Emerson NGA2000 TO2 Oxygen Equipment User Manual
Contents
1. ELECTRONICS SAMPLE IN gt gt O SAMPLE OUT Gee O SENSING CATHODE SECONDARY CATHODE O SENSING ANODE Figure 1 1 Trace Oxygen Detector Technology 1 2 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748374 F Model NGA2000 TO2 March 2003 Sensor Assembly Network Power Module Sensor Computer Sample Flow Board Sensor Power Board Figure 1 2 Trace Oxygen Analyzer Module Top View Rosemount Analytical Inc A Division of Emerson Process Management Description and Specifications 1 3 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 1 5 SPECIFICATIONS a b C d General Measurement Gpecles Trace Oxygen Ranges euch enasini alada 0 to 100 ppm output scalable down to 0 2 ppm fullscale ACCUIACY oeaiei aa ni 3 of reading or 0 02 of range except for ranges lt 100 ppm 3 of reading or 0 05 of range Sensitivity cooooooonnccnnnccononccinncnnancncnnn lt 10 ppb Oxygen Ke 1 of fullscale peak to peak A a TITO 1 of fullscale Response Time Typically 90 in less than 20 seconds Zero Drills iii lt 1 of fullscale 24 hours at constant temperature Span DIE is lt 1 of fullscale 24 hours at constant temperature Effect of Temperature 0 32 of reading per F from 70 F 0 58 of reading per C from 21 C Effect of Flow lt 2 of reading for a flow change of2. Fa AA E a AP LD Bech ZC r AA Mihe background ga concentralion ter background gas factor bad gat seal lachar CA ELA SANTO A Z i compute new adjusted gas scale lachen The Physical Measurements screen displays sample flow information as well as electrolyte level validity TETAN ESCAPE 7 4 Appendix A Menu Structure Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748374 F Model NGA2000 TO2 March 2003 Temperature Parameters selection directs the user to the sensor temperature information Sensor lemperalue ASA TN Sensor tempera conned STRE C ow temperaluse cakbraliog _ Af Sale ee igh Lempeaiurg calibration MAA TO A HOME ESCAPE It is recommended that the user not conduct temperature calibration of the sensor in the field Rosemount Analytical Inc A Division of Emerson Process Management Appendix A Menu Structure 7 5 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 7 6 Appendix A Menu Structure Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748374 F Model NGA2000 TO2 March 2003 SECTION 8 APPENDIX B USER INTERFACE HELP This section provides a means of rapidly finding This section consists of a series of titles describ any desired function or configuration factor in ing the function or configuration desired with a the menu system series of menu titles that show the path taken to that funct
3. SECTION 5 REPLACEMENT PARTS WARNING 5 1 MATRIX PARTS INTEGRITY Each analyzer is configured per the cus Tampering with or unauthorized substi tomer sales order Below is the TO2 sales tution of components may adversely af matrix which lists the various configurations fect safety of this product Use only available factory approved components for repair To identify the configuration of an analyzer locate the analyzer name rating plate The sales matrix identifier number appears on the analyzer name rating plate TO2 NGA2000 TO2 TRACE OXYGEN ANALYZER MODULE Code Software version 01 Current version software 02 v2 4 Software 03 v3 X Software Code CONFIGURATION IDENTIFIER A1 RANGE 0 100 ppm B1 RANGE 0 100 ppm with X GAS Sensor X99 Special Ranges Code CABLE SELECTION 00 None utilize mounting ears on analyzer module Al Base Plate Assembly TO2 01 Al B1 EXAMPLE 5 2 REPLACEMENT PARTS 658350 Computer Analysis Board 657466 LON Power Board 658300 Power Supply Board 902931 Sensor Gas Flow 904675 Sensor Oxygen 0 100 ppm 904676 Electrolyte Solution 903347 Fuse Time Delay 6A 250 VAC Rosemount Analytical Inc A Division of Emerson Process Management Replacement Parts 5 1 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 5 2 Replacement Parts Rosemount Analytical Inc A Division of Emerso
4. tilled or deionized water Sensor Cover Indicator TOP MIEW Enclosure Electrolyte Level Back Wall U Sensor Reservoir HA fi EJ Eege Mounting Screws 2 places SIDE VIEW Mounting Screws 3 places Flow Sensor Figure 4 1 Trace Oxygen Analyzer Sensor Assembly Rosemount Analytical Inc A Division of Emerson Process Management Maintenance and Troubleshooting 4 1 Instruction Manual 748374 F March 2003 a Water Addition To add water 1 Remove the top cover of the analyzer module 2 Unscrew the black sensor cover 3 Slide the cover back just enough to al low the neck of the fill bottle to fit into the sensor reservoir 4 Add distilled or deionized water using the fill bottle provided with the analyzer module Fill to approximately midway between the min and max level indica tors on the sensor label Be careful not to spill water splash electrolyte or over fill sensor 5 Replace the sensor cover securely 6 Replace the top cover of the analyzer module If the electrolyte alarm is activated but the sensor shows sufficient electrolyte the elec trolyte may have been contaminated by substances present in the sample which are chemically incompatible with the sensor or electrolyte If this should occur the electro lyte must
5. 250 cc min 0 5 SCFH Operating Temperature 32 F to 113 F 0 C to 45 C Power Heourements 24 VDC 5 10 W max Ripple and Noise lt 100 mV peak to peak Line and Load Regulations lt 1 Sample Sample uununsesssssnnsnnenannnnnnnnnnnnn Non flammable below 100 ofthe LEL Flow Hate 0 5 to 1 5 L min Supply Pressure 1027 to 1082 hPa absolute 0 2 to 1 0 psig Temperature 32 F to 113 F 0 C to 45 C Particulates nania filtered to lt 0 1 mg L non condensing at ambient temperature Sample Humidity non condensing at ambient temperatures Physical Materials in contact with sample Stainless steel Teflon Delrin neoprene DIMENSIONS See Figure 2 2 Trace Oxygen Analyzer Outline and Mounting Dimensions on page 2 3 Weight ee 6 8 kg 15 lbs MOUNT titi Horizontal external to Platform or custom installed in a panel Case Classification General Purpose for installation in weather protected area Max Separation from Platform 1600 m 1 mile Gas Connections Sample soria resina 1 4 inch O D tube fitting Sample Out 1 4 inch O D tube fitting See the Preface Section of the Platform manual for specifications regarding Platform related components 1 4 Description and Specifications Rosemount Analytical Inc A Division of Emerson Process Management Rosemount Analytical Inc Model NGA2000 TO2 Instruction Manual 748374 F Marc
6. Division Customer Service Center 1 800 433 6076 Rosemount Analytical Inc A Division of Emerson Process Management 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 repaired at the factory and re turned as directed by the purchase order and shipping instructions 6 2 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 6 3 TRAINING A comprehensive Factory Training Program of operator and service classes is available For a copy of the Current Operator and Service Train ing Schedule contact the Technical Services Department at Rosemount Analytical Inc Customer Service Center 1 800 433 6076 Return of Material 6 1 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 6 2 Return of Material Rosemount Analytical Inc A Division of Emerson Process Management Model NGA2000 TO2 Instruction Manual 748374
7. F March 2003 SECTION 7 APPENDIX A MENU STRUCTURE 7 1 NGA TO2 MENU STRUCTURE INTRODUCTION This Appendix contains a listing of the menus belonging to the TO2 Analyzer Module It also lists the available configuration elements and where they are to be found 7 2 NGA TO2 ANALYZER MODULE MENUS Main Menu Basic controls Expert controls and set up Operational configuration Technical level configuration Diagnostic and manufacturing serrice PARMS NEXT LOCK CN From the main menu you can access the three major menu trees Basic controls allows access to range num ber selection and range limit Quick Start initia tion and status and Sleep Mode status and cancellation i DEAA ange sppes bat CENAS Range and hanciiomal control OO alt deen mode nibiabe quick star Rosemount Analytical Inc A Division of Emerson Process Management Expert Controls and set up allows access to the Expert analyzer controls and Analyzer module set up sub menus Expert controls and set up Expert analyzer controls ZO Aisa Auxiliary module controls FO EE ALA System set up AY So Seas d Analyzer module set up ZC OG Gaam Auxiliary module set up EA AGGE LAG Aye F EL ZA Ar D ESCAPE The Expert Controls menu allows range num ber and functional control selection It also shows the range upper and lower limits DRANGE CUARENTA d INIA ange and functional co
8. Figure 1 1 Trace Oxygen Detector Technology 1 2 Figure 1 2 Trace Oxygen Analyzer Module Top View 1 3 Figure 2 1 Analyzer Module Interconnection with Instrument Platform 2 2 Figure 2 2 Trace Oxygen Analyzer Outline and Mounting Dimensions een 2 3 Figure 2 3 Trace Oxygen Analyzer Back Panel CONNECtIONS oooccconnncinnccnnncccconccnnnonananaccnnnos 2 4 Figure 2 4 Trace Oxygen Analyzer Front Panel c oncicinccinnnnnnnnccnnccccnnornnancnccancc rancia rnnnnccin 2 5 Figure 3 1 Run Mode Display eesi tenean aE a IRE nennen 3 1 Figure 352 Man M n acotada 3 1 Figure 3 3 Basic Controls Mem 3 2 Figure 3 4 Expert Controls Men 3 2 Figure 3 5 Analyzer Module Set up Mem 3 2 Figure 3 6 Typical Help Menu shown is Zero Span Calibration Help 3 2 Figure 4 1 Trace Oxygen Analyzer Sensor Assembly d ccconcccinncccnccnnonicnncccccanccnonrnnn nana nc 4 1 Figure 4 2 Load Factory Calibration Data Men 4 3 LIST OF TABLES Table 3 1 Trace Oxygen Analyzer Module Alarms ccccceceeeeeeeeeeeeeaeeeeneeeeeaeeesaeeneneeseaees 3 5 Rosemount Analytical Inc A Division of Emerson Process Management Contents iii Instruction Manual 748374 F March 2003 Model NGA2000 TO2 iv Contents Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748374 F Model NGA2000 TO2 March 2003 PREFACE INTENDED USE STATEMENT The purpose of this manual is to provide information concerning
9. al lows access to user calibration screens and the factory calibration data screens for viewing and data entry The Gas Scale Factor menu is also accessed from this menu own MLN Or EH de HA oad factory calibration data A art AT libration data display A A Pelt ass scale factor ESCAPE It is not recommended to conduct user zero and span calibration functions since the sensor is factory calibrated and does not exhibit detect able degradation of calibration over time The risk of erroneous calibration due to inaccurate gases is greater than the potential of factory calibration change ESCAPE Appendix A Menu Structure 7 3 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 The Load Factory Calibration screens allow The Gas Scale Factor screens allow the user the user to enter the factory calibration data to enter in information relating to the back unique to the sensor in the Analyzer Module H ground gas of the trace oxygen measurement the sensor is replaced this data must be en The total concentration of all entries must add tered from the data sheet provided with the re up to 100 or the unit will not compute the new placement sensor Additional data points can adjusted gas scale factor be accessed by pressing the MORE softkey Z MS Aa GG Z CT TEME e background gaz concendiation Z background gat concentrabion HI background gar concentration JHE background gas concentration
10. and destroy it 2 4 Installation Rosemount Analytical Inc A Division of Emerson Process Management Model NGA2000 TO2 Instruction Manual 748374 F March 2003 Network Connections Power Connection Fuse Power Indicator Light Figure 2 4 Trace Oxygen Analyzer Front Panel 2 5 ELECTRICAL CONNECTIONS NOTE Electrical connnections must be made in compliance with National Electrical Code ANSI NFPA 70 and or any applicable na tional or electical codes Two electrical connections are required on the Analyzer Module POWER and NETWORK See Figure 2 4 above On the Analyzer Mod ule two NETWORK connectors are available Rosemount Analytical Inc A Division of Emerson Process Management either of which is appropriate for 1 intercon nection with the Backplane of the Platform or 2 daisy chaining with other NGA2000 compo nents A star connection is acceptable for LON lengths under about 10 meters Comnect a source of 24 V 5A DC power to the power inlet Make sure that the ground connec tion is made and that this is separate from the power return lead Failure to ensure a good ground may result in random noise and distur bance in the analyzer readings Installation 2 5 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 2 6 Installation Rosemount Analytical Inc A Division of Emerson Process Manageme
11. and remove the black Sensor cover by unscrewing counterclockwise Add distilled or deionized water to the Sen sor to the maximum level indication on the Sensor reservoir Let Sensor stand for ap A Division of Emerson Process Management proximately 15 minutes and check for leaks around the base of the reservoir and at the seams and corners If a leak is found con tact the factory before proceeding Drain the Sensor Fill the Sensor with one bottle of electrolyte supplied with the analyzer module Use the entire contents of the bottle NOTE Do not add water The volume and con centration of the bottled electrolyte is pre measured Reinstall the black Sensor cover and care fully reinstall the Sensor Assembly inside the Analyzer Module Do not the tilt the Sensor Assembly excessively as electrolyte may leak out 2 3 LOCATION See Figure 2 2 on page 2 3 The TO2 Ana lyzer Module comes standard with mounting ears for easy installation on flat horizontal sur faces Install the TO2 Analyzer Module in a clean weather proofed vibration free location free from extreme temperature variations and moisture 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 81 F Temperature change should not exceed 10 C 18 F per hour The same temperature restrictions apply to the location of the zero and span gas cyl
12. complete Sensor Assembly from the Analyzer Module Remove the black sensor cover and invert the Sensor Assembly over a suitable receptacle Flush the Sensor twice with deionized water Dispose of the discarded electrolyte and rinse water in ac cordance with National Federal State and Lo cal regulations See MSDS in the rear of this manual Refill the Sensor with electrolyte as instructed in Section 2 2a on page 2 1 Reinstall the Sensor Assembly and reconnect J5 and J6 to the power board SENSOR REPLACEMENT If the Sensor cannot be regenerated by the ad dition of water or the replacement of electrolyte or if the Sensor shows signs of leakage it may be necessary to replace the Sensor To replace the Sensor remove the Sensor Assembly and remove the electrolyte as described in Section 4 3 above Reinstall the black sensor cover to catch any residual electrolyte Invert the Sensor Assembly and locate the four 4 mounting screws which hold the Sensor to the Sensor As sembly mounting plate Remove and retain the four screws Rosemount Analytical Inc A Division of Emerson Process Management Rosemount Analytical Inc Model NGA2000 TO2 Install replacement Sensor in reverse order Check Sensor for leaks and add electrolyte as described in Section 2 2a on page 2 1 Rein stall Sensor Assembly in Analyzer Module and reconnect J5 and J6 to the power board A ter installation of new Sensor it will be neces sary to load the
13. dias P 1 DOT EE P 1 Dally SUMIMANY TEE P 2 Authorized Personnel Roses eege ee Ee eene EEN P 2 General Precautions For Handling And Storing High Pressure Gas Cylinders P 4 DIU ao ls P 5 eu P 5 ER P 6 1 0 DESCRIPTION AND SPECIFICATIONS uuur22u04400044000nnn0nnnnnnnn ann nnnnannnnnannnnnnnnnannnnnn nenn 1 1 1 1 OVEIVIOW EAE A PI TEE EAA IE IET AITE TE da a aaa 1 1 1 2 Typical ee ee 1 1 1 3 Theory OF TEChnoloGy EE 1 1 1 4 Feuer ge ON 1 1 1 5 eet lee 1 4 ON 1 4 Dis SAMP ia EE 1 4 A E ea EE A reso oa ea ated EIERN ener 1 4 Os Gas G hnections u erases af atest Sap ands each eA tedden te a ete eee ae 1 4 2 0 INSTALLATION eessen DEES EEN 2 1 2 1 le le A ae i Ae A eh ec A av ee a 2 1 2 2 ASSOMDIY viii ar dee dn ai 2 1 a Electrolyte Addition 2 ea a 2 1 2 3 Location a ann niert 2 1 2 4 EE 2 1 DN e CEET 2 1 Dev een NEE 2 2 Cr Leak Test deta ld adds 2 4 2 5 Electrical GOnMe Ctions iii rta idea 2 5 3 0 STARTUP AND OPERATION uuusesnunnsansnnannnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnannnnnnnnnnnnnnnnannnnnennnnnnn 3 1 3 1 MEDIEN gees et gege Eder en 3 1 3 2 NEE CG 3 1 a Run Mode Display occiso fire fr 3 1 Diy Meru RTE 3 1 Gx Help EE 3 2 3 3 Startup ProcequIO isaac dano 3 3 3 4 Quick Start EStdt ad 3 3 3 5 Gas Scale Factor ASF RE na 3 3 3 6 AAA RR 3 3 3 7 Routine Operation 2a a lodi E 3 4 3 8 Alarm Teller e EE 3 5 Rosemount Analytical Inc A Division of Emerson Pro
14. 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 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
15. range s upper limit Sleep mode and quick start status It also allows quick start initiation or exit from sleep mode In the figure above the words in italics are the names of the network variables whose values are in fact shown on the screen The Expert controls menu is as follows Expert controls Measurement range number Range lower limit CURRENTRNGHI Range upper limit Range and functional control CONTROL ESCAPE Figure 3 4 Expert Controls Menu This menu shows the current range number and range limits 3 2 Startup and Operation Model NGA2000 TO2 The analyzer range settings may be config ured through the Analyzer Module set up menu under Expert controls and set up Analyzer module set up Range settings Displayed parameters Analyzer tag ESCAPE Figure 3 5 Analyzer Module Set up Menu c Help Displays The Help structure is intended to be an on line tutorial context sensitive and topic interconnected so that the user can practi cally operate NGA2000 without the need of an instruction manual A typical help menu Zero Span calibration help This allows manual control of the zero and span Flow zero gas and make sure the zero gas value is right Press the zero key to make the analyzer zero Or select Factors and individually adjust the reading on each range In this way you can make the analyzer read what you want Do the same with span gas If the zero was not a r
16. to return to the pre vious menu 10 You can view the new calibration data in the Calibration data display screen To access this screen go to the Expert controls and set up sub menu and select Analyzer module Startup and Operation Model NGA2000 TO2 set up From the Analyzer module set up sub menu select Calibration and from the Advanced Expert calibration sub menu se lect Calibration data display This screen is a view only display and data cannot be edited from this screen 11 If for any reason you want to restore the original factory calibration data you can do so from the Advanced Expert calibration sub menu see step 9 above for directions to this sub menu Select Restore factory calibration and the original values will be restored NOTE Do not alter data in the Load factory calibra tion data sub menu except when replacing sensors Any changes made to this sub menu will become the new default restore factory calibration values 12 Press the HOME softkey to re enter the Main Menu 13 Press DISPLAY softkey for the Run Mode display If you are unable to calibrate the module for some reason see the NGA Reference manual for a list of possible causes and solutions The most likely cause is the use of incorrect span gases 3 7 ROUTINE OPERATION The TO2 Analyzer Module is designed to ana lyze the sample stream continuously Normally it is never powered off except for servicing or for a prol
17. AGE Do not pressure check the sample line with the sensor connected Over pressurization of the sensor can result in damage A Division of Emerson Process Management The TO2 analyzer exhibits flow sensitivity Check to make sure that your vent line is not blocked If you see a rise in reading with an in crease in flow you may be over pressurizing the sensor due to a blocked vent Since the Maintenance and Troubleshooting 4 3 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 sensor is a partial pressure measuring device an increase in sample pressure will cause an increase in reading If the reading drops with increased flow conduct the leak check outlined in the troubleshooting tip above The TO2 analyzer gives erratic and very in sensitive readings Check to see that the electrolyte level is within the limits indicated on the reservoir Add dis tilled water as required If the level is within lim its the electrolyte may have been contaminated Refer to Section 4 3 on page 4 2 above for proper procedure to replace electro lyte If replacement of electrolyte does not im prove the performance of the sensor the sensor may have been damaged due to over pressurization or poisoning Sensor replace ment may be required as described in Section 4 4 on page 4 2 4 4 Maintenance and Troubleshooting Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model NGA2000 TO2 O
18. Instruction Manual 748374 F March 2003 Model NGA2000 TO2 Trace Oxygen Analyzer ROSEMOUNT 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 in ternational 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 f 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 Instruc tion Manual and per applicable local and national codes Connect all
19. 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 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 748374 F March 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 emerson
20. Trace oxygen in product nitrogen and argon streams from air separation plants e Trace oxygen in inerting atmospheres for heat treat furnaces e Trace oxygen in glove box applications 1 3 THEORY OF TECHNOLOGY The TO2 Analyzer Module uses the coulometric principle of oxygen detection This technology is A Division of Emerson Process Management based on the fact that oxygen in the sample is reduced by an electrochemical reaction This reduction occurs at the cathode and results in the generation of hydroxyl ions These hy droxyl ions migrate to the anode where they are oxidized to reform oxygen The oxidation reac tion generates four electrons which in turn mi grate to the anode to participate in the reduction reaction Cathode Reaction 0 2H 0 4e gt 40H Anode Reaction 40H gt 02 2H 0 4e A polarizing voltage of approximately 1 3 VDC is applied between the anode and cathode to drive the oxidation and reduction reactions The resulting current flow produced by the flow of electrons is directly proportional to the oxygen content in the sample gas 1 4 FEATURES Among the features included in the TO2 Ana lyzer Module are e Quick start feature e Electrolyte level alarm e High oxygen protection circuit with alarm e Sample flow indication Description and Specifications 1 1 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 SECONDARY ANODE BI STRATA DIFFUSION BARRIER
21. be drained and replaced with fresh electrolyte Refer to Section 4 3 below for the proper procedure for replacing electrolyte Several other components may require re placement These are discussed in the fol lowing sections 4 2 FUSES 4 2 Remove power to the Analyzer Module prior to fuse replacement To replace the Power Fuse locate the fuse cover on the front panel of the Analyzer Module as shown partially in Figure 2 3 on page 2 4 Push and turn the fuseholder cover 1 4 turn counterclockwise Remove and replace the fuse as required There are no other fuses in the Analyzer Module Maintenance and Troubleshooting Model NGA2000 TO2 4 3 ELECTROLYTE REPLACEMENT Before replacing the electrolyte be sure to turn off and disconnect all gas connections to the analyzer module Turn off or disconnect the power to the analyzer module To replace the Sensor electrolyte remove the Analyzer Module from its mounting location and place on a sturdy work surface Be careful not to tilt the module from its horizontal position as the Sensor contains liquid that can spill Re move the cover of the Analyzer Module and lo cate the 5 mounting screws that hold the Sensor Assembly onto the Analyzer Module chassis see Figure 4 1 on page 4 1 Remove the 5 screws and retain Do not lose the screws they have metric threads Disconnect the Sensor signal connector J5 and the Flow Sensor connector J6 from the power board Remove the
22. cess Management Contents i Instruction Manual 748374 F March 2003 Model NGA2000 TO2 4 0 MAINTENANCE AND TROUBLESHOOTING encccocccconcnonncccnnnnnnnrnnna recrean 4 1 4 1 WEIEN e E A A a eege A E date dis Ecos 4 1 a Water Add inci a NEE E AA AAA RA eee 4 2 4 2 FUSES 2 2 AE m AA AA A ss 4 2 4 3 Electrolyte Replacement annv nera ieiuniis arna i a vi oia a 4 2 4 4 Sensor Replacement ccccccccescceceeeceeeseceesaeeeeccesaeeeeaaeceeaaesaaaesesaeaseaaesaaessaeeeesaeseeaaesseaees 4 2 4 5 Flow Sensor Replacement AA 4 3 4 6 Printed Circuit Ee EE 4 3 4 7 B rel EEN DEE 4 3 5 0 REPLACEMENT PARTS ci ia 5 1 5 1 MAT o A e a lid 5 1 5 2 Replacement Parts iia iii 5 1 6 0 RETURN OF MATERIAL 2 22 22 ae nenne 6 1 6 1 Return Of Material EE 6 1 6 2 Eeler 6 1 6 3 TAMING WEE 6 1 7 0 APPENDIX A MENU STRUCTURE 0 ccseeceseeeeeeeeeseeeenseeeeeeeeeaneeeenseeeeeeeeeseaesenenenseeeeeas 7 1 7 1 NGA TO2 Menu Structure Introduction oononcinncnnnnnccnnnnonnnccnnncccnnrnn narran cnc cnn rana 7 1 7 2 NGA TO2 Analyzer Module Menus ooococooccconociconoccnonccononcnononnnanc ccoo rca nn rana r narran rra 7 1 8 0 APPENDIX B USER INTERFACE HELP uunsnunsssnnsnnnnnnnnnnunnnnnnnnnnnnannnnnnnnnnnnnnnnannnnnnnnnnnn 8 1 9 0 INDEX idas 9 1 748377 MATERIAL SAFETY DATA SHEET ii Contents Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748374 F Model NGA2000 TO2 March 2003 LIST OF ILLUSTRATIONS
23. 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 should 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 748374 F Model NGA2000 TO2 March 2003 DOCUMENTATION The following NGA2000 Trace Oxygen Analyzer Module instruction materials are available Contact Cus tomer Service Center page 6 1 748374 Instruction Manual this document COMPLIANCES This product may carry approvals from several certifying agencies for use in non hazardous indoor loca tions lf so the product will carry approval insignia on the product name rating plate ep NRTL C Rosemount Analytical Inc has satisfied all obligations from the European Legislation to harmonize the product requirements in Europe These products comply 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 Zealand N96 Rosemount Analytical Inc A Div
24. e used when the analyzer is first turned on to decrease the time required for the sensor to reach equilibrium This function is most effec tive for gas sample measurements below 100 ppm To maintain sensor life it is recom mended that this feature be used no more than two times in any 24 hour period Under the Basic Controls sub menu move the cursor to Initiate quick start and press the key The unit will begin the quick start function immediately This procedure will last for ap proximately 45 seconds The last measured value is held for the duration of the procedure to prevent false reading fluctuations 3 5 GAS SCALE FACTOR GSF The Gas Scale Factor is used to correct for background gases other than nitrogen When the background of the sample is other than ni trogen the diffusion rate of oxygen into the sen sor changes By correcting for the background A Division of Emerson Process Management Instruction Manual 748374 F March 2003 difference the diffusion change can be com pensated in software The GSF can be entered manually or calculated automatically Calcula tion of the GSF requires the user to enter the sample gas composition In most applications the GSF is not required However some back grounds exhibit significantly different diffusion characteristics versus nitrogen such as helium or hydrogen and the GSF may improve per formance Under the Technical Level Configuration sub menu select Diagnost
25. eal zero the span action will change the zero reading gt Set cal gas values in the Calibration gas list screen ESCAPE CALINFO Figure 3 6 Typical Help Menu shown is Zero Span Calibration Help This is the help screen for the calibration menus Rosemount Analytical Inc A Division of Emerson Process Management Rosemount Analytical Inc Model NGA2000 TO2 3 3 STARTUP PROCEDURE Establish sample or zero gas flow through the analyzer module at a nominal flow rate of 2 SCFH 1 l min Allow gas to flow for 15 to 30 seconds before applying power Apply power to the TO2 Analyzer Module Upon initial startup the separate modules Con troller Board and network self install The dis play shows the progress of the automatic installation routine together with a button marked RE_INIT If the initialization hangs up pressing the RE_INIT button will restart it but will cause all the binding information to be erased The Display will then appear as above For details on binding please consult the Plat form instruction manual Establish that sample flow rate is within specifi cations see Section 1 5 SPECIFICATIONS on page 1 4 Input security codes see NGA Ref erence manual calibrate and begin routine operation as following subsections indicate 3 4 QUICK START FEATURE This analyzer module is equipped with a quick start feature which allows the sensor to begin measuring low ppm oxygen faster This feature can b
26. efore disconnecting any wiring This helps in reassembly The Power board and Computer board are located on a common bracket 4 7 TROUBLESHOOTING The following provides a short list of common troubleshooting tips Additional information is contained in the Platform Manual The TO2 analyzer fails to purge down to ppm levels Prior to conducting any changes to the system try running a quick start sequence see Section 3 4 on page 3 3 to see if the oxygen reading goes lower If the reading does decrease the sensor has not been allowed sufficient time to consume the dissolved oxygen in the electro lyte If the reading continues to read high a leak may exist in the sample lines The number one problem associated with trace oxygen analyzer installation is the occurrence of leaks in your sample plumbing If the oxygen reading will not come down to ppm levels or is reading higher than expected the sample plumbing prior to the instrument may have a leak A quick check can be conducted by observing the oxygen reading at two different flow levels 0 5 and 2 0 scfh If the oxygen reading drops significantly when the flow is increased from 0 5 to 2 0 scfh this is a good indication that a leak exists To check for leaks prior to the sensor discon nect the Analyzer Module and cap the inlet line Pressurize the inlet line to 5 10 psig and check all connections with a soapy solution SNOOP to identify leaks WARNING SENSOR DAM
27. ensor factory calibration data Technical configuration menu System set up Ag f Sieste Service menus d SEAS Diagnostic menus ZA Pee Other module diagnostic menus EEE TADA Ar 0 Ar T ZA dr 35 ESCAPE concerning the configuration of the Analyzer SENSOR A fe a AMM TE AED TE SE Sd TE D RER Appendix A Menu Structure Rosemount Analytical Inc A Division of Emerson Process Management Rosemount Analytical Inc Model NGA2000 TO2 From the Analyzer Diagnostics menu all ana lyzer health diagnostic information can be ac cessed Calibration controls are also accessible from this menu de 3 dis Ait St AD CAN MERA emperabure parameters MEA A Salterare dignos Af Eli d s kam messages walid for AA A A PF Analyzer Diagnostros Power Supply Voltages SIS HIY WEF be FS imay Electrode solabed 15 ESCAPE The Primary Variable Parameters screen pro vides details on the sensor and advises the cur rent status of the sleep mode If the oxygen concentration exceeds 100 ppm the sleep mode timer begins counting At the end of 45 minutes if the concentration has not dropped below 100 ppm the Analyzer Module will go into sleep mode to protect the sensor from damage due to high oxygen exposure Ha EA LEAT a L n UE LE E FLEE MODE A Division of Emerson Process Management Instruction Manual 748374 F March 2003 The Advanced Expert Calibration menu
28. er Controller Board Connector Fuse Power Indicator Light Power Pressure Constant between 13 8 and 69 hPa gauge 0 2 and 1 0 psig sample inlet pressure is recommended If a needle valve is used upstream of the Analyzer Module to control flow the inlet pressure to the needle valve should not exceed 345 hPa 5 psig A constant sample flow rate between 1 0 to 3 0 SCFH 0 5 to 1 5 l min is recommended for best results The Analyzer Module must vent to atmosphere to avoid back pressure influences on the oxygen reading Connections See Figure 2 3 on page 2 4 Connect inlet and outlet lines for sample to appropriately labeled fittings on the rear panel SAMPLE IN and SAMPLE OUT are 1 4 inch ferrule type compression fittings Zero and span gases should be introduced at the SAMPLE IN fitting at normal sample inlet flow rate Metallic tubing is recommended for the sample line The use of plastic Teflon or other non metallic tubing can result in am bient oxygen permeation through the tubing causing higher than expected reading Ex haust tubing should be 1 4 inch 6 3 mm or larger and can be metallic or non metallic BACKPLANE CONNECTIONS ae Network Hz p A a Figure 2 1 Analyzer Module Interconnection with Instrument Platform Installation Rosemount Analytical Inc A Division of Emerson Process Management Instruction Man
29. erson Process Management Instruction Manual 748374 F Model NGA2000 TO2 March 2003 SECTION 4 MAINTENANCE AND TROUBLESHOOTING 4 1 OVERVIEW The sensor is designed to hold at least 100 cc of electrolyte Typically bone dry sample gas CAUTION can extract approximately 5 10 cc of water per month from the sensor It is recommended to QUALIFIED PERSONNEL check the electrolyte level every 3 4 months to assure that the electrolyte level is within the ac ceptable operating limits as indicated by the la bel on the reservoir section of the sensor This equipment should not be adjusted or repaired by anyone except properly qualified service personnel The TO2 analyzer module is equipped with a low electrolyte alarm which indicates when re WARNING plenishment of the sensor is required Please refer to the Platform manual for details on con Tampering with or unauthorized substitution of components may adversely affect safety of this product Use only factory approved CAUTION components for repair REFILLING SENSOR When refilling the sensor only use distilled The TO2 Analyzer Module requires very little or deionized water Do not use electrolyte or maintenance during normal operation tap water as they can cause damage to the sensor Take care not to overfill The sensor in the TO2 utilizes a liquid electro lyte When measuring dry gases it may be necessary to replenish the liquid by adding dis
30. h 2003 SECTION 2 INSTALLATION 2 1 UNPACKING If the Trace Oxygen TO2 Analyzer Module is received as a separate unit carefully examine the shipping carton and contents for signs of damage Immediately notify the shipping carrier if the carton or contents is damaged Retain the carton and packing material until all components associated with the TO2 Analyzer Module are operational 2 2 ASSEMBLY Before installation of the TO2 Analyzer Module electrolyte must be added to the Sensor Follow the procedure described below under Section 2 2a below After addition of electrolyte locate the analyzer module on an appropriate mounting surface and connect the network cable to either the NET WORK 1 or NETWORK 2 connection on the Analyzer Module and the NETWORK connec tion on the Platform network l O port See Figure 2 1 on page 2 2 and Figure 2 4 on page 2 5 a Electrolyte Addition Before adding electrolyte to the Sensor it is recommended to check the Sensor for pos sible leakage caused by damage in ship ment To check the Sensor for leakage remove the top cover of the Analyzer Mod ule and locate and remove the 5 mounting screws which hold the Sensor Assembly Sensor flow meter plumbing inlet outlet fittings to the module see Figure 4 1 on page 4 1 Be careful not to lose these screws as they have metric threads Care fully lift out the Sensor assembly and re move from the analyzer module Place ona flat surface
31. ic menus and then se lect Analyzer Module Diagnostics In the Analyzer Module Diagnostics sub menu select Calibration Parameters In the Ad vanced Expert Calibration sub menu select Gas Scale Factor To use the GSF enter the volumetric percentages of each component pre sent in the sample gas To view more back ground components press the MORE softkey The total must add up to 100 or a new factor will not be computed If you have a background component which is not shown in this menu please consult the factory for assistance Once you have entered all the background composition information move the cursor to Compute new adjusted gas scale factor and press the key and the analyzer module will automatically calculate the new gas scale factor 3 6 CALIBRATION The TO2 analyzer module is fully factory cali brated using certified gas standards prior to shipment If the analyzer is operated within its specified operating conditions no calibration is required The zero calibration is very stable and does not require checking more than once a year Depending upon the nature of your appli cation it may be beneficial to verify the span calibration of the analyzer module every 3 4 months The following procedure illustrates how to initiate a zero span calibration Under the Expert Controls sub menu select Ex pert Analyzer Controls and Measurement set the Range Number to the range that will be used during sample anal
32. inders GASES a Requirements The TO2 Analyzer Module requires only a standard of accurately known composition for use as a span gas The span gas should be supplied from a cylinder equipped Installation 2 1 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 with a clean metallic diaphragm two stage regulator A shutoff valve is recommended Calibration Gases The TO2 module does not require routine zero calibration The zero is factory set and does not experience routine drift Over long periods of time the zero may experience minor drift For low ppm range analyzers you may wish to check the zero at one year intervals Oxygen free nitrogen is recom mended for use as zero gas This gas is certified to lt 0 5 ppm oxygen and can be improved by passing the zero gas through an oxygen scrubber such as Millipore Waferpure or Semigas Nanochem resin purifiers A mixture of trace oxygen ina background of nitrogen is recommended as span gas For maximum accuracy the con centration of trace oxygen in the span gas should be as high as possible for the range of measurement Sample The sample must be clean and dry before entering the Analyzer Module Sample should be filtered for particulates down to two microns and should have a dewpoint at least 5 C 13 F below the coldest ex pected ambient temperature ANALYZER MODULE CONNECTIONS L Network 1 Backplane Network 2 Pow
33. ion The NGA menu system is necessarily complex due to the wide variety of configuration possibili The menu selections are sometimes abbrevi ties available with the NGA architecture ated Basic Controls is referred to as Basic for example Expert controls and setup as Expert and Technical level as well as Technical Menu Items ITEM PATH NOTES Technical Service menus Service history Analyzer module history Add service date Technical Listing of all modules Analog UO Select I O module Relay status Analyzer specific Expert Auxiliary module setup Select Analog Add a service date Alarm enabling alarms output module Alarm conditions Ve Only Technical Diagnostic menus Analyzer mod Analyzer diagnostics ule diagnostics Analyzer specific con Expert Auxiliary module setup Select Analog v 2 3 only trols remote output module Input line control Binding Technical System setup Module Binding z Expert Analyzer module setup Displayed pa Technical Diagnostic menus Analyzer mod Electrolyte level ule diagnostics Physical measurements Exit sleep mode Technical Diagnostic menus Analyzer mod Gas scale factor ule diagnostics Calibration parameters Gas scale factor Initiate quick start Last service dat Technical Service menus Service history User updated Analyzer module history List of detected NGA Jumps from there into their Technical Listing of all
34. ision of Emerson Process Management Preface P 5 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 P 6 GLOSSARY OF TERMS Analyzer Module The module that contains all sensor detector components for development of a Primary Variable signal in cludes all signal conditioning and temperature control circuitry Backplane The interconnect circuit board which the Controller Board Power Supply Analyzer Module power and net work 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 HO 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 Boa
35. l injury and damage to this equipment and on site property all per sonnel 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 WARNING PARTS INTEGRITY Tampering with or unauthorized substitution of components may adversely affect safety of this product Use only factory approved components for repair PRESSURIZED GAS This module requires periodic use of pressurized gas See General Precautions For Handling And Storing High Pressure Gas Cylinders on page P 4 CAUSTIC LIQUID Electrolyte is a caustic solution Review the Material Safety Data Sheet in the rear of this manual POSSIBLE EXPLOSION HAZARD This equipment is not designed and should not be used in the analysis of flammable samples Use of this equipment in this way could result in explosion and death P 2 Preface Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual Model NGA2000 TO2 O 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 800 441 7245 to order software upgrade kit PN 657150 for the Platform You can locate the version of each NGA2000 compone
36. l module data Technical Diagnostic menus Analyzer mod Span calibration ule diagnostics Calibration parameters User span calibration Technical Service menus Manufacturing data Analyzer module data Technical Listing of all modules Analog UO Select I O module Relay status Technical Diagnostic menus Analyzer mod Software diagnostics Software revision level Highly recommend not to be conducted in the field Tag number User editable Test relay operation View sensor calibration data ule diagnostics Calibration parameters Calibration data display Technical Diagnostic menus Analyzer mod Zero calibration ule diagnostics Calibration parameters User zero calibration Highly recommend not to be conducted in the field 8 2 Appendix B User Interface Help Rosemount Analytical Inc A Division of Emerson Process Management Model NGA2000 TO2 2 24 V 5A DC power 2 5 A alarm electrolyte 4 1 4 2 indications 3 5 Analyzer Module electrical connections 2 5 general operation of software 3 4 leak test 2 4 Applications 1 1 automatic installation 3 3 B background gas 3 3 7 4 binding 3 3 C calibration maximum interval between 3 4 restore factory data 3 4 span 3 3 unable 3 4 viewing data 3 4 zero 3 3 Controller Board 3 3 E electrolyte 2 1 4 1 4 2 4 3 7 4 9 1 alarm 4 1 leak check 2 1 level 4 4 level check 4 1 replacement 4 2 rep
37. lacing 4 2 sensor capacity 4 1 Exhaust 2 2 Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748374 F March 2003 SECTION 9 INDEX F Flow Sensor 4 2 4 3 Flow Sensor connector 4 2 G Gas calibration 2 2 sample 2 2 span 2 1 Gas Scale Factor 3 3 7 3 7 4 GSF Gas Scale Factor 3 3 installation location 2 1 mounting 2 1 operating temperature 2 1 IO modules 3 4 L leak check 4 3 LON 2 5 5 2 measuring dry gases 4 1 N NGA Reference manual 3 3 3 4 3 5 O oxygen scrubber 2 2 P Platform 1 4 2 1 2 2 2 5 3 1 3 3 3 4 4 1 4 3 Power Fuse 4 2 Index 9 1 Instruction Manual 748374 F March 2003 R Return Authorization 6 1 S sample connections 2 2 flow rate 2 2 inlet pressure 2 2 security codes 3 3 sensor electrolyte 4 2 life 3 3 load new calibration data 4 3 maximum psig 2 4 signal connector 4 2 span calibration 3 3 span gas 2 1 2 2 2 4 3 4 9 2 Index Model NGA2000 TO2 T Theory of operation 1 1 Z zero calibration 3 3 zero gas 2 2 3 3 3 4 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
38. m 02 ce 0 Range 3 50 1 4403 mA MO Sensor temperature vim i Temperature current 2 01 mA Pe a 511 ml min MN Sensor current Sample Flow DISPLAY Figure 3 1 Run Mode Display b Menu Displays The Menu structure enables the user to ac cess data and functions and put informa tion onto the network From the Run Mode display press the MENUS softkey to gain access to the Main Menu Main Menu Basic controls Expert controls and setup Operational configuration Technical level configuration Diagnostic and manufacturing service DISPLAY Figure 3 2 Main Menu The Main Menu is subdivided into three lev els of control based generally on which per sonnel is likely to use it Basic Controls Operators Expert Controls and set up System Engineers and Technical level con figuration Analyzer technicians Many lay ers of the menu structure are described at appropriate places throughout this manual Startup and Operation 3 1 Instruction Manual 748374 F March 2003 From the Run Mode display press the MENUS softkey to gain access to the Main Menu The Basic controls menu is as follows Basic Controls Measurement range number Range upper limit CURRENTRNGHI Range and functional control CONTROL Sleep Mode Exit Sleep Mode Initiate Quick Start Quick Start ESCAPE Figure 3 3 Basic Controls Menu This menu allows the user to view the cur rent
39. modules modules diagnostic screens Load factory calibration Technical Diagnostic menus Analyzer mod Required when changing data ule diagnostics Calibration parameters sensor Technical Service menus Manufacturing Manufacturing data data Analyzer module data Expert Analyzer module setup Range set Maximum range upper tings limit Expert Analyzer module setup Range set tings Technical Diagnostic menus Analyzer mod ule diagnostics Power supply voltages Quick start status Basic Maximum range Minimum range Minimum range upper limit Power supply voltages Rosemount Analytical Inc A Division of Emerson Process Management Appendix B User Interface Help 8 1 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 ITEM PATH NOTES tion Range lower limits FS Analyzer module setup Range set Range upper limits ne Analyzer module setup Range set Technical Service menus Service history E Analyzer module history List notes Reset system Resolution of main Technical System setup Main display con reading figuration Display resolution Sensor current Technical Diagnostics menus Analyzer mod temperature ule diagnostics Primary variable parameters Sleep mode status Technical Diagnostics menus Analyzer mod IMPI ule nee Primary variable er Technical Diagnostic menus Control module diagnostics Technical Service menus Manufacturing data Contro
40. n Process Management Model NGA2000 TO2 Instruction Manual 748374 F March 2003 SECTION 6 RETURN OF MATERIAL 6 1 RETURN OF MATERIAL If factory repair of defective equipment is re quired proceed as follows 1 Secure a return authorization from a Rose mount Analytical Inc Sales Office or Repre sentative before returning the equipment Equipment must be returned with complete identification in accordance with Rosemount instructions or it will not be accepted 2 Rosemount CSC will provide the shipping address for your instrument 3 Inno event will Rosemount be responsible for equipment returned without proper au thorization and identification 4 Carefully pack the defective unit in a sturdy box with sufficient shock absorbing material to ensure no additional damage occurs dur ing shipping 5 In a cover letter describe completely e The symptoms that determined the equipment is faulty e The environment in which the equip ment was operating housing weather vibration dust etc e Site from where the equipment was re moved e Whether warranty or non warranty ser vice is expected e Complete shipping instructions for the return of the equipment 6 Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in the Rosemount Return Authorization prepaid to the ad dress provided by Rosemount CSC Rosemount Analytical Inc Process Analytical
41. new calibration data supplied with the Sensor Enter the new calibration data by entering the Load Factory Calibration Data menu You can get to this menu as follows Main Menu Technical Level Configuration Ana lyzer Module Diagnostics Calibration Parame ters Load Factory Calibration Data This menu screen will look as follows Load factory calibration data Concentration 1 Output 1 Temperature 1 Concentration 2 Output 2 Temperature 2 Concentration 3 Output 3 Temperature 3 ESCAPE Figure 4 2 Load Factory Calibration Data Menu The data is supplied with the new sensor and must be entered exactly as shown on the sen sor data sheet To enter the data for data points 4 amp 5 and the sensor model press the MORE soft key to access the next screen 4 5 FLOW SENSOR REPLACEMENT See Figure 1 2 on page 1 3 for Flow Sensor lo cation To replace Flow Sensor remove all connecting hardware and undo connections to the sample line The Flow Sensor is mounted to the Sensor Assembly mounting plate by two screws Be sure to install the new Flow Sensor with the flow indication toward the outlet 4 6 PRINTED CIRCUIT BOARDS All three printed circuit boards can be replaced if necessary Refer to Figure 1 2 on page 1 3 for location of the Power Network and Computer Boards Instruction Manual 748374 F March 2003 To remove any PCB disconnect the associated cables first Tag each connector and its location b
42. nt Instruction Manual 748374 F March 2003 Model NGA2000 TO2 SECTION 3 STARTUP AND OPERATION 3 1 OVERVIEW Prior to initial startup the user should perform the leak test procedure 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 refers 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 the Platform instruction manual 3 2 DISPLAYS Three kinds of Display screens are available to the user e Run Mode e Menu e Help a Run Mode Display The Run Mode is the normal mode of op eration In this mode the Display will show the current gas measurement the compo nent of interest the current operations of the softkeys and several graphics a bar representing the displayed concentration as a percent of fullscale and up to four lines showing user selectable secondary parame ters from either the Analyzer Module or any IO module bound to it See the Platform manual for information as to how to select these If more than one Analyzer Module is con nected to the system an additional Run Mode display will show as many as four five for version 2 3 and later gas meas urements on screen Rosemount Analytical Inc A Division of Emerson Process Management pp
43. nt 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 side of the Analyzer Module case 1 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 748374 F March 2003 Model NGA2000 TO2 GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS CYLINDERS Edited from selected paragraphs of the Compressed Gas Association s Handbook of Com pressed 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
44. ntrol ar EA ESCAPE The Analyzer Module Setup menu allows ac cess to the Range settings and Display pa rameters sub menus eup Ar fal SAS EE EA Dbisplayed parameters Af et ELA AC 3 Appendix A Menu Structure 7 1 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 The Range Settings menu allows configuration The Analyzer Manufacturing Data screen and of the upper and lower limit of the 4 ranges on Analyzer Module Service History screen are the Analyzer Module The maximum and mini both accessible from the Service menus sub mum range limits are shown and adjustment menu These screens provide factory set data 7 2 beyond these limits is not allowed Module inimum range AAA ANIMA Langg Add AAAS are 1 lover bg G i Range uppes Emit ange 2 lower limit Aral aching dele code ech gan code wieme revision number ange upper Emit oMmware rewisson number ame 3 lower bm The Displayed parameters are the secondary parameters shown on the Display screen see figure 3 1 The desired parameters can be se lected from this menu wet line s parameter Second lines parameter Thid lines parameler mamih Gree paramseher dd ra dala ap be displayed an bp apropiado line of ke single HOME ESCAPE anager display screen HOME ESCAPE Technical level configuration provides ac cess to the service and diagnostic menus in cluding calibration gas scale factor and s
45. onged shutdown Maximum permissible interval between calibration checks depends on the analytical ac curacy required and therefore cannot be speci fied Initially the instrument should be checked at least once every 3 4 months This practice should continue until experience indicates that some other interval is more appropriate For details as to the general operation of the NGA analyzer module software and the use of IO modules with the TO2 module see the Plat form Components manual Rosemount Analytical Inc A Division of Emerson Process Management Instruction Manual 748374 F Model NGA2000 TO2 March 2003 3 8 ALARM INDICATION NGA analyzer modules continuously monitor a number of internal parameters It is possible to make the analyzer generate certain kinds of alarm indications if these parameters values exceed or reduce below specified levels The general alarm variable will have its value changed if an alarm occurs See the NGA Ref erence manual for further details DESCRIPTION TYPE Low Electrolyte WARNING Low Sample Flow WARNING Sleep Mode WARNING Low Sensor Temperature WARNING High Sensor Temperature WARNING Software Error FAILURE Table 3 1 Trace Oxygen Analyzer Module Alarms Rosemount Analytical Inc A Division of Emerson Process Management Startup and Operation 3 5 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 3 6 Startup and Operation Rosemount Analytical Inc A Division of Em
46. process 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 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 TO2 LATIN AMERICA Fisher Rosemount Av das Americas 3333 sala 1004 Rio de Janeiro RJ Brazil 22631 003 T 55 21 2431 1882 O Rosemount Analytical Inc 2003 EMERSON F ager te IER a Process Management
47. products to the proper elec trical 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 Teflon is a registered trademark of E l duPont de Nemours and Co Inc SNOOP is a registered trademark of NUPRO Co Waferpure is a trademark of Millipore Corp Nanochem is a registered trademark of Semigas 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 cscOEmersonProcess com http www processanalytic com E M E RSO N u ag armor Wahagement e r Process Instruction Manual 748374 F Model NGA2000 TO2 March 2003 TABLE OF CONTENTS PRERPACE Eege P 1 Intended Use Sat iia ci td da aE n dt
48. rd that plugs into the front of the Backplane in a stand alone instrument to several larger ones that can power larger collections of modules and components Primary Variable The measured species concentration value from an Analyzer Module Secondary Variable Data placed on the network by a module regarding current status e g sample flow source voltage and other diagnostic information System Any collection of Analyzer Module s Platform s UO Module s and Expansion Module s Preface Rosemount Analytical Inc A Division of Emerson Process Management Rosemount Analytical Inc Model NGA2000 TO2 Instruction Manual 748374 F March 2003 SECTION 1 DESCRIPTION AND SPECIFICATIONS 1 1 OVERVIEW This manual describes the Trace Oxygen TO2 Analyzer Module of Rosemount Analytical s NGA2000 Series of gas analysis components The TO2 Analyzer Module is designed to con tinuously determine the concentration of trace oxygen in a flowing gaseous mixture The con centration is expressed in parts per million The TO2 Analyzer Module is configured as a shelf mount module designed to be installed external from the platform on an associated shelf capable of holding two modules side by side 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 TO2 Analyzer Module has specific applica tions in the following areas e
49. the components functions installation and maintenance of the Model NGA2000 TO2 and the System Accessories of the NGA2000 System Some sections may describe equipment not used in your configuration The user should become thor oughly familiar with the operation of this module before operating it Read this instruction manual com pletely 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 Manual 748374 F March 2003 Model NGA2000 TO2 SAFETY SUMMARY If this equipment is used in a manner not specified in these instructions protective systems may be im paired AUTHORIZED PERSONNEL To avoid explosion loss of life persona
50. ual 748374 F Model NGA2000 TO2 March 2003 A is Le 7 75 gt 197 at ASEE 6 5 78 147 SS DIA 18 56 471 12 00 305 11 00 279 1 Y 1 Ka Le 8 25 SH 206 Lei 8 10 206 ES os 2 70 68 Y 6 62 168 Figure 2 2 Trace Oxygen Analyzer Outline and Mounting Dimensions Rosemount Analytical Inc A Division of Emerson Process Management Installation 2 3 Instruction Manual 748374 F March 2003 Model NGA2000 TO2 E Sample Inlet 1 4 Tube C 4 Sample Exhaust 1 4 Tube Figure 2 3 Trace Oxygen Analyzer Back Panel Connections CAUTION c LEAK TEST GAS OVERPRESSURE The TO2 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 Caution Do not expose the Sensor to pressure in excess of 1 0 psig as this may cause damage At no time should sample zero or span gas inlet pressure exceed 69 hPa gauge 1 0 psig Damage to the Sensor may occur if this pressure level is exceeded CAUTION SAMPLE FLOW Do not test the sample pressure by blocking the exhaust When the pres sure is released the sudden surge of flow will spin the internal flowmeter off its bearings
51. ysis Return to the Main Menu by pressing the HOME softkey Startup and Operation 3 3 Instruction Manual 748374 F March 2003 3 4 Introduce zero gas into the SAMPLE INLET and after a stable reading is reached do the following 1 Move the cursor to Technical Level Configu ration and enter Select Diagnostic Menus then Analyzer Module Diagnos tics and then Calibration parameters and enter 2 Select the User zero calibration to enter the User zero calibration menu NOTE Before proceeding any further be sure that the zero value is stable and valid The zero may take 24 hours or longer to achieve sta ble zero for the low ranges 3 Move the cursor to the Press the select key for user zero calibration now 4 Press the key The new zero calibration will now be entered 5 Press the lt key to return to the previous menu 6 Introduce a suitable span gas into the SAMPLE INLET and allow reading to stabi lize Move the cursor to the User span cali bration line and press the key 7 Move the cursor to the Span gas concentra tion line and press the key Enter the correct span gas value by using the TY keys to change value and the lt gt keys to select position Press the key to enter the new span gas value 8 Move the cursor to the Press the select key for user span calibration now and press the key The new span calibration will now be entered 9 Press the lt arrow key
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