Rosemount Analytical NGA 2000 User manual

NGA 2000
NON-DISPERSIVE INFRARED
ANALYZER MODULE
Rosemount Analytical

NOTICE
THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE.
Manual Part Number 748332-D
June 1997
Printed 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.

CONTENTS
748332-D Rosemount Analytical June 1997 i
NGA Non-Dispersive Infrared Analyzer
PREFACE
PURPOSE/SAFETY SUMMARY........................................................................P-1
GLOSSARY ......................................................................................................P-4
SPECIFICATIONS..............................................................................................P-6
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE....P-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 CONNECTIONS .................................................................2-5

CONTENTS
ii June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
SECTION 3. STARTUP AND OPERATION
3.1 OVERVIEW...............................................................................................3-1
3.2 DISPLAY SCREENS.................................................................................3-1
3.2.1 RUN MODE DISPLAY............................................................................3-1
3.2.2 Menu Displays.............................................................................3-1
3.2.3 Help Displays...............................................................................3-2
3.3 STARTUP PROCEDURE..........................................................................3-2
3.4 BINDING ...................................................................................................3-5
3.5 CALIBRATION ..........................................................................................3-5
3.6 LINEARIZATION.......................................................................................3-8
3.7 ROUTINE OPERATION............................................................................3-9
SECTION 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 CLEANING CELLS ...................................................................................4-8
4-13 CELL DESICCANT ...................................................................................4-10
4.14 MODULATION CHECK.............................................................................4-10
SECTION 5. REPLACEMENT PARTS
5.1 REPLACEMENT PARTS ..........................................................................5-1
APPENDIX A. IDENTIFICATION MATRIX

CONTENTS
748332-D Rosemount Analytical June 1997 iii
NGA Non-Dispersive Infrared Analyzer
INFRARED ANALYZER DATA SHEET
GENERAL PRECAUTIONS FOR HANDLING & STORING HIGH PRESSURE CYLINDERS
WARRANTY
FIELD SERVICE AND REPAIR FACILITIES
FIGURES
1-1 NGA 2000 NDIR Analyzer Module (Typical - Actual configuration May
Vary)..............................................................................................1-3
1-2 NDIR Technology ......................................................................................1-4
2-1 Analyzer Module Installation Into Instrument Platform...............................2-1
2-2 Outline and Mounting Dimensions.............................................................2-4
2-3 NDIR Back Panel.......................................................................................2-5
2-4 NDIR Front Panel Electrical Connections..................................................2-5
2-5 NDIR Wiring Diagram................................................................................2-6
3-1 Run Mode Display .....................................................................................3-3
3-2 Main Menu Display....................................................................................3-3
3-3 Basic 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) ............................................................................3-14
4-1 Printed Circuit Board Fold-Out Panel Views..............................................4-2
4-2 Module Fan Assembly...............................................................................4-3
4-3 Motor/Source Assembly.............................................................................4-4
4-4 Cell, PCB Assembly (Exploded View)........................................................4-6
4-5 Oscillator Tune, Source Balance Shutter Adjustments..............................4-7
4-6 Detector Block (Exploded View) ................................................................4-7
4-7 Cell Disassembly.......................................................................................4-9
TABLES
2-1. Cell Purging Times at Atmospheric Sample Pressure...............................2-2
3-1 NDIR Analyzer Module Alarms..................................................................3-6
4-1 Cell Desiccant............................................................................................4-10

CONTENTS
iv June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
NOTES

PREFACE
748332-D Rosemount Analytical June 1997 P-1
NGA Non-Dispersive Infrared Analyzer
PURPOSE/SAFETY SUMMARY
The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of this particular NGA 2000 module.
Some sections may describe equipment not used in your configuration. The user
should become thoroughly familiar with the operation of this module before operating
it. Read this instruction manual completely.
To avoid explosion, loss of life, personal injury and damage to this equipment
and on-site property, all personnel authorized to install, operate and service this
equipment should be thoroughly familiar with and strictly follow the instructions
in this manual. SAVE THESE INSTRUCTIONS.
If this equipment is used in 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 is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.
NOTE is used to indicate installation, operation or maintenance information which is
important but not hazard-related.
Operate this equipment only when covers are secured. Servicing requires
access to live parts which can cause death or serious injury. Refer servicing to
qualified personnel.
For safety and proper performance, this module must be connected to a
properly grounded three-wire source of electrical power.
WARNING: ELECTRICAL SHOCK HAZARD

PREFACE
P-2 June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
This equipment is not designed for and should not be used in the analysis of
flammable samples. Use of this equipment in this way could result in explosion
and death.
Ensure that all gas connectors are made as labeled and are leak free. Improper
gas connections could result in explosion or death.
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 HAZARD
CAUTION: PRESSURIZED GAS
WARNING: POSSIBLE EXPLOSION HAZARD
WARNING: POSSIBLE EXPLOSION HAZARD

PREFACE
748332-D Rosemount Analytical June 1997 P-3
NGA Non-Dispersive Infrared Analyzer
Tampering with or unauthorized substitution of components may adversely
affect safety of this product. Use only factory approved components for repair.
This Analyzer Module may tip instrument over if 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 last resort.
CAUTION: PARTS INTEGRITY
CAUTION: OVERBALANCE HAZARD
WARNING: OVER-VOLTAGE SPIKING

PREFACE
P-4 June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
GLOSSARY
ANALYZER MODULE
The module that contains all sensor/detector components for development of a
Primary Variable signal; includes all signal conditioning and temperature control
circuitry.
BACKPLANE
The interconnect circuit board which the Controller Board, Power Supply, Analyzer
Module power and network cables, I/O Modules and Expansion Modules plug into.
CONTROL MODULE
The Operator Interface plus the Controller Board.
CONTROLLER BOARD
The computer board that serves as the Network Manager and operates the Display
and Keypad.
DISTRIBUTION ASSEMBLY
The Backplane and the card cages that hold I/O and Expansion Modules.
EXPANSION MODULE
A circuit board that plugs into the Backplane from the front of the Platform and
performs special features not related to I/O functions.
I/O MODULE
A circuit board that plugs into the Backplane from the rear of the Platform. Has a
connector terminal for communication with external data acquisition devices and
provides an input/output function.
OPERATOR INTERFACE
The Display and Keyboard.

PREFACE
748332-D Rosemount Analytical June 1997 P-5
NGA Non-Dispersive Infrared Analyzer
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 NGA 2000
components, from the Power Supply Board that plugs into the front of the Backplane
in a stand-alone instrument to several larger ones that can power larger collections of
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 panel display; they assume the function
displayed directly above each on the display, a function dictated by software.
SYSTEM
Any collection of Analyzer Module(s), Platform(s), I/O Module(s) and Expansion Module(s).

PREFACE
P-6 June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
SPECIFICATIONS - GENERAL
MEASUREMENT SPECIES:Heteroatomic gases such as ammonia (NH3), carbon dioxide
(CO2), carbon monoxide (CO), carbon monoxide + carbon
dioxide ethylene (C2H4), hexane (C6H14), methane (CH4), nitric
oxide (NO) and sulfur dioxide (SO2)
RANGES:10 ppm fullscale to 100% fullscale (application-dependent); 4
fullscale selections, including suppressed zero ranges
REPEATABILITY:±1% of fullscale (at constant temperature)
MINIMUM DETECTABLE
LEVEL:0.1% CO2 (at 1 atm. sample pressure; application dependent)
NOISE:<1% of fullscale, peak-to-peak
LINEARITY:±1% of fullscale with 4th order polynomial
RESPONSE TIME:.05 to 30 seconds (selectable) for 0 to 90% of fullscale
DRIFT (ZERO AND SPAN): <±1% of fullscale/24 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 rate is changed by ≤250
ml/min. (No effect if flow rate is between 0 and 500 ml/min.)
POWER REQUIREMENTS:24 VDC ±5%, 100 W max.; ripple and noise: <100 mV peak-to-
peak; line and load regulations: <±1%
SPECIFICATIONS - SAMPLE
TEMPERATURE:Non-flammable;: 0°C to 55°C (32°F to 138°F)
FLOW RATE:500 to 1400 ml/min.
PRESSURE:Maximum 690 hPa-gauge (10 psig), higher pressure in
pressurized cell applications
PARTICULATES:filtered to <2 microns
DEWPOINT:<40°C (104°F), no entrained liquid
MATERIALS IN CONTACT
WITH SAMPLE:Gold plated Pyrex, sapphire, quartz, Irtran, FEP Teflon, Viton-
A, 316 stainless steel

PREFACE
748332-D Rosemount Analytical June 1997 P-7
NGA Non-Dispersive Infrared Analyzer
SPECIFICATIONS - PHYSICAL
CASE CLASSIFICATION:General purpose for installation in weather-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.

PREFACE
P-8 June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD 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
RETURNING PARTS TO THE FACTORY
Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. 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 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:
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
TRAINING
A comprehensive Factory Training Program of operator and service classes is
available. For a copy of the Current Operator and Service Training Schedule contact
the Technical Services Department at:
Rosemount Analytical Inc.
Phone: [phone]
FAX: [phone]
DOCUMENTATION
The following NGA 2000 Non-Dispersive Infrared Analyzer instruction materials are
available. Contact Customer Service or the local representative to order.
748332 Instruction Manual (this document)

PREFACE
748332-D Rosemount Analytical June 1997 P-9
NGA Non-Dispersive Infrared Analyzer
COMPLIANCES
This product may carry approvals from several certifying agencies, including Factory
Mutual and the Canadian Standards Association (which is also an OSHA accredited,
Nationally Recognized Testing Laboratory), for use in non-hazardous, indoor locations
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
Australia and New Zealand.
NAMUR
N
9
6
APPROVED
FM ®
97-C219

PREFACE
P-10 June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infrared Analyzer
NOTES

1
INTRODUCTION
748332-D Rosemount Analytical June 1997 1-1
NGA Non-Dispersive Infraraed Analyzer
1.1 OVERVIEW
This manual describes the Non-Dispersive Infrared (NDIR) Analyzer Module of
Rosemount Analytical's NGA 200 Series of gas analysis components. See Figure 1-1.
The NDIR Analyzer Module is designed to continuously determine the concentration
of oxygen in a flowing gaseous mixture. The concentration is expressed in one of
three fashions:
•parts-per-million
•percent of composition
•percent of fullscale
The user can obtain an output that is linear with concentration by initiating a linearizer,
which is based on a fourth-order polynomial. The linearizer is incorporated in the
Analyzer Module's electronic circuitry and is adjustable through interconnection with
the network.
The entire Analyzer Module is designed as a slide-in module (if configured in stand-
alone instrument fashion), removable from the front of the Platform, with gas
connections made from the rear. All electronics relative to sample detection and
conditioning are included in this module.
1.2 TYPICAL APPLICATIONS
The NDIR Analyzer Module is designed to cover a wide range of process, stack and
automotive applications. Typical measurements include:
CHEMICAL AND PETROLEUM
•Carbon dioxide: Manufacture of ethylene oxide, phthalic anhydride and
ammonia; nitrogen generation; and producer gas monitoring
•Carbon Monoxide: Stack monitoring
•Methane: Ammonia manufacture
•Acetylene: Manufacture of acetylene, acrylonitrile, and vinyl chloride
•Sulfur Dioxide: Sulfuric acid stack gas

INTRODUCTION
1-2 June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infraraed Analyzer
FOOD AND AGRICULTURE
•Carbon Dioxide and Water Vapor: Blanketing of perishables, fermentation
processes, photosynthesis studies, personnel protection
AEROSPACE AND OCEANOGRAPHY
•Carbon Dioxide, Carbon Monoxide, and Water Vapor: Diving and space
chambers
METALS AND CERAMICS
•Carbon Dioxide: Monitoring of producer gas, steel converting, manufacture of
cement, soaking pit, heat treating
•Carbon Monoxide: Inert gas generation, producer gas monitoring, rotary kiln
roasting, tin plate annealing, 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 cell may be sealed or may contain a continuously flowing reference gas.
(See Figure 1-2.)
The infrared radiation is interrupted by a chopper at a frequency of 5 Hz.
During analysis, a portion of the infrared radiation is absorbed by the component of
interest in the sample. The quantity of infrared radiation that is absorbed is
proportional to the component concentration.

INTRODUCTION
748332-D Rosemount Analytical June 1997 1-3
NGA Non-Dispersive Infraraed Analyzer
FIGURE 1-1. NGA 2000 NDIR ANALYZER MODULE (TYPICAL - ACTUAL
CONFIGURATION MAY VARY)



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

INTRODUCTION
1-4 June 1997 Rosemount Analytical 748332-DNGA Non-Dispersive Infraraed Analyzer
SAMPLE IN
SAMPLE
OUT
COMPONENT OF INTEREST
NON-INTERFERING COMPOUNDS
INFRARED
SOURCE
DETECTOR
REFERENCE
CELL
STATIONARY
PLATE
CHOPPER
SAMPLE
CELL
DIAPHRAGM,
DISTENDED
DIAPHRAGM,
DARK STATE
The detector is a "gas microphone" based on the Luft principle. The detector is
generally filled with the same gas being analyzed. The infrared energy is therefore
absorbed at the same wavelengths in the detector as that in the sample cell, making
the detector specific for the analyzed component. The detector converts the
difference in energy between sample and reference cells to a capacitance change.
This change, which is proportional to component concentration, 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 1-2. NDIR TECHNOLOGY
1.4 SAMPLE REQUIREMENTS
Maximum allowable sample pressure is 690 hPa-gauge (10 psig) for a standard
configuration NDIR that has a flow restrictor which sets the flow at between 0.5 L/min.
to 1 L/min. Special high pressure cells (up to 10,350 hPa-gauge, 150 psig) are
available. Sample temperature range is 0°C to 55°C, and maximum dewpoint is 40°C.
The sample must be filtered to exclude particulates larger than 2 microns in size.
Consult factory for special configurations with specifications outside of those listed
above.