Rosemount NGA 2000 FRPMD O2 Analyzer Module SW 3.3-Rev A Owner's manual

F

AST

R

ESPONSE

P

ARAMAGNETIC

D

ETECTOR

A

NALYZER

M

ODULE

NGA2000

R

OSEMOUNT

A

NALYTICAL

748413-A

The information contained in this document is subject to change without notice.

This manual is based on the production version of the Fast Response Paramagnetic Detector Analyzer

Module. Hardware and/or software changes may have occurred since this printing.

Rosemount Analytical's NGA 2000 system of Modular Gas Analyzers and Controllers are patented,

under U.S. Patent 5.787.015.

Manual Part Number 748413-A

August 1999

Printed in U.S.A.

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

NOTICE

Viton-A® is a registered trademark of E.I. duPont de Nemours & Co.

Paliney No. 7™ is a trademark of J.M. Ney Co.

CONTENTS

748413-A

August 1999

i

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

P

REFACE

Purpose/Safety Summary.................................................................................1

Glossary ....................................................................................................4

Specifications...................................................................................................6

Specifications – Sample...................................................................................6

Specifications - Physical...................................................................................7

Customer Service, Technical Assistance and Field Service.............................8

Returning Parts to the Factory..........................................................................8

Training ....................................................................................................8

Documentation.................................................................................................9

Compliances ....................................................................................................9

S

ECTION

1. I

NTRODUCTION

1.1 Overview....................................................................................................1

1.2 Typical Applications...................................................................................1

1.3 Features....................................................................................................1

1.4 Theory of Technology................................................................................2

CONTENTS

748413-A

August 1999

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Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

S

ECTION

2. I

NSTALLATION

2.1 Unpacking................................................................................................. 5

2.2 Assembly.................................................................................................. 5

2.3 Location ................................................................................................... 6

2.4 Gases ...................................................................................................

2.4.1 Requirements................................................................................ 7

2.4.2 Connections.................................................................................. 10

2.4.3 Leak Test ..................................................................................... 10

2.5 Electrical Connections .............................................................................. 11

S

ECTION

3. S

TARTUP AND

O

PERATION

3.1 Overview................................................................................................... 13

3.2 Displays ................................................................................................... 13

3.3 Run Mode Display..................................................................................... 13

3.4 Menu Displays .......................................................................................... 15

3.5 Help Displays............................................................................................ 15

3.6 Startup Procedure..................................................................................... 18

3.7 Binding ................................................................................................... 18

3.8 Calibration................................................................................................. 19

3.9 Background Gas Compensation............................................................... 21

CONTENTS

748413-A

August 1999

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Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

S

ECTION

4. M

AINTENANCE AND

T

ROUBLESHOOTING

4.1 Overview....................................................................................................25

4.2 Printed Circuit Board Replacement...........................................................25

4.3 Flow Sensor Replacement ........................................................................26

4.4 Module Fan Replacement.........................................................................27

4.5 Power Fuse Replacement.........................................................................27

4.6 Thermal Fuse Replacement......................................................................28

S

ECTION

5. R

EPLACEMENT

P

ARTS

5.1 Replacement Parts....................................................................................31

A

PPENDIX

A. FR-PMD I

DENTIFICATION

M

ATRIX

General Precautions For Handling and Storing High Pressure Gas Cylinders

Warranty

Field Service and Repair Facilities

CONTENTS

748413-A

August 1999

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Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

F

IGURES

Figure 1-1. Spherical Body in Non-Uniform Magnetic Field.............................. 2

Figure 1-2. Paramagnetic Detector Technology................................................ 3

Figure 1-3. Fast Response Paramagnetic Detector Analyzer Module -

Top View....................................................................................... 4

Figure 2-1. Analyzer Module Installation into Instrument Platform.................... 5

Figure 2-2. FR-PMD Front Panel Connections ................................................. 9

Figure 2-3. FR-PMD Back Panel Connections.................................................. 9

Figure 2-4. Interconnection of Typical Gas Manifold to FR-PMD Analyzer

Module.......................................................................................... 10

Figure 2-5. FR-PMD Wiring Diagram................................................................ 11

Figure 2-6 Outline and Mounting Dimensions................................................... 12

Figure 3-1. Run Mode Display .......................................................................... 15

Figure 3-2. Main Menu Display......................................................................... 16

Figure 3-3. Basic Controls Menu....................................................................... 16

Figure 3-4. Expert Controls and Setup Menu.................................................... 16

Figure 3-5. Technical Level Configuration Menu .............................................. 17

Figure 3-6. Typical Help Screen........................................................................ 17

Figure 4-1. FR-PMD Module - Exploded View.................................................. 26

Figure 4-2. Module Fan Assembly.................................................................... 27

Figure 4-3. Power Fuse Location...................................................................... 27

Figure 4-4. Detector Assembly.......................................................................... 28

Figure 4-5. Detector - Exploded View ............................................................... 29

T

ABLES

Table 3-1. FR-PMD Analyzer Module Alarms................................................... 14

Table 3-2. Calibration Range for Various Zero Based Operating Ranges........ 20

Table 3-3. Oxygen Equivalents of Common Gases.......................................... 24

748413-A

August 1999

P1

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

PREFACE

PURPOSE/SAFETY SUMMARY

The purpose of this manual is to provide the procedures for the installation, operation and

maintenance of this NGA 2000 module.

Some sections may describe equipment not used in your NGA 2000 system configuration.

The user should become thoroughly familiar with the operation of this module before

operating it. Read this instruction manual completely.

To avoid explosion, loss of life, personal injury and damage to this equipment

and on-site property, all personnel authorized to install, operate and service

the this equipment should be thoroughly familiar with and strictly follow the

instructions in this manual. SAVE THESE INSTRUCTIONS.

If this equipment is used in a manner not specified in these instructions,

protective systems may be impaired.

DANGER is used to indicate the presence of a hazard which will cause severe personal

injury, death, or substantial property damage if the warning is ignored

WARNING is used to indicate the presence of a hazard which can cause severe personal

injury, death, or substantial property damage if the warning is ignored.

CAUTION is used to indicate the presence of a hazard which will or can cause minor

personal injury or property damage if the warning is ignored.

NOTE is used to indicate installation, operation, or maintenance information which is

important but not hazard-related.

WARNING: ELECTRICAL SHOCK HAZARD

Do not operate without covers secure. Servicing requires access to live parts

which can cause death or serious injury. Refer servicing to qualified personnel.

For safety and proper performance this instrument must be connected to a

properly grounded three-wire source of power.

748413-A

August 1999

P2

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

PREFACE

WARNING: POSSIBLE EXPLOSION HAZARD

This equipment is not designed for and should not be used in the analysis of

flammable samples. Use of this equipment in this way could result in explosion

and death.

WARNING: POSSIBLE EXPLOSION HAZARD

Verify that all gas connections are made as labeled and are leak free. Improper

gas connections could result in explosion or death.

NOTE

Apply leak test liquid to cell or detectors only as a last resort.

WARNING: PARTS INTEGRITY

Tampering or unauthorized substitution of components may adversely affect

safety of this product. Use only factory documented components for repair

WARNING: OVER-VOLTAGE SPIKING

If this Analyzer Module is used with a non-Rosemount Analytical power supply,

adding Rosemount Analytical PN 90331 Current Protector in series with the 24 V

positive line will prevent over-voltage spiking and resultant fuse blowing when

powering up the instrument.

CAUTION: PRESSURIZED GAS

This module requires periodic calibration with a known standard gas. See

General Precautions for Handling and Storing High Pressure Gas Cylinders in

the rear of this manual.

748413-A

August 1999

P3

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

PREFACE

CAUTION: HAND INJURY HAZARD

Do not place hands or fingers in Platform front handles when the front panel is

open. Dropping front panel while hand or fingers are inside either handle can

cause serious injury.

CAUTION: OVERBALANCE HAZARD

This Analyzer Module may tip instrument over if it is pulled out too far and the

Platform is not properly supported.

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August 1999

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Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

PREFACE

GLOSSARY

Analyzer Module

Self contained analysis modules that are designed to be installed into the NGA 2000

System. One Analyzer Module can be installed into a Single Enclosure containing the

Platform Module. Two Analyzer Modules can be installed into a Dual Enclosure. The

simplest NGA 2000 System consists of one Analyzer Module.

Backplane

The interconnect circuit board which the Controller Board, Power Supply Board, I/O

Board(s) and Expansion Board(s) are plugged into the Backplane

Control module

The operator interface plus the Controller Board.

Controller Board

The Controller Board in the Platform which runs the software program that operates the

Display, Keypad and Network Manager. The Controller Board plugs into the Backplane.

Distribution Assembly

The Distribution Assembly consists of the Backplane and the card cages in the Platform

Module that contain I/O Module(s) and Expansion Module(s).

Expansion Board

The Expansion Board performs special features not related to I/O functions. The Expansion

Board plugs into the Backplane from the Platform front.

I/O Module

An auxiliary module that provides some sort of interface to the outside world. I/O modules

may include analog outputs, relay contacts, and digital interfaces. In general, they are

mounted in platforms as options.

Operator Interface

The Display and Keyboard of the Platform.

748413-A

August 1999

P5

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

PREFACE

Platform

Any combination of the NGA case, the display and computer board, power supply, and I/O

modules. In general, it could be considered to be anything in the NGA system other than

the analyzer modules.

Power Supply

Any of a variety of components that provide conditioned power to other NGA 2000

components, from the Power Supply Board that plugs into the Backplane in a stand-alone

instrument to several larger ones that can power larger collections of modules and

components.

Primary Variable

The measured species concentration value from an Analyzer Module.

Secondary Variable

The current status data placed on the network by an Analyzer Module. This includes

sample flow, source voltage and other diagnostic information.

Softkeys

The five function keys located below the front panel display. The menu function for each

softkey is displayed directly above it and is controlled by the software.

System

A NGA 2000 System consisting of one (or more) Analyzer Modules, an optional Platform,

one or more optional I/O Boards, an optional Expansion Board and an optional

Supplemental Power Supply.

748413-A

August 1999

P6

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

PREFACE

SPECIFICATIONS

MEASUREMENT SPECIES:

Oxygen

R

ANGES

:

0 to 100% oxygen; four fullscale selections (for

suppressed ranges, consult factory)

REPEATABILITY:

±1% of fullscale (at constant temperature)

M

INIMUM

D

ETECTABLE

L

EVEL

:

0.01% oxygen

NOISE:

<1% of fullscale, peak-to-peak

L

INEARITY

:

±1% of fullscale

R

ESPONSE

T

IME

:

0 to 90% of fullscale in 2 seconds or less

D

RIFT

(Z

ERO AND

S

PAN

):

<±2% of fullscale/week of fullscale/week at constant

temperature;

<±1% of fullscale/24 hours of fullscale at constant

temperature

E

FFECT OF

T

EMPERATURE

:

<±1% of fullscale over any 10°C interval for rate of change no

greater than 10°C per hour

E

NVIRONMENT

:

Location - Class B controlled, indoor, non-hazardous

A

MBIENT

T

EMPERATURE

:

0 to 45°C (32 to 113°F)

E

FFECT OF

F

LOW

:

<1% of range when sample flow rate is changed by 100

ml/min.

P

OWER

R

EQUIREMENTS

:

24 VDC ±5%, 50 W max.; ripple and noise: <100 mV

peak-to-peak; line and load regulations: <±1%

SPECIFICATIONS – SAMPLE

T

EMPERATURE

:

10 to 66°C (50 to 150°F)

F

LOW

R

ATE

:

800 to 1400 ml/min.

E

XHAUST

P

RESSURE

:

-345 to 690 hPa-gauge (-5 to 10 psig)

P

ARTICLES

:

filtered to <2 microns

D

EWPOINT

:

below 43°C (110°F), no entrained liquid

M

ATERIALS IN

C

ONTACT WITH

S

AMPLE

:

Glass, 316 stainless steel, epoxy resin, Viton A,

platinum, polypropylene

748413-A

August 1999

P7

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

PREFACE

SPECIFICATIONS - PHYSICAL

C

ASE

C

LASSIFICATION

:

General purpose for installation in weather-protected

areas

D

IMENSIONS

:

See Outline and Mounting Dimensions, Figure 2-4

W

EIGHT

:

9 kg (19.8 lbs.)

MOUNTING:

Inside a Platform or custom-installed in a panel

M

AXIMUM

L

ENGTH OF

LON

C

ABLE

:

1600 m (1 mile) between Analyzer Module and Platform

See the Preface section of the Platform Components manual for specifications

regarding Platform-related components (e.g., case dimensions) and the Preface of

the I/O Module manual for specifications regarding I/O (e.g., relay outputs).

748413-A

August 1999

P8

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

PREFACE

CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE

For order administration, replacement Parts, application assistance, on-site or factory

repair, service or maintenance contract information, contact:

Rosemount Analytical Inc.

Process Analytical Division

Customer Service Center

1-800-433-6076

RETURNING PARTS TO THE FACTORY

Before returning parts, contact the Customer Service Center and request a Returned

Materials Authorization (RMA) number. Please have the following information when you

call: Model Number, Serial Number, and Purchase Order Number or Sales Order Number.

Prior authorization by the factory must be obtained before returned materials will be

accepted. Unauthorized returns will be returned to the sender, freight collect.

When returning any product or component that has been exposed to a toxic, corrosive or

other hazardous material or used in such a hazardous environment, the user must attach

an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification that the

material has been decontaminated, disinfected and/or detoxified.

Return to:

Rosemount Analytical Inc.

4125 East La Palma Avenue

Anaheim, California 92807-1802

TRAINING

A comprehensive Factory Training Program of operator and service classes is available.

For a copy of the Current Operator and Service Training Schedule contact the Technical

Services Department at:

Rosemount Analytical Inc.

Phone: 1-718-986-7600

FAX: 1-714-577-8006

748413-A

August 1999

P9

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

PREFACE

NAMUR

N

9

6

97-C219

DOCUMENTATION

The following Fast Response Paramagnetic Detector Analyzer Module instruction materials

are available. Contact Customer Service or the local representative to order.

748413 Instruction Manual (this document)

COMPLIANCES

This product may carry approvals from several certifying agencies, including Factory Mutual

and the Canadian Standards Association (which is also an OSHA accredited, Nationally

Recognized Testing Laboratory), for use in non-hazardous, indoor locations

Rosemount Analytical Inc. has satisfied all obligations from the European Legislation to

harmonize the product requirements in Europe.

This product complies with the standard level of NAMUR EMC. Recommendation (May

1993).

This product satisfies all obligations of all relevant standards of the EMC framework in

Australia and New Zealand.

®

NRTL /C

748413-A

August 1999

P10

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

PREFACE

NOTES

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

748413-A

August 1999

1

INTRODUCTION

1

1.1 OVERVIEW

This manual describes the Fast Response Paramagnetic Detector (FR-PMD) Analyzer

Module of Rosemount Analytical's NGA 200 Series of gas analysis components.

The FR-PMD Analyzer Module is designed to continuously determine the concentration of

oxygen in a flowing gaseous mixture. The concentration is expressed in ppm or percent

volume oxygen.

The 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

FR-PMD Analyzer Module applications include:

• engine exhaust (ICEE) analysis

• certain chemical production processes

1.3 FEATURES

Among the features incorporated into the FR-PMD Analyzer Module are:

• Improved shock and vibration resistance

• Insensitivity to sample flow variation

• Improved sample transport time

748413-A

August 1999

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Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

1

INTRODUCTION

Shaded

Pole

Piece

Sphere

(Magnetic Susceptibility = k

o

)

F

k

Sample Gas

(Magnetic Susceptibility = k

)

Note:

As percentage of oxygen in sample gas increases,

displacement force (F

k

) increases.

1.4 THEORY OF TECHNOLOGY

Oxygen is strongly paramagnetic (i.e., capable of becoming a temporary magnet when

placed in a magnetic field) while most other common gases are weakly diamagnetic (i.e.,

tend to be non-magnetic). See Figure 1-1.

The magnetic susceptibility of the flowing gas sample is sensed in the detector/magnet

assembly. As shown in Figure 1-2, a dumbbell shaped, nitrogen-filled, hollow gas test body

is suspended on a platinum/nickel alloy ribbon in a non-uniform magnetic field.

Because of a "magnetic buoyancy" effect, the spheres of the test body are subjected to

displacement forces, resulting in a displacement torque proportional to the magnetic

susceptibility of the gas surrounding the test body.

Measurement is accomplished by a null-balance system, whereby the displacement torque

is opposed by an equal and opposite restorative torque. The restoring current is

automatically maintained at the correct level by an electro-optical feedback system. A

beam of light from the source LED is reflected off the square mirror attached to the test

body onto a bi-cell (dual photodiode).

The current required to keep the test body to the null position is a linear function of the total

magnetic susceptibility of the sample gas.

F

IGURE

1-1. S

PHERICAL

B

ODY IN

N

ON

-U

NIFORM

M

AGNETIC

F

IELD

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

748413-A

August 1999

3

INTRODUCTION

1

F

IGURE

1-2. P

ARAMAGNETIC

D

ETECTOR

T

ECHNOLOGY

SIGNAL CONDITIONING

ASSEMBLY

Dual Photocell

Displacement

Torque

Restoring

Torque

Magnet

Platinum/Nickel Alloy

Suspension Ribbon

Balancing

Weight

Balancing Weight

Nitrogen-Filled Hollow Glass

Test Body

Mirror

Current Loop

TEST BODY DETAIL

Electromagnetic

Axis

Electromagnetic

Axis

Restoring

Current

Restoring

Current

Displacement

Torque

Restoring

Torque

DETECTOR/MAGNET

ASSEMBLY

Test Body

Shaded Pole Pieces (4)

LED Source

Restoring

Current

Span

Zero

SIGNAL OUTPUT

TO NETWORK

NULL BALANCE SYSTEM

748413-A

August 1999

4

Fast Response Paramagnetic Detector Analyzer Module

Rosemount Analytical NGA 2000

1

INTRODUCTION

PRESSURE

COMPENSATION

BOARD

NETWORK INPUT

DETECTOR

HOUSING

CASE

TEMPERATURE

SENSOR

FLOW SENSOR

COMPUTER

ANALYSIS BOARD

MODULE BOARD

F

IGURE

1-3. F

AST

R

ESPONSE

P

ARAMAGNETIC

D

ETECTOR

A

NALYZER

M

ODULE

- T

OP

V

IEW

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Rosemount NGA 2000 FRPMD O2 Analyzer Module SW 3.3-Rev A Owner's manual

Rosemount NGA 2000 FRPMD O2 Analyzer Module SW 3.3-Rev A Owner's manual

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