ABB NGC8200 User manual

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ABB MEASUREMENT & ANALYTICS | 2101510MNAH
Gas Chromatograph User Manual
NGC8200/PGC1000
Measurement made easy

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Contents
Contents ...........................................................................................................................2
List of tables .....................................................................................................................6
Additional information.......................................................................................................7
Compliance .......................................................................................................................7
Cyber security.................................................................................................................7
Malware prevention..........................................................................................................8
Waste Electrical and Electronic Equipment (WEEE).................................................................8
Safety...............................................................................................................................8
Potential safety hazards ....................................................................................................9
1. Product description.....................................................................................................10
1.1 Overview ............................................................................................................. 10
1.2 System components .............................................................................................. 10
1.3 Principle of operation: sample processing .................................................................. 11
2Hardware description..................................................................................................11
2.1 Analyzer standard hardware features........................................................................ 12
2.2 Cast aluminum enclosure........................................................................................ 13
2.2.1 Exterior enclosure dimensions..................................................................... 14
2.3 Feed-through assembly .......................................................................................... 16
2.3.1 Configurations.......................................................................................... 16
2.3.2 Inlets...................................................................................................... 16
2.3.3 Vents...................................................................................................... 16
2.4 Analytical module .................................................................................................. 16
2.4.1 GC module .............................................................................................. 17
2.4.2 Analytical processor/manifold assembly........................................................ 17
2.5 Digital controller assembly with VGA display .............................................................. 18
2.6 Termination board ................................................................................................. 21
2.7 Local communication options................................................................................... 22
3Embedded software and user interface........................................................................22
3.1 Embedded software ............................................................................................... 22
3.2 User interface (PCCU32)......................................................................................... 22
3.3 Audit quality data .................................................................................................. 22
3.4 Compressibility options........................................................................................... 23
3.5 Calculation options ................................................................................................ 23
3.6 Engineering units .................................................................................................. 23
3.7 Supported communication protocols ......................................................................... 23
3.8 Security............................................................................................................... 24
4Installation.................................................................................................................24
4.1 Plan for installation................................................................................................ 25
4.2 Unpack and inspect................................................................................................ 25
4.3 Analyzer installation............................................................................................... 25
4.3.1 Pipe installation for stand-alone mounting..................................................... 25

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4.3.2 Pipe saddle installation for pipe saddle mounting............................................ 26
4.3.3 Shelf installation....................................................................................... 26
4.3.4 Analyzer installation.................................................................................. 27
4.4 Sample system installation...................................................................................... 28
4.4.1 Sample system design considerations .......................................................... 28
4.4.2 Tube quality ............................................................................................ 28
4.4.3 Maintaining phase..................................................................................... 29
4.4.4 Sample probe installation........................................................................... 29
4.4.5 Sample conditioning modules...................................................................... 30
4.4.6 Sample line connections............................................................................. 34
4.5 Carrier and calibration system installation.................................................................. 36
4.5.1 Calibration/validation stream ...................................................................... 36
4.5.2 Cylinder rack installation on meter run ......................................................... 36
4.5.3 Carrier gas regulator installation ................................................................. 36
4.5.4 Calibration gas regulator installation ............................................................ 37
4.5.5 Carrier gas and calibration gas line connections ............................................. 39
4.6 Vent lines connections............................................................................................ 40
4.7 Security seal......................................................................................................... 41
5Wiring ........................................................................................................................42
5.1 Wire for serial communication ................................................................................. 42
5.2 Wire for power and grounding ................................................................................. 42
5.2.1 Power supply requirements ........................................................................ 43
5.2.2 Operating voltages and cable lengths ........................................................... 43
5.2.3 Other considerations ................................................................................. 44
5.2.4 Ground the analyzer.................................................................................. 44
5.2.5 Cathodic protection................................................................................... 44
5.2.6 Wire the analyzer power connector.............................................................. 44
6Startup .......................................................................................................................45
6.1 Download PCCU32 from the ABB website................................................................... 45
6.2 Install PCCU32...................................................................................................... 47
6.3 Establish initial local communication ......................................................................... 48
6.3.1 Connect using USB port (standard).............................................................. 48
6.3.2 Connect using RS-232 port......................................................................... 50
6.3.3 Connect using Ethernet port ....................................................................... 52
6.4 Power on sequence................................................................................................ 55
6.4.1 Initialization............................................................................................. 55
6.4.2 Startup diagnostics ................................................................................... 55
6.5 Startup wizard ...................................................................................................... 57
6.5.1 Set up the station..................................................................................... 59
6.5.2 Set up the stream..................................................................................... 59
6.5.3 Set up calibration ..................................................................................... 61
6.5.4 View diagnostics....................................................................................... 62
6.5.5 Update configuration ................................................................................. 63
6.5.6 Analyze the calibration stream .................................................................... 64

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6.5.7 Enable/Disable streams ............................................................................. 66
6.5.8 Run Analysis Process streams ..................................................................... 67
6.5.9 Complete startup...................................................................................... 68
6.6 Manual peak find................................................................................................... 69
6.6.1 Troubleshoot peak find .............................................................................. 73
7Calibrate the analyzer .................................................................................................75
7.1 Verify calibration data using peak find....................................................................... 78
8Configure for network connection................................................................................79
8.1 Basic topology ...................................................................................................... 79
8.2 IP addressing........................................................................................................ 80
8.3 Cabling for connection to network ............................................................................ 80
8.4 Enable Ethernet and configure IP parameters ............................................................. 81
8.5 Verify network connection....................................................................................... 83
8.6 Basic Ethernet connection troubleshooting ................................................................. 84
9Configure security.......................................................................................................84
9.1 Configure bi-level security....................................................................................... 85
9.2 Configure Role Base Access Control (RBAC) ............................................................... 88
9.2.1 Default access roles .................................................................................. 90
9.2.2 Set up and create a new RBAC security control file ......................................... 91
9.2.3 Create the administrator account................................................................. 91
9.2.4 Create additional user accounts with standard roles........................................ 93
9.2.5 Save RBAC configuration file....................................................................... 94
9.3 Save security configuration on the device .................................................................. 95
10 Maintenance ...............................................................................................................97
10.1 Maintaining cleanliness........................................................................................... 97
10.2 Visual inspection ................................................................................................... 97
10.3 Technical support and returns.................................................................................. 98
10.4 Spare part components .......................................................................................... 98
10.4.1 Replacement components .......................................................................... 98
10.4.2 Replacement parts.................................................................................... 98
10.4.3 Spare parts ........................................................................................... 100
10.5 Field tool kit ....................................................................................................... 100
10.6 Back up configuration files .................................................................................... 101
10.7 Update embedded software................................................................................... 101
10.8 Restore configuration files..................................................................................... 104
10.9 Reset procedures ................................................................................................ 105
10.9.1 Warm start............................................................................................ 105
10.9.2 Cold start .............................................................................................. 106
10.10 Restore factory defaults........................................................................................ 107
10.11 Lithium battery status .......................................................................................... 108
10.12 Change the clock................................................................................................. 108
10.12.1 Clock change not crossing a log period boundary ......................................... 108
10.12.2 Forward clock change crossing a log period boundary ................................... 108
10.12.3 Backward clock change crossing a log period boundary ................................. 109

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10.13 Replace calibration or carrier gas cylinder(s) ............................................................ 109
10.14 Replace the digital controller assembly.................................................................... 109
10.15 Replace the digital controller complete assembly ...................................................... 110
10.16 Replace the analytical module................................................................................ 111
10.17 Replace the GC Module......................................................................................... 113
10.18 Replace the termination panel ............................................................................... 114
10.19 Replace the feed-through assembly ........................................................................ 116
10.20 Replace the lithium battery ................................................................................... 117
10.21 Replace frit filters ................................................................................................ 118
10.22 Replace the feed-through interface gasket............................................................... 119
10.23 Replace the feed-through manifold gasket ............................................................... 120
10.24 Replace the termination panel to the digital controller cable........................................ 121
10.25 Replace the analytical processor to the termination panel cable................................... 122
11 Troubleshooting........................................................................................................123
11.1 Startup diagnostics troubleshooting........................................................................ 123
11.1.1 Carrier Pressure Regulator Test................................................................. 123
11.1.2 Oven Temperature Test ........................................................................... 124
11.1.3 Processor Control Test............................................................................. 124
11.1.4 Stream Test........................................................................................... 124
11.2 Troubleshooting Alarms ........................................................................................ 125
11.2.1 Alarm definitions .................................................................................... 126
11.2.2 Pressure Regulator 1 or 2 Alarm................................................................ 126
11.2.3 Sample Pressure Alarm............................................................................ 127
11.2.4 Oven Temperature Error Alarm ................................................................. 127
11.2.5 No Stream Valve Selected ........................................................................ 127
11.2.6 Digital-Analog Board Communication Error Alarm......................................... 128
11.2.7 Calculation Error Alarm............................................................................ 128
11.2.8 Calibration Un-normalized Error Alarm ....................................................... 128
11.2.9 Stream Sequence Error Alarm................................................................... 128
11.2.10 Calibration CV Percent Error Alarm ............................................................ 128
11.2.11 Calibration RF Percent Error Alarm............................................................. 129
11.2.12 Enclosure Temperature Alarm ................................................................... 129
11.2.13 Power Supply Alarm ................................................................................ 129
11.2.14 Low Carrier Gas Cylinder (DI1) Alarm ........................................................ 130
11.2.15 Low Cal Gas Cylinder (DI2) Alarm.............................................................. 130
11.2.16 GCM Processing Error Alarm ..................................................................... 130
11.2.17 Bad Bead Alarm ..................................................................................... 130
11.2.18 No Pilot Valve Change Detected Alarm........................................................ 130
11.2.19 Sample Flow Detection Alarm ................................................................... 130
11.2.20 CPU Loading Alarm ................................................................................. 131
11.2.21 System Memory Available Alarm ............................................................... 131
11.2.22 RAM File Available Alarm.......................................................................... 131
11.2.23 FLASH File Available Alarm ....................................................................... 131
11.2.24 Missing Peak - Calibration Not Used ........................................................... 131

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11.2.25 Stream Un-normalized Total ..................................................................... 132
11.3 Alarm troubleshooting tests................................................................................... 132
11.3.1 Column vent pressure test ....................................................................... 132
11.3.2 Sample pressure test .............................................................................. 132
11.3.3 Feed-through assembly blockage test......................................................... 133
11.3.4 Temperature sensor test.......................................................................... 133
11.3.5 Abnormal calibration gas depletion ............................................................ 133
11.4 Power troubleshooting.......................................................................................... 133
11.4.1 Overview............................................................................................... 133
11.4.2 Power supply voltage test ........................................................................ 133
11.4.3 Equipment isolation test........................................................................... 134
11.4.4 Analyzer module isolation test .................................................................. 134
11.5 Serial communications troubleshooting ................................................................... 135
11.5.1 RS-232 communication............................................................................ 135
11.5.2 RS-485 communications test .................................................................... 135
List of tables
Table 0-1: Related documentation...........................................................................................7
Table 2-1: Analyzer specifications ......................................................................................... 11
Table 4-1: Sample Conditioning module descriptions ................................................................ 31
Table 4-2: Calibration gas blend recommended components ...................................................... 36
Table 5-1: Serial Port 1 and Port 2 pinouts and terminations...................................................... 42
Table 5-2: 12 VDC battery power supply system maximum cable lengths .................................... 44
Table 6-1: Cable for USB connection...................................................................................... 49
Table 6-2: Required cables for connection with MMI port........................................................... 51
Table 6-3: Ethernet cabling for local connection....................................................................... 53
Table 6-4: Station setup basic parameters.............................................................................. 59
Table 6-5: Stream setup screens .......................................................................................... 60
Table 6-6: Peak find troubleshooting...................................................................................... 73
Table 6-7: Suggested carrier pressure setpoint adjustment values.............................................. 74
Table 8-1: Ethernet cabling for network connection.................................................................. 80
Table 9-1: Security guidelines .............................................................................................. 85
Table 9-2: Bi-level security .................................................................................................. 85
Table 9-3: Security switch status: Off ............................................Error! Bookmark not defined.
Table 9-4: Configure security codes (example)................................Error! Bookmark not defined.
Table 10-1: Spare parts .................................................................................................... 100
Table 10-2: Field tools ...................................................................................................... 101
Table 11-1: Startup diagnostics .......................................................................................... 123
Table 11-2: Carrier pressure regulator diagnostics ................................................................. 123
Table 11-3: Stream test diagnostics .................................................................................... 124
Table 11-4: Default alarms ................................................................................................ 125
Table 11-5: Alarm Severity ................................................................................................ 125
Table 11-6: Default alarm definitions ................................................................................... 126
Table 11-7: RS-232 Field wiring on analyzer termination panel ................................................ 135
Table 11-8: RS-485 Terminations........................................................................................ 135
Table 11-9: RS-485 pinouts (on termination panel)................................................................ 135

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Additional information
Additional free publications are available for download at www.abb.com/analytical.
Table 0-1: Related documentation
Document
Document number
Data sheets
NGC
8206
2101164
PGC1000
2101183
User drawings
NGC8200 Power Option 24 VDC solar power
2104134
NGC8200 Power Option 12 VDC solar power
210413
3
NGC8200 Phoenix
®
24 VDC power supply with UPS
2104132
NGC8200
Small weather enclosure drawing
2104224
Installation of sample, carrier
,
and calibration lines for NGC
2103085
NGC Illustrated parts breakdown
2103336
NGC820
0
to Phoenix
®
power supply
2103149
C
ontrol D
rawings
(CU
-
TR)
Control
Drawing,
NGC/PGC
,
GOST
-
R
2104758
(IECEx)
Control
Drawing,
NGC/PGC
, EX d, Zone 1
2102805
(ATEX) Control Drawing, NGC/PGC, EX d, Zone 1 2102250
(CSA) Control Drawing, NGC/PGC, DIV 1, C/US 2101429
(INMETRO) Control Drawing, NGC/PGC, Ex d 2106190
Other documentation
Technical bulletin - Upgrading NGCs TekBul 220
Modbus Registers for NGC8200 and PGC1000 2108309
Return Material Authorization (RMA) request form 2108308
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Compliance
Cyber security
This product is designed to be connected, and communicate information and data, via a network
interface. All ABB products should be connected to a secure network. It is the customer's sole
responsibility to provide,and continuously ensure,a secure connection between the product(s) and
the customer network as well as a secured and controlled physical access to the hardware equipment,
or any other network (as the case may be). The customer shall establish and maintain appropriate
measures (such as, but not limited to, the installation of firewalls, the application of authentication
measures, encryption of data, installation of antivirus programs, etc.) to protect the products, the
network, its system and its interfaces against any kind of security breaches, unauthorized access,

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interference, intrusion, leakage and/or theft of data or information. ABB Inc. and its affiliates are not
liable for damages and/or losses related to security breaches, unauthorized access, interference,
intrusion, leakage and/or theft of data or information.
Although ABB provides functionality testing on the products and updates it releases, the customer
should institute its own testing program for any product updates or other major system updates (to
include, but not limited to, code changes, configuration file changes, third party software updates or
patches, hardware change-out, etc.) to ensure that the security measures the customer has
implemented have not been compromised and that the system functions in the customer's
environment as expected.
Malware prevention
Recommendation: As with any downloaded software, scan ABB embedded software packages using a
malware prevention solution.
Waste Electrical and Electronic Equipment (WEEE)
EU Directive 2012/19/EU
ABB Industrial Automation, Measurement and Analytics is committed to actively protecting the
environment. Do not dispose of WEEE as unsorted municipal waste. Collect WEEE separately.
Participation in the management of WEEE is critical to the success of WEEE collection.
Electrical and electronic equipment marked using the crossed-out wheeled bin symbol
shall not be mixed with general household waste. Correct disposal at a recycling facility
will help save valuable resources and prevent potential negative effects on health and the
environment. These steps ensure compliance with the Waste Electrical and Electronic
Equipment (WEEE) Directive.
Waste electrical and electronic equipment (WEEE) shall be treated separately using the national
collection framework available to customers for the return, recycling, and treatment of WEEE.
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Safety
Read these instructions carefully before installation and commissioning. These instructions do not
contain all details on all types of devices and do not explain all assembly, operating, or maintenance
scenarios. Ask the manufacturer for further information.
Observe warning signs on packaging and on the device. Safety symbols are in accordance with IEC
60417 or ISO 7000.
Assign only qualified and authorized specialists for the assembly, electrical connection, commissioning,
and maintenance of the equipment. Specialist qualifications include:
–Training, instruction, and authorization to operate and maintain devices or systems according to
safety engineering standards for electrical circuits, high pressures, and aggressive media
–Training in accordance with safety engineering standards regarding maintenance and use of
adequate safety systems
WARNING: According to ISO 9996, use only sufficiently insulated tools for electrical
connection.
Also consider the following regulations:
–The applicable standards and safety regulations concerning the construction and operation of
electrical installations
–The regulation on technical working materials (safety guidelines for tools)
–The regulations and recommendations relating to explosion protection
–The recommendations for safe working in the case of installation in a Safety Integrity Level (SIL)
loop.
–The regulations and codes that apply in the country of use

2101510MNAH | NGC8200 AND PGC1000 USER MANUAL | 9
Potential safety hazards
WARNING – Bodily injury. Read and follow instructions contained in this guide before and
during equipment installation. Failure to do so could result in bodily injury or equipment damage.
WARNING – Bodily injury. A grounding conductor may or may not be required depending
on the hazardous classification. If required, any interruption of the grounding conductor inside
or outside the equipment, or a loose connection of the grounding conductor, can result in a
dangerous device. Intentional interruption of the grounding conductor is not permitted. If a
grounding conductor is required, it should be connected to the grounding terminal before any
other connections are made.
Before applying the power, check that the operating voltage listed on the equipment agrees
with the power being connected to the equipment.
WARNING – Bodily injury. Apply power only after the procedures are complete. Technicians
must perform the procedures in order: plan, install, wire, verify the power-on sequence, and
configure. Do not open the equipment to perform any adjustments, measurements,
maintenance, parts replacement or repairs until all external power supplies have been
disconnected. When opening covers or removing parts, exercise extreme care as live parts or
connections can be exposed. Capacitors in the equipment can still be charged even after the
device has been disconnected from all power supplies.
WARNING – Bodily injury. The device can be operated at high levels of pressure and with
aggressive media. Serious injury and/or considerable material damage can be caused if this
device is handled incorrectly.
DANGER – Explosion risk. Serious damage to health / risk to life. Ensure there is no
hazardous atmosphere present when performing maintenance on the device. Do not separate
components when energized. This applies to all connectors and connections, cabling, and wiring.
If the device is installed or to be installed in a hazardous location, the technician must follow the
guidelines stipulated in the certification drawings shipped with this device.
NOTICE – Equipment damage or loss of data. Potential electrostatic charging hazard: clean
only with a damp cloth.

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1.Product description
1.1 Overview
The ABB Natural Gas Chromatograph (NGC) and Process Gas Chromatograph (PGC) continually
analyze natural gas or process gas streams on-site, determine composition and calorific value, and
store the analysis information.
1.2 System components
This compact device requires minimal installation time and is configured and calibrated at the factory.
A typical installation has the following components:
Analyzer: a single analyzer supports a single or multiple streams (up to 4)
Sample probe: captures the gas sample from the pipeline
Sample conditioning module(s): prepares the sample before it enters the analyzer
Carrier gas: assists the flow of the gas sample
Calibration gas: gas blend with detectable components to determine baseline analysis
Tubing: gas lines to deliver and vent gas to and from the analyzer.
Figure 1-1 shows the analyzer in a typical single stream pipeline installation. This scenario includes a
sample probe, an optional sample conditioning module, and carrier and calibration gas. Lines for the
entry of the gas sample, carrier gas, and calibration gas are installed into the analyzer’s feedthrough
inlets. The sample probe captures the gas sample which is fed to the sample conditioning module for
processing before it enters the analyzer. Carrier gas assists the gas sample flow through the device.
Figure 1-1: Typical single stream installation
Figure 1-2 shows the analyzer in a multiple stream pipeline installation. Note that this illustration
shows the analyzer mounted on the first pipeline. It could be mounted on the middle pipe run. The
mounting location of the analyzer depends on the distance to each of the sample probes. Consider
tubing length requirements to determine appropriate mounting location in a multi-stream system.

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Figure 1-2: Typical multi-stream installation
1.3 Principle of operation: sample processing
To process a sample, a gas sample is extracted from the pipeline. The sample conditioning module
removes any particulates or liquids entrained in the sample. The sample conditioning module also acts
as a bypass loop to ensure that sample lag time is minimized. The sample is then transported to the
analyzer and analyzed using gas chromatography.
Analysis results provide mole percent values for each gas component. These values are used to
perform energy calculations. Calculated values include: gas compressibility, real relative density,
Btu/CV value, liquid GPM, Wobbe index, methane number and several other optional calculated
values. Gas compressibility selections include NX-19, AGA-8 detail, single virial summation factor, ISO
summation factor and none (a factor of one is used).
Analysis results are stored in the analyzer. Once a sample processing cycle is completed, the sample
is vented from the analyzer. Analysis results can be collected directly from the analyzer using the
operator interface (PCCU) or the analyzer can be configured to transmit results to other systems using
any of the supported communication protocols.
2 Hardware description
Table 2-1: Analyzer specifications
12 VDC
24 VDC
No.
a
ux.
h
eater
With
a
ux.
heater
No
a
ux.
h
eater
With
a
ux.
heater
Supply Voltage 10.5–16 VDC 10.5–16 VDC 21–28 VDC 21–28 VDC
Recommended AC Power
Supply
14.5 V 14.5 V 25 V 25 V
Maximum Instantaneous
Current (see note 1)
7
Amp
8.2 Amp
3.5
Amp
5.2 Amp
Avg. Power Consumption
After Startup (see note 2)
Up to 7 Watts Up to 53 Watts Up to 7 Watts Up to 64 Watts
Environment Temperature
Storage
-22 F to 140 F (-30 C to 60 C)
Normal Operation
0F to 131 F (-18 C to 55 C)
With environmental enclosure -40 F to 131 F (-40 C to 55 C)
Repeatability ±0.125 Btu at 1,000 Btu (±0.0125%) ambient;
±0.25 Btu at 1,000 Btu (±0.025%) over temperature range of 0 F
to
131 F (-18 C to 55 C)

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Helium Carrier Consumption rate: 12 ml/minute typical to 20 ml/minute maximum
Medium 800 to 1500 Btu per standard Cubic Foot (29.8 to 44.6
megajoules/meter3) with less than 100 PPM H2S
Analysis time Approx. 5 minutes; interval between cycles is adjustable
Calibration/validation
streams
Up to 2 dedicated (reduces sample stream for each dedicated
calibration streams). Must use dedicated stream(s) for Auto-Cal
feature.
Sample streams Up to 4 (with manual calibration streams)
Construction NEMA/Type 4X (IP56)
Aluminum Alloy with white polyester powder coating.
Explosion-Proof, see specification sheet for certifications.
Installation time Requires 2-3 hours for installation, minimum 8 hours run time for
repeatability.
Mounting Pipe run, free-standing pipe, shelf, and environmental enclosure
NGC8200 and PGC1000
dimensions
Width Height Depth Weight
US 9.5 inches 8.82 inches 15.64 inches 29 lbs.
Metric
241.3 mm
224.0 mm
397.3 mm
10.8 kg
Notes:
1. Usually experienced at startup. Use this for power supply sizing requirements (includes approx.
20% buffer and is calculated for maximum allowable power supply voltages).
2. At recommended AC power supply voltage. Highly temperature dependent, with feed-through
heater operating continuously. Usually occurs at only the coldest ambient operating temperature, i.e.,
0 °F (-18 °C).
2.1 Analyzer standard hardware features
The analyzer features a rugged, field-ready design. Hardware features include:
Enclosure
Cast aluminum housing with six exterior hubs
Powder coating
Weatherproof construction
Modular design (see Figure 2-1)
Digital controller assembly
Analytical module with compact design and single bolt replacement
Feed-through assembly with flame path arrestors
Termination panel
Electronics
32-bit digital controlling electronics (no analog control loops)
Low power operation
Dual digital carrier pressure regulation
Digital temperature control
Digital detector electronics
Low EMI/RFI design
Operates on Windows CE
Auto-start with diagnostics
Factory calibrated

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Figure 2-1: Analyzer modular design
The analyzer’s modular design is suited for quick repair. All modules are easily replaced in the field in
minimal time. See section 10.4.3 for a recommended spare parts list.
2.2 Cast aluminum enclosure
The explosion-proof enclosure consists of a cylindrical shaped cast aluminum housing, powder coated,
with front and rear end caps for access to internal components. Figure 2-2 through Figure 2-5 show
the outline dimensions of the NGC8200 and PGC1000.
The end caps have precision-engineered threading. The enclosure and all fittings, including feed-
through, MMI connection, and breather, are tested to Nema/Type 4X. Unauthorized removal of the
end caps is protected with a 1/16” hex socket set screw on each end cap.
Entries in the explosion-proof enclosure constitute a flameproof joint. Flameproof joints, including
threaded entries in the explosion-proof enclosure, are not intended to be repaired.
This enclosure may be pipe-mounted on a meter run using a pipe saddle, stand-alone pipe-mounted,
shelf-mounted, or optionally mounted in an environmental enclosure. The device may be directionally
positioned using 1/8” hex socket set screws located in the neck of the enclosure.

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2.2.1 Exterior enclosure dimensions
Figure 2-2: NGC8200 and PGC1000 enclosure face
Figure 2-3: NGC8200 and PGC1000 enclosure left side

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Figure 2-4: NGC8200 and PGC1000 enclosure right side
Figure 2-5: NGC8200 and PGC1000 enclosure underside

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2.3 Feed-through assembly
Independent sample streams are connected to the analyzer directly to the feed-through assembly
(see Figure 2-6), or through an optionally installed sample conditioning module. The feed-through
assembly also serves as the connection for carrier gas and calibration streams.
Figure 2-6: Analyzer feed-through assembly
NOTICE – Equipment damage risk. The 0.5 micron filters should not be considered a
replacement for the primary filtering system. Optional sample conditioning modules are
designed for this purpose.
2.3.1 Configurations
The feed-through assembly comes in three configurations:
Without auxiliary heater
With 12 VDC auxiliary heater
With 24 VDC auxiliary heater
The auxiliary heater has a replaceable temperature sensor cable which connects to the analytical
module. Note that this cable comes in two configurations: 12 VDC and 24 VDC.
2.3.2 Inlets
Feed-through assembly inlets take in the stream gas samples and carrier gas. They all have internal,
replaceable 0.5 micron filters. The inlets are:
4 process stream inputs (S1, S2, S3, and S4)
1 carrier gas input (CAR)
NOTICE – Equipment damage risk. The 0.5 micron filters should not be considered a
replacement for the primary filtering system. Optional sample conditioning modules are
designed for this purpose.
2.3.3 Vents
Feed-through assembly vents are outlets from which processed samples and used carrier gas exit the
analyzer. They do not have filters but require vent tubing to be attached and routed accordingly. The
vents are:
2 column vents (CV1 and CV2)
1 sample vent (SV)
1 gauge port vent (GPV)
2.4 Analytical module
The analytical module assembly is comprised of a manifold, the analytical processor assembly, and the
GC module. The entire analytical module can be removed and/or replaced by loosening a single bolt.

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The analytical module comes in two configurations: 12 VDC and 24 VDC.
Figure 2-7: Analytical module
2.4.1 GC module
Figure 2-8 shows the GC module with the oven wall removed. The module has the following
components: columns, chromatographic valve, and GC module circuit board. The valve controls the
flow of gas within the system. The columns perform the separation of the gas into component parts
for analysis. The GC module circuit board contains the sensors for the carrier pressure regulators, the
sample pressure sensor, and the thermal conductivity detectors (TCDs) which detect the different gas
components as they leave the GC columns. It also contains an EEPROM or FLASH memory for storage
of calibration and characterization information of the module and its sensors.
Replacement of this component is by single bolt removal.
Figure 2-8: GC module
2.4.2 Analytical processor/manifold assembly
Figure 2-9 shows the analytical processor/manifold assembly. This assembly is equivalent to a
complete analytical module without a GC module. The manifold portion of the assembly is comprised
of the manifold plate, heater, valves, and various cables to other major components. The manifold
plate and heater maintain constant temperature for the GC module and columns. The valves control
the stream processing, carrier, and calibration gases. The cables complete the information chain from
the GC module to the analytical processor and the digital controller assembly.
On the bottom of the assembly is the analytical processor assembly. The assembly contains the
analytical processor board, shield and mounting plates, and mounting standoffs. The analytical
processor board provides real-time system control and measurement of the processes within the
analyzer. It does this by interfacing with the sensors in the GC module (and optional feed-through
temperature sensor) as well as controlling the carrier pressure regulator valves, sample stream
valves, the pilot valve, and the heaters. The data generated by the analytical processor is passed to
the digital controller board via a high-speed serial interface.

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The analytical processor board has two status LEDs used for troubleshooting. The red LED indicates
that the board is powered on. If the board is powered down by the digital controller, or has no power,
this LED is off. The yellow LED indicates that the analytical processor's CPU has initiated its program
successfully and is controlling its processes as directed by the digital controller. This LED should be
flashing at a frequency of 20 to 40 Hz during normal operation. If this LED is off or is on solid with no
flashing, then the software in the analytical processor is not running properly.
This is a field-replaceable part.
Figure 2-9: Analytical processor/manifold assembly
2.5 Digital controller assembly with VGA display
The Digital Controller assembly (Figure 2-10) contains the digital electronic board, mounting assembly
and a VGA display.
The digital controller provides control parameters to the analytical processor board and stores and
processes the data sent from the analytical processor board. The digital controller also processes
communication with other devices.
The digital electronic board features:
16 MB Pseudo Static Ram (Application) with lithium battery
32 MB NAND Flash Memory (Boot/Application/Storage)
4 MB Static CMOS Memory (Storage)
1 secure digital card socket (with up to 4 GB removable storage optional)
Figure 2-10: Digital controller assembly with display

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The display board provides a VGA monochromatic display to monitor the process and results. It also
provides six magnetic switches to allow a user to navigate through various screens of data and control
the processes (stop operation, start operation, and calibrate). Navigate screens using the display
magnet.
The VGA display features:
VGA display circuit board
Two LED status indicators, user-programmable. The default left LED flashing light indicates a
fault alarm, and a solid light indicates a warning alarm. Right LED solid light indicates device is
not in auto run mode.
User interface, with hall-effect magnet navigation, for monitoring the analyzer’s operation.

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Figure 2-11: NGC VGA display screen