Emerson ROSEMOUNT NGA2000 HFID Instruction Manual

Heated flame ionisation detector analyzer module
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Instruction Manual
748297-E
June 2003
Model NGA2000 HFID
Heated Flame Ionization Detector Analyzer Module
http://www.processanalytic.com

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  • Page 1 Instruction Manual 748297-E June 2003 Model NGA2000 HFID Heated Flame Ionization Detector Analyzer Module http://www.processanalytic.com...
  • Page 2 The information contained in this document is subject to change without notice. ® Teflon is a registered trademark of E.I. duPont de Nemours and Co., Inc. Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH 44667-0901...
  • Page 3: Table Of Contents

    Electrical Connections ...2-6 Installation Considerations Checklist...2-9 STARTUP AND OPERATION ...3-1 overview...3-1 Startup Procedure ...3-1 Binding...3-4 Calibration...3-4 Routine Operation ...3-5 Safety System ...3-6 Rosemount Analytical Inc. A Division of Emerson Process Management TABLE OF CONTENTS Instruction Manual 748297-E June 2003 Contents...
  • Page 4 Matrix ...5-1 Replacement Parts ...5-2 a. General ...5-2 b. Pneumatics ...5-2 c. Oven Components ...5-3 RETURN OF MATERIAL ...6-1 Return Of Material ...6-1 Customer Service ...6-1 Training...6-1 Contents Model NGA2000 HFID Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 5 Figure 4-21. Accessing Front Panel Components ... 4-23 Figure 4-22. Rear Panel Components ... 4-27 Table 3-1. HFID Analyzer Module Alarms ... 3-8 Rosemount Analytical Inc. A Division of Emerson Process Management LIST OF ILLUSTRATIONS LIST OF TABLES Instruction Manual 748297-E...
  • Page 6 Instruction Manual 748297-E Model NGA2000 HFID June 2003 Contents Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 7: Preface

    Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness. Highlights an essential operating procedure, condition or statement. Rosemount Analytical Inc. A Division of Emerson Process Management PREFACE DEFINITIONS DANGER WARNING CAUTION.
  • Page 8: Safety Summary

    DO NOT RESTRICT THOSE VENTS.. Consult the factory if flammable samples will be measured. Preface SAFETY SUMMARY AUTHORIZED PERSONNEL DANGER. ELECTRICAL SHOCK HAZARD WARNING POSSIBLE EXPLOSION HAZARD WARNING FLAMMABLE SAMPLES Rosemount Analytical Inc. Model NGA2000 HFID A Division of Emerson Process Management...
  • Page 9 This module requires calibration with a known standard gas. See General Precautions for Handling and Storing High Pressure Gas Cylinders on page P-5. Rosemount Analytical Inc. A Division of Emerson Process Management WARNING. HIGH TEMPERATURE NOTE...
  • Page 10: Instruction Manual

    6 (six) minutes at the minimum pressure of 689 hPa (10 psig) Preface Model NGA2000 HFID WARNING POSSIBLE EXPLOSION HAZARD CAUTION OVER-VOLTAGE SPIKING WARNING PRESSURIZED ENCLOSURE HOT INTERNAL PARTS Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 11: General Precautions For Handling And Storing High Pressure Gas Cylinders

    8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding, precautions must be taken to prevent striking an arc against the cylinder. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748297-E...
  • Page 12: Documentation

    This product satisfies all obligations of all relevant standards of the EMC framework in Australia and New Zealand. Preface DOCUMENTATION COMPLIANCES ® NAMUR N 9 6 Rosemount Analytical Inc. Model NGA2000 HFID Contact Customer Service Center or the 97-C219 A Division of Emerson Process Management...
  • Page 13: Glossary

    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, source voltage and other diagnostic information. Rosemount Analytical Inc. A Division of Emerson Process Management Preface...
  • Page 14 The five function keys located below the front panel display; they assume the function displayed directly above each on the display, a function dictated by software. System Any collection of Analyzer Module(s), Platform(s), I/O Module(s) and Expansion Module(s). Preface Model NGA2000 HFID Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 15: Description And Specifications

    TYPICAL APPLICATIONS The monitoring of atmospheric air for low-level hydrocarbon contaminants and determining the hydrocarbon content of exhaust emissions Figure 1-1. Rosemount Analytical Inc. A Division of Emerson Process Management SECTION 1 +90V Sample Flame Ionization Detection Technology Instruction Manual...
  • Page 16: Gas Safety Features

    Do not remove fuel inlet restrictor. Do not use 100% hydrogen fuel. Replace only with a factory supplied fit- ting. Rosemount Analytical Inc. A Division of Emerson Process Management /60%...
  • Page 17: Figure 1-2. Heated Flame Ionization Detector Analyzer Module - Top View

    Burner Air Solenoid Valve Burner Air & Fuel Regulators (Stacked Vertically) Figure 1-2. Heated Flame Ionization Detector Analyzer Module – Top View Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748297-E June 2003 Purge Air Outlet Detector (Burner)
  • Page 18: Specifications

    10 C/hr. Rosemount Analytical Inc. A Division of Emerson Process Management at an oven setpoint between at an oven setpoint C to 204 C), maintained within...
  • Page 19: Gas Requirements

    Dimensions... See Outline and Mounting Dimensions, Figure 2-5 on page 2-7 Weight ... 15.9 kg (35 lbs.) Mounting... Horizontally, custom-installed in a panel Rosemount Analytical Inc. A Division of Emerson Process Management C to 230 C (230 F to 446 F), <20...
  • Page 20: Gas Connections

    Preface of the I/O Module manual for specifications regarding I/O (e.g., relay outputs. Description and Specifications Model NGA2000 HFID min. from horizontal) Note CAUTION PRESSURE RELIEF VALVE WARNING HIGH TEMPERATURE Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 21: Installation

    45°C wet bulb temperature. The cylinders of fuel, air, and calibration gas(es) and the source of purge and regulated air Rosemount Analytical Inc. A Division of Emerson Process Management SECTION 2 INSTALLATION should be located in an area of relatively constant ambient temperature.
  • Page 22 PRESSURE FUEL: 50 psig(3445 hPa) BURNER AIR: 50 psig (3445 hPa) SAMPLE: 8 psig (551 hPa) PURGE AIR: 20 psig (1378 hPa) REG AIR: 25 psig (1722 hPa) PRESSURE RELIEF VALVE HEATED SAMPLE IN A Division of Emerson Process Management...
  • Page 23: Pneumatic Connections

    Module, as installed, are not visible, the user should provide an indicator for the safety system as per ANSI/NFPA 496 standards. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual Fuel Gas Specification Standard analysis usually requires mixed fuel, i.e., 40% ±2%) hydrogen and 60% helium.
  • Page 24: Sample Gas Specification

    The user is also responsible for internal leak testing periodically and if any inter- nal pneumatic components are adjusted or replaced (with a test procedure cho- sen by the user). Rosemount Analytical Inc. A Division of Emerson Process Management CAUTION Note...
  • Page 25 COPPER PRESSURE SENSOR, REGULATED AIR 0 - 15 PSIG ELBOW 1/4T - 1/4MPT BRASS FIXED FLOW CONTROLLER, REGULATED AIR Rosemount Analytical Inc. A Division of Emerson Process Management BULKHEAD PRESSURE RESTRICTOR HEATED SAMPLE BURNER 1/4T - 1/4T SAMPLE BYPASS EXHAUST...
  • Page 26: Electrical Connections

    3 GND inflammable avant d ′ avoir pris connaissance des instructions contenues dans le manuel. Le non respect de ces instructions T 6A peut entrainer une explosion provoquant des blessure graves 250 V ou mortelles. A Division of Emerson Process Management...
  • Page 27: Figure 2-5. Hfid Outline And Mounting Dimensions

    FRONT VIEW [110] SIDE VIEW [6] DIA [17] REAR VIEW [35] [81] [83] Dimensions: INCHES [MM] Figure 2-5. Rosemount Analytical Inc. A Division of Emerson Process Management [208] [174] [28] [51] [152] 22.5 [571] [183] [137] [107] [103] [52] [27]...
  • Page 28 Figure 2-6. HFID Wiring Diagram Rosemount Analytical Inc. Model NGA2000 HFID SWITCH ASSEMBLY, MANUAL IGNITE POWER MODULE ASSEMBLY SENSOR, SENSOR, SENSOR, FUEL SAMPLE PRESSURE PRESSURE PRESSURE SENSOR BOARD OVEN CABLE ASSEMBLY, IGNITOR DETECTOR BLOCK ASSEMBLY A Division of Emerson Process Management...
  • Page 29: Installation Considerations Checklist

    The burner exhaust tube must be slanted down a minimum of 6 degrees from horizontal. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual • The bypass line connection must be slanted down a minimum of 6 degrees from horizontal for drainage of water condensation.
  • Page 30 Instruction Manual 748297-E Model NGA2000 HFID June 2003 Installation Rosemount Analytical Inc. A Division of Emerson Process Management 2-10...
  • Page 31: Startup And Operation

    2. Turn ON the purge gas only. Perform a leak check. Wait a minimum of 6 min- utes. Rosemount Analytical Inc. A Division of Emerson Process Management SECTION 3 3. Connect the LON cable(s) and the +24VDC power cable. 4. Turn power ON.
  • Page 32 11. Set and verify the internal gas pres- sures. TYPICAL OPERATING PRESSURES 965 to 1103 hPa-gauge (14 to 16 psig) 1516 to 1723 hPa-gauge (22 to 25 psig) 206 to 290 hPa-gauge (3.0 to 4.0 psig) Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 33 ON in "Light Flame" dis- play screen under Basic Controls and oven temperature must be at least 85°C. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual The manual ignition switch on the Ana- lyzer Module front panel must be ma- nipulated in the following ways: •...
  • Page 34: Binding

    8. Repeat steps 6 and 7. 9. Press the HOME softkey to re-enter the Main Menu. 10. Press DISPLAY softkey for the Run Mode display. Rosemount Analytical Inc. A Division of Emerson Process Management ), 1.0, ethane (C ), 3.00. These fac-...
  • Page 35: Routine Operation

    After case, oven, and sample temperature stabilization, calibration, and binding, proceed as follows: Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual Supply heated sample gas to SAMPLE INLET. Adjust external flow controller or throt- tle valve so that the sample inlet pressure is between 5 and 9 psig, 7 psig nominal.
  • Page 36: Safety System

    All front and rear panel screws must be installed. Do not over-torque rear panel screws. Rosemount Analytical Inc. A Division of Emerson Process Management Note...
  • Page 37: Figure 3-1. Typical Curves Of Module Response Vs. Pressure Setting On Fuel Pressure Regulator

    Figure 3-2. Typical Curves of Module Response vs. Pressure Setting on Air Pressure Regulator Rosemount Analytical Inc. A Division of Emerson Process Management FUEL PRESSURE FUEL: 30 psig (2064 hPa) H FUEL: 25 psig (1726 hPa) H FUEL: 20 psig (1376 hPa) H...
  • Page 38 Screw #4, 4 to 5 turns Screw #5, 4 to 5 turns Screw #6, 4 to 5 turns Repeat torque sequence until all screws are tight. The gasket must fill in between the front panel plate and the enclosure. A Division of Emerson Process Management...
  • Page 39: Maintenance And Troubleshooting

    HEATED SAMPLE BYPASS Cover/Rear Panel Securing Screws (6) Figure 4-1. Rosemount Analytical Inc. A Division of Emerson Process Management SECTION 4 1. Remove power to the unit; shut off gases and disconnect lines. Allow mod- ule to cool. 2. Refer to Figure 4-1 below. Remove the...
  • Page 40: Figure 4-2. Locations Of Major Assemblies Of The Hfid

    Fixed Flow Controller Assembly 657434 Figure 4-2. Maintenance and Troubleshooting Model NGA2000 HFID Electronics Assembly 656943 Locations of Major Assemblies of the HFID Rosemount Analytical Inc. DC Power Supply Module Assembly 657413 Front Panel Assembly 656949 A Division of Emerson Process Management...
  • Page 41: Component Replacement

    Refer to Figure 4-3 below, disconnect the oven's three gas lines and seven electri- Figure 4-3. Rosemount Analytical Inc. A Division of Emerson Process Management cal cables, noting location of mating con- nectors for re-installation. DO NOT remove the fittings from the gas lines on the detector.
  • Page 42: Burner Sensor, Detectors And Ignitor

    4. Gently grasp RTD detector wires and pull out of hole. 5. Insert replacement RTD detector into hole, snug down set screw. 6. Re-attach wiring connector. 7. Install oven cover. Rosemount Analytical Inc. A Division of Emerson Process Management Note...
  • Page 43 Outer Oven Outer Oven Front Panel 657356 For clarity, outer oven not shown in Figures B and C. Rosemount Analytical Inc. A Division of Emerson Process Management Oven Cover 657105 (with insulation 657346) Inner Oven Retaining Screw (2) and Washer (2)
  • Page 44: Figure 4-5. Burner - Sensor, Flameout Detector, Rtd Detector And Ignitor

    4. Install replacement flameout detector and new o-ring. Using open-end wrench, snug down. Do not over- tighten! 5. Re-attach wiring connector. 6. Install oven cover. O-Ring 903737 Flameout Sensor 657199 A Division of Emerson Process Management...
  • Page 45: Burner Internal Components

    Section 4-2a on page 4-3. Thermal Block Figure 4-6. Rosemount Analytical Inc. A Division of Emerson Process Management 2. Remove burner/thermal block from oven per Section 4-2b on page 4-4. 3. Refer to Figure 4-6 below. Discon- nect sample capillary nut at base of burner.
  • Page 46 3. Remove thermal block from burner per Section 4-2c on page 4-7. 4. Refer to Figure 4-7A below. Remove screws (2) holding burner cap re- tainer, remove retainer. Combustion Chamber O-Ring 904373 Burner Base A Division of Emerson Process Management...
  • Page 47 Sample Jet 657005 Rosemount Analytical Inc. A Division of Emerson Process Management 8. Refer to Figure 4-8 below. Lift air baf- 9. Remove the sample jet and gasket 10. Remove the jet nut. Grasp jet as-...
  • Page 48 7. See Figure 4-7A on page 4-8. Insert new gasket on combustion chamber, install burner cap and burner cap re- tainer, torque screws to 6 inch lbs. Rosemount Analytical Inc. A Division of Emerson Process Management Note...
  • Page 49: Thermal Block

    2. Remove burner/thermal block from oven per Section 4-2b on page 4-4. Rosemount Analytical Inc. A Division of Emerson Process Management 2. Disconnect the sample RTD wiring 3. Refer to Figure 4-9 below. Remove 4. Install replacement sample RTD, se- 5.
  • Page 50: Figure 4-10. Thermal Block Assembly

    5. Remove capillary nut, remove capil- lary. 6. Install replacement capillary. 7. Insert capillary into thermal block. The capillary may require bending to fit. 8. Install cover. Capillary Cover A Division of Emerson Process Management...
  • Page 51: Electronics Assembly

    Sensor Board Case Temperature Sensor Case Pressure Switch Figure 4-11. Rosemount Analytical Inc. A Division of Emerson Process Management 1. Remove the hex nut and screw as 2. Lay electronics assembly on bench, Screw Removing Electronics Assembly from Chassis Instruction Manual...
  • Page 52: Figure 4-12. Electronics Assembly – Exploded View

    Electronics Assembly – Exploded View Rosemount Analytical Inc. Model NGA2000 HFID Power Supply Board 655764 3. One at a time, remove the wiring con- nectors and attach to replacement board. Mount replacement board to electronics assembly. A Division of Emerson Process Management...
  • Page 53 3. Remove screw securing cable clamp holder to signal board. Figure 4-13. Rosemount Analytical Inc. A Division of Emerson Process Management 4. Remove case temperature sensor from cable clamp holder. 5. Per Figure 4-13 below insert re- placement case temperature sensor into cable clamp holder.
  • Page 54: Figure 4-14. Case Pressure Purge Switch Installation

    Maintenance and Troubleshooting Model NGA2000 HFID 3. Disconnect tube at pressure switch. 4. Remove mounting screws (2) and washers (2). Reverse procedure for installation of re- placement switch. Case Pressure Purge Switch Installation Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 55: Figure 4-15. Preamp Assembly Installation

    Top Bracket Preamp Assembly 656945 Figure 4-15. Rosemount Analytical Inc. A Division of Emerson Process Management 4. Remove the lower bracket from the 5. Slide replacement preamp assembly 6. Re-connect cables. Bottom Bracket Preamp Assembly Installation Instruction Manual...
  • Page 56: Fan Assembly

    Maintenance and Troubleshooting Fan Assembly 657414 Figure 4-16. Fan Assembly Installation Rosemount Analytical Inc. Model NGA2000 HFID 2. Remove the two hex nuts securing the fan to the chassis, lift fan as- sembly out. A Division of Emerson Process Management...
  • Page 57: Flow Controller

    Model NGA2000 HFID Flow Controller 1. Disconnect the all tubing and wiring connectors, note locations. Rosemount Analytical Inc. A Division of Emerson Process Management Figure 4-17. Flow Controller Replacement Instruction Manual 748297-E June 2003 2. Remove the four hex nuts securing the flow controller assembly to the analyzer module chassis.
  • Page 58: Figure 4-18. Flow Controller Assembly - Exploded View

    Maintenance and Troubleshooting Regulated Air In Remove red cap after installation Flow Controller Assembly – Exploded View Rosemount Analytical Inc. Model NGA2000 HFID Regulator 250 psi 023382 FLOW Regulated Air Out Sample Sensor 656418 A Division of Emerson Process Management...
  • Page 59: Dc Power Supply Module

    DC Power Supply Module module to chassis, remove module. 1. Disconnect and note location of all wiring to DC power supply module. Figure 4-19. DC Power Supply Module Replacement Rosemount Analytical Inc. A Division of Emerson Process Management Maintenance and Troubleshooting 4-21...
  • Page 60: Front Panel Components

    Fuel Regulator Burner Air Sensor Fuel Sensor Air Ignite Restrictor Air Measurement Restrictor Regulator Mounting Nut Regulator Mounting Bracket LON/Power Module 656560 Plugs O-Ring LED Indicator Assembly 010177 657029 O-Ring 011167 Toggle Switch Seal 898980 A Division of Emerson Process Management...
  • Page 61: Figure 4-21. Accessing Front Panel Components

    3. Remove the purge air regulator mounting bracket screws. Figure 4-21. Rosemount Analytical Inc. A Division of Emerson Process Management 4. The front panel can now be pulled away from the chassis. The wiring from front panel compo- nents is still connected. Do not dis- connect unless replacing that component.
  • Page 62 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. Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 63 7. Install mounting bracket onto regula- tor, hand snug mounting nut. 8. Attach mounting bracket to front panel, tighten regulator mounting nut. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual 748297-E June 2003 Purge Air Flow Switch and Diffuser 1.
  • Page 64 2. Disconnect tube going to air ignite re- strictor. 3. Remove restrictor from solenoid valve. 4. Add Teflon pipe thread tape to re- placement restrictor, install into sole- noid. 5. Re-connect tubes to restrictor, elbow and tee fitting. Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 65: Rear Panel Components

    VIEW FROM OUTSIDE ANALYZER MODULE Filter, Burner Air In 017154 Restrictor, Heated Sample Bypass Out – 10 Micron 619615 Rosemount Analytical Inc. A Division of Emerson Process Management Solenoid Valve, Fuel In 656218 Restrictor, Heated Sample In – 40 Micron 619616 Figure 4-22.
  • Page 66 4. Add Teflon pipe thread tape to check valve threads. 5. Install elbow onto check valve. 6. Install check valve into female con- nector, verifying orientation of elbow fitting as shown in Figure 4-22 on page 4-27. Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 67: Troubleshooting Checklist

    15. Verify Internal purge pressure is greater than 5.5 psig. 16. Verify the purge gas switch has been activated. Rosemount Analytical Inc. A Division of Emerson Process Management Instruction Manual Ignition 1. Verify that the fuel pressure/flow is correct. 2. Verify that the burner air pres- sure/flow is correct.
  • Page 68: Drift

    10. Verify purge out port vented to a constant atmospheric pressure. 11. Verify the collector wires are routed away from the heater. 12. Verify the collector wires are clean and not damaged. Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 69: Replacement Parts

    Software Version Standard 2.3 Version Software Special Code HFID Rosemount Analytical Inc. A Division of Emerson Process Management SECTION 5 REPLACEMENT PARTS WARNING PARTS INTEGRITY Configuration Identifier Mixed Fuel, 4 Selectable Ranges: 0-10 to 0-10,000 ppm CH Mixed Fuel, 4 Selectable Ranges: 0-100 to 0-10,000 ppm CH...
  • Page 70: Replacement Parts

    Regulated Air In Check Valve 903647 Case Pressure Relief Valve Replacement Parts Computer Board Preamp Assembly Safety Board Power Supply Board Sensor Board Case Temperature Sensor Regulator 250 psi Sample Sensor Rosemount Analytical Inc. Model NGA2000 HFID A Division of Emerson Process Management...
  • Page 71: Oven Components

    Model NGA2000 HFID Oven Components 659551 Oven Assembly 657359 659614 Rosemount Analytical Inc. A Division of Emerson Process Management Burner Assembly 657205 Ignitor Assembly 903736 O-Ring (Ignitor Assembly) 657063 RTD Detector 903125 Set Screw M3X0.5 x 10mm (RTD Detector) 657468...
  • Page 72 Instruction Manual 748297-E Model NGA2000 HFID June 2003 Replacement Parts Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 73: Return Of Material

    Rosemount Analytical Inc. Process Analytic Division Customer Service Center 1-800-433-6076 Rosemount Analytical Inc. A Division of Emerson Process Management SECTION 6 RETURN OF MATERIAL If warranty service is expected, the defective unit will be carefully inspected and tested at the factory. If the failure was due to the condi-...
  • Page 74 Instruction Manual 748297-E Model NGA2000 HFID June 2003 Return of Material Rosemount Analytical Inc. A Division of Emerson Process Management...
  • Page 75 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.
  • Page 76 Instruction Manual 748297-E June 2003 EMERSON PROCESS MANAGEMENT EUROPEAN TECHNOLOGY CENTER Rosemount Analytical Inc. Process Analytic Division Fisher-Rosemount GmbH & Co. 1201 N. Main St. Industriestrasse 1 Orrville, OH 44667-0901 63594 Hasselroth T (330) 682-9010 Germany F (330) 684-4434 T 49-6055-884 0 F 49-6055-884209 E gas.csc@emersonprocess.com...

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