Rosemount NGA 2000 FID User manual

NGA 2000
FLAME IONIZATION DETECTION
ANALYZER MODULE
Rosemount Analytical

NOTICE
THE INFORMATION CONTAINED IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE.
ROSEMOUNT ANALYTICAL'S NGA 2000 SYSTEM OF MODULAR GAS ANALYZERS AND CONTROLLERS ARE PATENTED,
UNDER U.S. PATENT 5.787.015.
Manual Part Number 748331-E
November 1998
Printed in U.S.A.
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
Teflon® is a registered trademark of E.I. duPont de Nemours and Co., Inc.
Kynar® is a registered trademark of Pennwalt, Inc.

CONTENTS
748331-E Rosemount Analytical November 1998 i
NGA 2000 Flame Ionization Detection Module
PREFACE
PURPOSE/SAFETY SUMMARY........................................................................P-1
GLOSSARY ......................................................................................................P-4
SPECIFICATIONS - GENERAL..........................................................................P-7
SPECIFICATIONS - GAS REQUIREMENTS .....................................................P-8
SPECIFICATIONS - PHYSICAL.........................................................................P-9
SPECIFICATIONS - GAS CONNECTIONS........................................................P-9
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE....P-10
RETURNING PARTS TO THE FACTORY .........................................................P-10
TRAINING ......................................................................................................P-10
DOCUMENTATION............................................................................................P-10
COMPLIANCES..................................................................................................P-11
SECTION 1. INTRODUCTION
1.1 OVERVIEW ..............................................................................................1-1
1.2 TYPICAL APPLICATIONS........................................................................1-1
1.3 THEORY OF TECHNOLOGY...................................................................1-1
1.4 GAS SAFETY FEATURES.......................................................................1-3
1.5 FUEL GAS OPTION .................................................................................1-3
SECTION 2. INSTALLATION
2.1 UNPACKING.............................................................................................2-1
2.2 ASSEMBLY...............................................................................................2-1
2.3 LOCATION ...............................................................................................2-2
2.4 GASES .....................................................................................................2-3
2.4.1 Overview.....................................................................................2-3

CONTENTS
ii November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
2.4.2 Connections................................................................................2-4
2.4.3 Specifications .............................................................................2-5
2.4.4 Leak Test....................................................................................2-7
2.5 ELECTRICAL CONNECTIONS................................................................2-7
SECTION 3. STARTUP AND OPERATION
3.1 OVERVIEW..............................................................................................3-1
3.2 DISPLAYS................................................................................................3-1
3.3 RUN MODE DISPLAY..............................................................................3-1
3.4 MENU DISPLAYS....................................................................................3-1
3.5 HELP DISPLAYS .....................................................................................3-2
3.6 STARTUP PROCEDURE.........................................................................3-6
3.7 BINDING ..................................................................................................3-9
3.8 CALIBRATION .........................................................................................3-9
3.9 ROUTINE OPERATION...........................................................................3-10
3.10 SAFETY SYSTEM....................................................................................3-11
SECTION 4. MAINTENANCE AND TROUBLESHOOTING
4.1 BURNER DISASSEMBLY AND CLEANING.............................................4-1
4.2 COMPONENT REPLACEMENT...............................................................4-3
4.3 BURNER STARTUP TROUBLESHOOTING ...........................................4-3
SECTION 5. REPLACEMENT PARTS
5.1 REPLACEMENT PARTS ..........................................................................5-1
5.1.1 Electronics..................................................................................5-1
5.1.2 Electro-Mechanical.....................................................................5-1
5.1.3 O-Rings and Gaskets .................................................................5-1
5.1.4 Burner Assembly and Components............................................5-2
5.1.5 Pneumatics.................................................................................5-2
APPENDIX A. FID IDENTIFICATION MATRIX
GENERAL PRECAUTIONS FOR HANDLING & STORING HIGH PRESSURE CYLINDERS
WARRANTY
FIELD SERVICE AND REPAIR FACILITIES

CONTENTS
748331-E Rosemount Analytical November 1998 iii
NGA 2000 Flame Ionization Detection Module
FIGURES
1-1 Flame Ionization Detection Technology....................................................1-1
1-2 NGA 2000 Flame Ionization Detection Module - Top View.......................1-2
2-1 Analyzer Module Installation Into Platform ...............................................2-1
2-2 Back Panel Connections...........................................................................2-2
2-3 FID Module Flow Diagram........................................................................2-4
2-4 Front Panel Connections, Controls and Indicators...................................2-5
2-5 Outline and Mounting Dimensions............................................................2-8
2-6 FID Wiring Diagram..................................................................................2-9
3-1 Run Mode Display ....................................................................................3-2
3-2 Main Menu Display...................................................................................3-2
3-3 Basic Controls Menu Display....................................................................3-3
3-4 Expert Controls and Setup Menu Display.................................................3-3
3-5 Technical Configuration Menu Display.....................................................3-3
3-6 Typical Help Screen..................................................................................3-4
3-7 Typical Curves of Module Response vs. Pressure Setting on Sample
Pressure Regulator........................................................................3-5
3-8 Typical Curves of Module Response vs. Pressure Setting on Fuel
Pressure Regulator........................................................................3-5
3-9 Typical Curves of Module Response vs. Pressure Setting on Air
Pressure Regulator........................................................................3-6
3-10 Front Panel Torquing Sequence...............................................................3-12
3-11 Display Screens (1 of 5) ...........................................................................3-13
3-12 Display Screens (2 of 5) ...........................................................................3-14
3-13 Display Screens (3 of 5) ...........................................................................3-15
3-14 Display Screens (4 of 5) ...........................................................................3-16
3-15 Display Screens (5 of 5) ...........................................................................3-17
4-1 FID Burner Assembly................................................................................4-2
TABLES
1-1 Analyzer Characteristics Relative to Fuel Gas...........................................1-5
3-1 FID Analyzer Module Alarms....................................................................3-4

CONTENTS
iv November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
NOTES

PREFACE
748331-E Rosemount Analytical November 1998 P-1
NGA 2000 Flame Ionization Detection Module
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 November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
WARNING: POSSIBLE EXPLOSION HAZARD
WARNING: PARTS INTEGRITY
WARNING: FLAMMABLE SAMPLES
CAUTION: OVERBALANCE HAZARD
CAUTION: PRESSURIZED GAS
WARNING: POSSIBLE EXPLOSION HAZARD
This equipment is used in the analysis of sample gases which may be
flammable, and the burner fuel used in the ionization process is flammable. A
continuous dilution purge system is factory-installed (in accordance with
Standard ANSI/NFPA 496-1993, Chapter 6, and it must be functional at all times
during operation. DO NOT DISABLE THIS PURGE SYSTEM.
Consult the factory if flammable samples will be measured.
Tampering with or unauthorized substitution of components may adversely
affect safety of this product. Use only factory-approved components for repair.
Ensure that all gas connections are made as labeled and are leak free. Improper
gas connections could result in explosion and death.
This module requires calibration with a known standard gas. See General
Precautions for Handling and Storing High Pressure Gas Cylinders at the rear of
this manual.
This Analyzer Module may tip instrument over if it is pulled out too far and the
Platform is not properly supported.

PREFACE
748331-E Rosemount Analytical November 1998 P-3
NGA 2000 Flame Ionization Detection Module
CAUTION: HAND INJURY HAZARD
CAUTION: PURGE AIR REQUIREMENT
CAUTION: OVER-VOLTAGE SPIKING
Dropping the front panel of the Platform while hand or fingers are inside either
case handle can cause serious injury.
This Analyzer Module must be used in conjunction with a device (Platform or PC
Interface) that can actively monitor network variables related to pressure or flow
of the continuous dilution purge, or the front panel LEDs of the Analyzer
Module, as installed, must be visible. The purpose of this requirement is to
maintain adherence to ANSI/NFPA 496 standard which assures the continued
viability of the purge system. Under no circumstances should any pressure or
flow indicator be connected to the PURGE AIR OUT outlet of the Analyzer
Module because this may affect the sealing performance of the module.
If this Analyzer Module is used with a non-Rosemount Analytical power supply,
adding Rosemount P/N 903341 Current Protector in series with the 24 V positive
power line will prevent over-voltage spiking and resultant fuse blowing when
powering up the instrument.
Note
This Analyzer Module is completely leak-tested at the factory for gas leakage.
The user is responsible for testing for leakage at the inlet and outlet fittings on
the rear panel (with a test procedure chosen by the user). The user is also
responsible for leak-testing periodically and if any internal pneumatic
components are adjusted or replaced. See leak test instructions in section 2.4.4.

PREFACE
P-4 November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
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.
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.

PREFACE
748331-E Rosemount Analytical November 1998 P-5
NGA 2000 Flame Ionization Detection Module
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 November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
NOTES

PREFACE
748331-E Rosemount Analytical November 1998 P-7
NGA 2000 Flame Ionization Detection Module
SPECIFICATIONS - GENERAL
MEASUREMENT SPECIES
Total hydrocarbons
RANGES 0 to 100 ppm (output scalable down to 0-2 ppm fullscale)
H2/HE FUEL
low range: 0 to 4 ppm CH4, through 0 to 1% CH4
high range:: 0 to 50 ppm CH4, through 0 to <5% CH4
H2 FUEL OPTION
low range: 0 to 1 ppm CH4, through 0 to 2500 ppm CH4
high range:: 0 to 10 ppm CH4, through 0 to 2% CH4
REPEATABILITY
≤1% of fullscale at a constant temperature, sample flow and fuel, burner
air and sample pressure
MINIMUM DETECTABLE LEVEL
0.04 ppm H2/He fuel
0.01 ppm H2fuel
NOISE ≤1% of fullscale, peak to peak
LINEARITY ≤±1% of fullscale for H2/He fuel and He fuel
RESPONSE TIME
CEMS ≤30 sec. For 10% to 90% of fullscale, with sample bypass flow at 0.5
L/min. (non-flammable sample)
ICEE ≤1 sec. For 10% to 90% of fullscale, with sample bypass flow at 0.5
L/min. (non-flammable sample)
ZERO DRIFT ≤±1% of fullscale/24 hours at constant temperature, hydrocarbon
concentration of supply gases, sample flow and fuel, burner air and
sample pressure
SPAN DRIFT ≤±1% of fullscale/24 hours at constant temperature, hydrocarbon
concentration of supply gases, sample flow and fuel, burner air and
sample pressure
EFFECT OF TEMPERATURE
≤±2% of fullscale for any temperature change of 10°C and rate of
change less than 10°C/hour
OPERATING TEMPERATURE
32°F to 113°F (0°C to 45°C)
POWER REQUIREMENTS
+24 VDC ±5%, 120 W max.. direct to analyzer module;
Ripple and Noise: <100 mV peak to peak
Line and Load Regulations: <±1%

PREFACE
P-8 November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
WARNING: POSSIBLE EXPLOSION HAZARD
SPECIFICATIONS - GAS REQUIREMENTS
BURNER AIR Zero-grade air
FLOW RATE 350 to 400 ml/min
THC ≤ppm, CH4
SUPPLY PRESSURE 1725 to 3450 hPa-gauge (25 to 50 psig)
FUEL GAS (STANDARD)Premixed 40% hydrogen and 60% helium
FLOW RATE 75 to 80 ml/min.
THC ≤0.5 ppm, CH4
SUPPLY PRESSURE 2415 to 3450 hPa-gauge (35 to 50 psig)
Unless this Analyzer Module is factory- or field-configured specifically for
using 100% hydrogen fuel, DO NOT USE PURE HYDROGEN FUEL. An
explosion resulting in severe personal injury or death could occur. Also,
each Analyzer Module is factory-configured for either mixed or pure
hydrogen fuel, and cannot use the fuel for which it was not configured
unless field reconfiguration is done.
FUEL GAS (H2OPTION)Zero-grade hydrogen
FLOW RATE 35 to 40 ml/min.
THC ≤0.5 ppm, CH4
SUPPLY PRESSURE 2415 to 3450 hPa-gauge (35 to 50 psig)
SAMPLE Non-flammable (below 100% of LEL)
FLOW RATE 0.5 to 40 ml/min.
THC ≤0.5 ppm, CH4
SUPPLY PRESSURE 483 to 1035 hPa-gauge (7 to 15 psig)
TEMPERATURE 32°F to 132°F (0°C to 55°C), <20°C variance/24 hours,
<10°C variance/hour
PARTICULATES Filtered to <2 microns
DEWPOINT <45°C
PURGE AIR Instrument air, nitrogen or other non-flammable gas (refer
to ANSI/NFPA 496 for the requirements for the Protective
Gas System)
FLOW RATE 16 to 18 L/min.
SUPPLY PRESSURE 689 to 1378 hPa-gauge (10 to 20 psig)

PREFACE
748331-E Rosemount Analytical November 1998 P-9
NGA 2000 Flame Ionization Detection Module
CAUTION: PRESSURE RELIEF
VALVE RESTRICTION
SPECIFICATIONS - PHYSICAL
MATERIALS IN CONTACT
WITH SAMPLE
Stainless steel, Teflon, glass-filled Teflon, brass, neoprene,
Kynar
DIMENSIONS See Figure 2-5, Outline and Mounting Dimensions
WEIGHT 10.43 kg (23 lbs.)
MOUNTING Horizontal, inside a Platform or custom installed in a panel
CASE CLASSIFICATION General Purpose for installation in weather protected area
MAX. SEPARATION
FROM PLATFORM
1600 m (1 mile)
SPECIFICATIONS - GAS CONNECTIONS
SAMPLE IN1/4 inch O.D. tube fitting
BURNER AIR IN1/4 inch O.D. tube fitting
FUEL IN1/4 inch O.D. tube fitting
PURGE AIR IN3/8 inch O.D. tube fitting
PURGE AIR OUT 3/8 inch O.D. tube fitting
BYPASS OUT 1/4 inch O.D. tube fitting
BURNER EXHAUST OUT 1/2 inch O.D. tube connection, tygon or equivalent (this
connection shall slope downward 6°minimum from
horizontal)
PRESSURE RELIEF
VALVE
No connection shall be made to this fitting. If this
caution is ignored, damage to the case seals may occur,
and the instrument will not operate properly.
See the Preface Section of the Platform manual for specifications regarding Platform
related components.

PREFACE
P-10 November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
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 Flame Ionization Detection Module instruction materials are
available. Contact Customer Service or the local representative to order.
748331 Instruction Manual (this document)

PREFACE
748331-E Rosemount Analytical November 1998 P-11
NGA 2000 Flame Ionization Detection Module
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-12 November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
NOTES

1
INTRODUCTION
748331-E Rosemount Analytical November 1998 1-1
NGA 2000 Flame Ionization Detection Module
1.1 OVERVIEW
This manual describes the Flame Ionization Detector (FID) Analyzer Module of
Rosemount Analytical's NGA 2000 Series of gas analysis components. See Figures
1-1 and 1-2.
The FID Analyzer Module is designed to continuously determine the concentration of
hydrocarbons in a flowing gaseous mixture. The concentration is expressed in
parts-per-million or percent of volume.
The entire FID 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 monitoring of atmospheric air for low-level hydrocarbon contaminants and
determining the hydrocarbon content of exhaust emissions from internal combustion
engines are examples of typical applications for the FID Analyzer Module.
1.3 THEORY OF TECHNOLOGY
This Analyzer Module uses the flame
ionization method of detection. The sensor is
a burner in which a regulated flow of sample
gas passes through a flame sustained by
regulated flows of a fuel gas (hydrogen or a
hydrogen/diluent mixture) and air.
Within the flame, the hydrocarbon
components of the sample stream undergo a
complex ionization that produces electrons
and positive ions. Polarized electrodes
collect these ions, causing current to flow
through an electronic measuring circuit.
Positive
Carbon
Ions
Signal
Conditioning
Sample
Air
Fuel
+90V
Negative Ion
Collection
Ring
FIGURE 1-1. FLAME IONIZATION
DETECTION

INTRODUCTION
1-2 November 1998 Rosemount Analytical 748331-ENGA 2000 Flame Ionization Detection Module
The ionization current is proportional to the rate at which carbon atoms enter the
burner, and is therefore a measure of the concentration of hydrocarbons in the
sample. This measure of concentration is placed on the network, where it is can be
shown on the Platform Display or on other data acquisition devices.
FIGURE 1-2. NGA 2000 FLAME IONIZATION DETECTION MODULE - TOP VIEW
Capillary
Gas Lines
(See Figure 2-2)
Fuel Shutoff
Solenoid Valve
Case Heater Silicon
Pad (On Base)
Fuel Pressure Sensor
Air Pressure Sensor
Ignite/Operate Mode
Burner-Air Flow
Solenoid Valve
Air Circulation Fan
Sample Pressure
Sensor
Burner Air
and Fuel
Regulators
(Stacked Vertically)
Preamp Board
(In Shield)
Detector (Burner)
Computer Board
Sample Bypass
Flow Sensor
DC-DC Converter
Safety Board
Power Supply Board
Network & Power Module
Manual Ignite Switch
Sample Back Pressure Regulators
Purge Air Outlet
Pressure Switch
Purge Air
Heater Cartridge
Purge Air Flow Switch
Purge Air
Pressure Regulator