Rosemount NGA 2000 TFID Hydrocarbon Analyzer Module Hardware -2nd Ed. Owner's manual

www.EmersonProcess.com

Instruction Manual

Thermo Flame Ionization Detector

FID Analyzer or Analyzer Module (combined with NGA

2000 Platform, MLT or CAT 200)

2

nd

Edition 04/2008

Instruction Manual

90003806

04/2008

TFID Thermo Flame Ionization Detector Instruction Manual

90003806

04/2008

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

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.

1

st

Edition 06/1998

2

nd

Edition 04/2008

©

2008 by Emerson Process Management

CONTENTS

I

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Rosemount Analytical

Table of Contents

SAFETY SUMMARY S - 1

General S - 2

Gases and Gas Conditioning (Sample Handling) S - 3

Supply Voltage S - 4

Analyzer specific notes for the user S - 5

Additional notes for service / maintenance S - 6

Electrostatic Discharge S - 7

PREFACE P - 1

DESCRIPTION

1. Technical Description 1 - 1

1.1 Front View 1 - 1

1.2 Rear Panel 1 - 3

1.3 Internal Construction 1 - 4

1.3.1 Thermo-FID Assembly 1 - 5

1.3.2 Printed Circuit Boards 1 - 6

1.4 Applications 1 - 8

2. Theory of Technology and Operation 2 - 1

2.1 Measuring Principle 2 - 1

2.2 TFID Mode of Operation 2 - 3

2.3 Sample Gas Transport 2 - 4

3. (vacant)

4. (vacant)

CONTENTS

II

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OPERATION

5. Preparation 5 - 1

5.1 Installation Site 5 - 2

5.2 Gas Conditioning (Sample Handling) 5 - 3

5.3 Gases 5 - 4

5.3.1 Supply Gases 5 - 4

5.3.2 Gas Connections 5 - 5

6. Switching On 6 - 1

7. Switching Off 7 - 1

8.

- (vacant)

14.

MAINTENANCE

15. Opening the Housing 15 - 1

15.1 Housing Cover 15 - 1

15.2 Front Panel 15 - 1

16.

- (vacant)

18.

19. Cleaning of Housing Outside 19 - 1

CONTENTS

III

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TECHNICAL DATA 20 - 1

20.1 Housing 20 - 1

20.2 Ambient Conditions 20 - 2

20.3 General Specifications 20 - 3

20.4 Voltage supply 20 - 3

20.4.1 Electrical Safety 20 - 4

20.5 Response Factors 20 - 4

SUPPLEMEMT

21. Pin Assignments 21 - 1

21.1 230 or 115 Vac (Input and Output) 21 - 1

21.2 Pt 100 (external heater) 21 - 1

21.3 Option SIO (Standard Input/Output Module) 21 - 2

21.3.1 Analog Signal Outputs 21 - 2

21.3.2 Relay Outputs / Serial Interfaces 21 - 2

21.4 Option DIO (Digital Input/Output Module) 21 - 3

21.4.1 Wiring with external actors 21 - 4

21.5 COM - Ports (for service use only) 21 - 6

INDEX I - 1

List of Figures I - 4

CONTENTS

IV

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SAFETY SUMMARY

S - 1

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Safety Summary

Outside and/or inside TFID or at operation manual resp. different symbols gives you a hint to

special sources of danger.

Source of danger !

See Operation Manual!

High Voltage !

Electrostatic Discharge (ESD) !

Explosives !

Hot components !

Toxic !

Risk to health !

Analyzer specific notes for the user !

In operation manual we will give partly additional informations to these symbols.

Strictly follow these instructions please !

GENERAL

SAFETY SUMMARY

S - 2

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GENERAL

1. General

◆ The following general safety precautions must be observed during all phases of operation,

service and repair of this instrument !

Failure to comply with these precautions or with specific warnings elsewhere in this manual

violates safety standards of design, manufacture and intended use of this instrument !

Failure to comply with these precautions may lead to personal injury and damage to this

instrument !

◆ Fisher-Rosemount GmbH & Co. does not take responsibility (liability) for the customer´s

failure to comply with these requirements !

◆ Do not attempt internal service or adjustment unless other person, capable of rendering first

aid and resuscitation, is present !

◆ Because of the danger of introducing additional hazards, do not perform any unauthorized

modification to the instrument !

Return the instrument to a Fisher-Rosemount Sales and Service office for service or repair

to ensure that safety features are maintained !

◆ Instruments which appear damaged or defective should be made inoperative and secured

against unintended operation until they can be repaired by qualified service personnel.

SAFETY SUMMARY

S - 3

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GENERAL / GASES AND GAS CONDITIONING (SAMPLE HANDLING)

Operating personnel must not remove instrument covers !

Component replacement and internal adjustments must be made by qualified

service personnel only !

Read all operation manuals before attempting to operate with the instrument !

Be sure to observe the additional notes, safety precautions and warnings given

in the individual operation manuals (e. g. platform, analyzer modules and

I/O-modules) !

Do not operate the instrument in the presence of flammable gases or explosive

atmosphere without supplementary protective measures !

At heated components there could be exist hot components !

If any moisture or objects come into the internal of the instrument disconnect

power and all supply gases.

2. Gases and Gas Conditioning (Sample Handling)

Be sure to observe the safety regulations for the respective gases

(sample gas and test gases / span gases) and the gas bottles !

All pneumatic supplies and mains, especially the hydrogen mains, have to be

tight ! All gases used must have the right input pressure !

Inflammable or explosive gas mixtures must not be purged into the instrument

without supplementary protective measures !

To avoid a danger to the operators by explosive, toxic or unhealthy gas

components, first purge the gas lines with ambient air or nitrogen (N

2

) before

cleaning or exchange parts of the gas paths.

SAFETY SUMMARY

S - 4

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SUPPLY VOLTAGE

3. Supply Voltage

The socket outlet shall be installed near the equipment and shall be easily

accessible to disconnect the device from the socket outlet.

Verify before operation whether the line voltage stated on the label of the

instrument ore power supply agrees with that of your mains line!

Do not put any object on the supply voltage cable. Install the line voltage cable

in such a manner that nobody can step on it or fall over it.

Protect the line voltage and signal cables for damage and moisture ingress.

◆ This product is a Safety Class 1 instruments

This product is provided with a protective earth terminal.

To prevent shock hazard, the instrument chassis and cabinet must be connected

to an electrical ground. The instrument must be connected to the AC power

supply mains through a three-conductor power cable, with the third wire firmly

connected to an electrical ground (safety ground) at the power outlet.

If the instrument is to be energized via an external power supply, that goes for the

power supply too.

Any interruption of the protective (grounding) conductor or disconnection of the

protective earth terminal will cause a potential shock hazard that could result in

personal injury. Deliberate disconnection is inadmissible / prohibited !

SAFETY SUMMARY

S - 5

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4. Analyzer specific notes for the user

First of all operations unscrew transfer safety lock (knurled-head screws)

for the optional sucking pump of the analyzer (Item 5. of operation manual) !

The installation site for the instrument has to be dry and remain above freezing

point at all times.

The instrument must be exposed neither to direct sunlight nor to strong sources

of heat. Be sure to observe the permissible ambient temperature !

For outdoor sites, we recommend to install the instrument in a protective cabinet.

At least, the instrument has to be protected against rain (e.g., shelter).

Free flow of air into and out of the equipment must not be hindered by

nearby objects or walls !

For rack installation be sure, that the TFID has space on top and on bottom of

min. 1/2 HU to avoid overheating !

Do not interchange gas inlets and gas outlets !

All gases have to be supplied to the analyzer as conditioned gases !

When the instrument is used with corrosive gases, it is to be verified that there

are no gas components which may damage the gas path components.

The exhaust gas lines have to be mounted in a declining, descending,

pressureless and frost-free and according to the valid emission legislation !

In case it is necessary to open the gas paths, close the analyzers

gas connections with PVC caps immediatly !

Use only from our factory optional delivered cables or equivalent shielded cables

to be in agreement with the CE - conformity.

The customer has to guarantee, that the shield is be connected bothsided.

Shield and connectors housing have to be connected conductive.

Sub.-min.-D-plugs/sockets have to be screwed to the analyzer.

By using of optional delivering terminal strip adapters the analyzer is not be in

agreement with the CE - conformity. In this case CE - conformity is to be declared

by customer as “manufacturer of system”.

ANALYZER SPECIFIC NOTES FOR USER

SAFETY SUMMARY

S - 6

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Rosemount Analytical

5. Additional notes for service / maintenance

Operating personnel must not remove instrument covers !

Component replacement and internal adjustments must be made by qualified

service personnel only !

Always disconnect power, discharge circuits and remove external voltage

sources before troubleshooting, repair or replacement of any component !

Any work inside the instrument without switching off the power must be

performed by a specialist, who is familiar with the related danger, only !

In case of exchanging fuses the customer has to be certain that fuses of specified

type and rated current are used. It is prohibited to use repaired fuses or defective

fuse holders or to short-circuit fuse carriers (fire hazard).

In case of exchanging optional sucking pump, verify whether the line voltage

stated on the label of the TFID agrees with that of the sucking pump !

At component replacement or installation the RF shielding contacts must not be

bended !

ADDITIONAL NOTES FOR SERVICE / MAINTENANCE

SAFETY SUMMARY

S - 7

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Rosemount Analytical

5.1 Electrostatic Discharge

The electronic parts of the analyzer 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.

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).

ELECTROSTATIC DISCHARGE

SAFETY SUMMARY

S - 8

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P - 1

PREFACE

90003806(1) NGA-TFID e 16.06.98

Rosemount Analytical

Preface

The Thermo-FID (TFID) as member of the NGA 2000 familiy has all the advantages of a modular

analyzer system. A TFID Analyzer Module (AM) as “blind” analysis unit it can be part of a multiple

NGA analyzer system or special customer-developed control unit. TFID with front panel display/

operator interface is a stand-alone analyzer or central interface (control module) for multiple

analyzer modules.

The TFID is used in several areas of industry, safety of environment, research and develop-ment.

Typical applications are the LEL control, the emission and ambient air control or the exhaust gas

analysis in the chemistry and combustion engine development. But you can also use the TFID to

optimize a process or to control any limits at operating position.

A lot of auxiliary functions are available by the micro electronic of the TFID. The integrated CPU

allows the operation via menu, the automatic self control and error diagnostics. The display shows

all instruction notes and auxiliary reports in plain language. The very small currents of the FID

detector are always evaluated in the optimum range by the processor controlled dynamic amplifier.

The amplified signals will be digitalized directly at the detector and sent out to the CPU. So, a

falsification of the small detector signal will become impossible and the high resistant screened

cable will become unnecessary.

Technical Properties of Measurement

❏ Integrated licensed backfiring flame trap of the “Ex s IIC class”

❏ Electronic control of the sample gas flow

❏ Electronic control of the accelerating voltage

❏ Flame control with automatic ignition

❏ Electronic control of the ignition power

❏ Automatic calibration of the flame size

❏ Self calibration without any other valves or components

❏ Large range of linearization without switching of the coupling

❏ FID amplifier and A/D transformer are connected with the detector directly wireless

❏ Integrated thermic catalyst for burning air, zero gas and stripper

❏ Determination of organic carbon (org. C) in superheat vapor or condensate

❏ Determination of organically bound carbon down to LEL

❏ Determination of organically bound carbon according to “17

th

BImSchV” (in progress)

P - 2

PREFACE

90003806(1) NGA-TFID e 16.06.98

Rosemount Analytical

TECHNICAL DESCRIPTION

1 - 1

90003806(1) NGA-TFID e 22.06.98

Rosemount Analytical

1. Technical Description

All components of analyzer or analyzer module are incorporated into a 1/1 19" housing.

The housing is available as rack mounting (R) or as table-top (T) versions. For analyzer modules

there is mounted a blind plate instead of an operation front panel.

The Flame Ionization Detector (FID) is designed to continuously determine concentrations of

hydrocarbons.

The TFID offers the following Advantages:

a) The instrument is designed modular according to function groups resulting in:

❏ Easy troubleshooting

❏ Fast error removal

❏ High availability

b) The analyzer is sucking automatically sample gas via a pump system being installed behind

the detector.

c) The sample gas is sucked direct into the detector without using a superposed sample gas

pump. Therefrom:

❏ No heated sample gas pump

❏ No additional heating of sample gas inlet (or heated bypass as option)

❏ No “cold” connections leading to condensation; in that way avoiding corrosion and

signal falsification

❏ Fast response (to achieve values)

1.1 Front View

The front panel of the analyzer is the operating front panel (see Fig. 1-1).

Measured values and the entire operating procedure are displayed on a LC display. The operation

and programming of the instrument is performed by using the four cursor keys, the ENTER key

and the five soft keys

For analyzer modules there is mounted a blind plate instead of an operation front panel.

TECHNICAL DESCRIPTION

1 - 2

90003806(1) NGA-TFID e 16.06.98

Rosemount Analytical

Fastening screws for rack mounting or carrying-strap bracket

ENTER key

LC display

Cursor keys

Soft keys

(function is depending on Software Menu)

Fastening screws for rack mounting or carrying-strap bracket

Fig. 1-1: Operation front panel, Front view

FRONT PANEL

Fig. 1-2: TFID, Front view

optional Fan

(together with internal sucking pump option)

Blind plate or

operation front panel

TECHNICAL DESCRIPTION

1 - 3

90003806(1) NGA-TFID e 16.06.98

Rosemount Analytical

REAR PANEL

1.2 Rear Panel

On the rear panel the connector for 230 or 115 Vac supply, the gas connections, the network

connections and the connectors of optional PCBs (see optional, separate Operation Manuals) are

accommodated.

Fig. 1-3: TFID, Rear view

Network connection

(RJ 45 socket)

Input 230 or 115 Vac

Gas connections

(Item 5.3)

optional PCB

[SIO/DIO e.g.]

Connection Pump Control

for optional internal sucking pump

(Sub. Min. D. 9 pin)

Gas connections

(optional internal

sucking pump)

Output 230 or 115 Vac

(max. 4 A)

TECHNICAL DESCRIPTION

1 - 4

90003806(1) NGA-TFID e 22.06.98

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INTERNAL CONSTRUCTION

1.3 Internal Construction

By frontal view, the electronic unit with interconnection PCB and other PCBs is located on the right.

The analysis assembly and other parts are located on the left.

analysis assembly internal power supply optional I/O-boards

ACU PCB

sucking pump

(option)

front panel

Fig. 1-4: TFID, internal construction

PCB LEM 02

(network in)

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Rosemount NGA 2000 TFID Hydrocarbon Analyzer Module Hardware -2nd Ed. Owner's manual

Rosemount NGA 2000 TFID Hydrocarbon Analyzer Module Hardware -2nd Ed. Owner's manual

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