a variety of components that provides conditioned power to other NGA 2000 components, from the Power Supply Board that plugs into the front of the Backplane in a stand-alone instrument to several larger ones that can power larger collections of modules and components. 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.
PREFACE SPECIFICATIONS - 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 o o o o o o Adjustable from 200 F to 400 F (93 C to 204 C), maintained within ±11 F (±6 C) from the setpoint.
PREFACE SPECIFICATIONS - GAS REQUIREMENTS SAMPLE FLOW RATE Non-flammable, below 100% of LEL 1.0 to 2.5 L/min. PARTICULATES 345 to 620 hPa-gauge (5 to 9 psig) o o o o o 110oC to 230 C (230 F to 446 F), <20 C variance/24 hours, <10 C variance/hr. filtered to <2 microns DEWPOINT <15 C below the setpoint SUPPLY PRESSURE TEMPERATURE REGULATED AIR FLOW RATE o Instrument air or nitrogen 2 to 4 L/min.
PREFACE SPECIFICATIONS - PHYSICAL CASE CLASSIFICATION: General purpose for installation in weather-protected area MAXIMUM SEPARATION 1600m (1 mile) from Analyzer Module to Platform MATERIALS IN CONTACT WITH SAMPLE 1 Stainless steel and glass-filled Teflon DIMENSIONS See Outline and Mounting Dimensions, Figure 2-5 WEIGHT 15.9 kg (35 lbs.) MOUNTING Horizontally, custom-installed in a panel SPECIFICATIONS - GAS CONNECTIONS SAMPLE IN: 1/4" O.D. tube fitting, stainless steel REGULATED AIR IN: 1/4" O.D.
PREFACE SPECIFICATIONS - GAS CONNECTIONS (CONTINUED) PRESSURE RELIEF VALVE See Caution below . CAUTION: PRESSURE RELIEF VALVE No connection shall be made to this fitting. If this caution is ignored, damage to the case seals could occur, and the instrument will not operate properly. WARNING: HIGH TEMPERATURE The Sample In, Bypass Out, and Burner Exhaust Out connections can reach temperatures of up to 250°C (480°F). Severe burns could result from touching these connections.
PREFACE CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE For order administration, replacement Parts, application assistance, on-site or factory repair, service or maintenance contract information, contact: Rosemount Analytical Inc. Process Analytical Division Customer Service Center 1-800-433-6076 RETURNING PARTS TO THE FACTORY Before returning parts, contact the Customer Service Center and request a Returned Materials Authorization (RMA) number.
PREFACE DOCUMENTATION The following Heated Flame Ionization Detector Analyzre Module instruction materials are available. Contact Customer Service or the local representative to order.
PREFACE NOTES P12 Heated Flame Ionization Detector Analyzre Module Rosemount Analytical NGA 2000 748414-A August 1999
INTRODUCTION 1 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 Figures 1-1 and 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). The concentration is expressed in ppm or percent of volume.
1 INTRODUCTION A standard HFID Analyzer Module is only equipped to analyze a non-flammable sample, below 100% of the LEL. WARNING: POSSIBLE EXPLOSION HAZARD Protection against explosion depends upon a special fuel flow restrictor in the fuel inlet fitting. Do not remove fuel inlet restrictor. Do not use 100% hydrogen fuel. Replace only with a factory supplied fitting.
INTRODUCTION 1 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 (a hydrogen/diluent mixture) and air. Within the flame, the hydrocarbon components of the sample stream undergo a complex ionization that produces electrons and positive ions.
1 INTRODUCTION 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.
INSTALLATION 2 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. 2.2 ASSEMBLY If the Analyzer Module requires assembly with other components, do so at this time.
2 INSTALLATION 2.4 GASES 2.4.1 OVERVIEW During normal operation, the Analyzer Module requires fuel and air to maintain the burner flame as well as suitable standard gases for calibration and instrument air for purge requirements. In addition, instrument air for regulated air in is required to control the sample pressure at the sample capillary. Criteria for selection of these gases follow in section 2.4.3.
INSTALLATION ! WARNING Possible electric shock, explosion or toxic gas hazard.
2 INSTALLATION CAUTION: PURGE AIR REQUIREMENTS The front panel LEDs of the Analyzer Module, as installed, are not visible, the user should provide an indicator for the safety system as per ANSI/NFPA 496 standards. 2.4.3 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.
INSTALLATION 2 Span Gas - Span gas consists of a specified concentration of methane or other hydrocarbon in a background gas such as nitrogen. Analysis is affected by the background gas of the sample. Therefore, span gas containing the same background gas as the sample is recommended. Then, the background effect is canceled out. Sample Gas Sample gas should be nonflammable (below 100% of the sample's LEL). For high sensitivity applications requiring background gas compensation, contact the factory.
2 INSTALLATION Leak Test The analyzer module is completely leak tested at the factory. The user is responsible for testing for leakage at the inlet and outlet fittings on the rear panel. The user is also responsible for internal leak testing periodically and if any internal pneumatic components are adjusted or replaced (with a test procedure chosen by the user).
INSTALLATION 2.5 ELECTRICAL CONNECTIONS NETWORK1 Two electrical connections are required on the Analyzer Module: POWER and NETWORK (See Figure 2-3). 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. Connect Analyzer Module POWER to an external +24 VDC power source with a voltage tolerance of ±5% and a minimum power rating of 120 watts.
2 INSTALLATION 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] .9 [23] 3.2 [81] 1.0 [25] 2.4 [60] 3.1 3.0 [78] [75] Dimensions: INCHES [MM] FIGURE 2-5.
748414-A August 1999 COMPUTER ANALYSIS BOARD J1 J2 J3 P1 P2 P3 EI P1 E2 J1 PREAMP BOARD E3 OVEN RTD J1 POL VOL CABLE ASSEMBLY, IGNITOR P1 SENSOR ASSEMBLY, REF TEMP CABLE ASSEMBLY, OVEN HEATER SENSOR ASSEMBLY, FLAME OUT J18 P3 J3 P5 J5 P4 J4 J14 P15 J15 P16 J16 CABLE ASSEMBLY, SENSOR BD TO HARNESS P13 J13 J10 P10 P11 J11 J8 P8 J7 P7 J9 P9 J10 P10 J12 P12 J11 P11 J10 P10 J12 P12 SENSOR, FUEL PRESSURE ANODE OVEN HEATER CHASSIS GND SENSOR, AIR PRESSURE CATHODE GND ST
2 INSTALLATION 2.6 INSTALLATION CONSIDERATIONS CHECKLIST Verify the following: • The Analyzer’s location should be: Clean A well ventilated area weatherproofed Non-hazardous Vibration-free Have stable ambient temperature 14 • The gas cylinders should be equipped with a clean, hydrocarbon free two stage regulator and shut off valve. • All external tubing, regulators, valves, pumps, fittings, etc. are clean. • The correct fuel type is being used.
INSTALLATION • All external gas connections have been leak checked. • The dead volume for external sample and fuel lines have been minimized. • The stainless steel tubing used for the fuel and sample lines is clean.
2 INSTALLATION NOTES 16 Heated Flame Ionization Detector Analyzer Module Rosemount Analytical NGA 2000 748414-A August 1999
STARTUP AND OPERATION 3 3.1 OVERVIEW Prior to initial startup, the user should leak test the module as outlined in Section 2. For the remainder of this section, Analyzer Module interconnection with a control module or some interfacing component will be assumed operational. 3.2 STARTUP PROCEDURE WARNING: PRESSURIZED ENCLOSURE This enclosure shall not be opened unless the area is known to be free of flammable materials or unless all devices within have been de-energized.
3 STARTUP AND OPERATION the network to locate and identify all components on the network. The user will have to bind appropriate combinations of components after the startup sequence. (See section 3.3.) 7. Check the general health of the analyzer by reviewing the status of the Self Tests. All “Pass” conditions should be obtained. These test results can be found by selecting the following from the Main Menu: Technical Level Configuration, Diagnostic Menus, Analyzer Module Diagnostics, Self Test.
STARTUP AND OPERATION 3 The self-test can be repeated at any time by activating the TEST softkey in the Self Test Results menu. 8. Set the desired oven setpoint in the range of 93°C to 204°C (200°F to 400°F). 9. Wait for the Purge Air green LED to illuminate. 10. Introduce the remaining supply gases. Perform leak check. (See Specifications page(s) in the Preface section of this manual) 11. Set and verify the internal gas pressures.
3 STARTUP AND OPERATION 12. Manual or Auto-ignite the flame. The Flame-On green LED should be illuminated. Two methods of burner ignition are possible: auto-ignition and manual ignition. (Note: The burner is easier to ignite when the oven has reached the desired setpoint temperature.) Auto-ignition provides fuel override and three attempted ignitions (default setting), if necessary.
STARTUP AND OPERATION 3 15. Check and re-adjust the internal pressures if required. 16. The unit is ready for operation. 3.3 BINDING To achieve full coordination between Analyzer Modules and associated I/O Modules, the user must bind those components together in the System Set Up portion of the Technical Configuration Menu in software. 3.4 CALIBRATION Calibration gas setup is as follows: 1. Set oven temperature setpoint. 2. Apply regulated air at a pressure between 10 and 25 psig. 3.
3 STARTUP AND OPERATION 4. Verify the capillary type in the Analyzer Manufacturing Data menu (under the Technical Configuration menu structure, select the following from the Main Menu: Technical Level Configuration, Service Menus, Manufacturing Data, Analyzer Module Data). 5.
STARTUP AND OPERATION 4. 3 Enable Calibration Adjustment Limits in the Calibration Parameters menu. NOTE If the range selections straddle 725 ppm, CH4, the zero and span calibration for each range must be done separately. 3.5 ROUTINE OPERATION After case, oven, and sample temperature stabilization, calibration, and binding, proceed as follows: Supply heated sample gas to SAMPLE INLET.
3 STARTUP AND OPERATION 3.6 SAFETY SYSTEM The HFID Analyzer Module safety system will not allow ignition or continuous burner function unless the following conditions are present: • The internal purge gas pressure is at least 380 hPa - gauge (5.5 psig). (Monitor display message, Purge Gas Pressure in Physical Measurements menu, 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.
STARTUP AND OPERATION 3 1.0 0.8 0.6 AIR: 30 psig (2064 hPa) AIR: 20 psig (1376 hPa) AIR: 10 psig (688 hPa) RESPONSE (100 ppm CH4 fullscale) 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 0.8 FUEL: 25 psig (1726 hPa) H2 FUEL: 20 psig (1376 hPa) H2 0.6 RESPONSE (100 ppm CH4 fullscale) 0.
3 STARTUP AND OPERATION DISPLAY MESSAGE 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 Flame Temperature Fuel Pressure Linearizer Error Power Supply -15V Power Supply +10V REF Power Supply +15V Polarizing Volts Sample Pressure Calibration Error FID Purge Air Software Error AIR FET AIR PRESS BAIR FLOW BAROMETER BFUEL FLOW BLOCK FET CASE TEMP CRUDE NOISE C
MAINTENANCE AND TROUBLESHOOTING 4 WARNING: QUALIFIED PERSONNEL This equipment should not be adjusted or repaired by anyone except properly qualified service personnel. 4.1 OVERVIEW This section contains instructions and procedures for troubleshooting and maintaining the HFID analyzer module. To access the internal components of the analyzer module, perform the following: 1. Remove power to the unit; shut off gases and disconnect lines. Allow module to cool. 2. Refer to Figure 4-1.
4 MAINTENANCE AND TROUBLESHOOTING Figure 4-2 illustrates the locations of major components of the 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 COMPONENT REPLACEMENT 4.2.1 OVEN Though the oven can be replaced as a complete unit, all internal components are field replaceable. 4.2.1.
MAINTENANCE AND TROUBLESHOOTING 4 Oven Assembly 659551 FIGURE 4-3.
4 MAINTENANCE AND TROUBLESHOOTING 4.2.1.2 OVEN 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. Remove the nuts and ferrules from sample in and sample bypass out. CAUTION: PREAMP CONNECTORS The electrical preamp connectors are fragile, handle with care to avoid breaking solder connection. 4. Refer to Figure 4-4B.
MAINTENANCE AND TROUBLESHOOTING A 4 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. FIGURE 4-4.
4 MAINTENANCE AND TROUBLESHOOTING 4.2.2 BURNER SENSOR, DETECTORS AND IGNITOR This section covers burner components which can be replaced without removal of oven from the chassis. 4.2.2.1 TEMPERATURE SENSOR 1. Refer to Figure 4-4A. Remove the four screws on the oven cover, remove cover. 2. Refer to Figure 4-5. Remove the burner cap retainer. 3. Disconnect the temperature sensor wiring connector, note location. 4. Remove the temperature sensor. 5. Insert replacement sensor.
MAINTENANCE AND TROUBLESHOOTING 4 4. Install replacement ignitor and new o-ring. Using open-end wrench, snug down. Do not over-tighten! 5. Re-attach wiring connector. 6. Install oven cover 4.2.2.4 FLAMEOUT SENSOR 1. Refer to Figure 4-4A. Remove the four screws on the oven cover, remove cover. 2. Refer to Figure 4-5. Disconnect the flameout detector wiring connector, note location. 3. Lift up the burner cap until flameout sensor is accessible.
4 MAINTENANCE AND TROUBLESHOOTING 4.2.3 BURNER INTERNAL COMPONENTS WARNING: BURNER CONTAMINATION Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates. 4.2.3.1 DISASSEMBLY OF BURNER/THERMAL BLOCK 1. Remove oven from analyzer module per Section 4.2.1.1. 2. Remove burner/thermal block from oven per Section 4.2.1.2. 3. Refer to Figure 4-6. Disconnect sample capillary nut at base of burner. 4. Remove screw securing thermal block to burner. 5.
MAINTENANCE AND TROUBLESHOOTING 4 4.2.3.2 REPLACING BURNER JETS Disassemble the burner only if contaminants are evident. Combustion products or other contaminates which accumulate inside the burner may form electrical leakage paths between the collector and the burner contact, resulting in noisy readings. If the analyzer module is to be operated at the highest sensitivity, traces of such contaminates can cause erroneous readings.
4 MAINTENANCE AND TROUBLESHOOTING 7. Refer to Figure 4-8. Lift air baffle out of burner base. 8. Remove the sample jet and gasket from the bottom of the burner base. 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 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. Sample Jet 657005 ≈ .
MAINTENANCE AND TROUBLESHOOTING 4 Installation WARNING: BURNER CONTAMINATION Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates. 1. Install new lower gasket, jet assembly and upper gasket into burner base, finger-tight jet nut. 2. Install new sample jet (with gasket) and tighten. 3. Tighten jet nut. 4. Install air baffle per Figure 4-8. NOTE Incorrect installation of air baffle will cause ignition failure. 5. See Figure 4-7B.
4 MAINTENANCE AND TROUBLESHOOTING 4.2.4 THERMAL BLOCK The sample RTD can be replaced with the thermal block attached to burner and mounted in oven. The cartridge heater and thermostat are also replaceable with thermal block secured to burner, but must be removed from the oven. 4.2.4.1 SAMPLE RTD 1. Refer to Figure 4-4A. Remove the four screws securing the oven cover, remove cover. 2. Disconnect the sample RTD wiring connector, note location. 3. Refer to Figure 4-9.
MAINTENANCE AND TROUBLESHOOTING 4 4.2.4.2 CARTRIDGE HEATER 1. Remove oven from analyzer module per Section 4.2.1.1 2. Remove burner/thermal block from oven per Section 4.2.1.2. 3. Refer to Figure 4-9. Loosen retaining set screw, pull out cartridge heater. 4. Install replacement cartridge heater, snug down set screw. 5. Install burner/thermal block into oven. 6. Install oven into analyzer module. 4.2.4.3 THERMOSTAT 1. Remove oven from analyzer module per Section 4.2.1.1 2.
4 MAINTENANCE AND TROUBLESHOOTING Capillary Cover FIGURE 4-10.
MAINTENANCE AND TROUBLESHOOTING 4 4.2.5 ELECTRONICS ASSEMBLY The electronics assembly must be removed from the chassis if replacement of any of the following components is necessary: Power Supply Board Computer Analysis Board Sensor Board Case Pressure Switch Safety Board Preamp Assembly Case Temperature Sensor 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. Electronics Assembly 656943 Screw Hex Nut FIGURE 4-11.
4 MAINTENANCE AND TROUBLESHOOTING 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 4.2.5.1 PRINTED CIRCUIT BOARDS When replacing a circuit board, the following procedure is recommended: 42 1. Per Section 4.2.5, remove securing hardware from electronics assembly and lay on bench. 2.
MAINTENANCE AND TROUBLESHOOTING 4 4.2.5.2 CASE TEMPERATURE SENSOR 1. Per Section 4.2.5, remove securing hardware from electronics assembly and lay on bench. 2. Disconnect case temperature sensor cable. 3. Remove screw securing cable clamp holder to signal board. 4. Remove case temperature sensor from cable clamp holder. 5. Per Figure 4-13 insert replacement case temperature sensor into cable clamp holder. 6. Re-assemble to signal board mounting screw. Center sensor in cable clamp FIGURE 4-13.
4 MAINTENANCE AND TROUBLESHOOTING 4.2.5.3 CASE PRESSURE PURGE SWITCH 1. Per Section 4.2.5, remove securing hardware from electronics assembly and lay on bench. 2. Disconnect the two electrical terminals, note location. 3. Disconnect tube at pressure switch. 4. Remove mounting screws (2) and washers (2). 5. Reverse procedure for installation of replacement switch. Case Pressure Purge Switch 903690 The bracket does not have to be removed from the electronics assembly for this procedure.
MAINTENANCE AND TROUBLESHOOTING 4 4.2.5.4 PREAMP ASSEMBLY 1. Per Section 4.2.5, remove securing hardware from electronics assembly and lay on bench. 2. Disconnect and note location of cables. 3. Remove the two screws and washers from the top bracket and slide the preamp assembly out. 4. Remove the lower bracket from the preamp assembly and install on replacement preamp assembly. 5. Slide replacement preamp assembly into top bracket and secure with mounting hardware. 6. Re-connect cables.
4 MAINTENANCE AND TROUBLESHOOTING 4.2.6 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.
MAINTENANCE AND TROUBLESHOOTING 4 4.2.7 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.
4 MAINTENANCE AND TROUBLESHOOTING 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.
MAINTENANCE AND TROUBLESHOOTING 4 4.2.8 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.
4 MAINTENANCE AND TROUBLESHOOTING 4.2.
MAINTENANCE AND TROUBLESHOOTING 4 4.2.9.1 REPLACING FRONT PANEL COMPONENTS 1. To access components, remove the four front panel mounting screws (two on front, one on each side). 2. Remove the burner air regulator and fuel regulator mounting nuts. 3. Remove the purge air regulator mounting bracket screws. The front panel can now be pulled away from the chassis. NOTE The wiring from front panel components is still connected. Do not disconnect unless replacing that component.
4 MAINTENANCE AND TROUBLESHOOTING LON/POWER MODULE 1. Disconnect wiring connectors, note locations. 2. Refer to Figure 4-20. From the outside of the front panel, remove the two mounting screws. 3. Install replacement module in reverse order. LED INDICATOR ASSEMBLY 1. Disconnect wiring connector, note location. 2. Refer to Figure 4-20. From the inside of the front panel, remove the two hex nuts securing LED indicator assembly to front panel. Remove indicator assembly and o-rings (four). 3.
MAINTENANCE AND TROUBLESHOOTING 4 FUEL SENSOR 1. Disconnect wiring connector, note location. 2. Using an open-end wrench to hold the sensor fitting while using another open-end wrench to remove the sensor. 3. Replace the Teflon pipe thread tape on the treads of the sensor fitting. 4. Install sensor onto sensor fitting. 5. Re-connect wiring connector. BURNER AIR AND FUEL REGULATORS 1. Disconnect the two tubes and the sensor fitting on the rear of the regulator, note locations. 2.
4 MAINTENANCE AND TROUBLESHOOTING PURGE AIR FLOW SWITCH AND DIFFUSER 1. Unscrew flow switch from tee fitting. 2. Replace Teflon pipe thread tape on tee fitting. 3. Remove diffuser from flow switch and install into replacement flow switch. 4. Install replacement flow switch. 5. Install purge switch onto tee fitting. 6. Re-connect tubes. BURNER AIR SOLENOID VALVE 1. Disconnect the tube at the top elbow fitting. 2. Disconnect the tube at the tee fitting, remove valve analyzer module. 3.
MAINTENANCE AND TROUBLESHOOTING 4 4.2.
4 MAINTENANCE AND TROUBLESHOOTING FUEL IN 2-WAY SOLENOID VALVE 1. Disconnect wiring solenoid valve wiring connector, note location. 2. Inside the analyzer module, disconnect the tube going to the connector on the “out” port of the solenoid valve. 3. On the rear of the analyzer module at the fuel in port: a. Disconnect the fuel in tube. b. Remove nuts and washers. c. Remove solenoid valve from analyzer module 4. Remove the fittings from the solenoid valve and replace the Teflon pipe thread tape. 5.
MAINTENANCE AND TROUBLESHOOTING 4 5. Install elbow onto check valve. 6. Install check valve into female connector, verifying orientation of elbow fitting as shown in Figure 4-22.
4 MAINTENANCE AND TROUBLESHOOTING 4.3 TROUBLESHOOTING CHECKLIST 4.3.1 SAFETY SYSTEM 1. Verify purge supply pressure at bulkhead is between 10 and 20 psig. 2. Check case for leaks. 3. Check burner for leaks. 4. Verify purge pressure sensor tube connection. 5. Verify purge out port is vented to atmospheric pressure. 6. Verify Safety PCB connector J2 is attached. 7. Check for a +24V power glitch. 8. Verify that there is no large vibration shock. 9. Check for external leak in purge line. 10.
MAINTENANCE AND TROUBLESHOOTING 4 7. Verify auto-ignite parameters are properly set. 8. Verify burner is properly sealed. 9. Verify quality of air supply is good. 10. Verify quality of fuel supply is good. 11. Check burner tip for damage. 12. Check air and fuel restrictor for correct flow. 13. Check burner tip alignment. 14. Verify burner cone is tight. 15. Check burner air and fuel lines for leaks. 16. Verify oven temperature is greater than 85°C. 17.
4 MAINTENANCE AND TROUBLESHOOTING 4.3.4 NOISE 1. Check that the burner exhaust is free from water condensation. 2. Verify connection to the collector is correct. 3. Verify connection to the polarizing voltage is correct. 4. Check the ambient temperature is changing <10°C per hour. 5. Verify the +24VDC is clean and grounded properly. 6. Verify there are no strong magnetic fields near. 7. Check for excessive vibration. 8. Verify burner exhaust is vented to a constant atmospheric pressure. 9.
REPLACEMENT 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 5.1.
5 REPLACEMENT PARTS 5.1.3 OVEN COMPONENTS 659551 62 Oven Assembly 657359 Burner Assembly 657205 Ignitor Assembly 903736 O-Ring (Ignitor Assembly) 657063 RTD Detector 903125 Set Screw M3X0.5 x 10mm (RTD Detector) 657468 Temperature Sensor 657199 Flameout Sensor 903737 O-Ring (Flameout Sensor) 656931 Gasket 904373 O-Ring 102260 Air Baffle 657016 Jet Nut 102273 Gasket 657012 Jet Assembly 102256 Gasket 657005 Sample Jet 659614 Thermal Block Assembly 657486 Capillary, Mixed Fuel (Lo) 9.7 cc/min @ 3.
HFID IDENTIFICATION MATRIX A 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. The 12position sales matrix identifier number appears on the analyzer name-rating plate.
A HFID IDENTIFICATION MATRIX NOTES A2 Heated Flame Ionization Detector Analyzer Module Rosemount Analytical NGA 2000 748414-A August 1999
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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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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FIELD SERVICE AND REPAIR FACILITIES Field service and repair facilities are located worldwide. U.S.A. To obtain field service on-site or assistance with a service problem, contact (24 hours, 7 days a week): National Response Center 1-800-654-7768 INTERNATIONAL Contact your local Rosemount Sales and Service office for service support.
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INSTRUCTIONS 015-748434-A Rosemount Analytical ADDENDUM HFID INSTRUCTION MANUAL 748414 This addendum serves as an amendment to the HFID Instruction Manual 748414. The following information should be considered part of the manual, and supersedes any conflicting information in the body of the manual. Read this information and note the conflicts. MENU DISPLAYS Menu: 0 ANALOP Menu: 1 ANALSET Rosemount Analytical Inc.
ADDENDUM MENU: 2 FLOCHEK MENU: 3 FLOCHEKI1 MENU: 4 ACALSET 2 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 5 APARLST MENU: 6 ANALSETI1 MENU: 7 CALLIST 748434-A August 1999 Rosemount Analytical 3 of 42
ADDENDUM MENU: 8 CALLISTI1 MENU: 9 ACALSETI1 MENU: 10 APARLSTI1 4 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 11 AMMAN MENU: 12 AMMANI1 MENU: 13 AMSVC 748434-A August 1999 Rosemount Analytical 5 of 42
ADDENDUM MENU: 14 AMSVCI1 MENU: 15 ADIAG MENU: 16 AMPWR 6 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 17 AM1V MENU: 18 AMTEMP MENU: 19 AMMISC 748434-A August 1999 Rosemount Analytical 7 of 42
ADDENDUM MENU: 20 AMTREND MENU: 21 ADIAGI1 MENU: 22 RANGESETAM 8 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 23 RANGESSETI1 MENU: 24 LINRANGE1 MENU: 25 LINRANGE2 748434-A August 1999 Rosemount Analytical 9 of 42
ADDENDUM MENU: 26 LINRANGE3 MENU: 27 LINRANGE4 MENU: 28 LINRANGE0 10 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 29 AMPWRI1 MENU: 30 FLOCHEK1I1 MENU: 31 FILTER 748434-A August 1999 Rosemount Analytical 11 of 42
ADDENDUM MENU: 32 AM1VI1 MENU: 33 AMTEMPI1 MENU: 34 AM2VA 12 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 35 PLIMITSA MENU: 36 TLIMITSA MENU: 37 AMMISCI1 748434-A August 1999 Rosemount Analytical 13 of 42
ADDENDUM MENU: 38 ANALSIMPLE MENU: 39 FILTERI1 MENU: 40 LINRANGE0I1 14 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 41 PLIMITSAI1 MENU: 42 CALFACTORS MENU: 43 R1FACTORS 748434-A August 1999 Rosemount Analytical 15 of 42
ADDENDUM MENU: 44 RN2FACTORS MENU: 45 RN3FACTORS MENU: 46 RN4FACTORS 16 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 47 AMHELPINDEX MENU: 48 LINRANGE1I1 MENU: 49 CALFACTORSI1 748434-A August 1999 Rosemount Analytical 17 of 42
ADDENDUM MENU: 50 APARLST2 MENU: 51 APARLST4 MENU: 52 APARLST5 18 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 53 APARLST6 MENU: 54 IGNITION MENU: 55 LISTNOTES 748434-A August 1999 Rosemount Analytical 19 of 42
ADDENDUM MENU: 56 LIGHTFLAMEI1 MENU: 57 AUTOFLAMEI1 MENU: 58 DISPLAY 20 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 59 MPARMS MENU: 60 AMTOPINFO MENU: 61 ANALSET2 748434-A August 1999 Rosemount Analytical 21 of 42
ADDENDUM MENU: 62 MPARMSI1 MENU: 63 TLIMITSAI1 MENU: 64 IGNITIONI1 22 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 65 SELFTEST MENU: 66 AMHELPINDEX2 MENU: 67 SOFT_DIAG 748434-A August 1999 Rosemount Analytical 23 of 42
ADDENDUM MENU: 68 CALI1 MENU: 69 AM2VC MENU: 70 AM2VD 24 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 71 OVENTEMP MENU: 72 LINFUNCT MENU: 73 POLYSETUP 748434-A August 1999 Rosemount Analytical 25 of 42
ADDENDUM MENU: 74 MIDPOINT1 MENU: 75 POLYGAS1 MENU: 76 POLYSETI1 26 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 77 POLYGAS2 MENU: 78 POLYGAS3 MENU: 79 POLYGAS4 748434-A August 1999 Rosemount Analytical 27 of 42
ADDENDUM MENU: 80 POLYGAS5 MENU: 81 POLYGAS6 MENU: 82 POLYGAS7 28 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 83 POLYGAS8 MENU: 84 POLYGAS9 MENU: 85 POLYGAS0 748434-A August 1999 Rosemount Analytical 29 of 42
ADDENDUM MENU: 86 MIDPOINT2 MENU: 87 MIDPOINT3 MENU: 88 MIDPOINT4 30 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 89 LIGHTFLAME MENU: 90 EXP_CAL MENU: 91 ZEROI2 748434-A August 1999 Rosemount Analytical 31 of 42
ADDENDUM MENU: 92 EXP_CAL_DAT MENU: 93 EXP_CAL_DATI MENU: 94 UNITS 32 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 95 UNITSI1 MENU: 96 POLYSETI2 MENU: 97 POLYSETI3 748434-A August 1999 Rosemount Analytical 33 of 42
ADDENDUM MENU: 98 RESET MENU: 99 STORE MENU: 100 ANALOPI1A 34 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 101 RFHIST1A MENU: 102 RFACTORSIA MENU: 103 RFHIST2A 748434-A August 1999 Rosemount Analytical 35 of 42
ADDENDUM MENU: 104 RFHIST3A MENU: 105 RFHIST4A MENU: 106 SW_DIAGI1 36 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 107 TWEAKI1 MENU: 108 ANALSETI3 MENU: 109 STOREDPVA 748434-A August 1999 Rosemount Analytical 37 of 42
ADDENDUM MENU: 110 ZEROI2A MENU: 111 ZEROI1A MENU: 112 ZERO_NOW2 38 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 113 SPAN_NOW2 MENU: 114 AMMISC2 MENU: 115 MPARMS2 748434-A August 1999 Rosemount Analytical 39 of 42
ADDENDUM MENU: 116 AUTOFLAME MENU: 117 REBOOT MENU: 118 ABOUT 40 of 42 Rosemount Analytical August 1999 748434-A
ADDENDUM MENU: 119 ABOUT1 MENU: 120 ALARM1 MENU: 121 MANDATA 748434-A August 1999 Rosemount Analytical 41 of 42
ADDENDUM NOTES 42 of 42 Rosemount Analytical August 1999 748434-A
