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Emerson Process Management NGA2000 User's Manual

1. Figure 4 2 Power Fuse Location 4 2 Maintenance and Troubleshooting Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model NGA2000 NDIR oe 4 4 MODULE FAN REPLACEMENT The Analyzer Module fan assembly is Before doing so the entire optical bench must disassembled as shown in Figure 4 3 below be removed See Figure 4 50n page 4 5 AIR FLOW Figure 4 3 Fan Assembly Rosemount Analytical Inc A Division of Emerson Process Management Maintenance and Troubleshooting 4 3 Instruction Manual 748332 F April 2003 4 5 CHOPPER MOTOR REPLACEMENT See Figure 4 4 below for a exploded view of the Motor Source Assembly The entire optical bench must be removed to perform this replacement Housing Assembly Source Assemblies see detail below Assembly Ref Source Assemblies 2c eo Screw Source Case Lock Washer Insulator Insulator Source Figure 4 4 4 4 Maintenance and Troubleshooting Chopper Ref Housing Model NGA2000 NDIR 4 6 SOURCE REPLACEMENT See Figure 4 4 below for a exploded view of the Motor Source Assembly The entire optical bench must be removed to perform this replacement Dual Cap Assembly Screen Filter optional Washer Sour
2. Menu 61 ESCAPE HELP A Division of Emerson Process Management Index 7 21 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR Menu 62 MPARMSI1 Current measurement parameters help Shows the main measurement parameters These can be controlled in the various set up menus Menu 63 TLIMITSIAI Temperature limits The limits on the temperatures beyond which the analyzer will send a warning message Menu 64 BAROM PARMS Barometric pressure parameters Pressure transducer 000 Barometric pressure compensation 000 Measured pressure 000 Transducer offset 000 Transducer slope 000 Transducer PGA gain 000 7 22 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748417 B Model NGA2000 NDIR April 2003 Rosemount Analytical Inc Menu 65 ANALSETI2 Gas Measurement Parameters Linearization parameters lets you set up the linearizer coefficients and which set of coefficients is used for which range Response time delay parameters lets you adjust the filtering and output delay times so as to align outputs in time Set the upper and lower range limits in Range settings Menu 66 AMHELPINDEX2 Analyzer Module Help Select the function you want in the line below and note the path shown Function 000 Select 000 Then 000 Then 000 Then 000 Menu 67 MODTESTI1 Modulation check Flow ze
3. 23 2 CO Analyzer XXXXXXXX Technical configuration menu System set up Service menus Diagnostic menus Other module diagnostic menus listing of all modules Status normal Home Info Figure 3 5 Technical Level Configuration Menu Rosemount Analytical Inc A Division of Emerson Process Management Startup and Operation 3 3 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR 23 2 CO Analyzer XXXXXXXX Main Menu Help The Main Menu for the analyzer system Note that this menu refers to the particular analyzer selected from the run screen when used in a system The softkey marked HOME will always return you to this screen Help menu system Help on help Keyboard controls Editing controls Home Escape Map Figure 3 6 3 5 CALIBRATION Calibration can be executed from the Basic Controls menu Calibration gas data can be entered only through the Expert Controls and Setup menu To calibrate the Analyzer Module introduce zero gas into the SAMPLE INLET and do the following 1 If the multi Analyzer Module split Run Mode display is shown press the DISPLAY softkey until the desired Analyzer s Run Mode display is acquired 2 Press the MENUS softkey to enter the Main Menu and make the following selections from the Main Menu Expert Controls and Setup Analyzer Module Setup Calibration Gases 3 Input appropriate data in the Calibratio
4. Model NGA2000 NDIR See Figure 2 3 below On the Analyzer Module two NETWORK connections are available either of which is appropriate for 1 interconnection with Backplane of the Platform see Platform instruction manual or 2 daisy chaining with other NGA2000 components Connect Analyzer Module POWER 24 VDC power source either the Platform or external power source AL NETWORK 1 L network 2 Y AL power UY FUSE Figure 2 3 NDIR Front Panel Electrical Connections 2 4 Installation Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model NGA2000 NDIR April 2003 IV SAMPLE
5. Rosemount Analytical Inc Menu 107 POLYSETI1 Polynomial set up Select the range to linearize Make sure that the span gas value is correct Choose whether to define the gas concentrations as absolute values or as a percent of the span gas Use percent if you are diluting the span gas for this Get into the gas concentration screens and set the concentration for as many points as you want At each point flow the gas of the correct value and when the reading is stable press The analyzer will store the gas value and the reading mm 8 mm Menu 108 POLYSETI2 Polynomial set up When you have entered the desired number of points return to the polynomial set up screen and press polynomial and store it as the coefficients in the current range s linearizer function The order of the polynomial is optimized based on the number of data points provided You need at least 7 points for a fourth order polynomial correction You can modify the results with the piecewise linear correction also provided in this section Es ME E MOEN Menu 109 POLYSETI3 Polynomial set up WARNING the linearization curve must be monotonic If it is not the calibration routine will fail and the analyzer will not calibrate Test this by copying the values of the linearization coefficients into a spreadsheet program and plotting the result The analyzer does test for monotonicity when it spans but this test may not catch
6. STORE NEXT HISTORY INFO 7 16 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748417 B Model NGA2000 NDIR April 2003 Rosemount Analytical Inc Menu 47 RN3FACTORS Range 3 Factors Zero offset 000 Span factor 000 Full scale range at calibration 000 Measurement range number 000 Hardware zero offset 000 Raw measurement signal 000 STORE NEXT HISTORY INFO Menu 48 RN4FACTORS Range 4 Factors Zero offset 000 Span factor 000 Full scale range at calibration 000 Measurement range number 000 Hardware zero offset 000 Raw measurement signal 000 STORE FIRST HISTORY INFO Menu 49 AMHELPINDEX Analyzer Module Help The NGA2000 NDIR analyzer may be set up to measure a one of several different gases The particular gas and the range of concentrations available are viewable in the manufacturing data screens in the technical set up menus This analyzer works by passing infra red energy through a measurement and a reference gas cell and measuring the difference This is proportional to the amount of measured gas present The sensor used is specific to the gas measured A Division of Emerson Process Management Index 7 17 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR Menu 50 LINRANGE111 Linearity coefficients Edit the polynomial coefficients as desired Make sure that the curve upper limit is correct this
7. Bognor Regis West Sussex PO22 9SH England T 44 1243 863121 F 44 1243 845354 Model NGA2000 NDIR LATIN AMERICA Fisher Rosemount Av das Americas 3333 sala 1004 Rio de Janeiro RJ Brazil 22631 003 T 55 21 2431 1882 EMERSON Process Management Model NGA2000 NDIR Rosemount Analytical Inc Menu 29 LINRANGE4 Linearity coefficients Curve 4 AD coefficient Al coefficient 142 coefficient A3 coefficient A4 coefficient Curve upper limit Curve over range Curve under range ESCAPE Menu 30 LINRANGEO 000 000 000 000 000 000 000 000 Linearization parameters Range 1 linearizer If enabled uses curve no Range 2 linearizer If enabled uses curve no Range 3 linearizer If enabled uses curve no Range linearizer If enabled uses curve no Case temperature for coefficients Menu 31 AMPWRI1 000 000 000 000 000 000 000 000 000 Analyzer diagnostics Power supply voltages The the power supplies as described The unit was manufactured Changes of more than a few percent should be noted The 24Y supply may differ substantially if the unit is used on anything but a Rosemount power supply A Division of Emerson Process Management Instruction Manual 748417 B April 2003 Index 7 11 Instruction Manual ene Model NGA2000 NDIR Menu 32 FLOCHEK1 1 Physical Measurements These are the measurements made by
8. Copyright Fisher Rosemount Analytical Inc 1999 Manufactured by Rosemount Analytical Inc 4125 East La Palma Avenue Anaheim CA 92807 1802 USA Tel 714 986 7600 FAX 714 577 8739 Menu 115 ABOUT1 Analyzer Module Version Information Serial number 000 Manufacturing date 000 Hardware revision 000 Software revision 000 Revision date 000 Revision time 000 A Division of Emerson Process Management Index 7 39 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR Menu 116 ALARM1 Concentration Alarm Setup Alarm generation is 000 Level for Low Low alarm 000 Level for Low alarm 000 Level for High alarm 000 Level for High High alarm 000 Alarm delay 000 Low Low alarm 000 Low alarm 000 High alarm 000 7 40 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748417 B Model NGA2000 NDIR April 2003 SECTION 8 INDEX linear mode 3 6 A linearization coefficients calculating 3 6 linearizer 1 1 Luft principle 1 2 Analyzer Module applying power 3 1 calibration procedure 3 4 function 1 1 installation into Platform 2 1 M installation location 2 2 Maximum permissible interval between calibrations more that one in system 3 1 3 8 operating temperature 2 2 maximum range unable to calibrate 3 4 changing 3 8 B N binding 3 2 non linear mode 3 6 C P Calibration purge kit 1 3 failure
9. Return to the Main Menu and make the following selections Expert Controls and Setup Expert Controls CAL DATA softkey FACTORS softkey and Range 1 2 3 4 Factors do Steps 4 and 5 for each range Select Zero Offset press ENTER adjust the value to 500000 with the and 4 arrow keys and press ENTER Do not press ESCAPE at any time unless retention of prior settings is desired Instruction Manual 748332 F April 2003 Refer to the Data Sheet in the rear of this manual for Span Factors as originally set at the factory Select Span Factor press ENTER adjust the value to match the values on the Data Sheet with the 7 and 4 arrow keys and press ENTER If Data Sheet is not available enter 0 000015 with the 7 and J arrow keys and press ENTER Do not press ESCAPE unless retention of prior settings is desired Attempt to recalibrate the Analyzer Module according to the procedure outlined at the beginning of Section 3 5 on page 3 4 If recalibration fails return to the Range Factors menu readjust factors and try calibrating again Another cause of failure to calibrate is the following The value for Maximum range is lower than the upper limit value for the range inuse See the Range Settings menu for this information DISPLAY MESSAGE DESCRIPTION TYPE BAROMETER System Barometer WARNING CASE TEMP Case Temperature WARNING CHOP SPEED Chopper Speed WARNING CRUDE NOISE C
10. See calibration gas 2 2 R cells Readout accuracy high pressure is barometric pressure 3 8 Connections Return Authorization 6 1 electrical 2 4 inlet outlet 2 2 network 2 4 S power 2 4 sample dewpoint 1 3 2 2 D excessive flow rate 2 2 flow rate 2 2 pressure 1 3 pressure filtration 2 2 temperature 1 3 F shipping damage 2 1 for non standard fullscale ranges linearization coefficients 3 6 T I O Module W installation 2 1 initial startup 3 2 L leak test 2 2 daisy chaining 2 4 detector signal 3 2 tune signal 3 2 warm up perio 3 2 Rosemount Analytical Inc A Division of Emerson Process Management Index 8 1 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR 8 2 Index Rosemount Analytical Inc A Division of Emerson Process Management Model NGA2000 PMD NDIR Addendum 748461 B April 2003 VAISALA BAROMETRIC PRESSURE TRANSDUCER This addendum serves as an amendment to the Model NGA 2000 PMD and NDIR instruc tion manuals The following information should be considered part of the manual if your instrument has a Vaisala Barometric Pressure Transducer installed in it or if you are retrofitting a PMD or NDIR with a Vaisala transducer kit The Vaisala PTB100 series Analog Barometer is a N I S T traceable precision silicon capaci tive atmospheric pressure transducer The sensor delivers an analog voltage output that is inversely proportional to its inlet pressure It has an ope
11. l ID 5 TTT O te Le H POWER SUPPLY T je PIT BOARD CHOPPER MOTOR SOURCE H P FE CASE FU TEMPERATURE Eli Sson A PRESSURE COMPENSATION day BOARD OPTION CELLS at FLOW SENSOR 0 i N ca fam T I NS micro soar I DETECTOR 1 5 oa Ot THERMAL FUSE O O DETECTOR in ee f ALF TEMPERATURE CONTROL RTD DETECTOR COVER E U Ed 8 Wm SIGNAL BOARD ql am Jj H ll OSCILLATOR O O BOARD OSCILLATOR NETWORK INPUT SHUTTER ADJUST TUNE ADJUST MODULE ACCESS HOLES Figure 1 2 NGA2000 NDIR Analyzer Module Typical Actual Configuration May Vary 1 4 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 1 7 SPECIFICATIONS a General Measurement Species 0 Heteroatomic gases such as ammonia NH3 carbon dioxide CO carbon monoxide CO carbon monoxide carbon dioxide ethylene C2H4 hexane CsH14 methane CH3 nitric oxide NO and sulfur dioxide SO Range Siara aaa aat 10 ppm fullscale to 100 fullscale application dependent 4 fullscale selections including suppressed zero ranges Repeatability onnronnnonnrnnnvnnnnnnn 1 of fullscale at constant temperature Minimum Detectable Level 0 1 CO at 1 atm sample pressure application dependent NOISE ala tie lt 1 of fullscale peak to peak Lne ttyssraunesursitmdtsen
12. Help a Run Mode Display The Run Mode is the normal mode of operation In this mode the Display will show current gas measurement the component of interest the current operations of the softkeys a graphic bar representing the displayed concentration as a percent of fullscale and up to 4 user selectable secondary variables and associated bargraphs If more than one Analyzer Module is connected to the system the Run Mode display will show as many as four gas measurements on a single screen Alarm messages may also appear on the display See Table 3 1 on page 3 5 Rosemount Analytical Inc A Division of Emerson Process Management b Menu Displays The Menu structure enables the user to access data and functions and put information onto the network The Main Menu see Figure 3 2 on page 3 2 is subdivided into three levels of control based generally on which personnel is likely to use it Basic Controls Expert Controls and Setup and Technical Controls See Figure 3 3 through Figure 3 5 Many layers of the menu structure are described at appropriate places throughout this manual From the Run Mode display press the MENUS softkey to gain access to the Main Menu See Figure 3 2 on page 3 2 c Help Displays The Help structure is on line tutorial context sensitive and topic interconnected so that the user can practically operate NGA2000 without need of an instruction manual STARTUP PROCEDURE Introdu
13. J21 SOURCE J2 2 J9 J4 J5 J6 RECORDER REFERENCE J2 3 2 44 J J7 J5 OUTPUT SOURCE J2 4 POWER SIGNAL SUPPLY coupENSATION COMPUTER BOARD J4 BOARD BOARD BOARD Ji E jo J6 315 ri 7 J5 J7 J14 J6 Jolla 23 4a OHZ us J3 J2 gl FLOW SENSOR CASE TEMPERATURE AA SENSOR C G UC FAN ASSEMBLY RESISTOR MODULATION CHECK FUSE THERMAL U HEATER OSCILLATOR HEATSINK SOURCE CUTOFF DRIVER BOARD RTD TEMP CTRL SENSOR C d S MOTOR ASSEMBLY O DETECTOR BASE Ji LON POWER REF SOURCE BOARD SOURCE ASSY N SAMPLE SOURCE E2 24V E1 RTN OE3 CHASSIS 77 GROUND Figure 2 4 NDIR Wiring Diagram Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 5 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR 8 4 E 213 20 208 6 2 _ 6 157 15 5 13 O 28 4 3 71 109 3 A q 1 1 se 6 0 28 152 i 20 0 24 8 508 0 628 7 STANDARD EXTENDED 17 44 22 41 16 142 2 569 2 40 STANDARD EXTENDED d j Im g 6 15 8 4 213 1 1 28 11 27 q G POWER CABLE TO NETWORK F NETWORK CABLE CONNECTIONS TO PLATFORM E PUR
14. NDIR Menu 38 TLIMITSA Temperature limits Case upper limit 000 Case lower limit 000 Detector upper limit 000 Detector lower limit 000 Menu 39 AMMISCI1 Miscellaneous control parameters These are diagnostic variables used to determine if the analyzer is operating correctly The target source current is the set point for the current that flows through the two infra red sources The actual source current shows what is really flowing This current may be adjusted for best sensitivity or best life the source lasts longer if it is less hot Menu 40 MODTEST Modulation check Measurement range number 000 Detector signal 000 Signal gain setting modulation check 000 Status 000 Instructions 000 Then 000 Time remaining on this step 000 Percent modulation 000 ESCAPE START 7 14 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748417 B Model NGA2000 NDIR April 2003 Rosemount Analytical Inc Menu 41 ANALSIMPLE Basic Controls Measurement range number 000 Range upper limit 000 Range and functional control 000 Zero gas concentration 000 Span gas concentration 000 Ranges with valid calibration 000 Calibration status 000 If it won t calibrate Menu 42 FILTERI1 Filter and Delay Parameters This screen sets the final filtering for the analyzer primary variable output This is in addition
15. Presence of the Pressure Compensation Option ADJUSTMENT PROCEDURE Circuit adjustment can be made using Baro metric Pressure menu display or an external Digital voltmeter Display Method With no sample inlet lines connected and the instrument exhaust ported to atmosphere ad just R1 on the 661380 Interface board until the Barometric Pressure reading on the Barometric Pressure menu reads the correct ambient air pressure DMM Method Connect the DMM to TP1 on the 661380 Interface board to TP2 Set the DMM to measure mVDC With no sample inlet lines connected and the instrument exhaust ported to atmosphere adjust R1 on the Interface board until the DMM reads 0 000 Vdc 0 001 V The instrument is now calibrated at 1 ATM HIGH ALTITUDE VERSION OPTION For applications where the instrument is to be used above 5400 Feet MSL an alternate transducer option is available from the factory This version consists of a Vaisala model PTB100B transducer 900 1100 hPa range Please contact the factory if you require this option Addendum Vaisala Transducer Rosemount Analytical Inc A Division of Emerson Process Management 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 juncti
16. can be used as a tool for tracking the sensitivity of the Analyzer Module and for discovering potential detector source problems To perform a modulation check do the following Access the Primary Variable Parameters menu Select Modulation Check Follow the Instructions and Then line commands which are the following Flow zero gas press START softkey and wait A Division of Emerson Process Management Instruction Manual 748332 F April 2003 Flow span gas when prompted press START softkey and wait When the Instructions line again prompts the user to flow zero gas the modulation check is finished Note the value on the Percent Modulation line Find the Percent Modulation value on the Data Sheet in the rear of this manual Some standard Analyzer Modules will not have a value If a value is present compare this to the new value If 100 span gas was used during the modulation check the new value should be within 10 of value on the Data Sheet If it is out of this range call the factory for further interpretation lf modulation checks are used for trending variance from check to check should not exceed 20 per month Maintenance and Troubleshooting 4 11 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR 4 12 Maintenance and Troubleshooting Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model NGA2000 NDIR OOOO SECTION 5 REPLACEMENT PARTS PART
17. com ASIA PACIFIC Fisher Rosemount Singapore Private Ltd 1 Pandan Crescent Singapore 128461 Republic of Singapore T 65 777 8211 F 65 777 0947 http www processanalytic com O Rosemount Analytical Inc 2003 EUROPEAN TECHNOLOGY CENTER Fisher Rosemount GmbH amp Co Industriestrasse 1 63594 Hasselroth Germany T 49 6055 884 0 F 49 6055 884209 EUROPE MIDDLE EAST AFRICA Fisher Rosemount Ltd Heath Place Bognor Regis West Sussex PO22 9SH England T 44 1243 863121 F 44 1243 845354 Model NGA2000 NDIR LATIN AMERICA Fisher Rosemount Av das Americas 3333 sala 1004 Rio de Janeiro RJ Brazil 22631 003 T 55 21 2431 1882 EMERSON Process Management
18. menus Listing of all modules For Service set up and Service menus see preceding flow charts Diagnostic menus Control module diagnostics Analyzer module diagnostics Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Other module diagnostics This screen reserved for other modules if present Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Listing of all modules Lists all modules detected on the network Jumps to the module s diagnostic screen Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Model NGA2000 NDIR gt Control Unit Diagnostics See Platform manual Analyzer Diagnostics Power supply voltages Primary variable parameters Physical measurements Temperature control parameters Miscellaneous control parameters Barometric pressure parameters Software diagnostics gt For 1 O Module diagnostics see I O Modules manual Analyzer Diagnostics i See 8 above Figure 3 13 A Division of Emerson Process Management Analyzer diagnostics Power supply voltages 15V analog is 15V analog was 15V analog is 15V analog was 5V digital is 5V digital was 24V power is 24V power was 12V analog is 12V analog was Primary variable parameters Raw measurement signal 0 3258 Signal gain setting 4 Oscillator tune 85 Cho
19. msnrrnnnnvnnnnnrnnnnvvnrnrrennnrrnnnnvnnrrrrernnrrnnnnnnnenrenrsrresnnrnnnennennn 3 12 Figure 3 13 Display Screens 5 Of 5 manrrnnnnvrnnnnrnnnnvvnrnrrennnrrnnnnvnnrerrennnrrennnnnnenrenrsrresnnrnenennennn 3 13 Figure 4 1 Printed Circuit Board Fold Out Panel Views mmnrnranrnnnnvrnnnnvnnenvvnnnrrennnrnnnennnnennne 4 2 Figure 4 2 Power Fuse LoCatiON ooooooccccnnoccccnnnncncccnononcnnnnnonnnn nano cnn n areke nr r aeiy rra 4 2 Figure 4 3 Fan Assembly rrrronnrnnannvnnonvvnnnrrrnnnnvnnnnvenenrrrnnnrnnannvenenrensnrnnennvenennennnnrnsennnnnennenennn 4 3 Figure 4 4 Motor Source ASSEMDIY cccccceeeeeeeeeeeeceeeeeeeaeeeeeeeceaeeecaaaeseeeeeseeeesaeeesaeseeneeeaas 4 4 Figure 4 5 Cell PCB Assembly Exploded View rrrrnnnnrrnannvnnnnvvnnnrrennnnvnnnnvnnrrrrenrnrrnnnnnnnennne 4 5 Figure 4 6 Oscillator Tune Source Balance Shutter Adjustment cccccceesteeeseeeeees 4 7 Figure 4 7 Detector Block Exploded View oooooccccnnncccinnnococcnononcccnonononcno nana n cnn nnnnn cnn r nana cnn 4 7 Figure 4 8 Cell Assembly coocccoccconncccnncccnnnccnnncncnnnnnnnnnc nc 4 9 LIST OF TABLES Table 2 1 Cell Purging Times at Atmospheric Sample Pressure rrrrrannnnnnnrrnnnnrrnnnnrnnnrnrnnn 2 3 Table 3 1 NDIR Analyzer Module Alarm ooooccccnnnccccnnnoccconnnacccccnnnonnccnnnrrc cnn nr 3 5 Table 4 1 Cell Desi Mii da Aan dade neo ees 4 10 Rosemount Analytical Inc A Division of Emerson Process Management Contents ii
20. the analyzer module to make sure that it is working correctly and that sample and support gases if any are flowing The various temperatures are controlled to values set up in the diagnostic menus Limits give WARNING alarms when exceeded Menu 33 FILTER Response time delay parameters Range 1 t90 time 000 Range 2 t90 time 000 Range 3 t90 time 000 Range 4 t90 time 000 LON update rate 000 Output delay time 000 Menu 34 AM1VI1 Primary variable parameters Shows the parameters used to calculate the primary reading 7 12 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748417 B Model NGA2000 NDIR April 2003 Menu 35 AMTEMPI1 Temperature control These are the variables used to define the operation of the PID algorithms used for temperature control Adjust them at your own risk This analyzer controls its detector temperature while keeping its case temperature within rather wide limits Menu 36 AM2VA Physical Measurements Barometric pressure 000 Sample flow 000 Case temperature 000 Detector temperature 000 Flow limits Pressure limits Menu 37 PLIMITSA Pressure Limits Sample pressure upper limit 000 Sample pressure lower limit 000 A Division of Emerson Process Management Index 7 13 Rosemount Analytical Inc Instruction Manual 748417 B April 2003 Model NGA2000
21. to the inherent filtering in the analyzer The time delay simply delays the output by that time allowing the fastest responding analyzer systems to be synchronized with the slowest Menu 43 LINRANGEOI1 Linearization parameters The linearizer acts over a certain range not the same as the measurement range The system uses the linearizer polynomial appropriate for the measurement range chosen This is the polynomial with the next higher range However you may specify that the analyzer uses a wider range polynomial than that Note that use of different polynomials on different ranges will give different readings on a range change Coefficients may be edited for custom curves A Division of Emerson Process Management Index 7 15 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR Menu 44 CALFACTORS Calibration Factors Range 1 factors Range 2 factors Range 3 factors Range 4 factors Zero compensation factor 000 Span compensation factor 000 Menu 45 R1FACTORS Range 1 Factors Zero offset 000 Span factor 000 Full scale range at calibration 000 Measurement range number 000 Hardware zero offset 000 Raw measurement signal 000 STORE NEXT HISTORY INFO Menu 46 RN2FACTORS Range 2 Factors Zero offset 000 Span factor 000 Full scale range at calibration 000 Measurement range number 000 Hardware zero offset 000 Raw measurement signal 000
22. 0 1000 1500 2000 2500 3000 3500 4000 4500 5000 CONCENTRATION Display ppm ppm Figure 3 7 Typical Linearization Curve Linearizer OFF 1 0 9 0 8 0 7 0 6 CONCENTRATION NORMALIZED 0 5 0 4 0 3 0 2 0 1 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 READINGS NORMALIZED Axis Reversed Figure 3 8 Operator Determined Linearization Curve Normalized Rosemount Analytical Inc A Division of Emerson Process Management Startup and Operation 3 7 Instruction Manual 748332 F April 2003 3 7 ROUTINE OPERATION 3 8 Set the NDIR Analyzer Module for desired operating range Zero and span the module and then supply sample gas to the SAMPLE INLET at the rear of the module The NDIR Analyzer Module will now automatically and continuously analyze the sample stream As a check of instrument performance the operator should keep a log of zero span status Maximum permissible interval between calibrations depends on the analytical accuracy required A frequency of once every 24 hours is recommended initially and that practice should be continued unless experience indicates that some other interval is more appropriate Startup and Operation Model NGA2000 NDIR Readout accuracy is directly proportional to change in barometric pressure i e a change in cell pressure of 7 6mm of mercury will result in a readout error of about 1 of reading Therefore if barometric pressure changes significantly a recheck of calibration against a s
23. 1 of fullscale with 4th order polynomial Response Time mnnnrrnnnnnvnnnnnvnnenrn 05 to 30 seconds selectable for 0 to 90 of fullscale Drift Zero and Span 00 lt 1 of fullscale 24 hours at constant temperature application dependent lt 2 of fullscale week at constant temperature application dependent Effect of Temperature 0 lt 1 of fullscale over any 10 C interval for rate of change no greater than 10 C per hour application dependent Environment eneneranonnvnnrrrnnnnvnnrnnn Location Class B controlled indoor non hazardous Ambient Temperature 0 to 45 C 32 to 113 F Effect Of FIOW cecscceeeeeesteeeeees lt 1 of range when sample flow rate is changed by lt 250 ml min No effect if flow rate is between O and 500 ml min Power Requirements arxr norr 24 VDC 5 100 W max ripple and noise lt 100 mV peak to peak line and load regulations lt 1 Physical Case Classification General purpose for installation in weather protected areas Dimensions rennnnanvnnrnrrnnnnnnnnnnnnn See Outline and Mounting Dimensions Figure 2 5 on page 2 6 Weight viii cud aie enone Standard 11 kg 24 2 Ibs extended 12 5 kg 27 5 Ibs MOUNTING ene aa iea a Inside a Platform or custom installed in a panel Maximum Length of LON Cable 1600 m 1 mile between Analyzer Module and Platform Sample Temperature coocccccccnn
24. 1013 hPa 1 atmosphere ambient air pressure The summing node voltage is then buffered in verted and gain reduced by a factor of 8 to produce the Pressure Compensation Output voltage at J12 1 for the Computer Analysis board Low noise Low input current offset Op Amps and common substrate resistors are used to reduce gain tracking errors and null thermal coefficient effects INSTALLATION amp RETROFIT INSTRUCTIONS 1 Remove the original Rosemount trans ducer circuit board assembly located on the motherboard at J12 and J13 if pre sent 2 Install the transducer with the pressure inlet facing the rear of the instrument us ing the mounting studs provided on left hand side of the detector housing 3 Install the Interface board into it s mating sockets J12 and J13 on the mother board 4 Connect the 4 pin cable P1 from the in terface board noting pin polarity to the Vaisala Pressure Transducer EMERSON http www processanalytic com FELE ME rer Process Vanagement Addendum 748461 B April 2003 1 2 2 of 2 Model NGA2000 PMD NDIR 5 Connect the instrument sample inlet tub ing to the Vaisala Pressure Inlet port 6 Enable the Barometric Pressure Com pensation and the Use Local Reading op tions via the Expert Controls Analyzer Module Diagnostics Barometric Pres sure Compensation menus of the instru ment The instrument will automatically detect and report the
25. 48417 B Model NGA2000 NDIR April 2003 Rosemount Analytical Inc Menu 89 ZEROI2 If it won t calibrate Check that you are flowing the correct gas and the gas concentration is what it is supposed to be Make sure that the reading is stable before starting If you have changed the range full scale value or any linearizer coefficients or enabled or disabled it or done anything else that would affect how it measures the gas you may have made it hard for the algorithm to get to a calibration In this case manually adjust the coefficients until the readings are close to correct and try again Menu 90 EXP_CAL_DAT Zero span diagnostic data Date of last zero 000 Error message for last zero 000 Error percentage for last zero 000 Raw signal at last zero 000 Last zero gas would read 000 Date of last span 000 Error message for last span 000 Error percentage for last span 000 Raw signal at last span 000 ESCAPE FACTORS Menu 91 EXP_CAL_DATI Zero span diagnostic data Shows what happened at the last calibration The errors are expressed as a percentage of range The last zero and span readings are how the analyzer would read on those gases with the current calibration factors A Division of Emerson Process Management Index 7 31 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR Menu 92 UNITS Units Gas measurement units 000 Pressure measurement units 000 Temp
26. 7 by adjusting the sample shutter adjust screw clockwise If this reading exceeds 1 2 V then a cell cleaning is necessary see Section 4 12 on page 4 8 Rotate the shutter adjust screw clockwise until the display reads the value obtained in Step 8 Reassemble the Analyzer Module and if appropriate the Platform Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 DETECTOR ASSEMBLY COVER Front View Oscillator Tune Adjustment SHUTTER Sample OPEN CLOSE Source Balance Shutter Adjustment Screw Hole Figure 4 6 Oscillator Tune Source Balance Shutter Adjustments Detector Oscillator Board Resistive Temperature Detector Thermal Fuse I Detector Heater Figure 4 7 Detector Block Exploded View Rosemount Analytical Inc A Division of Emerson Process Management Maintenance and Troubleshooting 4 7 Instruction Manual 748332 F April 2003 4 12 CLEANING CELLS When zero gas is introduced in the SAMPLE IN inlet and the Detector signal is greater 1 2V the cells and windows require cleaning To do this follow this procedure See Figure 4 8 on page 4 9 to identify which detail drawing best matches the configuration in question Fold out the PCB panel Disassemble the optical bench according to Figur
27. ARY 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 Controller Board The computer board that serves as the Network Manager and operates the Display and Keypad Distribution Assembly The Backplane and the card cages that hold I O and Expansion Modules Expansion Module A circuit board that plugs into the Backplane from the front of the Platform and performs special features not related to I O functions I O Module A circuit board that plugs into the Backplane from the rear of the Platform Has a connector terminal for communication with external data acquisition devices and provides an input output function Operator Interface The Display and Keyboard Platform Any workable collection of the following Controller Board Power Supply Distribution Assembly Enclosure and Operator Interface Power Supply Any of a variety of components that provides conditioned power to other NGA2000 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 mo
28. Connect inlet and outlet lines for sample zero span and flowing reference if applicable to appropriately labeled fittings on the rear panel All four connections are 1 4 inch ferrule type compression fittings A Division of Emerson Process Management Instruction Manual Model NGA2000 NDIR Apri 2003 mm inch without inlet tube cell with inlet tube at 750 mm Hg 3 0 118 0 85 12 2 sec 4 0 157 1 14 12 2 sec 8 0 315 2 28 13 2 sec 16 0 630 3 56 16 2 sec 32 1 25 9 12 20 2 sec 64 2 52 18 24 25 3 sec 128 4 03 35 48 44 3 sec 232 9 13 65 12 73 6 sec 343 13 50 97 76 105 13 sec 381 15 00 108 60 116 14 sec Table 2 1 Cell Purging Times at Atmospheric Sample Pressure SAMPLE J N IN KO Nr 10 PSI MAX 69 kPa MAX REFERENCE A Sy IN NA 10W8 MAX 69 kPa MAX IS PURGE IN 15 PSI 103 kPa MAX YY LO Note Reference and purge gas connections are applicable only to certain applications Figure 2 2 NDIR Back Panel Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 3 Instruction Manual 748332 F April 2003 2 6 ELECTRICAL CONNECTIONS NOTE Electrical connections must be in compli ance with National Electrical Code ANSI NFPA 70 and or any applicable na tional or electrical codes Two electrical connections are required on the Analyzer Module POWER and NETWORK
29. ER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION BUYER AGREES THAT IN NO EVENT SHALL SELLER S LIABILITY EXTEND TO INCLUDE INCIDEN TAL OR CONSEQUENTIAL DAMAGES CONSEQUENTIAL DAMAGES SHALL INCLUDE BUT ARE NOT LIMITED TO LOSS OF ANTICIPATED PROFITS LOSS OF USE LOSS OF REVE NUE COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND OR INDEMNITY COVERAGE PROVIDED TO BUYER ITS ASSIGNS AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER Force Majeure Seller shall not be liable for failure to perform due to labor strikes or acts beyond Seller s direct control Instruction Manual 748332 F April 2003 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 ASIA PACIFIC Fisher Rosemount Singapore Private Ltd 1 Pandan Crescent Singapore 128461 Republic of Singapore T 65 777 8211 F 65 777 0947 http www processanalytic com O Rosemount Analytical Inc 2003 EUROPEAN TECHNOLOGY CENTER Fisher Rosemount GmbH amp Co Industriestrasse 1 63594 Hasselroth Germany T 49 6055 884 0 F 49 6055 884209 EUROPE MIDDLE EAST AFRICA Fisher Rosemount Ltd Heath Place
30. GE GAS IN 1 4 O D TUBE FITTING Bal ig 102 D REFERENCE IN 1 4 O D TUBE FITTING L 5 6 25 C REFERENCE OUT 1 4 O D TUBE FITTING 143 B SAMPLE OUT 1 4 O D TUBE FITTING A SAMPLE IN 1 4 O D TUBE FITTING DIMENSIONS 5 MODULE TO BE INSTALLED WITHIN 15 OF HORIZONTAL 4 POWER REQUIREMENTS 24 VDC 3 5 A INCH 3 ELECTRICAL INSTALLATION MUST BE IN COMPLIANCE WITH NATIONAL ELECTRICAL mm 2 6 CODE ANSI NFPA 70 AND OR ANY APPLICABLE NATIONAL OR LOCAL CODES MODULE IS NOT WEATHERPROOF APPROXIMATE WEIGHT 24 2 LB 11 0 kg Figure 2 5 Installation Outline and Mounting Dimensions Rosemount Analytical Inc A Division of Emerson Process Management Model NGA2000 NDIR SECTION 3 Instruction Manual 748332 F April 2003 STARTUP AND OPERATION 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 Platform or some interfacing component will be assumed Display and Keypad information shall refer to that which the user can expect to see and do with regard to the Front Panel of the Platform For a complete description of Platform Front Panel controls and indicators see Section 1 of the Platform Components instruction manual 3 2 DISPLAY SCREENS Three kinds of Display screens are available to the user See Figure 3 3 through Figure 3 6 e Run Mode e Menu e
31. ITED TO EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Limitations of Remedy SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DE LAY IN PERFORMANCE THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WAR RANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE IN NO CASE REGARDLESS OF THE FORM OF THE CAUSE OF AC TION SHALL SELLER S LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY SELLER GIVING RISE TO THE CAUSE OF ACTION BUYER AGREES THAT IN NO EVENT SHALL SELLER S LIABILITY EXTEND TO INCLUDE INCIDEN TAL OR CONSEQUENTIAL DAMAGES CONSEQUENTIAL DAMAGES SHALL INCLUDE BUT ARE NOT LIMITED TO LOSS OF ANTICIPATED PROFITS LOSS OF USE LOSS OF REVE NUE COST OF CAPITAL AND DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT IN NO EVENT SHALL SELLER BE OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR PROPERTY DAMAGE AND OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE AND OR INDEMNITY COVERAGE PROVIDED TO BUYER ITS ASSIGNS AND EACH SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER Force Majeure Seller shall not be liable for failure to perform due to labor strikes or acts beyond Seller s direct control Instruction Manual 748417 B April 2003 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
32. Instruction Manual 748332 F April 2003 Model NGA2000 NDIR Non Dispersive Infrared Analyzer T Analytical EMERSON http www processanalytic com Process Management 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 The following instructions MUST be adhered to and integrated into your safety program when installing using and maintaining Rosemount Analytical products Failure to follow the proper instructions may cause any one of the following situations to occur Loss of life personal injury property damage damage to this instrument and warranty invalidation e Read all instructions prior to installing operating and servicing the product e lf you do not understand any of the instructions contact your Rosemount Analytical representative for clarification e Follow all warnings cautions and instructions marked on and supplied with the product e Inform and educate your personnel in the proper installation operation and maintenance of the product e Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes Connect all
33. Manual 748332 F April 2003 Model NGA2000 NDIR 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 ELECTRICAL SHOCK HAZARD Do not operate without doors and covers secure Servicing requires access to live parts which can cause death or serious injury Refer servicing to qualified personnel For safety and proper performance this instrument must be connected to properly grounded three wire source of power POSSIBLE EXPLOSION HAZARD This equipment is not designed for and should not be used in the analysis of flammable samples Use of this equipment in this way could result in explosion and death Ensure that all gas connectors are made as labeled and are leak free Improper gas connections could result in explosion or death OVER VOLTAGE SPIKING If this Analyzer Module is used with a non Rosemount Analytical power supply adding Rosemount Analytical PN 903341 Current Protector in series with the 24V positive power line will prevent over voltage spiking and resultant fuse blowing when powering up the instrument CAUTION PRESSURIZED GAS This modul
34. RGE KITS A purge kit for the motor source or motor source flowing reference cell accompanies some NDIR modules The purpose of these kits is to improve performance and accuracy through the reduction of ambient CO2 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F April 2003 interference They do not provide protection from explosion hazard The purge gas vents into the case which has no outlet fitting for these types of purge gases 1 6 FEATURES Among the features available in the NDIR Analyzer Module are e Pressure compensation for barometric fluctuations optional e Flow sensing Description and Specifications 1 3 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR SAMPLE OUT REFERENCE OUT BOTTOM REFERENCE IN EN SAMPLE IN PURGE GAS IN N X a E zz
35. S INTEGRITY Tampering with or unauthorized substitution of components may adversely affect safety of this product Use only factory approved components for repair To identify the configuration of an analyzer 5 1 MATRIX locate the analyzer name rating plate The Each analyzer is configured per the customer 12 position sales matrix identifier number sales order Below is the NDIR sales matrix appears on the analyzer name rating plate which lists the various configurations available NDIR SINGLE CHANNEL INFRARED MEASUREMENT ANALYZER MODULE Code Software Version 01 Current Version Software 02 2 2 4 Version Software 03 3X Version Software specify version Code Configuration Identifier Configurations utilize EXTENDED housings 09 10 12 20 22 23 29 30 36 38 06 07 08 11 21 24 26 76 63 16 28 19 25 27 31 37 39 41 44 14 15 46 54 64 65 66 67 73 56 74 75 83 84 85 88 99 SPECIAL Code Linearized Non Standard Range Selection 01 Four Standard Ranges R1 One Non Standard Range R2 Two Non Standard Ranges R3 Three Non Standard Ranges R4 Four Non Standard Ranges 99 Special Code Flow Path 01 Standard No Flow Sensor 02 400 2000 cc min 99 Special NDIR 01 10 R1 01 Example Rosemou
36. SOURCE REFERENCE CELL DETECTOR STATIONARY PLATE April 2003 Model NGA2000 NDIR change which is proportional to component concentration is processed and expressed as the primary variable on the network Other modules comprising the NGA2000 unit then use this variable for a variety of purposes e g expressing the gas concentration on the Front Panel Display or sending it to external data acquisition devices For a general understanding of the electrical interconnections in the NDIR Analyzer Module see Figure 2 4 on page 2 5 _ CHOPPER fam SAMPLE IN SAMPLE CELL gt m SAMPLE OUT DIAPHRAGM DISTENDED COMPONENT OF INTEREST DIAPHRAGM NON INTERFERING COMPOUNDS DARK STATE Figure 1 1 NDIR Technology 1 2 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Model NGA2000 NDIR 1 4 SAMPLE REQUIREMENTS Maximum allowable sample pressure is 690 hPa gauge 10 psig for a standard configuration NDIR that has a flow restrictor which sets the flow at between 0 5 L min to 1 L min Special high pressure cells up to 10 350 hPa gauge 150 psig are available Sample temperature range is 0 C to 55 C and maximum dewpoint is 40 C The sample must be filtered to exclude particulates larger than 2 microns in size Consult factory for special configurations with specifications outside of those listed above 1 5 PU
37. Sensor ReplaceMent oococncccincccnnncconononnnoccccnrccnnnrn naar 4 6 4 10 Thermal Fuse Replacement ceratina nn 4 6 4 11 Oscillator Tune Source Balance Shutter Adjustment marsnnnonvnnnnrrrnnnrnnnnnvnrnrrnnnnrrennnnnernnnen 4 6 4212 Cleaning Cels ant ii ia AA 4 8 4213 Gell Desi Mii A el he eee ela tetas 4 10 4 14 Modulation Check ici ii ii eth eae teas 4 11 5 0 REPLACEMENT PAR TS eee eae Ean aan e aanere anaia en 5 1 5 1 ME EE EE EEE EE E EA 5 1 5 2 Replacement Parts iia add ear deed 5 2 6 0 RETURN OF MATERIAL iii 6 1 6 1 Return Of Material ici dennes drake AUNOR AA az 6 1 6 2 GUSTOMEN SEV ICG Nidia ida dt seeds 6 1 6 3 a O 6 1 7 0 APPENDIX A MENU DISPLAYS i mnrnnnvvnnnnvnnnnnnnnnnvnnnnnvnnnnnnnnnnvnnnnvennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 7 1 8 0 INDEX 8 1 ii Contents Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 LIST OF ILLUSTRATIONS Figure 1 1 NDIR Technology eocccccccccconiconocanonaccnonnnn anna canon cn nn nano narran rra rca 1 2 Figure 1 2 NGA2000 NDIR Analyzer Module Typical Actual Configuration May Vary 1 4 Figure 2 1 Analyzer Module Installation into Instrument Platform usnrenonrrnrnrrnnnnrrnnnnnnnrnnne 2 1 Figure S2 NDIR Back Panel cid did td 2 3 Figure 2 3 NDIR Front Panel Electrical Connections rrnannrnnonvvnnnrrvnnnvrnnnnnennnrrennnrnnnnnnnnennn 2 4 Figure 2 4 NDIR Wi
38. ailure error allowed Calibration time out Ranges zeroed Calibrate ranges Calibration adjustment limits A Division of Emerson Process Management 000 000 000 000 000 000 000 Instruction Manual 748417 B April 2003 Index 7 19 Instruction Manual ene Model NGA2000 NDIR Menu 56 APARLST6 Analyzer Parameter List Calibration Gases Zero gas range 1 000 je gas range 2 000 ero gas range 3 000 Zero gas range 4 000 Span gas range 1 000 Span gas range 2 000 Span gas range 3 000 Span gas range 4 000 ESCAPE Menu 57 LISTNOTES Analyzer module service notes You can write up to 22 characters in each line Menu 58 MPARMS2 Current measurement parameters Response time 000 Sample flow 000 Sample pressure 000 Case temperature 000 7 20 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model NGA2000 NDIR AoA 2005 Rosemount Analytical Inc Menu 59 DISPLAY Displayed parameters First line s parameter 000 Second line s parameter 000 Third line s parameter 000 Fourth line s parameter 000 May be displayed on the appropriate line of the single analyzer display screen Menu 60 ANALSET2 Measurement Parameters Linearization parameters Response time delay parameters Range settings Units Linearization functions
39. alculated Noise WARNING DET SIG Detector Signal WARNING DET TEMP Detector Temperature WARNING LIN ERROR Linearizer Error WARNING N15 VOLTS Power Supply 15V WARNING P12 VOLTS Power Supply 12V WARNING P15 VOLTS Power Supply 15V WARNING P24 VOLTS Power Supply 24V WARNING P5 VOLTS Power Supply 5V WARNING PERCENT MOD Percent Modulation WARNING RAW SIGNAL Raw Signal WARNING SVFLOW Sample Bypass Flow WARNING SW ERROR Software Error FAILURE Table 3 1 NDIR Analyzer Module Alarms A Division of Emerson Process Management Startup and Operation 3 5 Instruction Manual 748332 F April 2003 3 6 LINEARIZATION 3 6 The NDIR Analyzer Module can be operated in linear and non linear mode Linearization can be toggled ON OFF in the Expert Controls menu In the OFF position linearization is disabled for all ranges and the component of interest is measured in percent of fullscale In the ON position measurement is in engineering units Either ppm or percent of concentration The NDIR Analyzer Module is linearized with the following fourth order polynomial Y Ao A1X A2X A3X A4X Where X the normalized non linear input Ao Ai Az A3 Aa linearization coefficients Y the normalized linear output Linearization coefficients can be developed and stored for each range through the Expert Controls menu The operating range is selected by entering RANGE 1 2 3 or 4 in the Range Mode section that that menu Co
40. all possible errors Monotonic means that the curve does not roll over and start going back down as the gas concentration A Division of Emerson Process Management Index 7 37 Instruction Manual ene Model NGA2000 NDIR Menu 110 ANALSETI3 Midpoint correction set up Then go to the second set point and repeat You can use up to three midpoints When you are done set the correction to WARNING make sure that you do not have excessive corrections If the correction is too odd the calibration routine will fail and you will not be able to calibrate the analyzer In this case try it again You can perform this correction individually for each range Menu 111 MPARMS Current measurement parameters Analyzer gas measured 000 Measurement range number 000 Range change control 000 Linearization mode 000 Analyzer operational state 000 Analyzer alarm state 000 Alarm reporting level 000 Menu 112 FLOWLIMITS Flow limits Flow lower limit 000 Flow upper limit 000 7 38 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model NGA2000 NDIR AoA 2005 Rosemount Analytical Inc Menu 113 PLIMITSAI1 Pressure and flow Limits These are settable limits on the sample gas pressure and flow They force alarms to occur and also act as end points on the bar graph display of their variable Menu 114 ABOUT C
41. as concentrations Point 3 Gas value Raw reading Linearized value Point 4 Gas value Raw reading Linearized value Point to be measured ESCAPE Rosemount Analytical Inc A Division of Emerson Process Management 000 000 000 000 000 000 000 Instruction Index Manual 748417 B April 2003 7 27 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR Menu 80 POLYGAS3 Gas concentrations Point 5 Gas value 000 Raw reading 000 Linearized value 000 Point 6 Gas value 000 Raw reading 000 Linearized value 000 Point to be measured 000 ESCAPE Menu 81 POLYGAS4 Gas concentrations Point 7 Gas value 000 Raw reading 000 Linearized value 000 Point 8 Gas value 000 Raw reading 000 Linearized value 000 Point to be measured 000 ESCAPE Menu 82 POLYGAS5 Gas concentrations Point 9 Gas value 000 Raw reading 000 Linearized value 000 Point 10 Gas value 000 Raw reading 000 Linearized value 000 Point to be measured 000 7 28 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Model NGA2000 NDIR Menu 83 POLYGAS6 Gas concentrations Point 11 Gas value Raw reading Linearized value Point 12 Gas value Raw reading Linearized value Point to be measured ESCAPE Menu 84 POLYGAS7 000 000 000 000 000 000 000 Gas concentrat
42. be reversed as illustrated in Figure 3 7 on page 3 7 and Figure 3 8 on page 3 7 A multiple linear regression is then used to calculate coefficients For example If the range is 0 to 5000 ppm and readings are 0 to 100 then divide all of the concentrations by 5000 and the readings by 100 Put the normalized concentrations on the Y axis and the normalized readings on the X axis These data points can be entered into any program capable of computing a fourth order polynomial curve This curve will be the mirror image of the curve on the Calibration and Data Sheet provided in the rear of this manual however the linearization coefficients will be different Use the coefficients calculated with the curve in the polynomial shown on the previous page After taking the data points the operator may determine coefficients for user specific gas by either using any program capable of calculating a fourth order curve fit or calling the factory to have the specific coefficients calculated When entering the operator determined coefficients note that the microprocessor only recognizes five significant digits to the right of the decimal point e g 0 12345 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 100 READING FULLSCALE 50 0 0 50
43. ce Buffer Motor Source Assembly Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 4 7 DETECTOR REMOVAL See Figure 4 5 below and Figure 4 8 on page must be removed in order to perform this 4 9 for breakdowns of the optical bench The disassembly entire optical bench Oscillator Tune Adjust Detector Assembly Motor Source Assembly Power Transistor Heatsink Flow Sensor Figure 4 5 Cell PCB Assembly Exploded View Rosemount Analytical Inc A Division of Emerson Process Management Maintenance and Troubleshooting 4 5 Instruction Manual 748332 F April 2003 4 8 FLOW SENSOR REPLACEMENT See Figure 4 5 on page 4 5 for Flow Sensor location To replace Flow Sensor remove all connecting hardware and undo connections to the sample line 4 9 CASE TEMPERATURE SENSOR REPLACEMENT Case Temperature Sensor is attached to the motor source assembly To replace this sensor cut the Ty Rap binder and disconnect the sensor connector Reverse these instructions by reconnecting the new sensor and attaching with a new Ty Rap 4 10 THERMAL FUSE REPLACEMENT Disassemble and reassemble the Detector block according to Figure 4 7 on page 4 7 to replace the Detector Thermal Fuse 4 11 OSCILLATOR TUNE SOURCE BALANCE SHUTTER ADJUSTMENT The Analyzer Module is calibrated tuned and balanced at the factory If the diagnostic values for o
44. ce zero gas into SAMPLE INLET and reference and source purge gas if applicable into their respective inlets Ensure that gas pressures are set to requirements listed on the Specifications page of the Preface section of this manual Apply power to the NDIR Analyzer Module If it is associated with a Platform do this by plugging in the Platform to a power source The Platform has no ON OFF power switch Once power has been supplied to the Platform the NDIR Analyzer Module will be energized If the user s system contains only one Analyzer Module all system components the Startup and Operation 3 1 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR Controller Board and the network self install bind together during initial startup If the system contains more than one Analyzer Module the startup procedure will interrogate the network to locate and identify all components on the network The user will have to bind appropriate combinations of Diagnostic Service menus If both settings are within 5 tolerance of factory setting go to Section 3 4 below for binding and Section 3 5 on page 3 4 for calibration If not refer first to Section 4 11 on page 4 6 for instructions about oscillator tune source balance shutter adjustments components after the startup sequence After the warm up period about one hour for the NDIR Analyzer Module all modules are completely functional 3 4 BINDING To achieve full co
45. 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 NDIR Analyzer Module requires assembly with other components e g the Platform and associated I O Modules do so at this time Following the guides on the bottom left and bottom center of the Platform carefully slide the Analyzer Module halfway into place PIN SEATS CAUTION HAND INJURY HAZARD Do not place hands or fingers in Platform front handles when the front panel is open Dropping front panel while hand or fingers are inside either handle can cause serious injury Lift the spring loaded pins on the front of the Analyzer Module and carefully slide it the rest of the distance Secure the module in position by releasing the pins which seat in the available holes in the bottom of the case see Figure 2 1 below If the module and Platform are difficult to assemble remove the module ensure the top cover of the module is firmly seated on the hold down screws and repeat the assembly procedure Install I O Module s according to guidelines in the I O manual After startup and calibration have been performed secure the front panel with the six screws provided ANALYZER MODULE GUIDES 4 DISENGAGED FRONT PANEL Figure 2 1 Analyzer Module Installation into Instrum
46. d be subjected to a temperature higher than 125 F 52 C A flame should never be permitted to come in contact with any part of a compressed gas cylinder 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 P 4 Preface Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model NGA2000 NDIR oe DOCUMENTATION The following NGA2000 NDIR instruction materials are available Contact Customer Service Center or the local representative to order 748332 Instruction Manual this document COMPLIANCES This product may carry approvals from several certifying agencies including Factory Mutual and the Canadian Standards Association which is also an OSHA accredited Nationally Recognized Testing Laboratory for use in non hazardous indoor locations lt gt CEA APPROVED NRTL C 97 C219 Rosemount Analytical Inc has satisfied all obligations from the European Legislation to harmonize the product requirements in Europe This product complies with the standard level of NAMUR EMC Recommendation May 1993 NAMUR This product satisfies all obligations of all relevant standards of the EMC framework in Australia and New N96 Rosemount Analytical Inc A Division of Emerson Process Management Preface P 5 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR GLOSS
47. de of the Analyzer Module case I O Module Located on the backplane connector of the module If no label is present the module is Version 2 0 Rosemount Analytical Inc A Division of Emerson Process Management Preface P 3 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR 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 Cylinders may be stored in the open but in such cases should be protected against extremes of weather and to prevent rusting from the dampness of the ground Cylinders should be stored in the shade when located in areas where extreme temperatures are prevalent 3 The valve protection cap should be left on each cylinder until it has been secured against a wall or bench or placed in a cylinder stand and is ready to be used 4 Avoid dragging rolling or sliding cylinders even for a short distance they should be moved by using a suitable hand truck 5 Never tamper with safety devices in valves or cylinders 6 Do not store full and empty cylinders together Serious suckback can occur when an empty cylinder is attached to a pressurized system 7 No part of cylinder shoul
48. deer Ainsa P 1 DEA SE P 1 SAC Summary aaret P 2 General Precautions For Handling And Storing High Pressure Gas Cylinders msnrrnrrrrnnnnrrnnnnnvnrenr P 4 DOGUMOENTALION Sis scceteisca colirio cul ineatesadceandavan ERE P 5 Gomplanees aars P 5 Gloss ay Or Tama aires sete eee eS ice SUN a Fae tile caste gauuent cave EE A AN P 6 1 0 DESCRIPTION AND SPECIFICATIONS rannnnnnvnnnnvnnnnvnnnnnvnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnvennnnnnnnnnnnnnennn 1 1 1 1 OO Westland tala rd 1 1 1 2 Typical APPlICAONS criteria act iia 1 1 1 3 Theory Of TEChnOloGy ss roda 1 1 1 4 sample Requirements uvaner andet ut etteretning 1 3 1 5 A EEE ee 1 3 1 6 Features iii dd 1 3 1 7 Specifications aiita iar dis a A a atten Aaaa 1 5 A A 1 5 P URINVSICAL oia oa A A aa Ra 1 5 ES aaret k meer et eee rarer d raude 1 5 2 0 INSTALLATION 25 resepter semen eee andaa saoo kan poackstecued vanes sauces suctessdesduaee oaa a EnO urA aAa Naaras iaado aie 2 1 2 1 A g en A eee GAN evel va beat a Adda 2 1 2 2 ASSOMDIY iii II Wage duren dedi ct deena AD Ad 2 1 2 3 A aat y nde lyde Gee een et eden vere eevee 2 2 2 4 Gas Speciiications it it A ODE gidd ed gle a 2 2 a Gallbr tion CASOS iria dage i iaaii aiia ay eect eee de lie 2 2 De FION Rate EEE EN EE DE 2 2 C Sample Pressure Filtration nsina nasa derme kvinne dada 2 2 di Lea GET tua daa ad 2 2 2 5 CERE Ia oTa EREE EEE E AAE talla seer 2 2 2 6 Electrical CONNECTIONS csi a a a delene bead deviteevec
49. dules 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 sample flow source voltage and other diagnostic information P 6 Preface Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 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 Rosemount Analytical Inc A Division of Emerson Process Management Preface P 7 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR P 8 Preface Rosemount Analytical Inc A Division of Emerson Process Management Rosemount Analytical Inc Model NGA2000 NDIR Instruction Manual 748332 F April 2003 SECTION 1 DESCRIPTION AND SPECIFICATIONS OVERVIEW This manual describes the Non Dispersive Infrared NDIR Analyzer Module of Rosemount Analytical s NGA2000 Series of gas analysis components The NDIR Analyzer Module is designed to continuously determine the concentration of oxygen in a flowing gaseous mixture The concentration is expressed in one of three fashions e parts per million e percent of composition e percent of fullscale The
50. e 4 5 on page 4 5 and the cells according to Figure 4 8 on page 4 9 Rinse the cell with acetone If this does not remove all foreign matter use a soft brush Do not use any metallic object inside the cell because it will scratch the gold plating Loss of gold plating may require cell replacement After all matter has been removed rinse the cell with distilled water and allow to air dry Do not use towels Model NGA2000 NDIR Inspect the cell inside by holding it up to a bright light If particles are seen repeat Steps 5 and 6 as often as necessary After cleaning cell examine O rings at the source detector and end caps If damaged replace with new O rings Remove any contaminants from windows with a lint free cloth soaked in acetone Do not use alcohol or other solvents Allow to air dry Reverse disassemble instructions to reassemble the unit Perform a leak check Replace desiccant if required See Section 4 13 on page 4 10 After cleaning cells the Analyzer Module must be optically aligned if the diagnostic values for oscillator tune and detector signals are not within 5 of the factory settings If they are not within that range follow Steps 7 through 10 of Section 4 11 on page 4 6 4 8 Maintenance and Troubleshooting Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model NGA2000 NDIR REN ek Detector SHORT PATH CELLS Assembly O C 4mm TO 2 5 INCHES 7 Ls
51. e requires periodic calibration with a known standard gas See General Precautions for Handling and Storing High Pressure Gas Cylinders on page P 4 P 2 Preface Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 CAUTION HAND INJURY HAZARD Dropping the front panel of the Platform while hand or fingers are inside either case handle can cause serious injury CAUTION PARTS INTEGRITY Tampering with or unauthorized substitution of components may adversely affect safety of this product Use only factory approved components for repair CAUTION OVERBALANCE HAZARD This Analyzer Module may tip instrument over if it is pulled out too far and the Platform is not properly supported CAUTION POSSIBLE CELL DAMAGE Apply leak test liquid to cell or detectors only as a last resort NOTICE Software compatibility is necessary for all NGA2000 components in your system to work together The version of your Platform s software must be equal to or greater that the version of any other module s for successful compatibility If it is not contact Rosemount Analytical at 800 433 6076 to order software upgrade kit PN 657150 for the Platform You can locate the version of each NGA2000 component as follows Platform Controller Board Turn power ON The display will show Control Module V2 This is the software version Analyzer Module Located on the right si
52. ecurity Enabled Expert level security Enabled Technical level security Enabled Record basic level security code Record expert level security code Record technical level security code Manufacturing data Control module data Analyzer module data Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Service History Control module data Analyzer module data Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Record security codes Basic level security Enabled Expert level security Enabled Technical level security Enabled Record basic level security code Record expert level security code Record technical level security code See 7 above Model NGA2000 NDIR Select IO modules Select the modules you wish to bind to the current analyzer Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Modules Bound Analyzer module selected IR CO2 Auxiliary module Auto 1023 Auxiliary module Acal 2322 Auxiliary module HART 1092 Auxiliary module None Auxiliary module None Auxiliary module None Proposed new bind Record basic level security codes expert technical Press the softkeys in any order to define the code The actual code is represented by the order in which they are pressed and shown numerically below Press the left arrow key wh
53. eeicnedieepe eines 2 4 3 0 STARTUP AND OPERATION saaneen denne eia ile aneao aaan ais 3 1 3 1 ONLIN A EAE E A A A E E E 3 1 3 2 Display Screening maren re ias 3 1 a Run Mode DISPlay oran ara 3 1 Diy MenuDISplaysmui senn pa 3 1 ci Help Display Sti ccna ch avtatt eh ates ae ea A A a E 3 1 3 3 Stanup Procedures uanpa advent Wee ivi al eae e 3 1 3 4 BIONIC Beane 3 2 3 5 A a An Gn aan underrette WE rede 3 4 3 6 En arnzatomsanususausnatge cee Gude ak Ae ea ee A eel lel N 3 6 3 7 Routine Operation iii A Ne ee gne ag bleien 3 8 Rosemount Analytical Inc A Division of Emerson Process Management Contents i Instruction Manual 748332 F April 2003 Model NGA2000 NDIR 4 0 MAINTENANCE AND TROUBLESHOOTING mnnnnvnnnnvvnnnnvnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenn 4 1 4 1 Overview karies an Lite druer t Gatas le fig Weed fe inte 4 1 4 2 PCB Replacement sieve aes a 4 1 4 3 Power Fuse Replacement ccccceccecceeeeceeceeeeeeeeeeeeneneeeeeesaeceseeaeeeeeeneseseesseeeeeeneeeeesensneaes 4 2 4 4 Module Fan Replacement rrrannrnnannvnnonvvnnnrrrnnnrnnannvnnnnrnnannrnnnnnnnnenrennnrnnsnnnenennenernresnnrnnsnnnenen 4 3 4 5 Chopper Motor Replacement arnrnnonvnnrnrrnnnnrrnnnnrnnnnr renn nrnnnnnnnnenvennnrrennnrnnennnnrsnresnnnrnnsnnnerennen 4 4 4 6 Source Replacement insire aia AA dd aia aai 4 4 4 7 Detector Removal initial endar 4 5 4 8 Flow Sensor Replacement iii id added 4 6 4 9 Case Temperature
54. efficients for each selected range are automatically used when the module is in Linearization Mode The user instructs the Analyzer Module as to which set of coefficients are to be used for each range Maximum dynamic range is 3 1 When ordered special linearization coefficients for non standard fullscale ranges are entered in the appropriate range s at the factory If a range is not specified the set of coefficients will be for Range 4 The operator may want the module to output measurement in engineering units ppm This response is linear over the operating range The following coefficients will make no correction to the non linear response but will cause the NDIR Analyzer Module to output gas measurement in engineering units Startup and Operation Model NGA2000 NDIR AO 0 00000 A1 1 00000 A2 0 00000 A3 0 00000 A4 0 00000 To calculate linearization coefficients other than those installed at the factory take a minimum of 11 data points A more accurate curve can be obtained as the user approaches 21 data points If urgent a curve can be created with as few as four points but this is only a temporary fix A more accurate curve should be created as soon as possible These data points can be obtained with an accurate gas divider or other flow mixing device Before calculating coefficients the data must be normalized to ranges of 0 to 1 units for both percent and concentration readings Then the axis must
55. en you are done Actual code number 54321 Control Unit Manufacturing Data Control unit serial number 800002356 Manufacturing date code 12 08 93 Hardware revision number 1 00 Software revision number 1 09 Revision notes User tag number PVic Analyzer Manufacturing Data Analyzer module s n 900189342 Manufacturing data code Bench configuration code Hardware revision number Software revision number Minimum range Maximum range Measured gas User tag number Store historical data Are you sure STORE will copy current diagnostic data into the historical was variables overwriting what is currently there Reset Are you sure RESET will erase ALL configuration and manufacturing data including serial numbers Control Module Service History Manufacturing date 12 08 93 In service date 01 23 94 Last service date 01 23 94 List notes Add service date Analyzer module Service History Manufacturing date 17 08 93 In service date 21 06 94 Last zero calibration date 24 08 94 Last span calibration date 24 08 94 Last service date 21 06 94 List notes Add service date 1 0 module This function not applicable Slot position Display Screens 4 of 5 Rosemount Analytical Inc A Division of Emerson Process Management Rosemount Analytical Inc From MAIN MENU Technical configuration menu System set up Service menus Diagnostic menus Other module diagnostic
56. ent Platform A Division of Emerson Process Management Installation 2 1 Instruction Manual 748332 F April 2003 2 3 LOCATION Install the NDIR Analyzer Module in a clean non hazardous weather protected vibration free location free from extreme temperature variations For best results install the instrument near the sample stream to minimize sample transport time Operating ambient temperature is 0 C to 45 C 32 F to 113 F Sample dewpoint is 40 C or less NOTE Unrestricted air flow in the rear of the Ana lyzer Module is critical to its performance and reliability 2 4 GAS SPECIFICATIONS a Calibration Gases All applications require a zero standard gas to set the zero point on the display and external data acquisition devices if the factory provided Calibration and Data Sheet in the rear of the manual specifies a background gas use this as a zero gas If a background gas is not specified use dry nitrogen Span gas should be between 75 and 100 of fullscale span Flowing reference if used should be dry nitrogen b Flow Rate Recommended sample flow rate is 1 to 2 SCFH 500 TO 1000 cc min A lower flow rate will not affect readings but may result in an undesirable time lag Excessive flow can produce increases cell pressurization and reading error At higher cell pressures the nonlinearity of the calibration curve increases Therefore the calibration curve should be redrawn for higher flow
57. epaired at the factory and returned as directed by the purchase order and shipping instructions CUSTOMER 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 TRAINING A comprehensive Factory Training Program of operator and service classes is available For a copy of the Current Operator and Service Training Schedule contact the Technical Services Department at Rosemount Analytical Inc Customer Service Center 1 800 433 6076 Return of Material 6 1 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR 6 2 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 SECTION 7 INDEX linear mode 3 6 A linearization coefficients calculating 3 6 linearizer 1 1 Luft principle 1 2 Analyzer Module applying power 3 1 calibration procedure 3 4 function 1 1 installation into Platform 2 1 M installation location 2 2 Maximum permissible interval between calibrations more that one in system 3 1 3 8 operating temperature 2 2 maximum range unable to calibrate 3 4 changing 3 8 B N binding 3 2 non linear mode 3 6 C P Calibration purge kit 1 3 failure See calibration gas 2 2 R cells Readout accuracy high pressu
58. erature measurement units 000 ppm to mg Nm3 conversion factor 000 Lower explosion limit LEL 000 Upper explosion limit UEL 000 Menu 93 UNITSI1 Units Select the units in which you want the values to be displayed This does not affect the variable contents it merely affects how the control module displays them Note that all analyzer ranges will be set as percent or ppm you can t set some as ppm and others as percent Menu 94 RESET Reset Are you sure RESET will erase ALL the configuration and manufacturing data including serial numbers and everything else If you are sure press RESET again 7 32 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model NGA2000 NDIR AoA 2005 Rosemount Analytical Inc Menu 95 STORE Store historical data re you sure STORE will copy current diagnostic data into the historical currently there If you are sure press STORE again ESCAPE STORE Menu 96 RFHIST1A Range 1 Factors Manufacturer s settings Zero offset 000 Span factor 000 Stored settings Zero offset 000 Span factor 000 Menu 97 RFACTORSIA Range Factors Shows the calibration factors for this range Modify the zero factor for zero calibration and the span factor for spanning this range They take effect as soon as you press the enter key With zero gas the zero factor should be the
59. ers i Detector upper limit 69C First line s parameter Flow Detector lower limit Second line s parameter Flow Third line s parameter Flow Fourth line s parameter Flow May be displayed on the appropriate line of the single analyzer display screen Figure 3 11 Display Screens 3 of 5 Rosemount Analytical Inc A Division of Emerson Process Management Maintenance and Service 3 11 Instruction Manual 748332 F April 2003 3 12 From MAIN MENU Technical configuration menu System set up Service menus Diagnostic menus Other module diagnostic menus Listing of all modules For Diagnostic menus Other module diagnostic menus and Listing of all modules see Figure 3 11 System Set Up Main display configuration Front panel control Date and time Module binding System Reset Security codes System tag Rosemount Service Menus Manufacturing data Service history In maintenance since Record security codes Startup and Operation Figure 3 12 Main display configuration Front panel control and Date and time displays can be found in the Platform manual Module Binding Analyzer module selected IR CO2 Select modules Proposed bind View bindings Bind selections Unbind everything System Reset Are you sure Re initializing will destroy all the binds System reset Re initialize network Record security codes Basic level s
60. erting manufacture of cement soaking pit heat treating e Carbon Monoxide Inert gas generation producer gas monitoring rotary kiln roasting tin plate annealing steel converting aluminum power processing porcelain kilns tunnels e Water Vapor Heat treating hydrogen brazing nickel and chrome plating e Sulfur Dioxide Flash smelting e Ammonia Ammonia dissociation THEORY OF TECHNOLOGY Inside of the Analyzer Module two equal energy infrared beams are directed through two parallel optical cells a flow through sample cell and a reference cell The reference cell may be sealed or may contain a continuously flowing reference gas See Figure 1 1 below The infrared radiation is interrupted by a chopper at a frequency of 5 Hz Description and Specifications 1 1 Instruction Manual 748332 F During analysis a portion of the infrared radiation is absorbed by the component of interest in the sample The quantity of infrared radiation that is absorbed is proportional to the component concentration The detector is a gas microphone based on the Luft principle The detector is generally filled with the same gas being analyzed The infrared energy is therefore absorbed at the same wavelengths in the detector as that in the sample cell making the detector specific for the analyzed component The detector converts the difference in energy between sample and reference cells to a capacitance change This INFRARED
61. gnated factory transportation charges prepaid within the twelve 12 month period of warranty in the case of goods and part s and in the case of consumables within the ninety 90 day period of warranty This warranty shall be in effect for replacement or repaired goods part s and the remaining portion of the ninety 90 day warranty in the case of consumables A defect in goods part s and consumables of the com mercial unit shall not operate to condemn such commercial unit when such goods part s and consumables are capable of being renewed repaired or replaced The Seller shall not be liable to the Buyer or to any other person for the loss or damage directly or indirectly arising from the use of the equipment or goods from breach of any warranty or from any other cause All other warranties expressed or implied are hereby excluded IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY NO OTHER WAR RANTIES ARE GRANTED INCLUDING BUT NOT LIMITED TO EXPRESS AND IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Limitations of Remedy SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DE LAY IN PERFORMANCE THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WAR RANTY SHALL BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE IN NO CASE REGARDLESS OF THE FORM OF THE CAUSE OF AC TION SHALL SELLER S LIABILITY EXCEED THE PRICE TO BUY
62. gt AQ Z lt a I JER SE Shutter Block Assembly Spacer Sample Cell Desiccant Holders Motor Source Assembly Detector Assembly LONG PATH CELLS Sample Cell Shutter Block Assembly Motor Source Assembly Figure 4 8 Cell Assembly Rosemount Analytical Inc A Division of Emerson Process Management Maintenance and Troubleshooting 4 9 Instruction Manual 748332 F April 2003 4 13 CELL DESICCANT The reference cell may use a flowing reference If so desiccant is required A desiccant holder is used on the inlet and Model NGA2000 NDIR outlets to keep moisture from entering the reference cell see Figure 4 7 on page 4 7 The desiccant should be replaced each time the cell is opened refer to Table 4 1 below Before inserting desiccant purge cell with dry inert gas i e N2 GAS DESICCANT PART NUMBER CO Cardoxide 096218 CO Mg C104 2 096217 H20 Mg C10 2 096217 SOS Mg C104 2 096217 CH Mg C10 2 096217 Hexane Mg C10 2 096217 CO CO Cardoxide Mg C104 2 096217 096218 4 10 Maintenance and Troubleshooting Table 4 1 Cell Desiccant Rosemount Analytical Inc A Division of Emerson Process Management Rosemount Analytical Inc Model NGA2000 NDIR 4 14 MODULATION CHECK The modulation check is a measure of the energy absorption capacity of a gas mixture where total absorbency is 100 modulation and zero absorbency is 0 modulation The modulation check
63. i Instruction Manual 748332 F April 2003 Model NGA2000 NDIR iv Contents Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 PREFACE The purpose of this manual is to provide information concerning the components functions installation and maintenance of the NGA2000 NDIR and the System Accessories of the NGA2000 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 DEFINITIONS The following definitions apply to DANGERS WARNINGS CAUTIONS and NOTES found throughout this publication Highlights the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored WARNING Highlights an operation or maintenance procedure practice condition statement etc If not strictly observed could result in injury death or long term health hazards of personnel CAUTION 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 NOTE Highlights an essential operating procedure condition or statement Rosemount Analytical Inc A Division of Emerson Process Management Preface P 1 Instruction
64. ial set up controls Auxiliary module fj Calibration adjustment limits enabled if enabled uses curve no e Range to be linearized 1 controls and System set Calibration averaging time 5Secs Case temperature for coefficients 45 C Current span gas 9 69 ppm up menus see preceding Pl Calibration failure alarm Yes Set coefficients Calculated polynomial order 4 flow chard Local I O set Cal failure error allowed 5 Gas values shown as Percent Up mim ation i neuer Sato time out ES Gas concentrations E ero ranges i deg in the lodules manual pen ae SEPARATE Response time delay parameters Analyzer function Ready Range 1 t90 time 10 Secs Analyzer module set up i Range 2 190 time 1 Secs Calibration gas list E M t t Range 3 190 time 1 Secs fi s ibrati easurement parameters Range 4 t90 time 1 Secs Gas concentrations Calibration parameters Linearization parameters H Gas measurement parameters a LON update rate 1 per Sec Point 1 X Response time delay parameters ime i Analyzer parameter list i Range setting y Pi Output delay time 0 Secs i Gas value 0 Physical measurement parameters i Units sd i Raw reading 0 ppm Displayed physical parameters Linearization functions i Linearized values 0 ppm Analyzer tag IR Range Settings f Point 2 Minimum range 10 ppm i OG er 11 a i H Maximum range 7 5000 ppm Linearized values 10 ppm Auxiliary module set up i i Range lower limi
65. illator tune 85 Source current 1 212 A Percent modulation 85 Maintenance and Service 3 13 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR 3 14 Startup and Operation Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 SECTION 4 MAINTENANCE AND TROUBLESHOOTING balance adjustments These are factory set DANGER and should be adjusted only in the following ELECTRICAL SHOCK HAZARD cases Servicing requires access to live parts which can cause death or serious injury Refer servicing to qualified personnel if the operator has changed sources oscillator board or detector if the operator disassembles the bench to any 4 1 OVERVIEW degree NDIR Analyzer Module components that may require cleaning or replacement include Also available for maintenance adjustment through the Front Panel display and keypad e all printed circuit boards are the source current preamplifier gain referred to as Signal Gain on the sub menu e power fuse and the modulation check e the module fan 4 2 PCB REPLACEMENT Refer to Figure 4 1 on page 4 2 for locations e the chopper motor of the Signal Micro Power Supply Oscillator and optional Pressure Compensation boards e the source All PCBs except the Oscillator Board and the e the detector LON Power Board are secured to a side of the analyzer module that folds out while e flow sensor interc
66. ions Point 13 Gas value Raw reading Linearized value Point 14 Gas value Raw reading Linearized value Point to be measured ESCAPE Menu 85 POLYGAS8 000 000 000 000 000 000 000 Gas concentrations Point 15 Gas value Raw reading Linearized value Point16 Gas value Raw reading Linearized value Point to be measured ESCAPE Rosemount Analytical Inc A Division of Emerson Process Management 000 000 000 000 000 000 000 Instruction Manual 748417 B April 2003 Index 7 29 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR Menu 86 POLYGAS9 Gas concentrations Point 17 Gas value 000 Raw reading 000 Linearized value 000 Point 18 Gas value 000 Raw reading 000 Linearized value 000 Point to be measured 000 ESCAPE Menu 87 POLYGASO Gas concentrations Point 19 Gas value 000 Raw reading 000 Linearized value 000 Point 20 Gas value 000 Raw reading 000 Linearized value 000 Point to be measured 000 ESCAPE Menu 88 EXP_CAL Zero span calibration Measurement range number 000 Zero gas concentration 000 Span gas concentration 000 Sample flow 000 Raw measurement signal 000 Ranges with valid calibration 000 Status 000 Result FACTORS Zn SL 25 7 30 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 7
67. is the limit of the range that this polynomial will support The last line selects whether the curve is in use Menu 51 AMTRENDI1 Trend display control Select the two variables to be displayed Select the timebase The analyzer will now start recording these variables at a rate of 240 points over that time base averaging them To display the chart select display Menu 52 CALFACTORSI1 Calibration Factors The analyzer uses individual calibration factors for each range if so desired Select which range to examine 7 18 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Model NGA2000 NDIR Rosemount Analytical Inc Menu 53 APARLST2 Analyzer Parameter List Primary Variable Parameters Control mode Output delay time Range 1 upper limit Range 2 upper limit Range 3 upper limit Range 4 upper limit Range 1 lower limit Range 2 lower limit Range 3 lower limit Menu 54 APARLST4 000 000 000 000 000 000 000 000 000 Analyzer Parameter List Primary Variable Parameters Range 1 t90 time Range 2 t90 time Range 3 t90 time Range 4 t90 time Linearizer on range 1 Linearizer on range 2 Linearizer on range 3 Linearizer on range 4 Menu 55 APARLST5 000 000 000 000 000 000 000 000 Analyzer Parameter List Calibration Parameters Calibration averaging time Calibration failure alarm Cal f
68. it is supposed to be Make sure that the reading is stable before starting If you have changed the range fullscale value or any linearizer coefficients or enabled or disabled it or done anything else that would affect how it measures the gas you may have made it hard for the analyzer to calibrate If so manually adjust the coefficients until the readings are close to correct and try again Figure 3 9 Display Screens 1 of 5 Rosemount Analytical Inc A Division of Emerson Process Management Maintenance and Service 3 9 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR Expert controls and setup Expert analyzer controls Auxiliary module controls System set up Analyzer Module set up Auxiliary Module set up Local I O set up From MAIN MENU gt Analyzer module set up and Auxiliary module set up Outlined in the next flow chart Local I O set up information is included in the I O Modules manual Expert controls Measurement range number Range lower limit Range upper limit Linearizer Range and functional control Zero Span calibration Ranges with valid calibration Physical measurements analyzer Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag Module Tag CAL DATA Module Tag Auxiliary module controls This screen selects any module with a control screen This includes any auto calibration or sample module bound to this Dependent on which a
69. l and send an alarm if warning alarms are enabled In this case disable calibration limit checking and try again If you use non zero zero gases or the changes are 7 24 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748417 B Model NGA2000 NDIR April 2003 Rosemount Analytical Inc Menu 71 AM1VHIST Primary variable parameters Raw measurement signal 000 Signal gain setting 000 Oscillator tune 000 Chopper speed 000 Source current 000 Modulation check Percent modulation 000 Detector signal 000 Pk pk noise 000 Menu 72 LINFUNGT Linearization functions Polynomial set up Midpoint correction set up Use the polynomial set up to generate a linearizing polynomial from up to 20 gases With more than 6 gases it will produce a fourth order polynomial linearizer Use the midpoint correction for a piecewise linear final correction to bring up to three points precisely onto Menu 73 POLYSETUP Polynomial set up Range to be linearized 000 Current span gas 000 Calculated polynomial order 000 Gas values shown as 000 Gas concentrations A Division of Emerson Process Management Index 7 25 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR Menu 74 MIDPOINT1 Midpoint correction set up Range 1 Correction 000 Point being measured 000 Point 1 gas concentration 000 P
70. l from up to 20 gases Analyzer Parameter List Linearity coe Analyzer tag IR CO2 See 5 above First line s parameter Flow Second line s parameter Flow Third line s parameter Flow Fourth line s parameter Flow J Linearization parameters E NEXT Analyzer Parameter List Primary Variable Parameters Range 1 t90 time 10 Secs Range 2 190 time 1 Secs Range 3 t90 time 1 Secs Range 4 t90 time 1 Secs Linearizer on range 1 Enabled Linearizer on range 2 Enabled Linearizer on range 3 Enabled Linearizer on range 4 Enabled Analyzer Parameter List Calibration Parameters Calibration averaging time 5 Secs Calibration failure alarm Yes Cal failure error allowed 5 imi Calibration time out 60 Secs Pressure Limits Ranges zeroed TOGETHER Calibrate ranges SEPARATE Calibration adjustment limits ENABLED Physical Measurements tt Barometric pressure 10 13 hPa Sample pressure upper limit 15 kPa Sample flow 500 cc min Sample pressure lower limit 10 kPa Case temperature 45 C Detector temperature 52 C Pressure limits Analyzer Parameter List Temperature limits i Calibration Gases Zero gas range 1 0 ppm Zero gas range 2 0 ppm Zero gas range 3 0 ppm 550 Zero gas range 4 0 ppm Span gas range 1 9 3 ppm Span gas range 2 19 3 ppm Span gas range 3 101 1 ppm Span gas range 4 247 1 ppm Temperature Limits Case upper limit 60 C i Case lower limit 20C Displayed Paramet
71. min Sample pressure 12 3 kPa Case Temperature 55 3 C Basic controls Measurement range number 1 Range upper limit 10 ppm Range and functional control LOCAL Zero gas concentration 0 ppm Span gas concentration 9 89 ppm Ranges with valid calibration 182 Calibration status Ready If it won t calibrate Status Ready Expert controls and setup Expert analyzer controls Auxiliary module controls System set up Analyzer module set up Auxiliary module set up Local I O set up Expert and Technical menus follow in succeeding flow chart Technical configuration menu System set up Service menus Diagnostic menus Other module diagnostic menus Listing of all modules Analyzer Zero Are you sure You must have zero gas flowing through the analyzer This control does NOT control any auto cal Module bound to this analyzer If you are sure press ZERO again now Press left arrow key when you are done Calibration status Ready Error message for last zero 24 08 94 Analyzer Span Are you sure You must have zero gas flowing through the analyzer This control does NOT control any auto cal Module bound to this analyzer If you are sure press SPAN again now Press left arrow key when you are done Calibration status Ready Error message for last zero 24 08 94 If it won t calibrate Check that you are flowing the correct gas and the gas concentration is what
72. n Menu 103 SW DIAGI1 Software Diagnostics Shows the first detected software error since the variable on the bottom line was reset Please report any errors to your service representative They may mean nothing The analyzer has a lot of error recovery code Errors may therefore correct themselves Rosemount Analytical Inc A Division of Emerson Process Management Index 7 35 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR Menu 104 STOREDPVA Trend display control The analyzer stores 24 hours of 15 minute averages These values are only accessible via a PC Use the variables DATA INDEX and DATA POINT to access them Menu 105 ZERO NOW2 Analyzer zero re you sure You must have zero gas flowing through the analyzer This control does NOT control any auto calibration module bound to this analyzer If you are sure press ZERO again now Press the left arrow key when you are done Calibration status 000 ZERO Menu 106 SPAN NOW2 Analyzer span Are you sure You must have span gas flowing through the analyzer This control does NOT control any auto calibration module bound to this analyzer If you are sure press SPAN again now Press the left arrow key when you are done Calibration status 000 7 36 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748417 B Model NGA2000 NDIR April 2003
73. n Gas List menu 4 Press the HOME softkey to return to the Main Menu 5 Usethe J arrow key to select Basic Controls 3 4 Startup and Operation Typical Help Screen 6 Press the ZERO softkey to enter the Analyzer Zero menu press ZERO again and wait 7 Introduce span gas into the SAMPLE INLET press SPAN softkey to enter the Analyzer Span menu press SPAN again and wait 8 Press HOME to re enter the Main Menu 9 Press DISPLAY softkey for the Run Mode display If the user is unable to calibrate the Analyzer Module i e when ZERO or SPAN is initiated nothing happens a possible solution relates to the use of an incorrect gas for zeroing or spanning e g using a high concentration gas to zero or a zero gas to span the Analyzer Module Simply recalibrating with the appropriate gas es will not correct the problem because the ZERO OFFSET or SPAN FACTOR has been set to an extreme value in the process To remedy the problem do the following 1 Select the following from the Main Menu Expert Controls and Setup Rosemount Analytical Inc A Division of Emerson Process Management Rosemount Analytical Inc Model NGA2000 NDIR Analyzer Module Set Up and Calibration Parameters Using the 4 arrow select Zero Ranges press ENTER and using the up down arrows toggle to SEPARATE Do the same for the Calibrate Ranges selection Do not press ESCAPE at any time unless retention of prior settings is desired
74. n this flow chart Range 1 2 3 4 Factors Manufacturer s settings Zero offset 0 1000 500000 0 000015 10 ppm 1 0 0235 V 0 5250 V Span factor Stored settings Zero offset Span factor 500000 500000 Display Screens 2 of 5 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 From MAIN MENU Calibration gas list i Linearity coefficients i Zero gas range 1 Oppm Zero Span Calibration i Curve 1 2 3 4 Expert controls and setup i Span gas range 1 9 3 ppm AO coefficient 1 34523E 4 Expert analyzer controls i Zero gas range 2 0 ppm See 2 in Figure 3 10 d A1 coefficient 0 983751 Auxiliary module controls i Span gas range 2 19 3 ppm i A2 coefficient 0 115751 System set up i Zero gas range 3 0 ppm A3 coefficient 1 11575E 6 Analyzer Module set up i Span gas range 3 101 1 ppm Linearization parameters E A4 coefficient 7 3421E 12 Auxiliary Module set up i Zero gas range 4 0 ppm Range 1 linearizer Enabled i Curve upper limit 10 ppm Local I O set up i Span gas range 4 247 1 ppm if enabled uses curve no 1 i Curve over range 10 i Calibration Range 2 linearizer Enabled Curve under range 5 if enabled uses curve no 21 Status Enabled Range 3 linearizer Enabled i i if enabled uses curve no 3 For Expert analyzer Calibration Parameters Range 4 linearizer Enabled Polynom
75. nnonocccincnnnnnnnns Non flammable 0 C to 55 C 32 F to 138 F Flow Rate ccccceeeeeeeeeseeteeeeees 500 to 1400 ml min Pressure iis nn a id Maximum 690 hPa gauge 10 psig higher pressure in pressurized cell applications Particulates mmarorrrrrrrrrrnnernnrn filtered to lt 2 microns Dewpoint menonnvvnnnonnrrennnonnrrnnnennnr lt 40 C 104 F no entrained liquid Materials in Contact with Sample Gold plated Pyrex sapphire quartz Irtran FEP Teflon Viton A 316 stainless steel See the Preface section of the Platform manual for specifications regarding Platform related components e g case dimensions and the I O Module manual for specifications regarding I O e g relay outputs Rosemount Analytical Inc A Division of Emerson Process Management Description and Specifications 1 5 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR 1 6 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Rosemount Analytical Inc Model NGA2000 NDIR Instruction Manual 748332 F April 2003 SECTION 2 INSTALLATION Before starting to install this equipment read the Essential Instructions on the inside cover and the Safety Summary beginning on page P 2 Failure to follow the safety instructions could result in serious injury or death UNPACKING If the NDIR Analyzer Module is received as a separate unit carefully examine the shipping carton and
76. nt Analytical Inc A Division of Emerson Process Management Replacement Parts 5 1 Instruction Manual 748332 F April 2003 5 2 REPLACEMENT PARTS While the following sections list parts which are common to all NDIR Analyzer Modules the configuration number is required when ordering parts which are specific to an individual application The configuration number is on the Data Sheet in the rear of this manual 623998 Oscillator Board 657466 LON Power Board 655729 Detector Heater 622917 Temperature Sensor Detector 898733 Thermal Fuse with Q Pad 902931 Flow Sensor 655943 Case Temperature Sensor 655630 Power Supply Board 655670 Pressure Compensation Board 658350 Computer Analysis Board 655610 Signal Board 655893 Fan 655891 Chopper Motor 655925 Source Matched Pair 5 2 Replacement Parts Model NGA2000 NDIR Rosemount Analytical Inc A Division of Emerson Process Management Model NGA2000 NDIR 6 1 SECTION 6 Instruction Manual 748332 F April 2003 RETURN OF MATERIAL RETURN OF MATERIAL If factory repair of defective equipment is required proceed as follows 1 Rosemount Analytical Inc 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 inst
77. oint 2 gas concentration 000 Point 3 gas concentration 000 Point 1 reading 000 Point 2 reading 000 Point 3 reading 000 Span gas value 000 Menu 75 MIDPOINT2 Midpoint correction set up Range 2 Correction 000 Point being measured 000 Point 1 gas concentration 000 Point 2 gas concentration 000 Point 3 gas concentration 000 Point 1 reading 000 Point 2 reading 000 Point 3 reading 000 Span gas value 000 Menu 76 MIDPOINT3 Midpoint correction set up Range 3 Correction 000 Point being measured 000 Point 1 gas concentration 000 Point 2 gas concentration 000 Point 3 gas concentration 000 Point 1 reading 000 Point 2 reading 000 Point 3 reading 000 Span gas value 000 RANGE 4 7 26 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Model NGA2000 NDIR Menu 77 MIDPOINT4 Midpoint correction set up Range 4 Correction Point being measured Point I gas concentration Point 2 gas concentration Point 3 gas concentration Point 1 reading Point 2 reading Point 3 reading Span gas value ESCAPE Menu 78 POLYGAS1 000 000 000 000 000 000 000 000 000 Gas concentrations Point 1 Gas value Raw reading Linearized value Point 2 Gas value Raw reading Linearized value Point to be measured ESCAPE Menu 79 POLYGAS2 000 000 000 000 000 000 000 G
78. onnect wiring is still in place Remove the securing screws and fold out the entire e case temperature sensor panel To remove a particular board on the fold out panel label and unplug all interconnect wiring and remove securing hardware See to Figure 4 1 on page 4 2 Do the reverse to install a new board Use caution when installing connectors by observing correct position polarity and alignment of pins e Analysis cells and optical components e RTD detector temp controller e thermal fuse The only components that may require adjustment are the oscillator tune and shutter Rosemount Analytical Inc A Division of Emerson Process Management Maintenance and Troubleshooting 4 1 Instruction Manual AGE Model NGA2000 NDIR O TOP VIEW 7 A POWER SUPPLY PRESSURE MICRO BOARD SIGNAL BOARD COMPENSATION BOARD BOARD OF Eu O L SIDE VIEW I y 3 ees Cell ol bm om Figure 4 1 Printed Circuit Board Fold Out Panel Views shown in Figure 4 2 below and push and turn 4 3 POWER FUSE REPLACEMENT the fuseholder cap 1 4 turn counterclockwise Remove power to the Analyzer Module prior to Remove and replace the fuse as required fuse replacement To replace the Power Fuse view the front panel of the Analyzer Module as FRONT PANEL
79. ons electrolyte o rings etc are warranted to be free from defects in workmanship and ma terial under normal use and service for a period of ninety 90 days from date of shipment by Seller Goods part s and consumables proven by Seller to be defective in workmanship and or material shall be replaced or repaired free of charge F O B Seller s factory provided that the goods part s or consumables are returned to Seller s designated factory transportation charges prepaid within the twelve 12 month period of warranty in the case of goods and part s and in the case of consumables within the ninety 90 day period of warranty This warranty shall be in effect for replacement or repaired goods part s and the remaining portion of the ninety 90 day warranty in the case of consumables A defect in goods part s and consumables of the com mercial unit shall not operate to condemn such commercial unit when such goods part s and consumables are capable of being renewed repaired or replaced The Seller shall not be liable to the Buyer or to any other person for the loss or damage directly or indirectly arising from the use of the equipment or goods from breach of any warranty or from any other cause All other warranties expressed or implied are hereby excluded IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS SELLER GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY NO OTHER WAR RANTIES ARE GRANTED INCLUDING BUT NOT LIM
80. ordination 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 Check the tune and detector signal values against the factory settings listed in the 23 2 CO 0 ppm 50 Secondary Variable XXXX Secondary Variable XXX Secondary Variable XXXX Secondary Variable XXXX Menu Dual Info Run Mode Display Display Parms Figure 3 1 23 2 CO Analyzer XXXXXXXX Main Menu Basic Controls Expert controls and setup Operational configuration Technical level configuration Diagnostic and manufacturing service Delete alarm message Display Parms Info Main Menu Display Figure 3 2 3 2 Startup and Operation Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748332 F Model NGA2000 NDIR April 2003 23 2 CO Analyzer XXXXXXXX Basic Controls Measurement range Numbers Range upper limit 25 Range and functional control Local Calibration Status Ready Home Escape Zero Span Info Figure 3 3 Basic Controls Menu 23 2 CO Analyzer XXXXXXXX Expert controls and setup Expert analyzer controls Auxiliary module controls System set up Analyzer module set up Auxiliary module set up Home Escape Info Figure 3 4 Expert Controls and Setup Menu
81. pan gas is advised Also an optional Pressure Compensation Board is available that electronically compensates The Analyzer Module will not allow the user to increase the upper limit of a range beyond the maximum range software setting To change the maximum range value select the following from the Main Menu Technical Configuration Menu Service Menu Manufacturing Data Analyzer Manufacturing Data Select Maximum Range and use the arrow keys to scroll the indicated value The same applies for minimum range setting Rosemount Analytical Inc A Division of Emerson Process Management Main Menu Basic controls Expert controls and setup Operational configuration Technical level configuration Diagnostic and manufacturing service Basic level security expert technical Enter your security code with softkeys Security codes are set in the system setup menu in the Technical level menus Press five characters when Security code says READY Press six to return to READY Security code 54321 Model NGA2000 NDIR Analyzer alarm state Alarms report Gas Measurement Setup Analyzer operational state Instruction Manual 748332 F April 2003 Current measurement parameters Measurement range number Range change control Measured Gas Linearization mode 4 Local co2 ON ON Normal Normal Failure Current measurement parameters Response time 2 0 Secs Sample flow 1000 ml
82. pper speed 5Hz Source current 1 212 A Modulation check Percent modulation 20 Calibration time out 60 Secs Calibration factors Pk pk noise 0 ppm Physical measurements See 6 in Figure 3 12 Temperature control Fan lower setpoint Fan upper setpoint Minimum fan duty cycle Case temperature Detector setpoint Detector P gain Detector I gain Detector bias Detector temperature Miscellaneous control parameters Fan current 35 mA Fan duty cycle 50 Heater current 1 7A Heater duty cycle 50 Source current pot setting 50 Actual source current 1 212A Alarm messages valid for FAILURE Barometric pressure parameters Pressure transducer Present Barometric pres Compensation Enabled Measured pressure 12 3 kPa Transducer offset 1013 hPa Transducer slope 1 0 Transducer PGA gain 1 0 Software diagnostics Last message No error And No error And No error And No error And No error And No error And No error And No error Edit to reset Report Software error code 1 no error 1 Display Screens 5 of 5 Instruction Manual 748332 F April 2003 Modulation check l Measurement range number 1 Detector signal 7 0 Signal gain setting 4 gt Status Ready Instructions Flow zero Then Watt Percent modulation 20 updated only at the end of this test Calibration Factors See 3 in Figure 3 12 HISTORY y Primary variable parameters Signal gain settings 4 Osc
83. products to the proper electrical and pressure sources e To ensure proper performance use qualified personnel to install operate update program and maintain the product e When replacement parts are required ensure that qualified people use replacement parts specified by Rosemount Unauthorized parts and procedures can affect the product s performance place the safe operation of your process at risk and VOID YOUR WARRANTY Look alike substitutions may result in fire electrical hazards or improper operation e Ensure that all equipment doors are closed and protective covers are in place except when maintenance is being performed by qualified persons to prevent electrical shock and personal injury The information contained in this document is subject to change without notice Pyrex is a registered trademark of Corning Glass Works Irtran is a registered trademark of Eastman Kodak Co Teflon and Viton is a registered trademark of E I duPont de Nemours and Co Inc Ty Rap is a registered trademark of Thomas amp Betts Corp 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 mail gas csc EmersonProcess com http www processanalytic com E MM E RSO N lanagem k O mu raf Friece i ent Model NGA2000 NDIR Instruction Manual 748332 F April 2003 TABLE OF CONTENTS PREFAGE i
84. rates Also the effect of increased cell pressurization can be 2 2 Installation Rosemount Analytical Inc Model NGA2000 NDIR negated if the same flow rate is used for sample zero and span gases But if flow is high enough to cause elevated pressure careful control tighter tolerance of flow rate is required to avoid errors If flow is kept at or below 2 SCFH 1 L min sample and instrument temperatures reach equilibrium regardless of stream temperature within specifications 0 to 55 C At extremely high flow rates this may not be true although no such effect has been noted up to 18 SCFH 9 L min See Table 2 1 on page 2 3 for cell purging times at atmospheric sample pressure Sample Pressure Filtration Sample should be introduced to the Analyzer Module at a maximum 690 hPa gauge 10 psig Pressurized applications are available which require pressurized cells and careful control of flow rates consult factory for these applications Sample should be filtered for particulates down to two microns Leak Test The Analyzer Module is completely tested at the factory for gas leakage The user is responsible for testing for leakage only 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 2 5 GAS CONNECTIONS See Figure 2 2 on page 2 3
85. rational ambient pressure range of 800 to 1060 hPa The original PMD and NDIR instruments were designed for use with a resistance bridge type of pressure transducer requiring an external gain amplifier with an offset trim The Vaisala transducer contains an integral gain amplifier that is scaled for a 0 to 5 Vdc output The 661380 Interface Board contains the cir cuitry to convert the Vaisala single ended 0 to 5 V dc output into the referenced bridge 0 to 0 625 V dc output configuration that is re quired by the Analyzer module s Computer Analysis Board The Vaisala transducer kit is backward compatible with the original Rose mount pressure transducer Vaisala Interface Board Circuit Function The Vaisala Interface Circuit board adapts the single ended analog output of the Vaisala sensor into a Precision Voltage referenced balanced bridge at 1 atmosphere input con figuration A Bridge Balance pot on the Vaisala Interface Circuit board provides the fine trim Bridge Balancing calibration ad justment that is required to set up each indi ROSEMOUNT Analytical 1 1 vidual transducer at a known ambient air pressure Test points are provided on the cir cuit board for this adjustment The Vaisala transducer output range is 0 to 5 Vdc The Vaisala analog output voltage is inverted and fed into a balanced summing node that is referenced by a precision regulator The summing node voltage is 0 000 Vdc at
86. re is barometric pressure 3 8 Connections Return Authorization 6 1 electrical 2 4 inlet outlet 2 2 network 2 4 S power 2 4 sample dewpoint 1 3 2 2 D excessive flow rate 2 2 flow rate 2 2 pressure 1 3 pressure filtration 2 2 temperature 1 3 F shipping damage 2 1 for non standard fullscale ranges linearization coefficients 3 6 T I O Module W installation 2 1 initial startup 3 2 L leak test 2 2 daisy chaining 2 4 detector signal 3 2 tune signal 3 2 warm up perio 3 2 Rosemount Analytical Inc A Division of Emerson Process Management Index 7 1 Instruction Manual 748332 F April 2003 Model NGA2000 NDIR 7 2 Index Rosemount Analytical Inc A Division of Emerson Process Management 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 ma terial under normal use and service for a period of ninety 90 days from date of shipment by Seller Goods part s and consumables proven by Seller to be defective in workmanship and or material shall be replaced or repaired free of charge F O B Seller s factory provided that the goods part s or consumables are returned to Seller s desi
87. ring Diagram ooooccccnoccccnnnoccccccononcnncnnoncnc nano cnn aae nn nr narrar rra 2 5 Figure 2 5 Outline and Mounting Dimensions arrrrnrrnnnnvnnnnnvnnerrrrnnrrnnnnrenennnnrrrrenrnrnnnnnnenennn 2 6 Figure 3 1 Run Mode Display ecse a R a N E TRR TE 3 2 Figure 3 2 Main Menu Display rrsnnnvnnnnnnnvnnovnnnnvnnnnannvnnnnnnnvnnnnmnnnnnnnnnnnnsnnnnnnnnennnnvntenennennevennene 3 2 Figure 3 3 Basic Controls MeNU ooconnncccnncccnocccnnnnnnnancccnnncnn nora nn cnn crac anna 3 3 Figure 3 4 Expert Controls and Setup Men occcccincccnnncconocnnncccccnnnnnnrna nano cn cn nc cnn rca nr narran 3 3 Figure 3 5 Technical Level Configuration Menu rrrrrnnnrrnnnnvvnnnrrvnnnrrvnnnvnnnnnnnrrrrenrnrnnnennenennn 3 3 Figure 3 6 Typical Help Screen oooonnccccnccnnncinnncccnonncononnnn cnn cnn nnn cnn rca nc 3 4 Figure 3 7 Typical Linearization Curve Linearizer OFF mannrnnnnnvnnnnrrnnnnvennnvnnnnrrennnrrnnrnnenrnnne 3 7 Figure 3 8 Operator Determined Linearization Curve Normalized oooonnicccnccnnnnncnncnnnccccns 3 7 Figure 3 9 Display Screens 1 Of 5 mrnrrnnnrrnnnnrnnnenvvnrnrrvnnnrnnnnnrnrerrvrnnrrnnnnnnnnenresrrrresnnrnnennenennne 3 9 Figure 3 10 Display Screens 2 Of 5 mrnrrnnnnvrnnnnrnnnnvvnrnrrennnrrnnnnnnnrerrennnrrennnnenenrenrrrresnnrnnsennennn 3 10 Figure 3 11 Display Screens 3 Of 5 msnrrnnnnrnnnnnvnnnnvvnrnrrennnrrnnnnnnnrnrrernnrrennnnenenrenrsrreennrnensnnennn 3 11 Figure 3 12 Display Screens 4 Of 5
88. ro gas through the analyzer and allow it to stabilize Then press the START softkey and wait while the analyzer goes through its test sequence You can see the variable on the line titled Status change as it does so The analyzer will require you to flow span gas at one point When it is done it will calculate the percent modulation for you Percent modulation means the amount of absorption of light by the span gas compared with the complete lack of light from the measurement cell s source when A Division of Emerson Process Management Index 7 23 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR Menu 68 BAROM PARMI Barometric pressure parameters Shows whether the optional pressure transducer is installed or not Also this screen allows you to set the transducer Use the offset at atmospheric pressure and pull a yacuum of about 25cm H20 on the transducer and use the slope to make it read correctly Make sure that only one analyzer in a system is set to transmit its barometric pressure information Menu 69 SW_DIAG Software diagnostics Last message 000 And 000 And 000 And 000 And 000 And 000 And 000 And 000 Edit to reset 000 Menu 70 CALI1 Calibration info Use the calibration parameter menu to select whether to calibrate ranges together or not If together zeroing or spanning will go through each range one by one If the change required is too great it will fai
89. rument In no event will Rosemount be responsible for equipment returned without proper authorization and identification Carefully pack the defective unit in a sturdy box with sufficient shock absorbing material to ensure no additional damage occurs during shipping In a cover letter describe completely e The symptoms that determined the equipment is faulty e The environment in which the equipment was operating housing weather vibration dust etc e Site from where the equipment was removed e Whether warranty or non warranty service is expected e Complete shipping instructions for the return of the equipment Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in the Rosemount Return Authorization prepaid to the address provided by Rosemount CSC Rosemount Analytical Inc Process Analytical Division Customer Service Center 1 800 433 6076 A Division of Emerson Process Management 6 2 6 3 If warranty service is expected the defective unit will be carefully inspected and tested at the factory If the failure was due to the conditions listed in the standard Rosemount warranty the defective unit will be repaired or replaced at Rosemount s option and an operating unit will be returned to the customer in accordance with the shipping instructions furnished in the cover letter For equipment no longer under warranty the equipment will be r
90. same as the raw reading RSTR MN restores the manufacturing values RSTR ST restores the A Division of Emerson Process Management Index 7 33 Instruction Manual 748417 B April 2003 Model NGA2000 NDIR Menu 98 RFHIST2A Range 2 Factors Manufacturer s settings Zero offset 000 Span factor 000 Stored settings Zero offset 000 Span factor 000 Menu 99 RFHIST3A Range 3 Factors Manufacturer s settings Zero offset 000 Span factor 000 Stored settings Zero offset 000 Span factor 000 Menu 100 RFHIST4A Range 4 Factors Manufacturer s settings Zero offset 000 Span factor 000 Stored settings Zero offset 000 Span factor 000 7 34 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748417 B Model NGA2000 NDIR April 2003 Menu 101 TWEAKI1 Midpoint correction set up This function allows you to set up to three midpoints that the analyzer will It does this with a piece wise linear algorithm This polynomial linearization First disable the correction Set the Then enter the first midpoint gas value run the gas and when stable press SET the actual reading but the analyzer will mm dd mm Menu 102 INIT Re initialize the analyzer Are you sure INIT will erase ALL the configuration data but not manufacturing data including serial numbers etc If you are sure press INIT agai
91. scillator tune and detector signals are within 5 of the factory settings in Primary Variable Parameters and Modulation Check menus no adjustment is necessary If not see Figure 4 5 on page 4 5 and Figure 4 6 on page 4 7 for Oscillator Tune and Source Balance Shutter adjustments and do the following Open Platform front panel if present CAUTION HAND INJURY HAZARD Do not place hands or fingers in Platform front handles when the front panel is open Dropping front panel while hand or fingers are inside either handle can cause serious injury 4 6 Maintenance and Troubleshooting Model NGA2000 NDIR Open Analyzer Module front panel Access the oscillator tune value in the Primary Variable Parameters menu Adjust oscillator tune knob to its maximum setting and then turn it counterclockwise to 80 of that maximum setting Access the detector signal value in the Modulation Check menu Flow zero gas nitrogen through the sample cell until the display reading stabilizes CAUTION DELICATE COMPONENTS The shutter is a delicate component with only a six degree rotation Take care when making the required adjustments Using an appropriate screwdriver that will fit through the Source Balance Adjustment Screw Holes see Figure 4 5 on page 4 5 rotate the sample shutter adjust screw until a minimum reading on the display is obtained A typical reading is 0 2 through 0 5 Add 0 5 V to the value obtained in Step
92. t Oppm Point to be measured Point 1 Select an auxiliary module for set up i pales add pue Analyzer function Ready Local I O set up i odds de SE i Range 2 upper limit 100 ppm Module Tag E i Range 3 lower limit 0 ppm Module Ta i i Range 3 upper limit 250 ppm m a Module Tag i i Range 4 lower limit Oppm Midpoint correction set up Module Tag i Range 4 upper limit 1000 ppm E Range 1 2 3 4 Module Tag i i Correction Disabled Module Tag i Point being measured Pt1 i i Point 1 gas concentration 100 ppm Point 2 gas concentration 120 ppm Point 3 gas concentration 150 ppm i Point 1 reading 100 ppm Gas measurement units ppm f Point 2 reading 120 ppm Pressure measurement units psig Point 3 reading 150 ppm Dependent on which auxiliary module is Units present on the network i See I O Modules manual Temperature measurement units F Span gas value 100 ppm Variables are still sent as the basic SI unit Analyzer function Ready Linearization functions Polynomial set up Analyzer Parameter List Primary Variable Parameters Control mode LOGAL Output delay time 0 Secs Range 1 upper limit 10 ppm Range 2 upper limit 100 ppm Range 3 upper limit 250 ppm Range 4 upper limit 1000 ppm Range 1 lower limit 0 ppm Range 2 lower limit 0 ppm Range 3 lower limit 0 ppm Range 4 lower limit 0 ppm Midpoint correction set up Ed Use the polynomial set up to generate a linearizing polynomia
93. user can obtain an output that is linear with concentration by initiating a linearizer which is based on a fourth order polynomial The linearizer is incorporated in the Analyzer Module s electronic circuitry and is adjustable through interconnection with the network The entire Analyzer Module is designed as a slide in module if configured in stand alone instrument fashion removable from the front of the Platform with gas connections made from the rear All electronics relative to sample detection and conditioning are included in this module 1 2 TYPICAL APPLICATIONS The NDIR Analyzer Module is designed to cover a wide range of process stack and automotive 1 3 applications Typical measurements include E Chemical and Petroleum e Carbon dioxide Manufacture of ethylene oxide phthalic anhydride and ammonia nitrogen generation and producer gas monitoring e Carbon Monoxide Stack monitoring A Division of Emerson Process Management e Methane Ammonia manufacture e Acetylene Manufacture of acetylene acrylonitrile and vinyl chloride e Sulfur Dioxide Sulfuric acid stack gas Food and Agriculture e Carbon Dioxide and Water Vapor Blanketing of perishables fermentation processes photosynthesis studies personnel protection Aerospace and Oceanography e Carbon Dioxide Carbon Monoxide and Water Vapor Diving and space chambers Metals and Ceramics e Carbon Dioxide Monitoring of producer gas steel conv
94. uxiliary module is present on the network See I O Modules manual System Set Up Front panel control Display resolution Auxiliary lines See Platform manual for a flow chart of these displays Y Zero Span diagnostic data Date of last zero 24 08 94 Error message for last zero 24 08 94 Error percentage for last zero 5 Raw signal at last zero 500000 Last zero gas would read 0 83 ppm Date of last span 24 08 94 Error message for last span Great Error percentage for last span 5 Raw signal at last span 500000 The last span gas would read 11 3 ppm Zero gas concentration Span gas concentration Sample flow Status Result Calibration Factors Range 1 factors Range 2 factors Zero offset Span factor Range 3 factors Range 4 factors Zero compensation factor Span compensation factor Measurement range number Hardware zero offset Raw measurement signal Figure 3 10 3 10 Startup and Operation Zero Span Calibration Measurement range number 1 Raw measurement signal Ranges with valid calibration Calibration adjustment limits Range 1 2 3 4 Factors Fullscale range at calibration J Physical Measurements Sample flow 1000 ml min Flow lower limit 150 cc min Flow upper limit 250 cc min Barometric pressure 12 3 kPa Case temperature 54 38C 0 ppm 9 89 ppm 1000 ml min 0 3256 V 182 Ready Enabled See 1 o

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