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Rosemount Analytical NGA 2000, Manual

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4

M

AINTENANCE AND 

T

ROUBLESHOOTING

748332-D          Rosemount Analytical          June 1997

4-1

NGA 2000 Non-Dispersive Infrared Analyzer

Servicing requires access to live parts which can cause death or serious injury.
Refer servicing to qualified personnel.

4.1  OVERVIEW

NDIR Analyzer Module components that may require cleaning or replacement include:

•

 all printed circuit boards

•

 power  fuse

•

 the module fan

•

 the chopper motor

•

 the  source

•

 the  detector

•

 flow  sensor

•

 case temperature sensor

•

 Analysis cells and optical components

•

 RTD - detector temp. controller

•

 thermal  fuse

The only components that may require adjustment are the oscillator tune and shutter
balance adjustments. These are factory-set, and should be adjusted only in the
following cases:

•

 if the operator has changed sources, oscillator board or detector

•

 if the operator disassembles the bench to any degree.

Also available for maintenance adjustment through the Front Panel display and
keypad are the source current, preamplifier gain (referred to as Signal Gain on the
sub-menu) and the modulation check.

WARNING:  ELECTRICAL SHOCK HAZARD

Summary of Contents for NGA 2000

Page 1: ...NGA 2000 NON DISPERSIVE INFRARED ANALYZER MODULE Rosemount Analytical ...

Page 2: ...d in U S A Rosemount Analytical Inc 4125 East La Palma Avenue Anaheim California 92807 1802 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 Betts Corp ...

Page 3: ... 8 RETURNING PARTS TO THE FACTORY P 8 TRAINING P 8 DOCUMENTATION P 8 COMPLIANCES P 9 SECTION 1 INTRODUCTION 1 1 OVERVIEW 1 1 1 2 TYPICAL APPLICATIONS 1 1 1 3 THEORY OF TECHNOLOGY 1 2 1 4 SAMPLE REQUIREMENTS 1 4 1 5 PURGE KITS 1 5 1 6 FEATURES 1 5 SECTION 2 INSTALLATION 2 1 UNPACKING 2 1 2 2 ASSEMBLY 2 1 2 3 LOCATION 2 2 2 4 GASES 2 2 2 4 1 Specifications 2 2 2 4 2 Connections 2 3 2 5 ELECTRICAL CO...

Page 4: ... 4 MAINTENANCE AND TROUBLESHOOTING 4 1 OVERVIEW 4 1 4 2 PCB REPLACEMENT 4 2 4 3 POWER FUSE REPLACEMENT 4 2 4 4 MODULE FAN REPLACEMENT 4 2 4 5 CHOPPER MOTOR REPLACEMENT 4 3 4 6 SOURCE REPLACEMENT 4 3 4 7 DETECTOR REMOVAL 4 3 4 8 FLOW SENSOR REPLACEMENT 4 3 4 9 CASE TEMPERATURE SENSOR REPLACEMENT 4 4 4 10 THERMAL FUSE REPLACEMENT 4 4 4 11 OSCILLATOR TUNE SOURCE BALANCE SHUTTER ADJUSTMENT 4 4 4 12 CL...

Page 5: ...ic Controls Menu 3 3 3 4 Expert Controls and Setup Menu 3 4 3 5 Technical Level Configuration Menu 3 4 3 6 Typical Help Screen 3 4 3 7 Typical Linearization Curve Linearizer OFF 3 7 3 8 Operator Determined Linearization Curve Normalized 3 7 3 9 Display Screens 1 of 5 3 10 3 10 Display Screens 2 of 5 3 11 3 11 Display Screens 3 of 5 3 12 3 12 Display Screens 4 of 5 3 13 3 13 Display Screens 5 of 5 ...

Page 6: ...CONTENTS iv June 1997 Rosemount Analytical 748332 D NGA Non Dispersive Infrared Analyzer NOTES ...

Page 7: ... a manner not specified in these instructions protective systems may be impaired DANGER is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored WARNING is used to indicate the presence of a hazard which can cause severe personal injury death or substantial property damage if the warning is ignored CAUTION i...

Page 8: ...s labeled and are leak free Improper gas connections could result in explosion or death This module requires periodic calibration with a known standard gas See General Precautions for Handling and Storing High Pressure Gas Cylinders at the rear of this manual Dropping the front panel of the Platform while hand or fingers are inside either case handle can cause serious injury CAUTION HAND INJURY HA...

Page 9: ... it is pulled out too far and the Platform is not properly supported 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 Note Apply leak test liquid to cell or detectors only as a las...

Page 10: ...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 fun...

Page 11: ...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 SOFTKEYS The five function keys located below the front pane...

Page 12: ...4 hours at constant temperature application dependent 2 of fullscale week at constant temperature application dependent EFFECT OF TEMPERATURE 1 of fullscale over any 10 C interval for rate of change no greater than 10 C per hour application dependent ENVIRONMENT Location Class B controlled indoor non hazardous AMBIENT TEMPERATURE 0 to 45 C 32 to 113 F EFFECT OF FLOW 1 of range when sample flow rat...

Page 13: ...her protected areas DIMENSIONS See Outline and Mounting Dimensions Figure 2 3 WEIGHT Standard 11 kg 24 2 lbs extended 12 5 kg 27 5 lbs MOUNTING Inside a Platform or custom installed in a panel MAXIMUM LENGTH OF LON CABLE 1600 m 1 mile between Analyzer Module and Platform See the Preface Section of the Platform manual for specifications regarding Platform related components ...

Page 14: ...authorized returns will be returned to the sender freight collect When returning any product or component that has been exposed to a toxic corrosive or other hazardous material or used in such a hazardous environment the user must attach an appropriate Material Safety Data Sheet M S D S or a written certification that the material has been decontaminated disinfected and or detoxified Return to Ros...

Page 15: ...accredited Nationally Recognized Testing Laboratory for use in non hazardous indoor locations 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 This product satisfies all obligations of all relevant standards of the EMC framework in A...

Page 16: ...PREFACE P 10 June 1997 Rosemount Analytical 748332 D NGA Non Dispersive Infrared Analyzer NOTES ...

Page 17: ...orated 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 TYPIC...

Page 18: ...ealing steel converting aluminum power processing porcelain kilns tunnels Water Vapor Heat treating hydrogen brazing nickel and chrome plating Sulfur Dioxide Flash smelting Ammonia Ammonia dissociation 1 3 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 c...

Page 19: ...Y CASE TEMPERATURE SENSOR REFERENCE OUT REFERENCE IN PURGE GAS IN CHOPPER MOTOR SOURCE CELLS DETECTOR THERMAL FUSE DETECTOR COVER SHUTTER ADJUST ACCESS HOLES OSCILLATOR TUNE ADJUST NETWORK INPUT MODULE OSCILLATOR BOARD SIGNAL BOARD DETECTOR TEMPERATURE CONTROL RTD MICRO BOARD FLOW SENSOR PRESSURE COMPENSATION BOARD OPTION SAMPLE IN SAMPLE OUT BOTTOM FAN POWER SUPPLY BOARD ...

Page 20: ...ncentration is processed and expressed as the primary variable on the network Other modules comprising the NGA 2000 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 5 FIGURE 1 ...

Page 21: ...les The purpose of these kits is to improve performance and accuracy through the reduction of ambient CO2 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 Pressure compensation for barometric fluctuations optional Fl...

Page 22: ...INTRODUCTION 1 6 June 1997 Rosemount Analytical 748332 D NGA Non Dispersive Infraraed Analyzer NOTES ...

Page 23: ...ional 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 Do not place hands or fingers in the Platform front handles when front panel is open Dropping the front panel of the Plat...

Page 24: ...from extreme temperature variations For best results install the instrument near the sample stream to minimize sample transport time Operating ambient temperature is 0o C to 45o C 32o F to 113o F Sample dewpoint is 40 C or less Note Unrestricted air flow in the rear of the Analyzer Module is critical to its performance and reliability TABLE 2 1 CELL PURGING TIMES AT ATMOSPHERIC SAMPLE PRESSURE 2 4...

Page 25: ...e 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 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 ...

Page 26: ...ONS TO PLATFORM E PURGE GAS IN 1 4 O D TUBE FITTING D REFERENCE IN 1 4 O D TUBE FITTING C REFERENCE OUT 1 4 O D TUBE FITTING B SAMPLE OUT 1 4 O D TUBE FITTING A SAMPLE IN 1 4 O D TUBE FITTING 5 MODULE TO BE INSTALLED WITHIN 15 OF HORIZONTAL 4 POWER REQUIREMENTS 24 VDC 3 5 A 3 ELECTRICAL INSTALLATION MUST BE IN COMPLIANCE WITH NATIONAL ELECTRICAL CODE ANSI NFPA 70 AND OR ANY APPLICABLE NATIONAL OR ...

Page 27: ...WORK 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 NGA 2000 components Connect Analyzer Module POWER 24 VDC power source either the Platform or external power source FIGURE 2 3 NDIR BACK PANEL FIGURE 2 4 NDIR FRONT PANEL ELECTRICAL CONNECTIONS IN 10 PSI MAX 69 kPa MAX OUT ...

Page 28: ...7 J2 J4 J9 J3 J11 J8 J1 J15 J14 J6 J10 J5 1 2 3 4 1 2 FLOW SENSOR FAN ASSEMBLY RESISTOR MODULATION CHECK HEATSINK SOURCE DRIVER MOTOR ASSEMBLY REF SOURCE SOURCE ASSY SAMPLE SOURCE CASE TEMPERATURE SENSOR C CHASSIS GROUND DETECTOR BASE FUSE THERMAL CUTOFF RTD TEMP CTRL HEATER SENSOR C OSCILLATOR BOARD J1 LON POWER BOARD J5 E2 24V E1 RTN E3 RECORDER OUTPUT SIGNAL BOARD J7 J4 J6 J2 J3 J1 J5 COMPUTER ...

Page 29: ...ds of Display Screens are available to the user see Figures 3 1 through 3 6 Run Mode Menu Help 3 2 1 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 seco...

Page 30: ...e 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 Controller Board and ...

Page 31: ...iable XXXX Secondary Variable XXXX Display Parms Menu Dual Info F1 F2 F3 F4 F5 23 2 CO Analyzer XXXXXXXX Main Menu Expert controls and setup Operational configuration Technical level configuration Diagnostic and manufacturing service Display Parms Info F1 F2 F3 F4 F5 Basic Controls Delete alarm message 23 2 CO Analyzer XXXXXXXX Basic Controls Range upper limit 25 Range and functional control Local...

Page 32: ...enus listing of all modules Status normal 23 2 CO Analyzer XXXXXXXX Main Menu Help Home Escape Map F1 F2 F3 F4 F5 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 23 2 CO Analyzer...

Page 33: ...ng selections from the Main Menu Expert Controls and Setup Analyzer Module Setup Calibration Gases 3 Input appropriate data in the Calibration Gas List menu 4 Press the HOME softkey to return to the Main Menu 5 Use the arrow key to select Basic Controls 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 t...

Page 34: ...wing 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 4 Select Zero Offset press ENTER adjust the value to 500000 with the and arrow keys and press ENTER Do not press ESCAPE at any time unless retention of prior settings is desired 5 Refer to the Data Sheet in the rear of this manual for Span Factors as ...

Page 35: ... 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 1 0 9 0 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 READINGS NORMALIZED Axis Reversed 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 0 100 50 CONCENTRATION ppm READING FULLSCALE Display ppm FIGURE 3 7 TYPICAL LINEARIZATION CURVE LINEARIZER OFF FIGURE 3 8 OPERATOR DETERMINED LINEARIZATION CURVE NORMALIZED ...

Page 36: ... Expert Controls menu The operating range is selected by entering RANGE 1 2 3 or 4 in the Range Mode section that that menu Coefficients 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 coefficien...

Page 37: ... 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 sig...

Page 38: ...o 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 Analyzer Zero Are you sure...

Page 39: ... valid calibration 1 2 Physical measurements 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 From MAIN MENU 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 Dependent on which auxiliary module...

Page 40: ...sured Point 1 Analyzer function Ready Midpoint correction set up Range 1 2 3 4 Correction Disabled Point being measured Pt 1 Point 1 gas concentration 100 ppm Point 2 gas concentration 120 ppm Point 3 gas concentration 150 ppm Point 1 reading 100 ppm Point 2 reading 120 ppm Point 3 reading 150 ppm Span gas value 100 ppm Analyzer function Ready 5 Dependent on which auxiliary module is present on th...

Page 41: ...odule Auto 1023 Auxiliary module Acal 2322 Auxiliary module HART 1092 Auxiliary module None Auxiliary module None Auxiliary module None Proposed new bind 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 Record basic level security codes expert technical Press the softkeys in any ord...

Page 42: ...analog was 14 92V 15V analog is 14 85V 15V analog was 14 92V 5V digital is 5 02V 5V digital was 4 98V 24V power is 2 38V 24V power was 2 42V 12V analog is 11 88V 12V analog was 12 0V Analyzer Diagnostics See 8 above 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 Calibration F...

Page 43: ...w sensor case temperature sensor Analysis cells and optical components RTD detector temp controller thermal fuse The only components that may require adjustment are the oscillator tune and shutter balance adjustments These are factory set and should be adjusted only in the following cases if the operator has changed sources oscillator board or detector if the operator disassembles the bench to any...

Page 44: ...1 PRINTED CIRCUIT BOARD FOLD OUT PANEL VIEWS To remove a particular board on the fold out panel label and unplug all interconnect wiring and remove securing hardware See Figure 4 1 Do the reverse to install a new board Use caution when installing connectors by observing correct position polarity and alignment of pins 4 3 POWER FUSE REPLACEMENT Remove power to the Analyzer Module prior to fuse repl...

Page 45: ...rform this replacement 4 6 SOURCE REPLACEMENT See Figure 4 3 for a breakdown of the Motor Source Assembly The entire optical bench must be removed to perform this replacement 4 7 DETECTOR REMOVAL See Figures 4 4 and 4 6 for breakdowns of the optical bench The entire optical bench must be removed in order to perform this disassembly 4 8 FLOW SENSOR REPLACEMENT See Figure 4 4 for Flow Sensor locatio...

Page 46: ...ctor 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 oscillator tune and detector signals are within 5 of the factory settings see Figure 3 13 in Primary Variable Parameters and Modulation Check menus no adjustment is necessary If not see Figure 4 4 and 4 5 for Oscillator Tune and S...

Page 47: ... zero gas nitrogen through the sample cell until the display reading stabilizes The shutter is a delicate component with only a six degree rotation Take care when making the required adjustments 7 Using an appropriate screwdriver that will fit through the Source Balance Adjustment Screw Holes see Figure 4 5 rotate the sample shutter adjust screw until a minimum reading on the display is obtained A...

Page 48: ...une 1997 Rosemount Analytical 748332 D NGA 2000 Non Dispersive Infrared Analyzer Detector Assembly Oscillator Tune Adjust Shutter Shaft Motor Source Assembly Power Transistor Heatsink Flow Sensor FIGURE 4 4 CELL PCB ASSEMBLY EXPLODED VIEW ...

Page 49: ...Resistive Temperature Detector Thermal Fuse Oscillator Board Detector Detector Heater FIGURE 4 5 OSCILLATOR TUNE SOURCE BALANCE SHUTTER ADJUSTMENTS FIGURE 4 6 DETECTOR BLOCK EXPLODED VIEW CLOSE OPEN Sample SHUTTER DETECTOR ASSEMBLY COVER Front View Oscillator Tune Adjustment Source Balance Shutter Adjustment Screw Hole ...

Page 50: ...t 6 After all matter has been removed rinse the cell with distilled water and allow to air dry Do not use towels 7 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 8 After cleaning cell examine O rings at the source detector and end caps If damaged replace with new O rings 9 Remove any contaminants from windows with a lint ...

Page 51: ...ersive Infrared Analyzer Spacer Motor Source Assembly Sample Cell Shutter Block Assembly Detector Assembly Desiccant Holder SHORT PATH CELLS 4mm TO 2 5 INCHES Motor Source Assembly Sample Cell Shutter Block Assembly Detector Assembly Desiccant Holders LONG PATH CELLS FIGURE 4 7 CELL DISASSEMBLY ...

Page 52: ...he modulation check 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 1 Access the Primary Variable Parameters menu see Figure 3 13 2 Select Modulation Check 3 Follow the Instructions and Then line commands which are the following a Flow zero gas press START softkey and wai...

Page 53: ...uration 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 NL623998 Oscillator Board NL657466 LON Power Board NL655729 Detector Heater NL622917 Temperature Sensor Detector NL898733 Thermal Fuse with Q Pad NL902931 Flow Sensor NL655943 Case Temperature Sensor NL655630 Power Supply Board NL65...

Page 54: ...REPLACEMENT PARTS 5 2 June 1997 Rosemount Analytical 748332 D NGA 2000 Non Dispersive Infrared Analyzer NOTES ...

Page 55: ...late I SINGLE CHANNEL NON DISPERSIVE INFRARED ANALYZER MODULE Code Language A English X Special Code Configuration Identifier A09 A10 A12 A20 B22 B23 B2B30 B36 B38 A06 A07 A08 A11 B21 B24 B26 B76 F63 A16 A28 B19 B25 B27 C31 C37 C39 D41 D44 A14 A15 B46 E54 F64 F65 F66 F67 H73 E56 H74 H75 J83 H84 J85 J88 L99 SPECIAL Extended Length S99 SPECIAL Standard Length Code ZOO No Selection Code Linearized No...

Page 56: ...APPENDIX A NDIR IDENTIFICATION MATRIX A 2 June 1997 Rosemount Analytical 748332 D NGA 2000 Non Dispersive Infrared Analyzer NOTES ...

Page 57: ... 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 should be subjected to a temperature higher than ...

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Page 59: ... 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 WARRANTIES 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 LIAB...

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Page 61: ...r Please have the following information when you call Model Number Serial Number and Purchase Order Number or Sales Order Number Prior authorization by the factory must be obtained before returned materials will be accepted Unauthorized returns will be returned to the sender freight collect When returning any product or component that has been exposed to a toxic corrosive or other hazardous materi...

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