Emerson Instruction Manual HFID Heated Flame Ionization Detector NGA 2000 Hardware Manual for HFID Analyzer Module (combined with NGA 2000 Platform, MLT, CAT 200 or TFID Analyzer)

Instruction Manual HAS64E-IM-HW September 2008 Instruction Manual HFID Heated Flame Ionization Detector NGA 2000 Hardware Manual for HFID Analyzer Module (combined with NGA 2000 Platform, MLT, CAT 200 or TFID Analyzer) 1st Edition 09/2008 www.EmersonProcess.com ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING! Emerson Process Management (Rosemount Analytical) designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate within their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using and maintaining Emerson Process Management (Rosemount Analytical) products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation. • Read all instructions prior to installing, operating, and servicing the product. • If you do not understand any of the instructions, contact your Emerson Process Management (Rosemount Analytical) representative for clarification. • Follow all warnings, cautions, and instructions marked on and supplied with the product. • Inform and educate your personnel in the proper installation, operation, and maintenance of the product. • Install your equipment as specified in the Installation Instructions of the appropriate Instruction Manual and per applicable local and national codes. Connect all products to the proper electrical and pressure sources. • To ensure proper performance, use qualified personnel to install, operate, update, program, and maintain the product. • When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson Process Management (Rosemount Analytical). Unauthorized parts and procedures can affect the product’s performance, place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation. • Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury. The information contained in this document is subject to change without notice. Misprints reserved. 1st Edition: 09/2008 Teflon® and Viton® are registered trademarks of E. I. duPont de Nemours and Co., Inc. Kynar® is a registered trademark of Atochem North America, Inc. SNOOP® is a registered trademark of NUPRO Co. Emerson Process Management GmbH & Co. OHG Industriestrasse 1 D-63594 Hasselroth Germany T +49 (0) 6055 884-0 F +49 (0) 6055 884-209 Internet: www.EmersonProcess.com Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Table of Contents PREFACE ........................................................................................................................... P - 1 DEFINITIONS...................................................................................................................... P - 1 SAFETY INSTRUCTIONS WIRING AND INSTALLATION OF THIS APPARATUS ........ P - 2 OPERATING AND MAINTAINING THIS APPARATUS ........................................................ P - 3 GENERAL SAFETY NOTICE / RESIDUAL RISK ................................................................ P - 4 AUTHORIZED PERSONNEL .............................................................................................. P - 4 GASES AND GAS CONDITIONING (SAMPLE HANDLING) .............................................. P - 8 POWER SUPPLY ................................................................................................................ P - 9 ELECTROSTATIC DISCHARGE ....................................................................................... P - 10 GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS CYLINDERS ................................................................................................................. P - 11 DOCUMENTATION ........................................................................................................... P - 12 COMPLIANCES ................................................................................................................ P - 12 GLOSSARY OF TERMS ................................................................................................... P - 13 ANALYZER SYSTEM ARCHITECTURE ............................................................................A - 1 SECTION 1 DESCRIPTION AND SPECIFICATIONS ....................................................... 1 - 1 1-1 OVERVIEW ................................................................................................................ 1 - 1 1-2 TYPICAL APPLICATIONS .......................................................................................... 1 - 1 1-3 SAFETY GAS FEATURES.......................................................................................... 1 - 1 1-4 THEORY OF TECHNOLOGY ..................................................................................... 1 - 2 1-5 SPECIFICATIONS ...................................................................................................... 1 - 5 a. General ................................................................................................................... 1 - 5 b. Physical .................................................................................................................. 1 - 5 c. Gas requirements ................................................................................................... 1 - 6 d. Gas Connections .................................................................................................... 1 - 7 Emerson Process Management GmbH & Co.OHG Table of Contents I Instruction Manual NGA 2000 HFID HAS64E-IM-HW September 2008 SECTION 2 INSTALLATION .............................................................................................. 2 - 1 2-1 UNPACKING ............................................................................................................... 2 - 1 2-2 ASSEMBLY ................................................................................................................. 2 - 1 2-3 LOCATION .................................................................................................................. 2 - 2 2-4 GASES ....................................................................................................................... 2 - 2 a. Overview ................................................................................................................. 2 - 2 b. Pneumatic Connections .......................................................................................... 2 - 3 c. Specifications .......................................................................................................... 2 - 4 Fuel Gas ...............................................................................................................................2 - 4 Burner Air ............................................................................................................................. 2 - 4 Purge Air .............................................................................................................................. 2 - 4 Regulated Air ........................................................................................................................ 2 - 4 Calibration Gases ................................................................................................................. 2 - 4 Sample Gas ......................................................................................................................... 2 - 4 Flow Rate ............................................................................................................................. 2 - 4 Pressure / Filtration ..............................................................................................................2 - 5 2-5 LEAK TEST................................................................................................................. 2 - 5 2-6 ELECTRICAL CONNECTIONS .................................................................................. 2 - 6 2-7 INSTALLATION CONSIDERATIONS CHECKLIST ..................................................... 2 - 9 SECTION 3 OPERATION .................................................................................................. 3 - 1 3-1 OVERVIEW ................................................................................................................ 3 - 1 3-2 STARTUP & INITIALIZATION ..................................................................................... 3 - 1 a) Startup .................................................................................................................... 3 - 1 b) Temperature/Pressure Settings and Check ............................................................ 3 - 3 c) Ignition of the Flame ............................................................................................... 3 - 4 Auto-Ignition of the Flame ....................................................................................................3 - 4 Manual Ignition of the Flame ................................................................................................ 3 - 4 3-3 BINDING ..................................................................................................................... 3 - 4 3-4 CALIBRATION PROCEDURE .................................................................................... 3 - 5 a. Calibration Setup .................................................................................................... 3 - 5 Calibration Gas List ..............................................................................................................3 - 5 Calibration Parameters ........................................................................................................ 3 - 6 Check of capillary type .........................................................................................................3 - 6 b. Execution ................................................................................................................ 3 - 7 Zero Adjustment ...................................................................................................................3 - 7 Span Adjustment .................................................................................................................. 3 - 8 c) Problems with Calibration ....................................................................................... 3 - 8 II Table of Contents Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 3-5 ROUTINE OPERATION .............................................................................................. 3 - 9 a) Operation ................................................................................................................ 3 - 9 b) Sensitivity ............................................................................................................... 3 - 9 c) Shutdown ................................................................................................................ 3 - 9 3-6 SAFETY SYSTEM ...................................................................................................... 3 - 11 3-7 SYSTEM & NETWORK I/O MODULE CONTROLS (SETUP) - SYSTEM SIO ......... 3 - 14 a. Analog Output Setup ............................................................................................ 3 - 14 Output number: .................................................................................................................. 3 - 14 Choose signal source module... ......................................................................................... 3 - 14 Choose Signal... ................................................................................................................. 3 - 14 Signal value for 0% (100%) output: .................................................................................... 3 - 15 Output current: ................................................................................................................... 3 - 15 Hold output during calibration: ........................................................................................... 3 - 15 b. Serial interface Setup ........................................................................................... 3 - 17 c. Relay Outputs Setup............................................................................................. 3 - 18 Output number: .................................................................................................................. 3 - 18 Invert signal: ....................................................................................................................... 3 - 18 Choose source module... ................................................................................................... 3 - 18 Choose signal... ................................................................................................................. 3 - 18 SECTION 4 MAINTENANCE AND SERVICE .................................................................... 4 - 1 4-1 OVERVIEW ................................................................................................................ 4 - 1 4-2 FUSES ........................................................................................................................ 4 - 3 4-3 OVEN .......................................................................................................................... 4 - 4 a. Removal ................................................................................................................. 4 - 4 b. Disassembly ........................................................................................................... 4 - 4 4-4 BURNER ..................................................................................................................... 4 - 6 a. Temperature Sensor ............................................................................................... 4 - 6 b. RTD Detector .......................................................................................................... 4 - 6 c. Igniter ...................................................................................................................... 4 - 6 d. Flameout Sensor .................................................................................................... 4 - 6 4-5 BURNER INTERNAL COMPONENTS ....................................................................... 4 - 8 a. Disassembly of Burner / Thermal Block .................................................................. 4 - 8 b. Replacing Burner Jets ............................................................................................ 4 - 9 c. Burner Jet Installation ........................................................................................... 4 - 11 Emerson Process Management GmbH & Co.OHG Table of Contents III Instruction Manual NGA 2000 HFID HAS64E-IM-HW September 2008 4-6 THERMAL BLOCK .................................................................................................... 4 - 12 a. Sample RTD ......................................................................................................... 4 - 12 b. Cartridge Heater ................................................................................................... 4 - 12 c. Thermostat ........................................................................................................... 4 - 13 d. Sample Capillary .................................................................................................. 4 - 13 4-7 ELECTRONICS ASSEMBLY .................................................................................... 4 - 14 a. Printed Circuit Boards ........................................................................................... 4 - 15 b. Case Temperature Sensor .................................................................................... 4 - 16 c. Case Pressure Purge Switch ................................................................................ 4 - 16 d. Preamp Assembly ................................................................................................. 4 - 17 4-8 FAN ASSEMBLY ....................................................................................................... 4 - 18 4-9 FLOW CONTROLLER .............................................................................................. 4 - 19 4-10 DC POWER SUPPLY MODULE ............................................................................... 4 - 20 4-11 FRONT PANEL COMPONENTS .............................................................................. 4 - 21 Replacing Front Panel Components ......................................................................... 4 - 22 a. b. c. d. e. f. g. h. i. j. LON/Power Module ....................................................................................................... 4 - 23 LED Indicator Assembly ................................................................................................ 4 - 23 Manual Ignite Toggle Switch .......................................................................................... 4 - 23 Burner Air Sensor .......................................................................................................... 4 - 23 Fuel Sensor ................................................................................................................... 4 - 23 Burner Air and Fuel Regulator ....................................................................................... 4 - 23 Purge Air Regulator ....................................................................................................... 4 - 23 Purge Air Flow Switch and Diffuser ............................................................................... 4 - 24 Burner Air Solenoid Valve .............................................................................................. 4 - 24 Air Ignite Restrictor ........................................................................................................ 4 - 24 4-12 REAR PANEL COMPONENTS ................................................................................. 4 - 25 a. Fuel In 2-Way Solenoid Valve ............................................................................... 4 - 26 b. Burner Air In Filter ................................................................................................. 4 - 26 c. Heated Bypass Sample Out and Heated Sample In Restrictors ........................... 4 - 26 d. Regulated Air In Check Valve ............................................................................... 4 - 26 4-13 LEAKAGE TEST ....................................................................................................... 4 - 27 a) Required Tools ...................................................................................................... 4 - 27 b) Procedure ............................................................................................................. 4 - 27 IV Table of Contents Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 5 TROUBLESHOOTING .................................................................................... 5 - 1 5-1 TROUBLESHOOTING CHECKLIST ........................................................................... 5 - 1 a. Safety System ........................................................................................................ 5 - 1 b. Ignition .................................................................................................................... 5 - 1 c. Drift ......................................................................................................................... 5 - 2 d. Noise ...................................................................................................................... 5 - 2 SECTION 6 REPLACEMENT PARTS ................................................................................ 6 - 1 6-1 MATRIX ...................................................................................................................... 6 - 1 6-2 GENERAL ................................................................................................................... 6 - 2 6-3 PNEUMATICS............................................................................................................. 6 - 2 6-4 OVEN COMPONENTS ............................................................................................... 6 - 3 SECTION 7 RETURN OF MATERIAL ............................................................................... 7 - 1 7-1 RETURN OF MATERIAL ............................................................................................ 7 - 1 7-2 CUSTOMER SERVICE ............................................................................................... 7 - 2 7-3 TRAINING ................................................................................................................... 7 - 2 LIST OF FIGURES AND TABLES ....................................................................................... L -1 1 LIST OF FIGURES ...................................................................................................... L -1 2 LIST OF TABLES ......................................................................................................... L -2 SUPPLEMENT .....................................................................................................................S -1 1 EC DECLARATION OF CONFORMITY .......................................................................S -1 2 DECLARATION OF CONTAMINATION .......................................................................S -2 Emerson Process Management GmbH & Co.OHG Table of Contents V Instruction Manual NGA 2000 HFID VI Table of Contents HAS64E-IM-HW September 2008 Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID PREFACE The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the NGA 2000 HFID and the System Accessories of the NGA 2000 System. 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. DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication. WARNING Highlights on operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel. CAUTION Highlights on operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness. NOTE Highlights an essential operating procedure, condition or statement. Emerson Process Management GmbH & Co.OHG Preface P-1 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID IMPORTANT SAFETY INSTRUCTIONS WIRING AND INSTALLATION OF THIS APPARATUS The following safety instructions apply specifically to all EU member states. They should be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or National Standards. 1. Suitable grounding connections should be made at all connectors provided for this purpose. 2. All safety covers and grounding connections must be properly reinstated after maintenance work or troubleshooting. The integrity of all earth terminals must be maintained at all times. 3. To ensure safe operation of this equipment, connection to the mains supply should only be made through a circuit breaker which will disconnect all circuits carrying conductors during a fault situation. The circuit breaker may also include a mechanically operated isolating switch. Circuit breakers or switches must comply with a recognized standard such as IEC947. All wiring must conform with any local standards. 4. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be removed when power is removed from the equipment — and then by trained service personnel only. 5. Where equipment or covers are marked with the symbol to the right, there is a danger from hot surfaces beneath. These covers should only be removed by trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch. 6. Where equipment or covers are marked with the symbol to the right, refer to the Instruction Manual for instructions. 7. Further graphical symbols used in this product: Elektrostatic discharge (ESD) Harmful (to Health)! Explosion Hazard! Toxic! Flammable! Disconnect from Mains! All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864. P-2 Preface Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID OPERATING AND MAINTAINING THIS APPARATUS On leaving our factory, this instrument conformed to all applicable safety directives. In order to preserve this state of affairs, the operator must take care to strictly follow all the instructions and notes given in this manual and on the unit. Before switching on the instrument, ensure that the local nominal mains voltage corresponds to the factory-set operational voltage of this unit. Any interruption of the protective earth connections, whether inside or outside of the unit, or removal or interruption of its ground line connection, may result in exposure to the risk of electricity. Deliberately disconnected the protective earth is therefore strictly forbidden. Removing covers and opening panels may expose components conducting electric current. Connectors may also be energized. The unit therefore should be be disconnected from all electrical supplies before any kinds of maintenance, repair or calibration work requiring access to the inside of the unit. Only trained personnel who are aware of the risk involved may work on an open and energized unit! Fuses may only be replaced by fuses of an identical type and with identical ratings. It is forbidden to use repaired fuses or to bypass fuses. Take note of all applicable regulations when using this unit with an autotransformer or a variable transformer. Substances hazardous to health may escape from the unit‘s gas outlet. Please pay attention to the safety of your operation personnel. Protective measures must be taken, if required. NOTE Software compatibility is necessary for all NGA 2000 components in your system to work together. The version of your Platform’s software must be equal to or greater than the version of any other module(s) for successful compatibility. You can locate the version of each NGA 2000 component as follows: Platform Controller Board Turn power ON. The display should show „Control Module V3. ...“. This is the software version. Analyzer Module See note on the name plate label located on the right side of the Analyzer Module case. Emerson Process Management GmbH & Co.OHG Preface P-3 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID GENERAL SAFETY NOTICE / RESIDUAL RISK If this equipment is used in a manner not specified in these instructions, protective systems may be impaired. Despite of incoming goods inspections, production control, routine tests and application of state-ofthe-art measuring and test methods, an element of risk remains when operating a gas analyzer! Even when operated as intended and observing all applicable safety instructions some residual risks remain, including, but not limited to, the following: • An interruption of the protective earth line, e.g. in an extension cable, may result in risk to the user. • Live parts are accessible when operating the instrument with doors open or covers removed. • The emission of gases hazardous to health may even be possible when all gas connections have been correctly made. Avoid exposure to the dangers of these residual risks by taking particular care when ins-talling, operating, maintaining and servicing the analyzer. AUTHORIZED PERSONNEL In-depth specialist knowledge is an absolutely necessary condition for working with and on the unit. Authorized personnel for installing, operating, servicing and maintaining the analyzer are instructed and trained qualified personnel of the operating company and the manufac-turer. It is the responsibility of the operating company to • train staff, • observe safety regulations, • follow the instruction manual. Operators must • have been trained, • have read and understood all relevant sections of the instruction manual before commencing work, • know the safety mechanisms and regulations. To avoid personal injury and loss of property, do not install, operate, maintain or service this instrument before reading and understanding this instruction manual and receiving appropriate training. Save these instructions. P-4 Preface Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID WARNING ELECTRICAL SHOCK HAZARD Do not operate without covers secure. Do not open while energized. Installation and/or servicing requires access to live parts which can cause death or serious injury. Refer servicing to qualified personnel. For safety and proper performace this instrument must be connected to a properly grounded threewire source of power. 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 continous dilution purge system is factoryinstalled and it must be functional at all times during operation. Do not disable this purge system. WARNING POSSIBLE EXPLOSION HAZARD Protection against explosion depends upon a special fuel flow restrictor in the fuel inlet fitting. Do not remove fuel inlet restrictor. Use the correct fuel flow restrictor for the fuel being used. Replace only with factory applied fitting. WARNING POSSIBLE EXPLOSION HAZARD Ensure that all gas connections are made as labeled and described within this manual and leak free. Improper gas connections may cause explosion, serious injury or death. WARNING FLAMMABLE SAMPLES The internal compartment of the oven is vented to the main enclosure by the top and bottom vents. DO NOT RESTRICT THOSE VENTS. Consult the factory if flammable samples will be measured. Emerson Process Management GmbH & Co.OHG Preface P-5 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID WARNING HIGH TEMPERATURES This equipment is used in the analysis of sample gases at temperatures of up to 250°C. All components and material in contact with the sample, the oven and the burner can reach this temperature level. Operate this equipment only when covers are secured. Servicing requires access to "hot" parts which can cause serious injury. Refer servicing to qualified personnel. WARNING HIGH TEMPERATURES The Sample In, Byass Out and Burner Exhaust Out connections can reach temperatures of up to 250 °C (480 °F). Severe burns could result from touching these connections. WARNING UNAUTHORIZED SUBSTITUTION OF COMPONENTS Tampering with or unauthorized substitution of components may adversely affect the safety of this instrument. Use only factory documented/approved components for repair. Because of the danger of introducing additional hazards, do not perform any unauthorized modification to this 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. The user is also responsible for leak-testing periodically and if any internal pneumatic components are adjusted or replaced. WARNING OVERBALANCE HAZARD This analyzer module may tip instrument over if it is pulled out too far and the Platform is not properly supported. P-6 Preface Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID CAUTION POSSIBLE INSTRUMENT DAMAGE Do not interchange gas inlets and outlet! All gases must be conditioned before supplying! When supplying corrosive gases ensure that gas path components are not affected! Exhaust lines must be installed in a descending way, need to be pressureless, frost-protected and in compliance with applicable legislative requirements! WARNING HAZARDS BY SAMPLE GAS COMPONENTS! Before opening gas paths they must be purged with ambient air or neutral gas (N2) to avoid hazards caused by toxic, flammable, explosive or harmful to health sample gas components! CAUTION PURGE AIR REQUIREMENT This Analyzer Module must be used in conjuction with a device (Control Module or PC Interface) that can actively monitor network variables related to pressure or flow of the continous 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. CAUTION PRESSURIZED ENCLOSURE This enclosure shall not be opened unless the area is known to be free of flammable materials or unless all devices within have been de-energized. Area classification for the protected enclosure: Nonclassified. Pressurization: Type Z Temperature Identification Number: T4A Power shall not be restored after enclosure has been opened (or loss of purge) until enclosure has been purged for a minimum of 6 (six) minutes at the minimum pressure of 689 hPa (10 psig). Emerson Process Management GmbH & Co.OHG Preface P-7 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID GASES AND GAS CONDITIONING (SAMPLE HANDLING) WARNING GAS SAFETY Take care of the safety instructions applicable for the gases (sample gases, test gases and fuel gas)! CAUTION PRESSURIZED GAS This module requires periodic use of pressurized gas. See General Precautions for Handling and Storing High Pressure Gas Cylindes, page P-11. WARNING POSSIBLE EXPLOSION HAZARD Do not use 100% hydrogen fuel in a 40% H2 / 60% He configured Analyzer Module. An explosion resulting in severe personal injury or death could occur. P-8 Preface Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID POWER SUPPLY CAUTION ELECTRICAL HAZARD Verify the power voltage at site of installation corresponds to the analyzer module´s rated voltage as given on the nameplate label! Verify the safety instruction given by power supply unit manufacturer ! CAUTION ELECTRICAL HAZARD The mains socket has to be nearby the power supply unit and easily accessible! Disconnecting from power requires unplugging the power connector! To comply with the CE mark requirements use only power supply units of type SL5, SL10 or equivalent units. Equivalent units must provide SELV output voltages! Verify proper polarity when connecting DC 24 V operated analyzer modules ! Emerson Process Management GmbH & Co.OHG Preface P-9 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID ELECTROSTATIC DISCHARGE CAUTION ELECTROSTATIC DISCHARGE The electronic parts of the Analyzer Module can be irreparably damaged if exposed to electrostatic discharge (ESD). The instrument is ESD protected when the covers have been secured and safety precautions observed. When the housing is open, the internal components are not ESD Although the electronic parts are reasonable safe to handle, you should be aware of the following considerations: Best ESD example is when you walked across a carpet and then touched an electrical grounded metal doorknob. The tiny spark which has jumped is the result of electrostatic discharge (ESD). You prevent ESD by doing the following: Remove the charge from your body before opening the housing and maintain during work with opened housing, that no electrostatic charge can be built up. Ideally you are opening the housing and working at an ESD - protecting workstation. Here you can wear a wrist trap. However, if you do not have such a workstation, be sure to do the following procedure exactly: Discharge the electric charge from your body. Do this by touching a device that is grounded electrically (any device that has a three - prong plug is grounded electrically when it is plugged into a power receptacle). This should be done several times during the operation with opened housing (especially after leaving the service site because the movement on a low conducting floors or in the air might cause additional ESDs). P - 10 Preface Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS CYLINDERS Edited from selected paragraphs of the Compressed Gas Association´s „Handbook of Compressed Gases“ published in 1981. Compressed Gas Association 1235 Jefferson Davis Highway Arlington, Virginia 22202 Used by Permission 1. Never drop cylinders or permit them to strike each other violently. 2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when located in areas where extreme temperatures are prevalent. 3. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench, or placed in a cylinder stand, and is ready to be used. 4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a suitable hand-truck. 5. Never tamper with safety devices in valves or cylinders. 6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is attached to a pressurized system. 7. No part of cylinder should be subjected to a temperature higher than 52 °C (125 °F). A flame should never be permitted to come in contact with any part of a compressed gas cylinder. 8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding, precautions must be taken to prevent striking an arc against the cylinder. Emerson Process Management GmbH & Co.OHG Preface P - 11 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID DOCUMENTATION The following HFID instruction materials are available. Contact Customer Service Center or the local representative to order. HAS64E-IM-HW Instruction Manual NGA 2000 HFID (this document) 90002496 Instruction Manual NGA 2000 Platform COMPLIANCES This product may carry approvals from several certifying agencies, including the Canadian Standards Association*) (which is also an OSHA accredited, Nationally Recognized Testing Laboratory), for use in non-hazardous, indoor locations. Emerson Process Management 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). NAMUR This product satisfies all obligations of all relevant standards of the EMC framework in Australia and New Zealand. P - 12 Preface Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID GLOSSARY OF TERMS 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 operate the Display and Keypad. Distribution Assembly The Backplane and the card cages that hold I/O and Expansion Modules. 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. 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. Emerson Process Management GmbH & Co.OHG Preface P - 13 Instruction Manual NGA 2000 HFID HAS64E-IM-HW September 2008 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, temperature and pressure. Softkeys The five function softkeys 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) and I/O Module(s). P - 14 Preface Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID ANALYZER SYSTEM ARCHITECTURE The platform/MLT´s front panel can act as operator interface for a stand-alone analyzer or as the a central interface for multiple Analyzer Modules. In multi analyzer systems, this feature eliminates duplication of the display/operator interface. In addition to the obvious operational benefits there are significant cost and system packaging advantages not possible with conventional analyser configurations. The NGA 2000 HFID is available as a "stand-alone analyzer" or as a "blind" Analyzer Module (AM). The HFID analyzer module can be part of the stand-alone analyzer or a component of an analyzers system (Fig. A-1). The NGA 2000 system made it possible, to configure the HFID as a flexible "stand-alone analyzer" consisting of a HFID "Analyzer Module", a Platform (complete with front panel display/operator interface), and input/output (I/O) modules. This flexible network communication architecture is shown in the schematic of Fig. A-2. The “analyzer module” is a “blind” analysis unit but retains all the advanced design features. The AM variant is designed for integration as part of a NGA 2000 analysis system or special customer developed networks. ½ 19" MLT NGA Network Analyzer NGA 2000 NGA Network ROSEM OUNT Platform with MLT AM or 19" MLT Analyzer ROSEM OUNT NGA 2000 ROSEM OUNT NGA 2000 CLD ½ 19" MLT Analyzer ROSEM OUNT HFID NGA 2000 NGA Network PS CLD NGA 2000 Platform with MLT AM or 19" MLT Analyzer ROSEM OUNT HFID MLT MLT CLD HFID NGA 2000 PS NGA Network ROSEM OUNT NGA Network HFID NGA Network PMD ROSEM OUNT NGA 2000 PS Figure A-1: From separate analyzers to analyzer system Emerson Process Management GmbH & Co.OHG Analyzer System Architecture A-1 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID The modular configurable bi-directional network offers the following options: ❏ ❏ Stand-alone analyzers (Single devices) • analyzer modules in a platform including optional inputs and outputs (SIO/DIO). Simple interconnection of analyzer modules to an analyzer system based on one of the three structures - see below. These structures can be distinguished by acting of the host • with platform as host including system inputs and outputs (SIO/DIO) • with MLT/TFID/CAT 200 analyzer as controller including system inputs and outputs (SIO/ DIO) • with customer owned specific control units (not described in this manual, consult factory) For combination possibilities of NGA 2000 I/O´s see table A-1. Platform Analyzer Module Analyzer Module AC DC Network Cable Analyzer Module Network Cable Power supply 24VDC Cable 24VDC Cable DC AC Figure A-2: Example of NGA cabling A-2 Analyzer System Architecture Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Based on a platform, MLT or TFID analyzer the schematic on Figure A-3 illustrates the simplicity of a networked system which incorporates AM’s, such as Chemiluminesence Detectors, MLT's (NDIR/UV/VIS plus Oxygen or TCD) and Flame Ionisation Detectors. Other system functionality includes links to associated sample handling (PLC) and Data Acquisition Systems such as WinControl. Local I/O are existing to MLT, TFID and CAT 200 analyzers only and support the corresponding analyzer module only. The system I/O modules (SIO, DIO) of the platform (or MLT/TFID analyzer) support all integrated analyzer modules with analog, digital and serial interfaces as well as relay outputs. Local I/O’s via Internal System Bus DIO Analyzer Modules (AM’s) O2 PMD HC HFID NOx WCLD NO/NOx CLD System I/O’s via Internal System Bus ppm O2 TO2 HC FID HC TFID DIO SIO DIO CO/NO/SO2/ EO2 - MLT PO2 MLT NG A 200 0 Alternatively to Platform or MLT/TFID Analyzer Alternatively SIO 19" Platform/ TFID Analyzer Field PC Workstation RO SEMOUN T 8 Digital Inputs 24 Digital Outputs 3 Relay Outputs RS 232 / RS 485 Printer or PLC NG A 200 0 Alternatively MLT 2 Analyzer ½ 19" MLT Analyzer RO SEMOUN T Solenoid Valves SIO NGA Network 19" MLT 3/4 Analyzer RO SEMOUN T DIO SIO RO SEMOUN T NG A 200 0 NG A 200 0 Personal Computer Figure A-3: Example/Possibilities of NGA Analyzer Systems Emerson Process Management GmbH & Co.OHG Analyzer System Architecture A-3 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID System unit CLD/FID/HFID analyzer module (AM): SIO/DIO-Configuration • No local CLD/FID/HFID I/O’s • without front panel, i.e. without control unit (host) • can be combined with a a a a a platform, MLT analyzer, TFID analyzer; CAT 200 analyzer or customer developed control unit Platform (Control Module Software): • Control unit with front panel • Without measurement channels • 1 SIO and up to 4 DIO's (or 5 DIO's) can be installed in the platform (CM I/O’s) • SIO and DIO’s can be configured for all AM channels connected to the platform HFID analyzer • 1 SIO and 4 DIO’s (or 5 DIO’s) can be • HFID analyzer module into a platform with front panel installed in the platform • 1 SIO and 1 DIO (or 2 DIO’s) can be • HFID analyzer module combined with MLT/TFID/CAT 200 analyzer installed in the MLT/TFID/CAT 200 analyzer (CM I/O) • SIO and DIO can be configured for all AM’s connected to the MLT/TFID/CAT 200 analyzer Table A-1: Possibilities of NGA 2000 I/O combinations A-4 Analyzer System Architecture Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 1 DESCRIPTION AND SPECIFICATIONS 1-1 OVERVIEW This manual describes the Heated Flame Ionization Detector (HFID) Analyzer Module of Emerson Process Mangement´s NGA 2000 Series of gas analysis components (See Figure 1-2 and 1-3). The HFID Analyzer Module is designed to continously determine the concentration of hydrocarbons in a flowing gaseous mixture at a user-selectable temperature setpoint between 93 °C and 204 °C (200 °F and 400 °F). The concentration is expressed in parts-per-million or percent of volume.. The HFID 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 carbon bed scrubber for low-level hydrocarbon contaminants, determining of the hydrocarbon content of exhaust emissions from internal combustion engines and continuous emissions monitoring of fluegas emissions (e.g. incinerators) are examples of typical applications for the HFID Analyzer Module 1-3 SAFETY GAS FEATURES The HFID Analyzer Module is designed with a factoryinstalled continous dilution purge system in accordance with standard ANSI/NFPA 496-1993, Chapter 6. Frontpanel LEDs indicate that the burner flame is lit and that the purge system is enabled. In addition, fuel gas is automatically shut off when a flame-out condition occurs of the safety system is disabled. All tubing ahead of the burner is rigid metallic tubing assembled with ferrule/nut type compression fittings. However, should an internal fuel leak occur, a worst-case leak would be dissipated below 25% of the LEL of hydrogen through the combination of an inlet fuel flow restrictor and purge gas flow. This module is designed to use 40% H2/60% He fuel at a maximum inlet pressure of 3446 hPa-gauge (50 psig). A standard HFID Analyzer Module is only equipped to analyze a non-flammable sample, below 100% of the LEL. WARNING POSSIBLE EXPLOSION HAZARD Protection against explosion depends upon a special fuel flow restrictor in the fuel inlet fitting. Do not remove fuel inlet restrictor. Use the correct fuel flow restrictor for the fuel being used. Replace only with factory applied fitting. Do not use 100 % hydrogen fuel in a 40 % H2 / 60 % He configured Analyzer Module. An explosion resulting in severe personal injury or death could occur. The purge system is enabled only if there is proper purge gas flow in, purge gas pressure, and internal case pressure, and after five times the case volume has been exchanged. Emerson Process Management GmbH & Co.OHG Description and Specifications 1-1 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 1-4 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. With a 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. 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 aquisition devices. Negative Ion Collection Ring + 90 V Signal Conditioning Positive Carbon Ions Air Sample Fuel Figure 1-1: Function Principle of FID Measurement 1-2 Description and Specifications Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID BULKHEAD RESTRICTOR 1/4T - 1/4T SS PURGE AIR IN REGULATED AIR IN BULKHEAD 3/8T BRASS BURNER EXHAUST BULKHEAD 1/4T - 1/4T BRASS BULKHEAD 1/4T - 1/8T SS MANIFOLD, SAMPLE PLUG 1/8NPT CHECK VALVE 1/3 PSIG PLUG 1/4NPT DIFFUSER BULKHEAD PURGE 3/8T - 1/4MPT AIR OUT BRASS FILTER BULKHEAD REDUCER 1/4T - 1/8T BRASS RESTRICTOR, BYPASS ELBOW 1/4T - 1/4FPT BRASS SWITCH, PURGE FLOW PRESSURE RELIEF BURNER VALVE AIR IN FUEL IN BULKHEAD CONNECTOR 1/4T - 1/8NPT, SS FUEL RESTRICTOR SOLENOID VALVE REDUCER 3/8T - 1/4T BRASS REGULATOR, PURGE AIR HEATED SAMPLE SAMPLE BYPASS IN OUT SENSOR, SAMPLE TEMPERATURE ELBOW 1/4T - 1/4NPT BRASS PORT CONNECTOR 1/4 TUBING 1/4 OD VITON TUBING 1/8 OD COPPER ELBOW PURGE AIR RESTRICTOR BRASS CONNECTOR 1/16T - 1/8NPT SS BURNER DETECTOR PURGE PRESSURE SENSOR SENSOR, FUEL PRESSURE 0 - 30 PSIG ELBOW TUBING 1/8 OD 1/8T - 1/8T COPPER BRASS UNION 1/4T BRASS RUN TEE 1/8T - 1/8MPT BRASS TUBING 1/8 OD, SS AIR RESTRICTOR TUBING 1/4 OD COPPER FUEL RESTRICTOR 1/8T - 1/8T PRESSURE SENSOR, REGULATED AIR 0 - 15 PSIG GA OUT TUBING 1/8 OD COPPER TUBING 1/8 OD COPPER OUT OUT IN FIXED FLOW CONTROLLER, REGULATED AIR RUN TEE 1/4T - 1/4MPT BRASS AIR IGNITE RESTRICTOR IN SENSOR, BURNER AIR PRESSURE 0 - 30 PSIG GA IN REGULATOR, FUEL PRESSURE 0 - 30 PSIG TUBING 1/4 OD COPPER ELBOW 1/4T - 1/4MPT BRASS TUBING 1/8 OD SS PRESSURE SWITCH SAMPLE CAPILLARY (see table 1-1) ADAPTER 1/4T - 1/4NPT BRASS TUBING 1/4 OD VITON OUT RUN TEE 1/4T - 1/4FPT BRASS ELBOW 1/8T - 1/8MPT BRASS PRESSURE REGULATOR, BURNER AIR 0 - 60 PSIG Figure 1-2: HFID Analyzer Module - Flow Diagram Brief Description Part Number Sample Capillaries Sample Capillary 9.7 cc/min. @ 3.5 psig 657486 Sample Capillary 2.5 cc/min. @ 3.5 psig 657550 Table 1-1: Sample Capillary depending on Module Configuration Emerson Process Management GmbH & Co.OHG Description and Specifications 1-3 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Gas Lines (See Figure 2-2) Purge Air Outlet Fuel Shutoff Solenoid Valve Detector (Burner) Oven Preamp Board (in Shield) Case pressure switch Air circulation fan Computer Board Case Heater Sensor Board Sample Flow Controller Safety Board Purge Air Flow Switch DC-DC-Module Power Supply Board Burner Air Solenoid Valve Purge Air Regulator Burner Air & Fuel Regulators (Stacked Vertically) Network & Power Module Figure 1-3: HFID Analyzer Module - Top View 1-4 Description and Specifications Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 1-5 SPECIFICATIONS a. General Measurement Species: ........................ Total hydrocarbons Ranges (H2/Fuel): Low Range ............................ 0 to 10 ppm CH4 through 1 to 1 % CH4 at an oven setpoint between 113 °C and 191 °C (235 °F and 376 °F) High range ............................. 0 to 50 ppm CH4 through 0 to < 5 % CH4 at an oven setpoint between 113 °C and 191 °C (235 °F and 376 °F) Analysis temperature .......................... Adjustable from 93 °C to 204 °C (200 °F to 400 °F), maintained within ± 6 °C (± 11°F) from the setpoint Repeatability: ...................................... < 1 % of fullscale for successive identical samples, at a constant temperature, sample flow and fuel, burner air, regulated air and sample pressures Min. Detectable Level: ......................... 0.10 ppm CH4 Noise: .............................................. < ± 1 % of fullscale Linearity: ............................................. < ± 1 % of fullscale, < ± 2 % of data point (must be above the minimum detectable level) Response Time: .................................. < 1.5 sec., 0 % to 90 % of fullscale Drift: Zero ....................................... < ± 1% of fullscale / 24 hours at constant temperature, hydrocarbon concentration of supply gases, sample flow and fuel, burner air, regulated air and sample pressures Span ...................................... < ± 1 % of fullscale / 24 hours at constant temperature, hydrocarbon concentration of supply gases, sample flow and fuel, burner air, regulated air and sample pressures Effect of Temperature: ......................... < ± 2 % of fullscale for any temperature change of 10 K and rate of change less than 10 K/hour Operating Temperature: ...................... 15 °C to 35 °C (59 °F to 95 °F) Power Requirements: .......................... +24 VDC ±5%, 120W max.. direct to analyzer module: Ripple and Noise: < 100 mV peak to peak Line and Load Regulations: < ± 1 % b. Physical Case Classification: ............................. General purpose for installation in weather-protected area Dimensions: ........................................ See Figure 2-6: Outline and Mounting Dimensions Weight: .............................................. 15.9 kg (35 lbs.) Material in Contact with Sample .......... Stainless steel and glass-filled Teflon Mounting: ............................................ Horizontally, inside a Platform or custom-installed in a panel Max. Length of LON Cable: ................. 1,600m (1 mile) between Analyzer Module and Platform Emerson Process Management GmbH & Co.OHG Description and Specifications 1-5 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID c. Gas requirements Sample .............................................. Non-flammable, below 100 % of LEL Flow Rate: ............................. 1.0 to 2.5 l/min Supply Pressure .................... 345 to 620 hPa-gauge (5 to 9 psig) Temperature: ......................... 110 °C to 230 °C (230 °F to 446 °F), < 20 K variance / 24 hours, < 10 K variance / hour Particles: ................................ Filtered to < 2 microns Dewpoint: .............................. <15 °C below the setpoint Regulated Air: ...................................... Instrument air or Nitrogen Flow Rate: ............................. 1.0 to 4.0 l/min THC ....................................... < 2 ppm CH4 Supply Pressure .................... 689 to 1,723 hPa-gauge (10 to 25 psig) Particles: ................................ Filtered to < 2 microns 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: ............................. 16.0 to 18.0 l/min Supply Pressure .................... 689 to 1,378 hPa-gauge (10 to 20 psig) Fuel Gas: ............................................ Premixed 40 % hydrogen (H2) and 60 % helium (He) Flow Rate: ............................. 80 to 100 ml/min THC ....................................... < 0.5 ppm CH4 Supply Pressure .................... 3,101 to 3,446 hPa-gauge (45 to 50 psig) WARNING POSSIBLE EXPLOSION HAZARD Do not use pure (100%) hydrogen (H2) fuel in a 40% H2 / 60% He configured Analyzer Module. An explosion resulting in severe personal injury or death could occur. Burner Air: ........................................... Zero-grade air Flow Rate: ............................. 355 to 400 ml/min THC ....................................... < 1.0 ppm CH4 Supply Pressure .................... 1,723 to 3,446 hPa-gauge (25 to 50 psig) 1-6 Description and Specifications Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 d. NGA 2000 HFID Gas Connections Sample In: ........................................... 1/4" O.D. tube fitting, stainless steel Regulated Air In: .................................. 1/4" O.D. tube fitting, brass Burner Air In: ....................................... 1/4" O.D. tube fitting, brass Fuel In: ................................................ 1/4" O.D. tube fitting, stainless steel Purge Air In: ........................................ 3/8" O.D. tube fitting, brass Purge Air Out: ...................................... 3/8" O.D. tube fitting, brass Bypass Out: ......................................... 1/4" O.D. tube fitting, stainless steel Burner Exhaust Out: ............................ 3/8" O.D. tube connection, stainless steel (must slope downward 6 ° min. from horizontal) NOTE Burner Exhaust, Bypass Out and Purge Air Out to be vented to atmospheric pressure and to non-classified location in accordance with ANSI/NFPA-496 guidelines. Pressure Relief Valve: ......................... See Caution below CAUTION 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. WARNING HIGH TEMPERATURES The Sample In, Byass Out and Burner Exhaust Out connections can reach temperatures of up to 250°C (480°F). Severe burns could result from touching these connections. See the Preface section of the Platform manual for specifications regarding Platform-related components (e.g., case dimensions) and the I/O Module manual for specifications regarding I/O (e.g., relay outputs). Emerson Process Management GmbH & Co.OHG Description and Specifications 1-7 Instruction Manual NGA 2000 HFID 1-8 Description and Specifications HAS64E-IM-HW September 2008 Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 2 INSTALLATION 2-2 WARNING GENERAL HAZARD Before starting to install this equipment, read the "Essential instructions" on the inside cover and the Safety Summary beginning on page P-2. Failure to follow the safety instructions could result in serious injury or death. If the HFID Analyzer Module requires assembly with other components (e.g., the Platform and associated I/O Modules), do so at this time. To install the HFID Analyzer Module into a Platform: 1. 2. 2-1 UNPACKING If the HFID Analyzer Module is received as a separate unit, carefully examine the shipping carton and contents for signs of damage. Immediately notify the shipping carrier if the carton or contents is damaged. Retain the carton and packing material until all components associated with the HFID Analyzer Module are operational. ASSEMBLY 3. 4. 5. 6. Loosen the six fastening screws for the front panel of the Platform, hold the handles, and swing the front panel to the farest right. Following the guides on the bottom left and bottom center of the Platform, carefully slide the HFID Analyzer Module halfway into place Lift the spring-loaded pins on the front of the HFID Analyzer Module, and carefully slide in the rest of the distance. If the module and Platform are difficult to assemble, remove the module, ensure the top cover of the module is firmly seated on the hold-down screws, and repeat the assembly procedure. Secure the module in position by releasing the pins, which seat in the available holes in the bottom of the case (see Figure 2-1, below). Connect network cable and power cable to the Analyzer Module (refer to Section 2-6 for electrical connections). After startup and calibration have been performed, secure the front panel of the Platform with the six screws provided. Pin Seats Analyzer Module Guides Figure 2-1: Analyzer Module Installation into Instrument Platform (view without front panel) Emerson Process Management GmbH & Co.OHG Installation 2-1 Instruction Manual NGA 2000 HFID 2-3 HAS64E-IM-HW September 2008 LOCATION Install the Analyzer Module in a clean, weather-proofed, non-hazardous, vibration-free location free from extreme temperature variations. For best results, install the Analyzer Module near the sample stream to minimize sample transport time. WARNING INSTALLATION RESTRICTIONS For safety, the Analyzer Module should be installed in a non-confined, ventilated space. Do not block any of the rear panel outlets as they are part of the safety system. Operating ambient temperature is 15 °C to 35 °C (59 °F to 95 °F), limited to temperature changes of less than 10 K/hr. Acceptable dew point range is less than 95 % relative humidity, but not in excess of 45 °C (113 °F) wet bulb temperature. The cylinders of fuel, air, and calibration gas(es) and the source of purge and regulated air should be located in an area of relatively constant ambient temperature. 2-4 GASES a. Overview During normal operation, the Analyzer Module requires fuel and air to maintain the burner flame as well as suitable standard gases for calibration and instrument air for purge requirements. In addition, instrument air for regulated air in is required to control the sample pressure at the sample capillary. Criteria for selection of these gases follow in Section 2-4c. Note that this type of drift occurs only when the flame is burning. If drift occurs when the flame is extinguished, the electronic circuitry is at fault. To minimze drift, use clean fuel and air, keep the analyzer clean, and locate the gas cylinders in an area of relatively constant ambient temperature. The cylinders supplying all gases each should be equipped with a clean, hydrocarbon free, two stage regulator and a shutoff valve. All new external gas tubing (except for PURGE IN/OUT and SAMPLE BYPASS) is strongly recommended, preferably precleaned, stainless steel, gas chromatograph grade tubing. Thoroughly clean before use (if a hydrocarbon based cleaning solvent such as acetone is used, purge tubing with dry nitrogen or helium for several minutes before using). Gas line connections are compression fittings. Do not use pipe thread tape. Since the oxidation of hydrogen is accompanied by the formation of water vapor, the Exhaust tubing always should be slanted downward at least 6 degrees from horizontal. Otherwise, water may accumulate in the line, causing back pressure and noisy readings, or may back up in the line and flood the burner. Depending on the percent of vapor in the sample, the sample bypass out connection may be required. If the sample is toxic or noxious, or is to be reclaimed, connect the Bypass outlet to a suitable disposal system. Do not use any device that may cause back pressure in the line. Purge air and burner air should be supplied from separate sources. After initial startup or after startup following a prolonged shutdown, the analyzer may display baseline drift for a considerable period of time, particularly on the most sensitive range. Commonly, the drift is caused by small amounts of hydrocarbons in the inner walls of the tubing in both the internal flow system and the external gas supply system. Drift results from any factor influencing the equilibrium of these absorbed hydrocarbons, such as temperature or pressure. 2-2 Installation Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID ! WARNING Possible electric shock, explosion or toxic gas hazard. See front of module FUEL IN BURNER EXHAUST OUT PURGE AIR OUT VENT TO SAFE AREA SLOPE DOWNWARD 6• MINIMUM BURNER AIR IN WARNING HOT ! REGULATED AIR IN MAXIMUM INPUT PRESSURE FUEL: 50 psig(3445 hPa) BURNER AIR: 50 psig (3445 hPa) SAMPLE: 8 psig (551 hPa) PURGE AIR: 20 psig (1378 hPa) REG AIR: 25 psig (1722 hPa) ATTENTION PURGE AIR IN PRESSURE RELIEF VALVE CHAUD ! HEATED SAMPLE IN HEATED SAMPLE BYPASS OUT ! d'electrocution, d'explosion ou d'emanation de gaz ATTENTION Danger toxique. Se refere aux details inscrits surla face du module. Figure 2-2: HFID Rear Panel Connections b. Pneumatic Connections WARNING HIGH TEMPERATURES The Sample In, Byass Out and Burner Exhaust Out connections can reach temperatures of up to 250°C (480 °F). Severe burns could result from touching these connections. CAUTION POSSIBLE INSTRUMENT DAMAGE No connection should be made to the PRESSURE RELIEF VALVE fitting. Doing so may cause damage the instrument. Make connections to these fittings when the oven heater is disabled ot the moduleis powered down. CAUTION (See Figure 2-2) Connect inlet and outlet lines for sample, burner fuel and air, exhaust, bypass, regulated air, and purge to appropriately labeled fittings on the rear panel. All connections are 1/4 -inch ferrule-type compression fittings except the PURGE AIR IN and OUT connections, which are 3/8-inch compression fittings. The BURNER EXHAUST is a 3/8-inch connection. PURGE AIR REQUIREMENT If the front panel LEDs of the Analyzer Module, as installed, are not visible, the user should provide an indicator for the safety system as per ANSI/NFPA 496 standard. It is recommended that no connection be made to the PURGE AIR OUT port. If, however, the analyzer´s location requires interconnection with a venting system, the 3/8" O.D. line should be kept as short as possible, and no longer than four feet. Emerson Process Management GmbH & Co.OHG Installation 2-3 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID c. Calibration Gases Specifications Fuel Gas Standard analysis usually requires mixed fuel, i.e., 40 % (± 2 %) hydrogen and 60 % helium. H2/He mixed fuel is recommended over H2/N2 fuel because of better linearity in concentration output. Such blends are supplied by many gas vendors specifically for this use, with a guaranteed maximum total hydrocarbon content of 0.5 ppm, measured as methane. This specification should be used when obtaining these mixtures. NOTE The fuel restrictor is marked with a red dot, and the sample capillary is marked with a red or green dot for mixed fuel applications. Calibration method and gases depend on the operating range, and the desired measurement accurancy. In all methods, zero and span gases are used, and are introduced through the sample inlet at the rear of the module. ZERO GAS - Analysis is affected by the background gas of the sample. Therefore, it is recommended to use zero gas with as close to the background composition of the sample as possible. Normally less than 0.5 THC as CH4 is sufficient. SPAN GAS - Span gas consists of a specified concentration of methane or other hydrocarbon in a background gas such as nitrogen. NOTE Burner Air In order to ensure a low background signal, burner air should contain less than 1 ppm maximum total hydrocarbon content. An alternate source for burner air and zero gas (see CALIBRATION GASES below) is a combination diaphragm pump and heated palladium catalyst. This process continuously removes moderate amounts of hydrocarbons and carbon monoxide from ambient air. Purge Air Instrument quality air, nitrogen, or other nonflammable gas is required for the safety purge system. Regulated Air Instrument quality air or nitrogen is required. The air should contain less than 2 ppm maximum total hydrocarbon content. 2-4 Installation Analysis is affected by the background gas of the sample. Therefore, span gas containing the same background gas as the sample is recommended. Then, the background effect is canceled out. Sample Gas Sample gas should be nonflammable (below 100 % of the sample´s LEL). For high sensitivity applications requiring background gas compensation, contact the factory. Flow Rate The sample flow rate is 1.0 l/min to 2.5 l/min for a supply pressure between 5 and 9 psig. Flow rate for purge gas should be 16 to 18 l/min. Flow rate for regulated air should be 2 to 4 l/min. Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Pressure / Filtration 2-5 SAMPLE PRESSURE at the SAMPLE inlet should be within The Analyzer Module is completely tested at the factory for gas leakage (leakage rate - 7.5 hPa/min. (- 0.11 psig/ min.) with He or - 2.5 hPa/min. (- 0.036 psig/min.) with N2). The user is responsible for leakage testing at the inlet and outlet fittings on the rear panel minimum twice a year (see Section 4-13). the range 345 to 620 hPa-gauge (5 to 9 psig nominal), and internally, should be between 206.7 and 275.6 hPagauge (3.0 and 4.0 psig). BURNER FUEL PRESSURE should be: 3101 to 3450 hPa-gauge (45 to 50 psig) for cylinder regulator, 1723 hPa-gauge (25 psig) nominal for internal pressure. BURNER AIR PRESSURE should be: 1725 to 3450 hPa-gauge (25 to 50 psig) for cylinder regulator, 1035 hPa-gauge (15 psig) nominal for internal pressure. LEAK TEST The user is also responsible for internal leak testing periodically and if any internal pneumatic components are adjusted or replaced (with a test procedure chosen by the user). REGULATED AIR PRESSURE should be: 689 to 1725 hPa-gauge (10 to 25 psig) for cylinder regulator. PURGE AIR PRESSURE should be: 689 to 1380 hPa-gauge (10 to 20 psig). NOMINAL INTERNAL CASE PRESSURE is about 0.5 to 1.0 inch of water, and the pressure relief valve is set at 1/3 psig (nominal). CAUTION OVER PRESSURE DAMAGE Noncompliance with these specifications, particulary tose concerning purge air, could cause over-pressure damage to the module. Emerson Process Management GmbH & Co.OHG Installation 2-5 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 2-6 ELECTRICAL CONNECTIONS Network Connection “1” NOTE Electrical installation must be in compliance with the requirements of NAMUR and DIN VDE and/or any applicable national or local codes (like local electricity supply enterprises (ESE)). Network Connection “2” Refer to figure 2-3 and 2-4. Two electrical connections are required on the Analyzer Module: POWER and NETWORK. On the Analyzer Module, two NETWORK connectors are available, either of which is appropriate for: 1. 2. Power Connection Fuse [T 6A 250 V (6x32 mm)] Interconnection with the Backplane of the Platform. (See Instruction Manual for the NGA 2000 Platform). "Daisy-chaining" with other NGA 2000 components. Connect Analyzer Module POWER to a 24 VDC power source with a voltage tolerance of ± 5 % and a minimum power rating of 120 watts (either the Platform or external power source). Pressure Regulator Burner Air Figure 2-3: Front Panel Electrical Connections Front Panel LEDs ! WARNING POSSIBLE EXPLOSION HAZARD Hydrogen fuel gas is used in this instrument. Do not remove fuel restrictor or operate at greater than 50 psig. An explosion resulting in severe personal injury or death could occur. BURNER AIR FUEL ! ATTENTION DANGER D′EXPLOSION Cet instrument contient du gaz hydrogene. Ne retirez pas le limitateur d′de combustible, et n′operez pas au plus de 50 psig Ces conditions peuventprovoquer une explosion entrainant des blessures graves mortelles. HFID POWER LON 1 OVEN HEAT FLAME ON LON 2 PURGE AIR 1+ 24V 2 3 GND FUEL OVERRIDE T 6A IGNITE 250 V ! WARNING POSSIBLE EXPLOSION Do not operate flammable sample without following instructions in the Manual. An explosion resulting in severe personal injury or death could occur. ! ATTENTION DANGER Ne pas utiliser l′echantillon inflammable avant d′avoir pris connaissance des instructions contenues dans le manuel. Le non respect de ces instructions peut entrainer une explosion provoquant des blessure graves ou mortelles. Pressure Regulator Fuel Figure 2-4: Front Panel Controls, Indicators and Electrical Connections 2-6 Installation Emerson Process Management GmbH & Co.OHG Brief Description J1 J2 J3 P1 P2 P3 9.7 cc/min. @ 3.5 psig 659551 2.5 cc/min. @ 3.5 psig 658338 COMPUTER ANALYSIS BOARD 1 Emerson Process Management GmbH & Co.OHG EI P1 E2 J1 PREAMP BOARD E3 J1 POL VOL CABLE ASSEMBLY, IGNITOR P1 SENSOR ASSEMBLY, REF TEMP CABLE ASSEMBLY, OVEN HEATER SENSOR ASSEMBLY, FLAME OUT P3 J3 J14 P15 J15 P16 J16 P13 J13 J10 P10 P11 J11 J8 P8 J7 P7 J9 P9 J10 P10 J12 P12 J10 P10 J12 P12 J11 P11 THERMOSTAT P3 J3 FAN ASSEMBLY HEATER ASSEMBLY MODULE POWER J5 +10V REF J2 P2 J8 P8 JP1 RTN J2 OVEN HEATER CHASSIS GND P5 J5 P4 J4 CABLE ASSEMBLY, SENSOR BD TO HARNESS SENSOR, FUEL PRESSURE ANODE OVEN RTD SAMPLE RTD J18 P18 POWER RESISTOR J17 J11 P11 J6 PURGE AIR FLAMEON OVEN HEAT POWER CABLE ASSEMBLY, FLAT 10 COND E3 E1 RTN E2 24VOLT LED INDICATOR ASSEMBLY P2 J2 P1 J1 BLK RED GRN HAS64E-IM-HW September 2008 CATHODE GND STRAP P17 J14 HARNESS, CHASSIS SENSOR, AIR PRESSURE THERMAL OVEN SAMPLE SWITCH RTD RTD J7 P14 RED BLK RED BLK P10 CABLE ASSEMBLY, THERMAL FUSE P7 P5 CABLE ASSEMBLY, ANODE MTG STUD FLOW SW HARNESS, GLOW PLUG FLOW SW CABLE ASSEMBLY, CATHODE P3 CASE PRESS SWITCH HARNESS P4 SENSOR, CASE TEMP J10 J7 P7 J3 3-WAY SOLENOID AIR AIR P3 J9 2-WAY SOLENOID FUEL IN J15 OVEN HEATER P9 J6 CABLE ASSY, PRESSURE SWITCH J16 P15 FUEL SOL. J5 SHIELD FLOW SWITCH SAFETY BOARD 1 2 3 4 5 6 7 8 J4 P1 P16 P5 P2 + + + - P6 PUR J3 J1 J5 P4 J2 J4 YEL GRN BLU BRN RED ORN P1 J1 CABLE ASSEMBLY, FLAT 24 COND POWER SUPPLY BOARD GRY J6 P6 CABLE ASSEMBLY, FLAT 20 COND CABLE ASSEMBLY, FLAT 3 COND SHIELD J5 P5 CABLE ASSEMBLY, FLAT 16 COND LON/POWER MODULE R37 R38 P4 J4 CABLE ASSEMBLY, FLAT 30 COND CABLE ASSEMBLY, FLAT 3 COND Instruction Manual NGA 2000 HFID PWR MOD J1 J1 SWITCH ASSEMBLY, MANUAL IGNITE J6 J4 SENSOR, SAMPLE PRESSURE NC SENSOR BOARD NC DETECTOR BLOCK ASSEMBLY 1 Part Number Figure 2-5: HFID Wiring Diagram Installation 2-7 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID FRONT VIEW 8.2 [208] 6.8 [174] 3.6 .7 [91] [18] 1.9 [48] .6 [15] 1.1 [28] 4.3 [110] 2.8 [71] 2.0 [51] 6.0 [152] 1.1 [28] SIDE VIEW 22.5 [571] .3 [7] 1.4 [34] .25 [6] DIA .7 [17] .2 [6] 7.2 [183] 5.4 [137] REAR VIEW 4.2 [107] 4.0 [103] 2.0 [52] 1.1 [27] 1.4 [35] 3.3 [83] 1.0 [25] .9 [23] 2.4 [60] 3.2 [81] 3.1 3.0 [78] [75] Dimensions: INCHES [MM] Figure 2-6: Outline and Mounting Dimensions 2-8 Installation Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 2-7 INSTALLATION CONSIDERATIONS CHECKLIST Verify the following: • The Analyzer´s location should be: • • • • • • • • Clean A well ventilated area NGA 2000 HFID • The heated line is at the correct temperature. • The sample, zero, and span gases are at the correct temperature. • The heated line to have over temperature protection. • The sample, bypass, and burner exhaust tubing material must handle high temperature and have thermal insulation to protect from burns. • The purge air out tubing to be 3/8 inch and less than 4 feet in length. Weatherproofed Non-hazardous Vibration-free Have stable ambient temperature • The gas cylinders should be equipped with a clean, hydrocarbon free two stage regulator and shut off valve. All external gas connections have been leak checked. • The dead volume for external sample and fuel lines have been minimized. All external tubing, regulators, valves, pumps, fittings, etc. are clean. • The stainless steel tubing used for the fuel and sample lines is clean. • The correct fuel type is being used. • The THC content of the supply gases are compatible with the analysis range. • The calibration background gases are similar to the sample • The purge air out, burner exhaust, and bypass are vented to atmospheric pressure. The pressure should be constant. • The burner exhaust tube must be slanted downa minimum of 6 degrees from horizontal. • The bypass line connection must be slanted down a minimum of 6 degrees from horizontal for drainage of water condensation. • If required, thermal insulation around the bypass fitting to prevent condensation to minimize the cold spot. Emerson Process Management GmbH & Co.OHG Installation 2-9 Instruction Manual NGA 2000 HFID 2 - 10 Installation HAS64E-IM-HW September 2008 Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 3 OPERATION 3-1 OVERVIEW 3-2 STARTUP & INITIALIZATION Once the HFID has been correctly assembled and installed, the analyzer module is ready for operation. CAUTION Before operating the system, verify that the Leak Checks have been performed in accordance with Section 2-5. PRESSURIZED ENCLOSURE In this section, all operations for starting up the analyzer are explained. For more detailed information about software screens see associated Software Manual. This enclosure shall not be opened unless the area is known to be free of flammable materials or unless all devices within have been de-energized. Area classification for the protected enclosure: For the remainder of this section, Analyzer Module interconnection with a Platform or some interfacing component is assumed. Display and Keypad information refers to that which the user can expect to see and do with regard to the Front Panel of the Platform. Depending from the software version that is installed, menu layout can change, whereas the principle of operation always stays the same. Nonclassified. Pressurization: Type Z Temperature Identification Number: T4A Power shall not be restored after enclosure has been opened (or loss of purge) until enclosure has been purged for a minimum of 6 (six) minutes at the minimum pressure of 689 hPa (10 psig). For safety, the Analyzer Module should be installed in a non-confined, ventilated space. Do not block any of the rear panel outlets as they are part of the safety system. a) Startup 1. Connect supply gases and outlets to/from module. 2. Turn ON the purge gas only. Wait a minimum of 6 minutes (see Section 3-2b, too) 3. Apply LON connection and power to the HFID Analyzer Module. If it is associated with a Platform, do this by plugging in the Platform to a power source. The Platform has no ON/OFF power button. Once power has been supplied to the Platform, the HFID Analyzer Module will be energized. After switching on the HFID, the analyzer will begin its booting procedure which is apparent on the screen. The first part of the initialization procedure is a self check of the software and analyzer components. Various displays will show the status of the initialization. Emerson Process Management GmbH & Co.OHG Operation 3-1 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID If the user´s system contains only one Analyzer Module, all system components, the Controller Board and the network "self-install" (bind together) during initial startup. If the system contains more than one Analyzer Module, the startup sequence will interrogate the network to locate and identify all components on the network. The user will have to bind appropriate combinations of components after the startup sequence. See the Platform manual for instructions on binding combinations of modules. Pressing the F1 key during initializing will reset the HFID brightness and contrast to factory settings. Pressing the F3 softkey will abort the network initializing, aborting any connection to other analyzers. In that case, only the menus of the local analyzer will be available. At the end of the initializing routine the "measure" screen will display. This screen is the access to all other channels, menus and submenus. The actual display may differ from that shown depending on any custom configuration. After the warm-up period (about one hour for the HFID Analyzer Module), all modules are completely functional. 3. Check the 4 LEDs. The power green LED should be illuminated. The Oven amber LED should be blinking or on. The other LEDs should be off. 4. Check the general health of the analyzer by reviewing the status of the Self Tests. All "Pass" conditions should be obtained. All tested parameters should indicate "Pass". Enter the menu "Self test" as follows, using the softkeys F1 through F5: Main (Menu)... System Configurations and Diagnostics... Diagnostic Menu... Analyzer Module Diagnostic... Self Test... 3-2 Operation 0.000 ppm Line#1 Self Test Results Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass EEPROM Test: EPROM Test: RAM Test: Power Supply Test: Network Test: 20 bit ADC test: 12 bit ADC test: Power Supply PCB Test: Safety PCB Test: Case Temperature Test: Oven/Sample Temperature Test: HOME ESCAPE TEST Figure 3-1: Self Test Menu Descriptions of the tests performed below: • EEPROM test - Check the EEPROM on the Analysis Computer PCB. • EPROM test - Checks the EPROM on the Analysis Computer PCB. • RAM test - Checks the RAM on the Analysis Computer PCB. • Power supply test - Verifies that all internal DC voltages are within the required tolerances. • Network test - Checks the internal network interface. • 20bit ADC test - Checks the 20-bit ADC on the Analysis Computer PCB by sending a DC signal through the Preamp PCB and reading the signal back with the 20-bit ADC. • 12bit ADC test - Checks the 12-bit ADC on the Analysis Computer PCB by sending a DC signal and reading the signal back with the 12-bit ADC. • Power supply PCB test - Checks the presence of the Power Supply PCB by activating the 3-way air solenoid. • Safety PCB test - Checks the presence of the Safety PCB by sending a command and reading it back. Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID • Case temperature test - Compares the temperature read between Preamp temperature sensor and the case temperature sensor. They must be within 10°C of each other. This test sometimes fails if the case is opened. The sensor in the Preamp will take longer to cool off since it is in an enclosure. Re-running the self-test after thermal equilibrium will produce a positive result if the sensors are working properly. • Oven/Sample Temperature test - Compares the temperature read between the sample temperature sensor and the oven temperature sensor. They must be within 50°C of each other. 5. This, the user should set the external purge air pressure initially at 689 hPa-gauge (10 psig). Check the "Miscellaneous Control Parameters" screen (Figure 3-2), and note whether the Purge Gas (switch) variable is "ON". If it is "OFF", increase purge air supply by 69 hPa-gauge (1 psig), and recheck the Purge Gas variable until it reads "ON". DO NOT EXCEED 1378 hPa-GAUGE (20 PSIG). If the maximum setting is reached, and the Purge Gas variable does not read "ON", contact factory. If the safety system is initiated successfully (Purge Gas variable is "ON"), continue with the remainder of the startup procedure. Wait for the Purge Air green LED to illuminate. NOTE b) 1. 2. Temperature/Pressure Settings and Check Do not restrict the PURGE OUT port and the pressure relief valve. They must be vented to atmospheric pressure. Introduce the remaining supply gases. (See section 1-5 Specifications) Set and verify the internal gas pressures. Check pressure settings with the values defined in your Test Data Sheet (Figure 3-12). Internal Pressure Typical Operating Pressures Regulator Burner Air 965 to 1103 hPa-gauge (14 to 16 psig), nominal 1030 hPa (15 psig) Fuel 1516 to 1723 hPa-gauge (22 to 25 psig), nominal 1640 hPa (23.8 psig) 206 to 290 hPa-gauge (3.0 to 4.0 psig), Sample nominal 260 hPa (3.8 psig) (non-adjustable) Table 3-1: Typical Operation Pressures Purge air of the following specifications must be present: Flow: 16 to 18 l/min Supply Pressure: 689 to 1,378 hPa-gauge (10 to 20 psig) Main (Menu)... System Configurations and Diagnostics... Diagnostic Menu... Analyzer Module Diagnostic... Miscellaneous Control Parameters... Line#1 0.000 ppm Miscellaneous Control Parameters Case Heater Current: Burner Air Valve Current: Alarm Messages valid for: Ignition Command Status: Fuel Enrichment Status: Flame Status: Purge Gas Switch: Ignition Status: Fuel Type: HOME ESCAPE 410 mA 0.3 mA FAILURE OFF OFF ON OFF OFF H2-He TEST Figure 3-2: Miscellaneous Control Parameters Noncompliance could case damage to the module. At the very least, the module´s safety system, which requires a certain volume of purge air flowing through the case before allowing burner ignition, will not allow the instrument to operate. The lowest purge air flow/pressure setting possible during burner operation is preferable. Emerson Process Management GmbH & Co.OHG Operation 3-3 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID c) 1. Ignition of the Flame 4. Manual or Auto-Ignite the flame. The Flame-On green LED should be illuminated. Two methods of burner ignition are possible: auto-ignition and manual ignition Note the four LEDs on the front panel of the Analyzer Module. They provide necessary information for either ignition procedure. The LEDs, when illuminated, denote the following information: • Green - unit powered on • Amber . continous illumination implies oven has reached operating temp. within ± 6 °C of setpoint. • Green - flame on • Green - purge air system intact (it has filled five volumes of the module interior) (Note: The burner is easier to ignite when the oven has reached the desired setpoint temperature.) Auto-Ignition of the Flame Auto-ignition provides fuel override and three attempted ignitions (default setting), if necessary. Before ignition and operation, Fuel Flow must be set on "ON" in "Light Flame" display screen under Basic Controls (Figure 3-7) and oven temperature must be at least 85°C. Manual Ignition of the Flame The manual iginition switch on the Analyzer Module front panel must be manipulated in the following ways: • Press up and hold for one minute. This opens burner fuel and air solenoids. • Press down to ignite burner glow plug for up to 10 seconds. • Repeat as necessary (if fuel and air sources are farther away than 10 feet, several more attempts may be necessary). • If the flame has been lit, but the flame temperature increases slowly, perform the following steps: 1) After igniting flame, release switch for 2 seconds 2) Press switch down for 2 seconds 3) Repeat release switch and press down steps as necessary. 2. Allow the case and oven to warm up approximately 1 to 2 hours. 3. Verify that all 4 LEDs are illuminated. 3-4 Operation 5. Check and re-adjust the internal pressures if required . The unit is ready for operation. 3-3 BINDING To achieve full coordination between Analyzer Modules and associated I/O Modules, the user must bind those components together in the System Set Up portion of the Technical Configuration Menu in software. Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 3-4 NGA 2000 HFID Common HC factors are: CALIBRATION PROCEDURE The HFID analyzer module may require periodic calibration with known zero and span gases in order to maintain a desire level of analytical accurancy. It is recommended, after initial startup, that the HFID Analyzer Module is calibrated at least once every eight hours. This practice should continue until evidence indicates that some other interval is more appropriate depending on the analytical accurancy required. Calibration is the process of flowing known zero or span calibration gas into the analyzer for a specified period (averaging time), after which the analyzer will automatically set its zero or span factors so that the concentration measurement equals the calibration gas value. A limit can be set, beyond which any attempt by the analyzer to reset its concentration measurement will cause a warning alarm. In this case, user intervention would be required to reset the alarm and attempt another calibration. a. Calibration Setup Main (Menu)... Analyzer and I/O expert controls & setup... Analyzer module setup... Calibration gas list... 0.000 ppm Calibration Gas List HOME ESCAPE Propane (C3H8): 3.0 These factors are not used to compensate the reading, but are used to select the proper preamp sense resistor. In case that measuring ranges differ from ordering code, put in the measuring ranges: Main (Menu)... Analyzer and I/O, expert controls & setup... Analyzer module setup... Gas measurement parameters... Range settings... 0.000 ppm Range Settings This menu is used to set the concentration values of the calibration gases for each range, the Operational Sample Pressure and the Calibration Gas HC Response Factor. Zero gas - range 1: Span gas - range 1: Zero gas - range 2: Span gas - range 2: Zero gas - range 3: Span gas - range 3: Zero gas - range 4: Span gas - range 4: Calibration gas HC response factor: Operational sample pressure: Calibration... Ethane (C2H6): 1.9 Line#1 Calibration Gas List Line#1 Methane (CH4): 1.0 0.00 ppm 10.00 ppm 0.00 ppm 25.00 ppm 0.00 ppm 100.00 ppm 0.00 ppm 250.00 ppm 1.00 344 hPa Minimum Range: Maximum Range: Range 1 lower limit: Range 1 upper limit: Range 2 lower limit: Range 2 upper limit: Range 3 lower limit: Range 3 upper limit: Range 4 lower limit: Range 4 upper limit: Pressure limits... HOME 10.0 ppm 1000.0 ppm 0.0 ppm 10.0 ppm 0.0 ppm 25.0 ppm 0.0 ppm 100.0 ppm 0.0 ppm 250.0 ppm ESCAPE INFO Figure 3-4: Range Settings Menu NOTE In case that only one measuring range is in use, we suggest to set all other measuring ranges to the same value to prevent calibration failure. When doing so, set also all test gas values to the same value. INFO Figure 3-3: Calibration Gas List Emerson Process Management GmbH & Co.OHG Operation 3-5 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Calibration Parameters Purge time: This menu provides various parameter settings for all calibration performed from Basic or Expert modes. Sets how long the analyzer will wait befor performing an adjustment. Main (Menu)... Analyzer and I/O expert controls & setup... Analyzer module setup... Calibration parameters... Line#1 0.000 ppm Calibration Parameters Calibration adjustment limits: Calibration averaging time: Calibration failure alarm: Cal failure error allowed: Calibration time out: Purge time Zero ranges: Span ranges: HOME ESCAPE Disabled 9s Yes 50 % 59 s 0s SEPARATELY SEPARATELY CAL INFO Figure 3-5: Calibration Parameters Display Calibration adjustment limits: Set to "Disable" to recover from a calibration failure. Calibration averaging time: Set the time used by the analyzer to average its reading during calibration. A longer time will give a better calibration. When using a system calibration, take care that averaging time is long enough for the analyzer to reach a settled reading. Otherwise, calibration may fail ! Zero (Span) ranges: Used to select wether to calibrate ranges "TOGETHER" or "SEPARATELY". If together, zeroing or spanning will go through each range one by one. If the change required is too great, it will fail and send an alarm if warning alarms are enabled. In this case, Disable Calibration Adjustment Limits and try again. First check that the calibration gases are correct. If non-zero gases are used, or the changes are great, zero and span may have to be repeated a few times. In case that a system calibration is used, set all ranges to "SEPARATELY". Please note that Software will accept only span gas values that are a factor of 10-110% of the measuring range. From that, it is possible, that not all of the four measuring ranges can be calibrated altogether. In that case you will have to set the option to "SEPARATELY". In case that a calibration is not possible because the difference of display to the true value is too great, switch of the "CalCheck" option. Check of capillary type Verify the capillary type in the "Analyzer Manufacturing Data". Main (Menu)... "F5" (MFG Data)... Analyzer module manufacturing data... Calibration failure alarm: When turned on ("yes"), issues a warning if the analyzer has to change its calibration by more than the Cal Failure Error, if warning alarms are enabled. Line#1 0.000 ppm Analyzer Manufacturing Data More... 10.00 ppm Cal failure error allowed: The percentage by which the calibration can change before an alarm is triggered if the Calibration Failure Alarm is enabled. Calibration time out: Sets how long the analyzer will wait for the signal to stabilize before issuing a Warning. 3-6 Operation Minimum range: Maximum range: Measured Gas: Capillary: Flow sensor: HOME 10.00 ppm 10000.00 ppm THC 9.7 ml/min @ 3.5 psig Present ESCAPE INFO Figure 3-6: Analyzer Module Factoring Data Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 b. NGA 2000 HFID Execution Zero Adjustment Calibration execution is as follows: 1. 2. 3. Set oven temperature setpoint according to Analyzer Module specific Test Data Sheet Test Data Sheet (Figure 3-12). Apply regulated air at a pressure between 689 to 1,723 hPa-gauge (10 to 25 psig) according to Analyzer Module specific Test Data Sheet Test Data Sheet (Figure 3-12). Allow case, oven, and sample temperatures to stabilize. Supply heated zero gas to sample inlet. Adjust external flow controller or throttle valve so that the sample inlet pressure is between 345 to 620 hPa-gauge (5 to 9 psig.), 485 hPa-gauge (7 psig.) nominal. In the Basic Controls menu (Fig. 3-7), push the F3 softkey and enter the Analyzer Zero menu. Line#1 0.000 ppm Analyzer Zero Are you sure ? You must have zero gas flowing through the analyzer. Main (Menu)... Analyzer basic controls (calibration) & setup... Line#1 0.000 ppm Basic Controls HOME Measurement range number: Range upper limit: Span gas concentration: Automatic range change control: Bypass Sample Flow: Ranges with valid calibration: Calibration status: 1 24.9 ppm 10.0 ppm Disabled 0.0 l/min. 1&2 READY Flame Condition: Light Flame... HOME ESCAPE ON ZERO Calibration time: Measurement range number: Zero ranges: Calibration status: Error message for last zero: . ESCAPE 24 s 1 SEPARATELY READY CAL OK INFO ZERO Figure 3-8: Analyzer Zero Menu Push the F3 softkey again, to start the zeroing process. Be sure to have zero gas flowing through your analyzer and to have it purged from sample gas before. When the zeroing process is finished, "Calibration status" will turn to "READY". SPAN Figure 3-7: Basic Controls Menu Emerson Process Management GmbH & Co.OHG Operation 3-7 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Span Adjustment c) After that, perform a Span adjust in the same measuring range: If the user is unable to calibrate the Analyzer Module (i.e., when ZERO or SPAN is initiated, nothing happens), several possible solutions present themselves. One solution relates to the use of an incorrect gas for zeroing or spanning (e.g., using a high concentration gas to zero or a zero gas to span the Analyzer Module). Simply recalibrating with the appropriate gas(es) will not correct the problem because the ZERO OFFSET or SPAN FACTOR has been set to an extreme value in the process. Supply heated span gas to sample input. The reading of the sample pressure, oven, and sample temperatures should be the same as that used during the adjustment of the zero gas. For that, push the F4 softkey in the Basic Controls menu, so that the Analyzer Span menu turns up: Line#1 0.000 ppm Analyzer Span Are you sure ? To remedy the problem, do the following: 1. Verify the correct zero and span calibration gases are being used properly. If so, attempt to recalibrate according to instructions at the beginning of Section 3-4, ensuring that the oven, sample and case temperatures and displayed measurement reading are stable before initiating the calibration routine. If incorrect gases were used in the initial, failed calibration, skip to step 2. 2. Disable Calibration Adjustment Limits (Figure 3-5). 3. Recalibrate the analyzer module according to instructions at the beginning of section 3-4, ensuring that oven, sample, and case temperatures and displayed measurement reading are stable before initiating the calibration routine. 4. Enable Calibration Adjustment Limits in the Calibration Parameters menu (Figure 3-5). You must have span gas flowing through the analyzer. Calibration time: Measurement range number: Span ranges: Calibration status: Error message for last span: HOME ESCAPE 24 s 1 SEPARATELY READY CAL OK SPAN INFO Figure 3-9: Analyzer Span Menu Push the softkey F4 again to start the spanning sequence. Be sure to have span gas flowing through your analyzer and to have it purged before. When the spanning sequence is finished, the "Calibration status" will turn to "READY". If the user is unable to calibrate the Analyzer Module (i.e., when ZERO or SPAN is initiated, nothing happens), several possible solutions present themselves. One solution relates to the use of an incorrect gas for zeroing or spanning (e.g., using a high concentration gas to zero or a zero gas to span the Analyzer Module). Simply recalibrating with the appropriate gas(es) will not correct the problem because the ZERO OFFSET or SPAN FACTOR has been set to an extreme value in the process. 3-8 Operation Problems with Calibration NOTE If the range selections straddle 72 5ppm, CH4, the zero and span calibration for each range must be done separately. Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 3-5 ROUTINE OPERATION a) Operation After case, oven, and sample temperature stabilization, calibration, and binding, proceed as follows: Supply heated sample gas to SAMPLE INLET. Adjust external flow controller or throttle valve so that the sample inlet pressure is between 345 to 620 hPa-gauge (5 to 9 psig.), 485 hPa-gauge (7 psig.) nominal. The reading on the SAMPLE pressure gauge and sample and oven temperatures should be the same as that used during adjustment of the zero and span calibration gas control. Adjust the Range Number setting. The Analyzer Module will now automatically and continously output the measured hydrocarbon content of the sample. Output is in terms of particular hydrocarbon present in the span gas. Note that readings obtained during operation depend on the concentration of total hydrocarbons in the sample. The Analyzer Module will not allow the user to increase the upper limit of a range beyond the "maximum range" software setting. You will find excerpt of a Test Data Sheeta as an example on the next page in figure 3-12. Enter the diagnostics menu "Physical Measurements" as follows, using the softkeys F1 through F5: Main (Menu)... Expert Controls and Setup... Analyzer Module Controls... Physical Measurements... 7.50 Physical Measurements Bypass Sample Flow: Flow lower limit: Flow upper limit: Sample Pressure: Fuel Supply Pressure: Burner Air Pressure: Purge Gas Pressure: Case temperature: ppm THC 0.00 Range 1 Sample pressure: Case temperature: Flame status: Raw signal: Status... 10.00 340 hPa 50.0 51.4 C 47.0 490.0 61.0 ON 900000 524401 100000 Main... Channel BasicCal Figure 3-10: Measure Mode Display After starting up the Analyzer Module, the Measure Mode Display is displayed as shown in figure 3-10. After initial startup, or startup following a prolonged shutdown, the Analyzer Module requires about one day´s continous operation to stabilize. For several days afterwards, calibrate daily. The frequency of subsequent calibrations can be reduced as experience dictates, consistent with the accurancy requirements of the particular application. Emerson Process Management GmbH & Co.OHG 0.000 ppm Line#1 HOME HFID Display To now check back physical parameters of the HFID Analyzer Module with the values defined in your Test Data Sheet, that you received with the analyzer, you have to select the "Physical Measurements"-Menu. 1996 ml/min 400 ml/min 2000 ml/min 340 hPa 1600.3 hPa 1041 hPa 691 hPa 54.0 C ESCAPE INFO Figure 3-11: Physical Measurements Display The menu "Physical Measurements" lets you monitor physical measurement parameters of the HFID analyzer. b) Sensitivity If maximum sensitivity is required from the HFID Analyzer Module, use an optimum combination of settings on the FUEL, and AIR pressure regulators. Settings must be determined experimentally, but the curves in Figures 3-14 and 3-15 may be used as guides. c) Shutdown During shutdown, always turn off fuel gas first, then the air and sample gases. The flame can also be turned off by setting Ignition System Enable to "Off" on the Light Flame menu (under Basic Controls, Figure 3-7). Subsequently, remember to set Ignition System Enable to "On" before attempting to ignite the flame. Operation 3-9 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID External physical parameters are adjusted as follows Supply Pressure Fuel Gas Supply Pressure Burner Air Supply Pressure Sample Gas Supply Pressure Regulated Air (N2) Supply Pressure Purge Gas Min. Sample Flow 3500,00 2000,00 600,00 700,00 691,00 hPa hPa hPa hPa hPa 50,76 29,01 8,70 10,15 10,02 no sensor psig psig psig psig psig cc/min 3,67 23,82 10,02 15,10 50,0 148,7 226 56,4 190 191 4560 472,5 75,2 9,7 cc/min @ 3,5 psig psig psig psig psig °C °C °C °C °C °C cc/min cc/min cc/min cc/min The following parameters can be checked in menu "Physical Measurements" Operation: Main Menu... Expert Controls and Setup... Analyzer Module Setup... Physical Measurements... Internal physical parameters are adjusted as follows Sample Pressure Fuel Gas Pressure Purge Gas Pressure Burner Air Pressure Case Temperature Reference Temperature Flame Temperature Preamp Temperature Sample Temperature Oven Temperature Bypass Flow Burner Air Flow Fuel Gas Flow Capillary Flow Rate 253,00 1642,00 691,00 1041,00 hPa hPa hPa hPa Figure 3-12: Excerpt of a Test Data Sheet with values that are to be compaired with physical measurements 3 - 10 Operation Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID • 3-6 SAFETY SYSTEM The HFID Analyzer Module safety system will not allow ignition or continous burner function unless the following conditions are present: • The internal purge gas pressure is at least 380 hPa-gauge (5.5 psig). Monitor message "Purge Gas Pressure" in "Physical Measurements" menu (Figure 3-11) for proper setting. • Flow rate for purge air in is at least 16 l/min and case pressure is greater than 0.5 inches of water. (Monitor display message "Purge Gas (ON)" in "Miscellaneous Control Paramteres" menu (Figure 3-2) for correct state. Proper sealing hardware must be used in order to obtain the required purge air in flow rate and case pressure). Five case volumes of purge air have been achieved and the three above conditions are present. The time duration to achieve a safe system is a minimum of 6 min. (Monitor the Purge Air Green LED (ON), Purge Control Status (ON), or Purge Air Alarm for indication of the state of the safety system.) As stated above, proper sealing hardware is crucial to the successful operation of the safety system. Therefore, a specific torque sequence (shown in Figure 3-13) must be followed when the front panel of the module is being reinstalled after removal. All front and rear panel screws must be installed. NOTE Do not over-torque rear panel screws. Torque Sequence: Screw #1, 4 to 5 turns Screw #2, 4 to 5 turns Screw #3, 4 to 5 turns Screw #4, 4 to 5 turns Screw #5, 4 to 5 turns Screw #6, 4 to 5 turns Repeat torque sequence until all screws are tight. 6 1 4 The gasket must fill in between the front panel plate 3 5 2 Figure 3-13: Front Panel Torque Sequence Emerson Process Management GmbH & Co.OHG Operation 3 - 11 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 1.0 0.8 RESPONSE (100 ppm CH4 fullscale) 0.6 AIR 30 psig (2064 hPa) AIR 20 psig (1376 hPa) AIR 10 psig (688 hPa) 0.4 SAMPLE: 100 ppm CH4 in N2 at 3.5 psig (241 hPa) 0.2 0 _5_ 344 _10_ 688 _15_ 1032 FUEL PRESSURE _20_ 1376 _25_ 1726 _30_ 2064 psig hPa Figure 3-14: Typical Curve of Module Response vs. Pressure Setting on Fuel Pressure Regulator 1.0 FUEL 30 psig (2064 hPa) 0.8 FUEL 25 psig (1726 hPa) RESPONSE (100 ppm CH4 fullscale) FUEL 20 psig (1376 hPa) 0.6 0.4 SAMPLE: 100 ppm CH4 in N2 at 3.5 psig (241 hPa) 0.2 0 _5_ 344 _10_ 688 _15_ 1032 _20_ 1376 _25_ 1726 _30_ 2064 psig hPa Figure 3-15: Typical Curve of Module Response vs. Pressure Setting on Air Pressure Regulator FUEL PRESSURE 3 - 12 Operation Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID DISPLAY MESSAGE AIR FET AIR PRESS BAIR FLOW BAROMETER BFUEL FLOW BLOCK FET CASE TEMP CRUDE NOISE CURRENTRNGHI CURRENTRNGLO CURRENTSFAC FLAME TEMP FUEL PRES LIN ERROR N15 VOLTS P10 VOLTS P15 VOLTS POL VOLTS SAMP PRES CALRESULT PURGE AIR SW ERROR DESCRIPTION FID Air FET current FID Air Pressure Burner Air Flow System Barometer Burner Fuel Flow Heater current Case Temperature Calculated Noise Current, High Range Current, Low Range Current Range Flame Temperature Fuel Pressure Linearizer Error Power Supply -15V Power Supply +10V REF Power Supply +15V Polarizing Volts Sample Pressure Calibration Error FID Purge Air Software Error TYPE WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING FAILURE FAILURE FAILURE Table 3-2: HFID Analyzer Module Alarms Emerson Process Management GmbH & Co.OHG Operation 3 - 13 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 3-7 SYSTEM & NETWORK I/O MODULE CONTROLS (SETUP) - SYSTEM SIO Output number: Choose the desired analog output (1-8) to set the parameters. The number of outputs depends on the analyzer configuration as 2, 4, 6 or 8. To adjust SIO functions, select Main (Menu)... Analyzer and I/O, expert controls & setup... System & network I/O module controls... System SIO module... Line#1 Choose signal source module... 0.000 ppm -- System SIO Module -- Select the "Analyzer Modules" submenu by selecting the "Choose signal source module..." line and pressing the Return (↵) softkey. Select the tag of the desired reference channel with the ↑ or ↓ softkeys and then press the ↵ or → softkey. The display will return to the previous menu automatically and the selected reference channel will be displayed in the "Source module:" line. Analog output setup... Serial interface setup... Relay outputs setup... Module installed... YES . MEASURE The available selections may be different depending on the installed modules. Line#1 Back... 0.000 ppm -- Analyzer Modules -1 Control Module: 0.0 1000723 Line#1: 1.0 HFID: 2.0 MLT/CH3 Figure 3-16: System SIO Module Menu System SIO module menu allows you to adjust different SIO functions, like analog outputs and serial interfaces. a. Analog Output Setup In the System SIO Module menu (Figure 3-16) select "Analog output setup..." 0.000 ppm Line#1 -- Analog Output Setup -Output number: Choose signal source module... Choose signal... Signal value for 0% output: Signal value for 100% output: Output current: Hold output during calibration: Signal name: Current signal value: Source module: Measure HOME NO/NOx ZERO SPAN INFO Figure 3-18: Analyzer Modules Menu Choose Signal... 1 0.00 100.00 0...20 mA No ???? -10.00 Line#1 Back... More... Figure 3-17: Analog Output Setup Menu Select the "Signals" submenu by selecting the "Choose Signal..." line and pressing the ↵ softkey. (The list of signals will depend on the module chosen.) Press the F5 softkey to go to additional menus to choose the Primary Variable signal for the analog output. The Primary Variable is the actual NO or NOx concentration. See Section 5.2.1.1 of HFID Software Manual for complete list of signals. The signal chosen here will be applied to the analog output (1-8) chosen above. 3 - 14 Operation Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID -- Signals -- Burner air press.: Air sense: Burner air: Burner fuel flow: Burner fuel press.: Sample press.: Sample flow: Purge control status: Measure <<< Back... >>> >>> 0.000 ppm Line#1 -- Signals -- Case temp.: Preamp temp.: Flame status: AutoIgnition: t-90 time: Delay time: Linearizer: Calibration: Measure <<< Back... >>> Figure 3-19: Signals Menu Signal value for 0% (100%) output: It is possible to set the signal value for 0 % output and for 100% output so as to output only a portion of the entire range. Example: • • • • NOTE 0.000 ppm Line#1 Range from 0 to 1,000 ppm 0% value to be 400 ppm, 100% value to be 700 ppm. Analog output normally: 0 V = 0 ppm, 10 V = 1,000 ppm After changing the output scaling: 0 V = 400 ppm, 10 V = 700 ppm. If the measurement range is changed, the settings done in this menu will revert back to the standard values of the range. The output values can be changed permanently in the menu "Range Settings." NOTE The signal range of the analog output should be less than the smallest range of the channel. Otherwise the analog output may exhibit excessive noise. Output current: Select the desired output range in the "Output current range:" line. The options are 0...20 mA or 4...20 mA. Hold output during calibration: Enable this option to hold the analog output to the last value during calibration. Pressing the F5 (More...) softkey changes the to the submenus "Output Signal if Assigned Module Fails" and "Fine Adjustment." Line#1 0.000 ppm -- Output Signal If Assigned Module Fails -- Output(s) value on analyzer failure: BeginOfRange - 10% -- Fine Adjustment -Output number: Operation mode: Fine adjustment for 0% output: Fine adjustment for 100% output: Measure 1 Normal 4096 819 Back... More... Figure 3-20: Output Signal If Assigned Module Fails Menu Move the cursor to the "Signal value for 0 % output:" line and adjust the value to 400. Then change to the "Signal value for 100 % output:" line and adjust the value to 700. Emerson Process Management GmbH & Co.OHG Operation 3 - 15 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Output(s) value on analyzer failure: Choose the desired signal level to cause a failure condition. The choices are: • • • • • Acutal BeginOfRange EndOfRange BeginOfRange-10% BeginOfRange+10% Output number: Choose the output number (1-8) for setting the fine adjustment. Operation mode: Source module: The name of the module chosen in the "Choose signal source module" menu. Pressing the F5 (More...) softkey changes to the submenu "Special Scaling for Concentration Signal" Line#1 0.000 ppm -- Special Scaling for Concentration Signal -(Scaling is the same as range limits) Output Output Output Output Output Output Output Output #1: #2: #3: #4: #5: #6: #7: #8: Measure Yes Yes Yes Yes Yes Yes Yes Yes Back... More... Normal: The absolute measurement signal will be sent to the analog output. Figure 3-21: Special Scaling for Concentration Signal Menu Adjust 0V: Used to set the display equal to the analog output for 0 V and 0 mA. Life zero signals (4 - 20 mA and 2 - 10 V) are set automatically and cannot be adjusted. This menu allows for the setting of each of the 8 outputs to be the same as the range limits "Yes" or as to set on the previous menus. Adjust 10V: Used to set the display equal to the analog output for 10V und 20mA. Select the "Fine adjustment for 0% output" and/or "Fine adjustment for 100 % output" lines with the ↵ or → softkey. Adjust to the desired value with the ↑ or ↓ softkey and confirm with the ↵ softkey. The range of values are: • • 3,000 to 6,000 for 0 % (default 4096) 600 to 1,000 for 100 % (default 819) The last three lines of the "Analog Output Setup" menu are displayed only for configuration values of the analog output. Signal name: The name of the signal chosen the "Choose signal" menu. Pressing the F5 (More...) softkey changes to the submenu "Analog Output Updates per Second." 0.000 ppm Line#1 -- Analog Output Updates Per Second -Output Output Output Output Output Output Output Output 1 0 0 0 0 0 0 0 0 #1: #2: #3: #4: #5: #6: #7: #8: Measure Back... Figure 3-22: Analog Output Updates per Second Menu. This menu allows for the setting of the update rate for each of the 8 outputs. Current signal value: The current value of the variable. 3 - 16 Operation Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 b. NGA 2000 HFID Serial interface Setup 0.000 ppm Line#1 The submenu "Serial interface Setup" is used to set the parameters for data transfer between the analyzer and external devices. The choices in this menu depend on the configuration of the analyzer. The full specification of the serial interface is described in its own manual. -- AK Protocol Deifinitions -Device address (RS-485 only): 1 In the System SIO Module menu (Figure 3-16) select "Serial interface setup..." 0.000 ppm Line#1 -- Serial Interface Setup -Baud rate: Data bits: Stop bits: Parity: Echo mode: Handshake: Transmission delay: Type of installed serial interface: Communication protocol: Special protocol definitions... Pressure limits... 19200 8 1 None Disabled Xon/Xoff 0 RS232 AK Measure Measure Back... More... Figure 3-24: AK Protocol Definitions Menu The value can range from 1 to 50. Back... Figure 3-23: Serial Interface Setup Menu Options: • • • • • • • Baud rate: 300, 1200, 2400, 4800, 9600, 19200 Data bits: 7, 8 Stop bits: 1, 2 Parity: None, Even, Odd Echo mode: Enabled, Disabled Handshake: None, Xon, Xoff Transmission delay: 0...100. Type of installed serial interface: RS232, RS485/2w, RS485/4w, RS485/4w bus, None. Communication protocol: AK, MODBUS RTU, None (not applicable to HFID) NOTE The "special protocol definitions..." line accesses a submenu for setting the parameters of the AK and MODBUS RTU (not available yet) communication protocols. Emerson Process Management GmbH & Co.OHG Operation 3 - 17 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID c. Relay Outputs Setup Choose signal... There are three relays on the SIO board. The contact logic can be set with a jumper on the SIO board to select NO (normally open) or NC (normally closed). Full details of the SIO board are contained in its own manual. Line#1 0.000 ppm -- Choose Signal -1 Function control Maintenance request Failure Cal. In progress Zero in progress Span in progress Zero failed Span failed In the System SIO Module menu (Figure 3-16) select "Relay outputs setup..." 0.000 ppm Line#1 -- Relay Outputs Setup -Output number: Invert signal: Choose source module... Choose signal... 1 Disabled Pressure limits... Measure <<< Back... >>> Figure 3-27: Choose Signal Menu Signal comes from: Signal name: Actual status: ???? ???? Off Measure Choose desired signal for the relay output number (1-3) being configured. The list of signals will depend on the chosen module. If available, press the >>> (F5) softkey for additional signals. Back... Figure 3-25: Relay Outputs Setup Menu The three lines displayed at the bottom of the "Relay Outputs Setup" menu show the current status of the selected relay output. Output number: Corresponds to the relay number 1-3. Invert signal: "Disabled" signal is normal, "Enabled" signal is inverted. Choose source module... 0.000 ppm Line#1 -- Choose Source Module -- Signal comes from: The module chosenfrom the "Choose Source Module" menu. Signal name: The signal chosen from the "Choose Signal" menu. Actual status: The current status of the signal; Off or On. Control Module: 0.0 1000723 Line#1: 1.0 Measure <<< Back... >>> Figure 3-26: Choose Source Module Menu Choose desired source module for the relay output number (1-3) being configured. The list of modules will depend on the installed modules. 3 - 18 Operation Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 4 MAINTENANCE AND SERVICE CAUTION WARNING GENERAL HAZARD PRESSURIZED ENCLOSURE Before starting of maintenance and service to this equipment, read the "Essential instructions" on the inside cover and the Safety Summary beginning on page P-2.Failure to follow the safety instructions could result in serious injury or death. This enclosure shall not be opened unless the area is known to be free of flammable materials or unless all devices within have been de-energized. This equipment should not be adjusted or repaired by anyone except properly qualified service personnal! WARNING ELECTRICAL SHOCK HAZARD 4-1 OVERVIEW Do not open while energized. This section contains instructions and procedures for troubleshooting and maintaining the HFID analyzer module. Disconnect power to the module(s) prior to replacing components. The HFID Analyzer Module requires very little maintenance during normal operation. This equipment should not be adjusted or repaired by anyone except properly qualified service personnel. The gas path system should be leak tested at least twice a year and after maintenance, replacement or repair of gas path parts. Do not operate without covers secure. WARNING UNAUTHORIZED SUBSTITUTION OF COMPONENTS Tampering with or unauthorized substitution of components may adversely affect the safety of this instrument. Use only factory documented/approved components for repair. Because of the danger of introducing additional hazards, do not perform any unauthorized modification to this instrument! Several components may require replacement. These are discussed in the following sections. Tag each connector and its location before disconnecting any wiring. This helps in reassembly. To access the internal components of the analyzer module, perform the following: 1. 2. Remove power to the unit; shut off gases and disconnect lines. Allow module to cool. Refer to Figure 4-1. Remove the six screws securing the front panel, then the six screws securing the cover to the rear panel. Slide cover towards rear panel to remove. Loosen four screws securing inner insulation shield to base, lift up to remove. Figure 4-2 illustrates the locations of major components of the HFID. Emerson Process Management GmbH & Co.OHG Maintenance and Service 4-1 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Cover Insulation Shield WARNING FUEL IN PURGE AIR OUT BURNER AIR IN REGULATED AIR IN PURGE AIR IN BURNER EXHAUST OUT WARNING ATTENTION PRESSURE RELIEF VALVE HEATED SAMPLE IN HEATED SAMPLE BYPASS Cover/Rear Panel Securing Screws (6) Securing Screws (4) Front Panel Securing Screws (6) Figure 4-1: Removal of Cover and Insulation Shield 4-2 Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Rear Panel Assembly 656954 Electronic Assembly 656943 DC Power Supply Module Assembly 657413 Oven Assembly Brief Description Part Number 9.7 cc/min. @ 3.5 psig 659551 2.5 cc/min. @ 3.5 psig 658338 Fan Assembly 657414 Fixed Flow Controller Assembly 657434 Front Panel Assembly 656949 Figure 4-2: Location of Major Assemblies of the HFID Module 4-2 FUSES The main power fuse may require replacement. NOTE Before replacing the fuse, remove power to the Analyzer Module. See figure 2-3 for the location of the main power fuse [T 6A 250 V (6x32 mm)], which protects 24 VDC input to the module. NOTE Use only fuses of the correct type and current ratings as replacements. Using repaired fuses and short circuiting of fuse holders is prohibited. Emerson Process Management GmbH & Co.OHG Maintenance and Service 4-3 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-3 OVEN b. Though the oven can be replaced as a complete unit, all internal components are field replaceable. a. 1. 2. Removal Refer to Figure 4-3, disconnect the oven´s three gas lines and seven electrical cables, noting location of mating connectors for re-installation. 3. Disassembly Refer to Figure 4-4A. Remove the tour retaining screws on the oven cover, remove cover. Removethe two screws and one nut securing the outer oven front panel to the outer oven, remove front panel. Remove the nuts and ferrules from sample in and sample bypass out. NOTE CAUTION DO NOT remove the fittings from the gas lines on the detector. Remove the two hex nuts securing the oven to the chassis and the two screws securing oven to the rear panel. Lift oven assembly from analyzer. PREAMP CONNECTORS ! The electrical preamp connectors are fragile, handle with care to avoid breaking solder connection! 4. Oven Assembly Brief Description Part Number 9.7 cc/min. @ 3.5 psig 659551 2.5 cc/min. @ 3.5 psig 658338 5. 6. 7. 8. Refer to Figure 4-4B. Remove the two nuts and washers form the electrical preamp connectors on the inner oven front panel. Do not unsolder these connections. Unscrew the three screws from inner front panel and remove it. Refer to Figure 4-4C. Remove the two hex nuts securing the burner to the bottom of the inner oven. Disconnect the sample input and output bypass fittings. Lift the burner/thermal block up and out, while disconnecting exhaust. Reverse Procedure for installation. Figure 4-3: Removal of Oven from Chassis 4-4 Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 A NGA 2000 HFID Oven Cover 657105 (with insulation 657346) B Exhaust Nuts and Ferrules (2 ea.) Inner Oven Retaining Screw (2) and Washer (2) Inner Oven Inner Oven Front Panel 657352 Preamp Connector Nut, Washer (type 2) Outer Oven Outer Oven Front Panel 657356 Burner 657359 C Spring, Heated Bridge 904294 Heated Bridge 659955 Heater/Cable Assembly 659643 Jam Nuts 659550 Insulating Washers 073737 For clarity, outer oven not shown in Figures B and C. Figure 4-4: Oven Assembly Emerson Process Management GmbH & Co.OHG Maintenance and Service 4-5 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-4 BURNER c. This section covers burner components which can be replaced without removal of oven from the chassis. a. 1. 2. 3. 4. 5. Temperature Sensor Refer to Figure 4-4A. Remove the four screws on the oven cover, remove cover. Refer to figure 4-5. Remove the burner cap retainer. Disconnect the temperature sensor wiring connector, note location. Remove the temperature sensor. Insert replacement sensor. NOTE The leads of the temperature sensor must be leading away and down from the sensor to enable proper fit of burner cap retainer. 6. 7. 8. b. 1. 2. 3. 4. 5. 6. 7. 4-6 Install the burner cap retainer. U-slot must be located above temperature sensor. Re-attach wiring connector. Install oven cover. 1. 2. 3. 4. 5. 6. d. 1. 2. 3. 4. RTD Detector Refer to Figure 4-4A. Remove the four screws on the oven cover, remove cover. Refer to Figure 4-5. Loosen the set screw securing RTD detector. Disconnect RTD detector wiring connector, note location. Gently grasp RTD detector wires and pull out of hole. Insert replacement RTD detector into hole, snug down set screw. Re-attach wiring connector. Install oven cover. Maintenance and Service 5. 6. Igniter Refer to Figure 4-4A. Remove the four screws on the oven cover, remove cover. Refer to Figure 4-5. Disconnect the Igniter wiring connector, note location. Using an open-end wrench, unscrew the igniter assembly from the burner. Verify that o-ring is also removed. Install replacement igniter and new o-ring. Using open-end wrench, snug down. Do not over-tighten! Re-attach wiring connector. Install oven cover Flameout Sensor Refer to Figure 4-4A. Remove the four screws on the oven cover, remove cover. Refer to Figure 4-5. Disconnect the flameout detector wiring connector, note location. Lift up the burner cap until flameout sensor is accessible. Using an open-end wrench, unscrew the flameout detector from the burner. Verify that oring is also removed. Install replacement flameout detector and new oring. Using open-end wrench, snug down. Do not over-tighten! Re-attach wiring connector. Install oven cover. Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Retainer, Burner Cap Temperature Sensor 657468 O-Ring 903736 O-Ring 903737 Flameout Sensor 657199 Igniter Assembly 657205 RTD Detector 657063 Set Screw M3X0.5x10 mm 903125 The components shown can be replaced without removing burner/thermal block from oven. Oven not shown for clarity. Thermal block shown in phantom for clarity. Figure 4-5: Burner-Sensor, Flameout Detector, RTD Detector and Igniter Emerson Process Management GmbH & Co.OHG Maintenance and Service 4-7 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-5 BURNER INTERNAL COMPONENTS a. 1. CAUTION BURNER CONTAMINATION Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates. 2. 3. 4. 5. Disassembly of Burner / Thermal Block Remove oven from analyzer module per Section 4-3a. Remove burner / thermal block from oven per Section 4-3b. Refer to Figure 4-6. Disconnect sample capillary nut at base of burner. Remove screw securing thermal block to burner. Carefully pull burner away from thermal block. Burner Sample Capillary input Thermal Block Sample Capillary Figure 4-6: Burner/Thermal Block Disassembly 4-8 Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 b. NGA 2000 HFID Replacing Burner Jets For best performance, replace the burner jet as follows: Disassemble the burner only if contaminants are evident. Combustion products or other contaminates which accumulate inside the burner may form electrical leakage paths between the collector and the burner contact, resulting in noisy readings. If the analyzer module is to be operated at the highest sensitivity, traces of such contaminates can cause erroneous readings. 1. 2. 3. 4. 5. CAUTION BURNER CONTAMINATION 6. Remove oven from analyzer module per Section 4-3a. Remove burner / thermal block from oven per Section 4-3b. Remove thermal block from burner per Section 4-5a. Refer to Figure 4-7A. Remove screws (2) holding burner cap retainer, remove retainer. Holding burner base, lift burner cap off assembly, set aside, remove gasket. Refer to Figure 4-7B. Holding burner base, lift combustion chamber off, set aside. Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates. A Burner Cap Retainer B Combustion Chamber Burner Cap O-Ring 03656580 O-Ring ETC01463 Burner Base Burner Base Figure 4-7: Burner Disassembly Emerson Process Management GmbH & Co.OHG Maintenance and Service 4-9 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 7. 8. Refer to Figure 4-8. Lift air baffle out of burner base. Remove the sample jet and gasket from the bottom of the burner base. 9. Remove the jet nut. Grasp jet assembly and lift out (along with upper gasket) of burner base. Remove bottom gasket. Air Baffle (Ref) 102260 (see below) Nut, Jet 016005 Gasket 102273 Sample Jet 657005 Gasket 102256 Air Baffle End bent to raise it above the tab a distance equal to the height of the tab. Sample Jet 657005 ≈ .06 Position with tab over the air hole (approximately 1/16" to the right). Figure 4-8: Burner Jets 4 - 10 Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 c. NGA 2000 HFID Burner Jet Installation 3. 4. CAUTION BURNER CONTAMINATION Do not handle internal parts of the burner with bare hands. All tools used for maintenance must be free of contaminates. 1. 2. Install new lower gasket, jet assembly and upper gasket into burner base, finger-tight jet nut. Install new sample jet (with gasket) and tighten. Emerson Process Management GmbH & Co.OHG Tighten jet nut. Install air baffle per Figure 4-8. NOTE Incorrect installation of air baffle will cause ignition failure. 5. 6. 7. See Figure 4-7B. Insert new o-ring into burner base. Set combustion chamber into burner base being careful not to move air baffle. See Figure 4-7A. Insert new gasket on combustion chamber, install burner cap and burner cap retainer, torque screws to 6 inch lbs. Maintenance and Service 4 - 11 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-6 THERMAL BLOCK b. The sample RTD can be replaced with the thermal block attached to burner and mounted in oven. The cartridge heater and thermostat are also replaceable with thermal block secured to burner, but must be removed from the oven. a. 1. 2. 3. 4. 5. 6. Sample RTD 1. 2. 3. 4. Refer to Figure 4-4A. Remove the four screws securing the oven cover, remove cover. Disconnect the sample RTD wiring connector, note location. Refer to Figure 4-9. Remove the two screws securing the sample RTD, pull sample RTD out. Install replacement sample RTD, secure with screws. Attach sample RTD wiring connector. Re-attach oven cover. 5. 6. Cartridge Heater Remove oven from analyzer module per Section 4-3a. Remove burner / thermal block from oven per Section 4-3b. Refer to Figure 4-9. Loosen retaining set screw, pull out cartridge heater. Install replacement cartridge heater, snug down set screw. Install burner / thermal block into oven. Install oven into analyzer module. Sample RTD 657061 Cartridge Heater 659643 Thermostat 659068 Figure 4-9: Thermal Block- Sample RTD, Cartridge Heater and Thermostat 4 - 12 Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 c. 1. 2. 3. 4. 5. 6. NGA 2000 HFID Thermostat d. Remove oven from analyzer module per Section 4-3a. Remove burner / thermal block from oven per Section 4-3b. Refer to Figure 4-9. Remove the two retaining screws, pull thermostat out. Install replacement thermostat, attach with the two retaining screws. Install burner / thermal block into oven. Install oven into analyzer module. 1. 2. 3. 4. 5. 6. 7. 8. Sample Capillary Remove oven from analyzer module per Section 4-3a. Remove burner / thermal block from oven per Section 4-3b. Remove burner from thermal block per Section 4-5a. Refer to Figure 4-10. Remove the two screws securing the capillary cover to thermal block, remove cover. Remove capillary nut, remove capillary. Install replacement capillary. Insert capillary into thermal block. The capillary may require bending to fit. Install cover. Capillary Cover Figure 4-10: Thermal Block Assembly Emerson Process Management GmbH & Co.OHG Maintenance and Service 4 - 13 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-7 ELECTRONICS ASSEMBLY CAUTION The electronics assembly must be removed from the chassis of replacement of any of the following components is necessary: Power Supply Board Safety Board ELECTROSTATIC DISCHARGE Computer Analysis Board The electronic parts of the Analyzer Module can be irreparably damaged if exposed to electrostatic discharge (ESD). The instrument is ESD protected when the covers have been secured and safety precautions observed. When the housing is open, the internal components are not ESD protected anymore. Preamp Assembly Sensor Board Case Temperature Sensor Case Pressure Switch 1. 2. Remove the hex nut and screw as shown in Figure 4-11. Lay electronics assembly on bench, do not disconnect cables or tubing. Electronics Assembly 656943 Screw Hex Nut Figure 4-11: Removing Electronics Assembly from Chassis 4 - 14 Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Preamp Assembly 656945 Case Pressure Purge Switch 903690 Computer Analysis Board 658350 Sensor Board 657060 Safety Board 43500271 Power Supply Board 655764 Case Temperature Sensor 656026 Figure 4-12: Electronics Assembly - Exploded View a. Printed Circuit Boards When replacing a circuit board, the following procedure is recommended: One at a time, remove the wiring connectors and attach to replacement board. Per Section 4-7, remove securing hardware from electronics assembly and lay on bench. Mount replacement board to electronics assembly. Remove securing hardware from printed circuit board to be replaced, do not disconnect cable(s). Emerson Process Management GmbH & Co.OHG Maintenance and Service 4 - 15 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID b. 1. 2. 3. Case Temperature Sensor Per Section 4-7, remove securing hardware from electronics assembly and lay on bench. Disconnect case temperature sensor cable. Remove screw securing cable clamp holder to signal board. 4. 5. 6. Remove case temperature sensor from cable clamp holder. Per Figure 4-13 insert replacement case temperature sensor into cable clamp holder. Re-assemble to signal board mounting screw. Center Sensor in Cable Clamp Figure 4-13: Case Temperature Sensor Installation c. 1. 2. Case Pressure Purge Switch Per Section 4-7, remove securing hardware from electronics assembly and lay on bench. Disconnect the two electrical terminals, note location. 3. 4. 5. Disconnect tube at pressure switch. Remove mounting screws (2) and washers (2). Reverse procedure for installation of replacement switch. Case Pressure Purge Switch 903690 The bracket does not have to be removed from the electronics assembly for this procedure Figure 4-14: Case Pressure Purge Switch Installation 4 - 16 Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 d. 1. 2. 3. NGA 2000 HFID Preamp Assembly Per Section 4-7, remove securing hardware from electronics assembly and lay on bench. Disconnect and note location of cables. Remove the two screws and washers from the top bracket and slide the preamp assembly out. 4. 5. 6. Remove the lower bracket from the preamp assembly and install on replacement preamp assembly. Slide replacement preamp assembly into top bracket and secure with mounting hardware. Re-connect cables. Preamp Assembly 656945 Bottom Bracket Figure 4-15: Preamp Assembly Installation Emerson Process Management GmbH & Co.OHG Maintenance and Service 4 - 17 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-8 1. 2. FAN ASSEMBLY Disconnect and note location of cables. Remove the two hex nuts securing the fan to the chassis, lift fan assembly out. Fan Assembly 657414 Figure 4-16: Fan Assembly Installation 4 - 18 Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 4-9 1. 2. NGA 2000 HFID FLOW CONTROLLER Disconnect the all tubing and wiring connectors, note locations. Remove the four hex nuts securing the flow controller assembly to the analyzer module chassis. Flow Controller Assembly 657434 Figure 4-17: Flow Controller Replacement Regulated Air IN Remove red cap after installation Regulator 250 psi 023382 Flow Regulated Air OUT Sample Sensor 656418 Remove and discard bracket supplied with regulator, assembly as shown. Figure 4-18: Flow Controller Assembly Emerson Process Management GmbH & Co.OHG Maintenance and Service 4 - 19 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-10 DC POWER SUPPLY MODULE 1. 2. Disconnect and note location of all wiring to DC power supply module. Remove the two hex nuts securing module to chassis, remove module. DC Power Supply Module Figure 4-19: DC Power Supply Module Replacement 4 - 20 Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-11 FRONT PANEL COMPONENTS The following components are mounted to the front panel: • • LON/Power Module Manual Ignite Toggle Switch Connector fitting Air Measurement Restirctor 656888 • • • • • • • • • • LED Indicator Assembly Purge Air Regulator Purge Air Flow Switch Burner Air Solenoid Valve Burner Air Regulator Fuel Regulator Burner Air Sensor Fuel Sensor Air Ignite Restrictor Air Measurement Restrictor Burner Air Solenoid Valve 656219 Regulator Mounting Nut Diffuser 657548 Regulator Mounting Nut Air Ignite Restirctor 655794 Purge Air Flow Switch 656533 LON/Power Module 656560 Purge Air Regulator 871672 Burner Air Sensor 656443 Male Adapter Fitting Plugs Manual Ignite Toggle Switch 655794 Fuel Sensor 656444 O-Ring 011177 LED Indicator Assembly 657029 O-Ring 011167 Sensor Fitings 657412 Burner Air Regulator 902832 Fuel Regulator 902832 O-Rings / Thrust Rings 008025 42716383 Toggle Switch Seal 898980 Figure 4-20: Front Panel - Exploded View Emerson Process Management GmbH & Co.OHG Maintenance and Service 4 - 21 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID Replacing Front Panel Components 1. 2. To access components, remove the four front panel mounting screws (two on front, one on each side). Remove the burner air regulator and fuel regulator mounting nuts. 3. Remove the purge air regulator mounting bracket screws. The front panel can now be pulled away from the chassis. NOTE The wiring from front panel components is still connected. Do not disconnect unless replacing that component. Front panel mounting screw (opposite side also) Front panel mounting screws Figure 4-21: Accessing Front Panel Components 4 - 22 Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 a. 1. 2. 3. LON/Power Module Disconnect wiring connectors, note locations. Refer to Figure 4-20. From the outside of the front panel, remove the two mounting screws. Install replacement module in reverse order. NGA 2000 HFID e. 1. 2. 3. b. 1. 2. 3. 4. c. 1. 2. 3. 4. 5. 6. d. 1. 2. 3. 4. 5. LED Indicator Assembly Disconnect wiring connector, note location. Refer to Figure 4-20. From the inside of the front panel, remove the two hex nuts securing LED indicator assembly to front panel. Remove indicator assembly and o-rings (four). Inspect o-rings for damage, replace if necessary. Install o-rings on replacement indicator assembly, mount assembly on mounting studs with hex nuts. Re-connect wiring connector. 4. 5. f. 1. 2. 3. 4. Manual Ignite Toggle Switch Disconnect wiring connector, note location. Refer to Figure 4-20. From the outside of the front panel, remove the toggle switch seal. Pull the switch and o-ring out from inside the front panel. Inspect o-ring for damage, replace if necessary. Install o-ring on replacement switch, insert through front panel from the inside. Install switch seal. Re-connect wiring connector. Burner Air Sensor Disconnect wiring connector, note location. Using an open-end wrench to hold the sensor fitting while using another open-end wrench to remove the sensor. Replace the Teflon pipe thread tape on the treads of the sensor fitting. Install sensor onto sensor fitting. Re-connect wiring connector. 5. 6. 7. g. 1. 2. 3. 4. 5. 6. 7. 8. Emerson Process Management GmbH & Co.OHG Fuel Sensor Disconnect wiring connector, note location. Using an open-end wrench to hold the sensor fitting while using another open-end wrench to remove the sensor. Replace the Teflon pipe thread tape on the treads of the sensor fitting. Install sensor onto sensor fitting. Re-connect wiring connector. Burner Air and Fuel Regulator Disconnect the two tubes and the sensor fitting on the rear of the regulator, note locations. Replace the Teflon pipe thread tape on the threads of the sensor fitting. Remove the regulator and o-ring. The replacement regulator comes with two panel mounting nuts, remove both and discard one of them. Inspect o-ring for damage, replace if necessary. Install o-ring onto regulator threaded shaft. Insert regulator into front panel, secure with mounting nut. Re-attach the three tubes. Purge Air Regulator Remove the regulator mounting nut, remove mounting bracket. Loosen nut on tee fitting attached to purge air flow switch. Disconnect tube at elbow, remove regulator. Remove the two plugs, elbow and male adapter fittings from the regulator. Replace the Teflon pipe thread tape on the two plugs, the elbow and the male adapter and install into replacement regulator. Connect tube to elbow, insert male adapter into tee fitting. Install mounting bracket onto regulator, hand snug mounting nut. Attach mounting bracket to front panel, tighten regulator mounting nut. Maintenance and Service 4 - 23 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID h. 1. 2. 3. 4. 5. 6. i. 1. 2. 3. 4. 5. 6. 7. 8. 9. 4 - 24 Purge Air Flow Switch and Diffuser j. Air Ignite Restrictor Unscrew flow switch from tee fitting. Replace Teflon pipe thread tape on tee fitting. Remove diffuser from flow switch and install into replacement flow switch. Install replacement flow switch. Install purge switch onto tee fitting. Re-connect tubes. 1. Burner Air Solenoid Valve 2. Disconnect the tube at the top elbow fitting. Disconnect the tube at the tee fitting, remove valve analyzer module. Holding the air ignite restrictor, unscrew the solenoid valve. On the solenoid valve, remove the connector fitting. Replace the Teflon pipe thread tape on the elbow, connector and restrictor. Verify replacement solenoid valve wires (flat side of body) are exiting on the same side as the COM port as shown in Figure 4-20. If not, use an openend wrench to hold the N.O. hex port while rotating body. Install air ignite restrictor into N.C. port. Install elbow into COM port and connector fitting into N.O. port. Re-connecto tubes. Maintenance and Service 3. On the burner air solenoid valve: a. Disconnect the tube at the top elbow fitting. b. Disconnect tube at tee fitting. c. Lift solenoid valve from analyzer module. d. Disconnect tube going to air ignite restrictor. e. Remove restrictor from solenoid valve. Add Teflon pipe thread tape to replacement restrictor, install into solenoid. Re-connect tubes to restrictor, elbow and tee fitting. Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-12 REAR PANEL COMPONENTS The following components are mounted to the rear panel: • • Fuel In 2-Way Solenoid Valve Regulated Air In Check Valve • • • Burner Air In Filter Heated Sample Bypass Out Restrictor Heated Sample In Restrictor VIEW FROM INSIDE ANALYZER MODULE Check Valve, Regulated Air IN 903728 Solenoid Valve, Fuel IN 656218 VIEW FROM OUTSIDE ANALYZER MODULE Filter, Burner Air IN 017154 Restrictor, Bypass OUT 10 Micron 619615 Restrictor, Heated Sample IN 40 Micron 619616 Figure 4-22: Rear Panel Components Emerson Process Management GmbH & Co.OHG Maintenance and Service 4 - 25 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID a. 1. 2. 3. 4. 5. 6. b. 1. 2. 3. 4. 4 - 26 Fuel In 2-Way Solenoid Valve Disconnect wiring solenoid valve wiring connector, note location. Inside the analyzer module, disconnect the tube going to the connector on the "out" port of the solenoid valve. On the rear of the analyzer module at the fuel in port: a. Disconnect the fuel in tube. b. Remove nuts and washers c. Remove solenoid valve from analyzer module Remove the fittings from the solenoid valve and replace the Teflon pipe thread tape. Verify that body of replacement solenoid valve is oriented as shown in Figure 4-22. If not, rotate till wires are in-line with "out" port. Install fittings into replacement solenoid valve, reinstall in analyzer module. c. 1. 2. 3. d. 1. 2. 3. 4. 5. 6. Heated Bypass Sample Out and Heated Sample In Restrictors On the outside of the rear panel, disconnect tube and remove nut. Insert a small spade screwdriver into the bulkhead and remove the restrictor. Install in reverse order. Regulated Air In Check Valve Disconnect tube at elbow. Remove check valve from female connector. Remove elbow from check valve. Add Teflon pipe thread tape to check valve threads. Install elbow onto check valve. Install check valve into female connector, verifying orientation of elbow fitting as shown in Figure 4-22. Burner Air In Filter Leaving the bulkhead fitting secured to the rear panel, remove the tubes, nuts and ferrules from the fitting. Insert a clean, rigid piece of tube or rod (smaller than .25 inch diameter) into the bulkhead fitting to force out the filter disc. Install the replacement filter in the same manner, through the rear of the bulkhead fittings. Re-connect tubes. Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 4-13 LEAKAGE TEST The gas path system should be leak tested at least twice a year and after maintenance, replacement or repair of gas path parts. a) 4. 5. 6. Required Tools • • • • • Test Medium external Manometer Swagelok® Blind Unions SS (2) Swagelok® Blind Unions brass (2) tube piece with rubber stopper b) Connect a pressure meter to „Sample IN“ fitting Connect test medium supply (N2 or He) to the pressure meter Supply Analyzer Module with the test medium with a pressure of max. 250 hPa (3.63 psig) and close supply. Since HFID internal it comes to equalization of pressure, supply is to open and to close repeatedly until manometer doesn’t show pressure changes. CAUTION POSSIBLE INSTRUMENT DAMAGE The pressure of the test medium must not exceed 250 hPa (3.63 psig) ! Procedure To perform a leakage testing, proceed as follows (see figure 4-23): 1. 2. 3. Close gas supplies and disconnect the gas connections Close „Fuel IN“, „Burner Air IN“, „Bypass OUT“ and „Regulated Air IN“ with blind unions Close „Exhaust“ with a tube piece with rubber stopper. Watch the manometer. Over a period of about 5 minutes the pressure drop may not be higher than 7.5 hPa/min. (- 0.11 psig/min.) using Helium (He) or 2.5 hPa/min. (- 0.036 psig/min.) using Nitrogen (N2). If the specifications (see table 4-1) were adhered to, then the test is finished. Closed Gas Connections: „Fuel IN“, „Burner Air IN“, „Bypass OUT“, „Exhaust“, „Regulated Air IN“ External Manometer: 3.63 psig = 250 hPa Gas source with test medium N2 or He 7. HFID Analyzer Module P Sample In Figure 4-23: Principle Leakage Test Assembly Test Medium Test Pressure Test Time permissible Drop in Pressure Nitrogen (N2) Helium (He) 3.63 psig / 250 hPa / 0.25 bar 3.63 psig / 250 hPa / 0.25 bar 5 min 5 min 2.5 hPa (0.036 psig) / min 7.5 hPa (0.11 psig) / min Table 4-1: Leakage Test Specifications Emerson Process Management GmbH & Co.OHG Maintenance and Service 4 - 27 Instruction Manual NGA 2000 HFID HAS64E-IM-HW September 2008 If there is a leakage, then proceed as follows: a) Using Helium (He) for test medium • Supply Analyzer Module with the test medium with a pressure of max. 250 hPa (3.63 psig). • Look for the leak with a helium leak detector. b) Using Nitrogen (N2) for test medium • Supply Analyzer Module with the test medium with a pressure of max. 250 hPa (3.63 psig). • Liberally cover all fittings, seals, and other possible sources of leakage with a suitable leak test liquid such as SNOOP. Bubbling or foaming indicates leakage. • • Remove the source of leak. Perform a leakage test once more as decribed obove. . 4 - 28 Maintenance and Service Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 5 TROUBLESHOOTING WARNING GENERAL HAZARD Before starting troubleshooting to this equipment, read the "Essential instructions" on the inside cover and the Safety Summary beginning on page P-2. Failure to follow the safety instructions could result in serious injury or death. 5-1 TROUBLESHOOTING CHECKLIST b. Ignition a. Safety System 1. Verify that the fuel pressure/flow is correct. 1. Verify purge supply pressure at bulkhead is between 689 hPa and 1,378 hPa (10 psig and 20 psig). 2. Verify that the burner air pressure/flow is correct. 3. Verify that the igniter is generating enough heat. 4. Verify the burner exhaust is vented to atmosphere. 5. Verify safety system has been activated. 6. Verify the manual switch is operating correctly. 7. Verify auto-ignite parameters are properly set. 8. Verify burner is properly seated. 2. Check case for leaks. 3. Check burner for leaks. 4. Verify purge pressure sensor tube connection. 5. Verify purge out port is vented to atmospheric pressure. 6. Verify Safety PCB connector J2 is attached. 9. Verify quality of air supply is good. 7. Check for a +24V power glitch. 10. Verify quality of fuel supply is good. 8. Verify that there is no large vibration shock. 11. Check burner tip for damage. 9. Check for external leak in purge line. 12. Check air and fuel restrictor for correct flow. 10. Verify case pressure is greater than 0.5" of water. 13. Check burner tip alignment. 11. Check case for over-pressurization. 14. Verify burner cone is tight. 12. Verify the purge flow/pressure switch harness is routed away from the solenoid valves. 15. Check burner air and fuel lines for leaks. 16. 13. Verify the purge timer is counting. Verify oven temperature is greater than 85°C (185 °F). 14. Verify purge timer jumper is correctly installed. 17. Verify the reference thermistor is 100K ohm ±15% at 25°C (77 °F). 15. Verify Internal purge pressure is greater than 380 hPa (5.5 psig). 18. Verify that there is + 10 VDC to be the reference thermistor. 16. Verify the purge gas switch has been activated. Emerson Process Management GmbH & Co.OHG Troubleshooting 5-1 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID c. Drift d. Noise 1. Verify that the sample, burner air, and fuel supply pressures are constant. 1. Check that the burner exhaust is free from water condensation. 2. Check that the sample, burner air, and fuel supply pressures are constant. 2. Verify connection to the collector is correct. 3. 3. Verify that the oxygen level in the burner air and sample are constant. Verify connection to the polarizing voltage is correct. 4. 4. Verify the THC level is correct for the burner air and fuel supply. Check the ambient temperature is changing < 10 K per hour. 5. 5. Check that the ambient temperature is changing < 10 K per hour. Verify the + 24 VDC is clean and grounded properly. 6. Verify there are no strong magnetic fields near. 6. Verify the burner is clean. 7. Check for excessive vibration. 7. Verify temperature of the sample gas, case, burner, and oven has stabilized. 8. Verify burner exhaust is vented to a constant atmospheric pressure. 8. Verify the Preamp PCB is clean. 9. 9. Verify atmospheric pressure at burner exhaust is constant. Verify bypass line is vented to a constant atmospheric pressure. 10. 10. Verify purge gas pressure is constant. Verify purge out port vented to a constant atmospheric pressure. 11. Verify burner has been on and stabilized. 11. 12. Check for gas leaks. Verify the collector wires are routed away from the heater. 12. Verify the collector wires are clean and not damaged. 5-2 Troubleshooting Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 6 REPLACEMENT PARTS WARNING UNAUTHORIZED SUBSTITUTION OF COMPONENTS Tampering with or unauthorized substitution of components may adversely affect the safety of this instrument. Use only factory documented/approved components for repair. Because of the danger of introducing additional hazards, do not perform any unauthorized modification to this instrument! 6-1 MATRIX Each analyzer is configured per the customer sales order. To identify the configuration of an analyzer, locate the analyzer name plate label. The analyzer matrix appears on the analyzer name plate label. Measuring Range (Fullsclae Range) Serial Number Analyzer Matrix Figure 6-1: Name Plate Label Emerson Process Management GmbH & Co.OHG Replacement Parts 6-1 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 6-2 GENERAL 813344 903107 657029 656560 657413 657053 657414 656943 6-3 PNEUMATICS 017154 902832 657434 871672 655794 656888 656443 656444 656418 656219 656218 903690 6-2 Fuse, 6A Fuse, Thermal Cutoff 72° (2 Required - Safety and Power Supply PCB's) LED Indicator Assembly LON/Power Module DC Power Supply Module Manual Ignite Switch Assembly Fan Assembly Electronics Assembly 658350 Computer Board 656945 Preamp Assembly 43500721 Safety Board 655764 Power Supply Board 657060 Sensor Board 656026 Case Temperature Sensor 657094 PROM SW-Version 2.3 659894-R1 PROM SW-Version 3.3.1 659894-R2 PROM SW-Version 3.3.3 659894-RB PROM SW-Version 3.3.4 659894-R3 PROM SW-Version 3.6 659894-R4 PROM SW-Version 3.7.0 659894-R5 PROM SW-Version 3.7.1 659894-R6 PROM SW-Version 3.7.2 659894-R7 PROM SW-Version 3.9.3 659894-R8 PROM SW-Version 3.9.4 Filter, .25 DIA x .06 - .09 THK 50-100 Microns (Burner Air) Regulator 0-60 PSI (Fuel and Burner Air) Fixed Flow Controller Assembly 023382 Regulator 250 psi 656418 Sample Sensor Purge Air Regulator Air Ignite Restrictor Air Measurement Restrictor Burner Air Sensor Fuel Sensor Flow Control Sample Pressure Sensor Burner Air 3-Way Solenoid Valve Fuel In Solenoid Valve Case Pressure Purge Switch Replacement Parts Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 656533 903728 903647 6-4 NGA 2000 HFID Purge Air Flow Switch Regulated Air In Check Valve Case Pressure Relief Valve OVEN COMPONENTS 659551 658338 Oven Assembly 9.7 cc/min @ 3.5 psig Oven Assembly 2.5 cc/min @ 3.5 psig 657359 Burner Assembly 657205 Igniter Assembly 903736 O-Ring (Igniter Assembly) 657063 RTD Detector 903125 Set Screw M3x0.5 x 10mm (RTD Detector) 657468 Temperature Sensor 657199 Flameout Sensor 903737 O-Ring (Flameout Sensor) 03656580 O-Ring ETC01463 O-Ring 102260 Air Baffle 657016 Jet Nut 102273 Gasket 657012 Jet Assembly 102256 Gasket 657005 Sample Jet 659614 Thermal Block Assembly 42716459 Spare Part Kit compl. (incl. ferrules) 9.7 cc/min @ 3.5 psig 657486 Capillary, Mixed Fuel (Lo) 9.7 cc/min @ 3.5 psig 42716460 Spare Part Kit compl. (incl. ferrules) 2.5 cc/min @ 3.5 psig 657550 Capillary, Mixed Fuel (Hi) 2.5 cc/min @ 3.5 psig 657061 Sample RTD 659618 Heated Bypass Sample Out Restrictor Assembly - 10 Microns 659615 Restrictor, Heated Bypass Sample Out - 10 Microns 659619 Heated Sample In Restrictor Assembly - 40 Microns 659616 Restrictor, Heated Sample In - 40 Microns 657065 Thermostat 232 °C (450 °F) 659643 Cartridge Heater Emerson Process Management GmbH & Co.OHG Replacement Parts 6-3 Instruction Manual NGA 2000 HFID 6-4 Replacement Parts HAS64E-IM-HW September 2008 Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SECTION 7 RETURN OF MATERIAL 7-1 RETURN OF MATERIAL If factory repair of defective equipment is required, proceed as follows: 1. 2. 3. Secure a return authorization from a Emerson Processs Management Sales Office or Representative before returning the equipment. Equipment must be returned with complete identification in accordance with Emerson instructions or it will not be accepted. In no event will Emerson be responsible for equipment returned without proper authorization and identification. Carefully pack the defective unit in a sturdy box with sufficient shock absorbing material to ensure no additional damage occurs during shipping. The completed and signed Declaration of Contamination (page S-2) must be included with the instrument (we recommend to attach it to the packaging outside)! 4. In a cover letter, describe completely: a. The symptoms that determined the equipment is faulty. b. The environment in which the equipment was operating (housing, weather, vibration, dust, etc.). c. Site from where the equipment was removed. d. Whether warranty or non-warranty service is expected. e. Complete shipping instructions for the return of the equipment. 5. Enclose a cover letter and purchase order and ship the defective equipment according to instructions provided in the Emerson Return Authorization, prepaid, to: In US: EMERSON Process Management Rosemount Analytical Inc. Customer Service Center USA: 1-800-433-6076 1-440-914-1261 In Europe: EMERSON Process Management GmbH & Co. OHG Service Department Deutschland D-63594 Hasselroth, Germany Industriestrasse 1 +49 6055 884-470/-472 Fax: -209 In Asia Pacific: EMERSON Process Management Asia Pacific Pte Limited Singapore +65-6-777-8211 If warranty service is expected, the defective unit will be carefully inspected and tested at the factory. If the failure was due to the conditions listed in the standard Emerson warranty, the defective unit will be repaired or replaced at Emerson´s option, and an operating unit will be returned to the customer in accordance with the shipping instructions furnished in the cover letter. For equipment no longer under warranty, the equipment will be repaired at the factory and returned as directed by the purchase order and shipping instructions. Emerson Process Management GmbH & Co.OHG Return of Material 7-1 Instruction Manual NGA 2000 HFID 7-2 HAS64E-IM-HW September 2008 CUSTOMER SERVICE For order administration, replacement parts, application assistance, on-site or factory repair, service or maintenance contract information, contact: EMERSON Process Management Process Analytic Division Customer Service Center USA: +1 (800) 433-6076 EU: +49 (6055) 884-470 7-3 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: EMERSON Process Management GmbH & Co. OHG D-63594 Hasselroth, Germany Industriestrasse 1 EU: +49 (6055) 884-470/-472 Fax: -469 EMERSON Process Management Rosemount Analytical Inc. Customer Service Center USA: +1 (800) 433-6076 7-2 Return of Materials Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID LIST OF FIGURES AND TABLES 1 LIST OF FIGURES Figure A-1: From separate analyzers to analyzer system ............................................................... A - 1 Figure A-2: Example of NGA cabling ............................................................................................... A - 2 Figure A-3: Example/Possibilities of NGA Analyzer System ............................................................ A - 3 Figure 1-1: Function Principle of FID Measurement ........................................................................ 1 - 2 Figure 1-2: HFID Analyzer Module - Flow Diagram ......................................................................... 1 - 3 Figure 1-3: HFID Analyzer Module - Top View ................................................................................. 1 - 4 Figure 2-1: Figure 2-2: Figure 2-3: Figure 2-4: Figure 2-5: Figure 2-6: Analyzer Module Installation into Instrument Platform (view without front panel) .......... 2 - 1 HFID Rear Panel Connections ...................................................................................... 2 - 3 Front Panel Electrical Connections................................................................................ 2 - 6 Front Panel Controls, Indicators and Electrical Connections ......................................... 2 - 6 HFID Wiring Diagram ..................................................................................................... 2 - 7 Outline and Mounting Dimensions ................................................................................. 2 - 8 Figure 3-1: Self Test Menu ............................................................................................................... 3 - 2 Figure 3-2: Miscellaneous Control Parameters ................................................................................ 3 - 3 Figure 3-3: Calibration Gas List ....................................................................................................... 3 - 5 Figure 3-4: Range Settings Menu .................................................................................................... 3 - 5 Figure 3-5: Calibration Parameters Display ..................................................................................... 3 - 6 Figure 3-6: Analyzer Module Factoring Data ................................................................................... 3 - 6 Figure 3-7: Basic Controls Menu ...................................................................................................... 3 - 7 Figure 3-8: Analyzer Zero Menu ...................................................................................................... 3 - 7 Figure 3-9: Analyzer Span Menu ...................................................................................................... 3 - 8 Figure 3-10: Measure Mode Display .................................................................................................. 3 - 9 Figure 3-11: Physical Measurements Display .................................................................................... 3 - 9 Figure 3-12: Excerpt of a Test Data Sheet with values that are to be compaired with .............................. physical measurements. .............................................................................................. 3 - 10 Figure 3-13: Front Panel Torque Sequence ..................................................................................... 3 - 11 Figure 3-14: Typical Curve of Module Response vs. Pressure Setting on Fuel Press. Regulator ... 3 - 12 Figure 3-15: Typical Curve of Module Response vs. Pressure Setting on Air Press. Regulator ...... 3 - 12 Figure 3-16: System SIO Module Menu ........................................................................................... 3 - 14 Figure 3-17: Analog Output Setup Menu ......................................................................................... 3 - 14 Figure 3-18: Analyzer Modules Menu ..............................................................................................3 - 14 Figure 3-19: Signals Menu ............................................................................................................... 3 - 15 Figure 3-20: Output Signal If Assigned Module Fails Menu ............................................................. 3 - 15 Figure 3-21: Special Scaling for Concentration Signal Menu ........................................................... 3 - 16 Figure 3-22: Analog Output Updates per Second Menu. ................................................................. 3 - 16 Emerson Process Management GmbH & Co.OHG List of Figures and Tables L-1 Instruction Manual NGA 2000 HFID HAS64E-IM-HW September 2008 Figure 3-23: Serial Interface Setup Menu ........................................................................................ 3 - 17 Figure 3-24: AK Protocol Definitions Menu ...................................................................................... 3 - 17 Figure 3-25: Relay Outputs Setup Menu .......................................................................................... 3 - 18 Figure 3-26: Choose Source Module Menu ..................................................................................... 3 - 18 Figure 3-27: Choose Signal Menu ................................................................................................... 3 - 18 Figure 4-1: Removal of Cover and Insulation Shield ........................................................................ 4 - 2 Figure 4-2: Location of Major Assemblies of the HFID Module ........................................................ 4 - 3 Figure 4-3: Removal of Oven from Chassis ..................................................................................... 4 - 4 Figure 4-4: Oven Assembly ..............................................................................................................4 - 5 Figure 4-5: Burner-Sensor, Flameout Detector, RTD Detector and Igniter ......................................4 - 7 Figure 4-6: Burner/Thermal Block Disassembly ............................................................................... 4 - 8 Figure 4-7: Burner Disassembly ....................................................................................................... 4 - 9 Figure 4-8: Burner Jets .................................................................................................................. 4 - 10 Figure 4-9: Thermal Block- Sample RTD, Cartridge Heater and Thermostat ................................ 4 - 12 Figure 4-10: Thermal Block Assembly .............................................................................................4 - 13 Figure 4-11: Removing Electronics Assembly from Chassis ............................................................ 4 - 14 Figure 4-12: Electronics Assembly - Exploded View ........................................................................ 4 - 15 Figure 4-13: Case Temperature Sensor Installation ......................................................................... 4 - 16 Figure 4-14: Case Pressure Purge Switch Installation ..................................................................... 4 - 16 Figure 4-15: Preamp Assembly Installation ...................................................................................... 4 - 17 Figure 4-16: Fan Assembly Installation ............................................................................................ 4 - 18 Figure 4-17: Flow Controller Replacement ...................................................................................... 4 - 19 Figure 4-18: Flow Controller Assembly ............................................................................................ 4 - 19 Figure 4-19: DC Power Supply Module Replacement ..................................................................... 4 - 20 Figure 4-20: Front Panel - Exploded View ....................................................................................... 4 - 21 Figure 4-21: Accessing Front Panel Components ........................................................................... 4 - 22 Figure 4-22: Rear Panel Components ............................................................................................. 4 - 25 Figure 4-23: Principle Leakage Test Assembly ................................................................................ 4 - 27 Figure 6-1: Name Plate Label .......................................................................................................... 6 - 1 2 LIST OF TABLES Table A-1: Possibilities of NGA 2000 I/O combinations ................................................................. A - 4 Table 1-1: Sample Capillary depending on Module Configuration ..................................................1 - 3 Table 3-1: Table 3-2: Typical Operation Pressures ..........................................................................................3 - 3 HFID Analyzer Module Alarms ..................................................................................... 3 - 13 Table 4-1: Leakage Test Specifications ........................................................................................ 4 - 27 L-2 List of Figures and Tables Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID SUPPLEMENT 1 EC DECLARATION OF CONFORMITY Emerson Process Management GmbH & Co.OHG Supplement S-1 Instruction Manual HAS64E-IM-HW September 2008 NGA 2000 HFID 2 DECLARATION OF CONTAMINATION Because of legal regulations and for the safety of Emerson Process Management employees and operating equipment, we need this „Declaration of Contamination“, signed by an authorized person, prior to processing your order. Ensure to include it with the shipping documents, or (recommended) attach it to the outside of the packaging. Instrument details Process details Analyzer model serial no. Temperature Pressure 9 Please check where applicable, include safety data sheet and, if necessary, special handling instructions ! This medium was used during Medium and concentration CAS No. toxic harmful corrosive flammable other 1) harmless Process Process cleaning Cleaning returned parts 1) e.g. explosive, radioactive, environmentally hazadous, of biological risk, etc. Declaration and Sender Data We hereby declare that the retumed parts have been carefully cleaned. To the best of our knowledge they are free from any residues in dangerous quantities. Company Contact Person / Function Adress Phone Location, Date S-2 Supplement Signature Emerson Process Management GmbH & Co.OHG Instruction Manual HAS64E-IM-HW September 2008 Emerson Process Management GmbH & Co.OHG NGA 2000 HFID Instruction Manual NGA 2000 HFID EUROPE Emerson Process Management GmbH & Co. OHG Industriestrasse 1 D-63594 Hasselroth Germany T +49 (6055) 884-0 F +49 (6055) 884-209 Internet: www.emersonprocess.de EUROPE, MIDDLE EAST, AFRICA Emerson Process Management Shared Services Limited Heath Place Bognor Regis West Sussex PO22 9SH England T +44-1243-863121 F +44-1243-845354 Internet: www.emersonprocess.co.uk NORTH AMERICA Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH 44667-0901 T +1 (330) 682-9010 F +1 (330) 684-4434 Internet: www.emersonprocess.com LATIN AMERICA Emerson Process Management Ltda. Avenida Hollingsworth, 325 Iporanga-SorocabeSP 18087-000 Brazil T:+55 (152) 38-3788 F:+55 (152) 38-3300 Internet: www.emersonprocess.com.br ASIA - PACIFIC Emerson Process Management Asia Pacific Pte. Ltd. 1 Pandan Crescent Singapore 128461 Tel +65 6777 8211 Fax +65 6777 0947 Internet: www.ap.emersonprocess.com © 2008 Emerson Process Management GmbH & Co.OHG HAS64E-IM-HW September 2008