Rosemount NGA 2000 PMD O2 Analyzer Module SW 2.2-Rev E Owner's manual

Rosemount
Brand
Rosemount
Model
NGA 2000 PMD O2 Analyzer Module SW 2.2-Rev E
Type
Owner's manual
NGA 2000
PARAMAGNETIC DETECTOR
ANALYZER MODULE
Rosemount Analytical
N
OTICE
The information contained in this document is subject to change without notice.
Rosemount Analytical's system of NGA 2000 Modular Gas Analyzers and Controllers are patented,
under U.S. Patent 5.787.015.
Manual Part Number 748330-E
June 2000
Printed in U.S.A.
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
Viton-A® is a registered trademark of E.I. duPont de Nemours & Co.
Paliney No. 7™ is a trademark of J.M. Ney Co.
C
ONTENTS
748330-E Rosemount Analytical June 2000
i
NGA 2000 Paramagnetic Detector
PREFACE
PURPOSE/SAFETY SUMMARY........................................................................P-1
GLOSSARY ......................................................................................................P-5
SPECIFICATIONS - PLATFORM.......................................................................P-7
SPECIFICATIONS - SAMPLE............................................................................P-7
SPECIFICATIONS - PHYSICAL.........................................................................P-7
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE....P-8
RETURNING PARTS TO THE FACTORY.........................................................P-8
TRAINING ......................................................................................................P-8
DOCUMENTATION............................................................................................P-8
COMPLIANCES .................................................................................................P-9
S
ECTION
1. I
NTRODUCTION
1.1 OVERVIEW..............................................................................................1-1
1.2 TYPICAL APPLICATIONS .......................................................................1-1
1.3 THEORY OF TECHNOLOGY...................................................................1-1
1.4 FEATURES ..............................................................................................1-2
S
ECTION
2. I
NSTALLATION
2.1 UNPACKING............................................................................................2-1
2.2 ASSEMBLY..............................................................................................2-1
2.3 LOCATION...............................................................................................2-2
2.4 GASES.....................................................................................................2-2
2.4.1 Requirements..............................................................................2-2
2.4.2 Connections................................................................................2-5
2.4.3 Leak Test....................................................................................2-5
2.5 ELECTRICAL CONNECTIONS................................................................2-5
C
ONTENTS
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June 2000 Rosemount Analytical 748330-ENGA 2000 Paramagnetic Detector
SECTION 3. STARTUP AND OPERATION
3.1 OVERVIEW ............................................................................................. 3-1
3.2 DISPLAYS ............................................................................................... 3-1
3.3 RUN MODE DISPLAY ............................................................................. 3-1
3.4 MENU DISPLAYS.................................................................................... 3-1
3.5 HELP DISPLAYS..................................................................................... 3-3
3.6 STARTUP PROCEDURE ........................................................................ 3-5
3.7 BINDING.................................................................................................. 3-5
3.8 CALIBRATION......................................................................................... 3-5
3.9 BACKGROUND GAS COMPENSATION................................................. 3-7
3.10 BAROMETRIC PRESSURE COMPENSATION .................................... 3-10
SECTION 4. MAINTENANCE AND TROUBLESHOOTING
4.1 OVERVIEW ............................................................................................. 4-1
4.2 PRINTED CIRCUIT BOARD REPLACEMENT........................................ 4-1
4.3 MODULE FAN REPLACEMENT.............................................................. 4-2
4.4 THERMAL FUSE REPLACEMENT ......................................................... 4-3
4.5 FLOW SENSOR REPLACEMENT .......................................................... 4-4
4.6 POWER FUSE REPLACEMENT............................................................. 4-4
S
ECTION
5.
REPLACEMENT
P
ARTS
5.1 REPLACEMENT PARTS......................................................................... 5-1
APPENDIX A. PMD IDENTIFICATION MATRIX
G
ENERAL
P
RECAUTIONS FOR
H
ANDLING AND
S
TORING
H
IGH
P
RESSURE
C
YLINDERS
W
ARRANTY
F
IELD
S
ERVICE AND
R
EPAIR
F
ACILITIES
C
ONTENTS
748330-E Rosemount Analytical June 2000
iii
NGA 2000 Paramagnetic Detector
FIGURES
1-1 Spherical Body in Non-Uniform Magnetic Field........................................1-2
1-2 Paramagnetic Detector Technology.........................................................1-3
2-1 Analyzer Module Installation into Instrument Platform .............................2-1
2-2 PMD Front Panel Connections.................................................................2-4
2-3 PMD Back Panel Connections .................................................................2-4
2-4 Interconnection of Typical Gas Manifold to PMD Analyzer Module..........2-5
2-5 PMD Wiring Diagram................................................................................2-6
2-6 Outline and Mounting Dimensions............................................................2-7
3-1 Run Mode Display....................................................................................3-3
3-2 Main Menu Display...................................................................................3-3
3-3 Basic Controls Menu................................................................................3-3
3-4 Expert Controls and Setup Menu .............................................................3-4
3-5 Technical Level Configuration Menu........................................................3-4
3-6 Typical Help Screen.................................................................................3-4
3-7 Display Screens (1 of 5)...........................................................................3-10
3-8 Display Screens (2 of 5)...........................................................................3-11
3-9 Display Screens (3 of 5)...........................................................................3-12
3-10 Display Screens (4 of 5)...........................................................................3-13
3-11 Display Screens (5 of 5)...........................................................................3-14
4-1 PMD Module - Major Components...........................................................4-2
4-2 Module Fan Assembly..............................................................................4-2
4-3 Detector Assembly...................................................................................4-3
TABLES
3-1 PMD Analyzer Module Alarms..................................................................3-2
3-2 Calibration Range for Various Zero Bases Operating Ranges.................3-6
3-3 Calibration Range for Various Suppressed Range Operations................3-6
3-4 Oxygen Equivalents of Common Gases...................................................3-10
C
ONTENTS
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June 2000 Rosemount Analytical 748330-ENGA 2000 Paramagnetic Detector
NOTES
P
REFACE
748330-E Rosemount Analytical June 2000
P-1
NGA 2000 Paramagnetic Detector
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.
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.
WARNING: ELECTRICAL SHOCK HAZARD
P
REFACE
P-2
June 2000 Rosemount Analytical 748330-ENGA 2000 Paramagnetic Detector
WARNING: POSSIBLE EXPLOSION HAZARD
WARNING: PARTS INTEGRITY
WARNING: POSSIBLE EXPLOSION HAZARD
WARNING: OVER-VOLTAGE SPIKING
CAUTION: PRESSURIZED GAS
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.
Note
Apply leak test liquid to cell or detectors only as a last resort.
Verify that all gas connections are made as labeled and are leak free. Improper
gas connections could result in explosion or death. See Section 2.4.3 for Leak
test procedure.
Tampering or unauthorized substitution of components may adversely affect
safety of this product. Use only factory documented components for repair
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.
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.
P
REFACE
748330-E Rosemount Analytical June 2000
P-3
NGA 2000 Paramagnetic Detector
CAUTION: HAND INJURY HAZARD
CAUTION: OVERBALANCE 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.
This Analyzer Module may tip instrument over if it is pulled out too far and the
Platform is not properly supported.
P
REFACE
P-4
June 2000 Rosemount Analytical 748330-ENGA 2000 Paramagnetic Detector
NOTES
P
REFACE
748330-E Rosemount Analytical June 2000
P-5
NGA 2000 Paramagnetic Detector
GLOSSARY
A
NALYZER
M
ODULE
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.
B
ACKPLANE
The interconnect circuit board which the Controller Board, Power Supply Board, I/O
Board(s) and Expansion Board(s) are plugged into the Backplane
C
ONTROL MODULE
The operator interface plus the Controller Board.
C
ONTROLLER
B
OARD
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.
D
ISTRIBUTION
A
SSEMBLY
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).
E
XPANSION
B
OARD
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 M
ODULE
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.
O
PERATOR
I
NTERFACE
The Display and Keyboard of the Platform.
P
REFACE
P-6
June 2000 Rosemount Analytical 748330-ENGA 2000 Paramagnetic Detector
P
LATFORM
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.
P
OWER
S
UPPLY
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.
P
RIMARY
V
ARIABLE
The measured species concentration value from an Analyzer Module.
S
ECONDARY
V
ARIABLE
The current status data placed on the network by an Analyzer Module. This includes
sample flow, source voltage and other diagnostic information.
S
OFTKEYS
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.
S
YSTEM
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.
P
REFACE
748330-E Rosemount Analytical June 2000
P-7
NGA 2000 Paramagnetic Detector
SPECIFICATIONS
MEASUREMENT SPECIES:
Oxygen
RANGES:
0 to 100% oxygen; four fullscale selections, including suppressed
zero ranges in 1% increments
R
EPEATABILITY
:
±1% of fullscale (at constant temperature)
M
INIMUM
D
ETECTABLE
L
EVEL
:
0.01% oxygen
N
OISE
:
<1% of fullscale, peak-to-peak; <±1% for suppressed ranges
LINEARITY:
±1% of fullscale
R
ESPONSE
T
IME
:
0 to 90% of fullscale in 20 seconds (±2 seconds)
D
RIFT
(Z
ERO AND
S
PAN
):
<±1% of fullscale/24 hours, <±2% of fullscale/week at constant
temperature;
<±2% of fullscale/24 hours, <±4% of fullscale/week of range for 99
to 100% (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 20 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%
S
PECIFICATIONS
- S
AMPLE
T
EMPERATURE
:
Non-flammable;: 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, titanium, Paliney No. 7, epoxy
resin, Viton A, platinum, nickel, rhodium and MgF
2
S
PECIFICATIONS
- P
HYSICAL
C
ASE
C
LASSIFICATION
:
General purpose for installation in weather-protected areas
D
IMENSIONS
:
See Outline and Mounting Dimensions, Figure 2-4
W
EIGHT
:
8 kg (17.6 lbs.
M
OUNTING
:
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).
P
REFACE
P-8
June 2000 Rosemount Analytical 748330-ENGA 2000 Paramagnetic Detector
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: 1-714-986-7600
FAX: 1-714-577-8006
D
OCUMENTATION
The following NGA 2000 Paramagnetic Detector instruction materials are available.
Contact Customer Service or the local representative to order.
748330 Instruction Manual (this document)
P
REFACE
748330-E Rosemount Analytical June 2000
P-9
NGA 2000 Paramagnetic Detector
COMPLIANCES
This product may carry approvals from several certifying agencies, including Factory
Mutual and the Canadian Standards Association (which is also an OSHA accredited,
Nationally Recognized Testing Laboratory), for use in non-hazardous, indoor locations
Rosemount Analytical Inc. has satisfied all obligations from the European
Legislation to harmonize the product requirements in Europe.
This product complies with the standard level of NAMUR EMC.
Recommendation (May 1993).
This product satisfies all obligations of all relevant standards of the EMC framework in
Australia and New Zealand.
NAMUR
N
9
6
APPROVED
FM
®
97-C219
P
REFACE
P-10
June 2000 Rosemount Analytical 748330-ENGA 2000 Paramagnetic Detector
NOTES
1
I
NTRODUCTION
748330-E Rosemount Analytical June 2000
1-1
NGA 2000 Paramagnetic Detector
1.1 OVERVIEW
This manual describes the Paramagnetic Detector (PMD) Analyzer Module of
Rosemount Analytical's NGA 200 Series of gas analysis components.
The 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 O
2
.
The entire Analyzer Module is designed as a slide-in module (if configured in stand-
alone instrument fashion), removable from the front of the Platform, with gas
connections made from the rear. All electronics relative to sample detection and
conditioning are included in this module.
1.2 TYPICAL APPLICATIONS
PMD Analyzer Module applications include:
• process control
• continuous emissions monitoring systems (CEMS)
• industrial gas production
• fermentation process monitoring
1.3 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.
I
NTRODUCTION
1-2
June 2000 Rosemount Analytical 748330-ENGA 2000 Paramagnetic Detector
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.
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.
See Figures 4-1, 4-2, and 4-3 for
component configuration.
F
IGURE
1-1. S
PHERICAL
B
ODY IN
N
ON
-
U
NIFORM
M
AGNETIC
F
IELD
1.4 FEATURES
Among the features incorporated into the PMD Analyzer Module is a flow splitter
(≈2:1) that allows for greater sample flow, decreased lag time and faster analyzer
response.
The "Time Alignment" feature can be used to delay sending the Primary Variable from
the PMD Analyzer Module for up to 30 seconds in 0.1 second intervals. This feature
allows Primary Variables form more than one PMD Analyzer Module to be "time
aligned" if necessary.
I
NTRODUCTION
748330-E Rosemount Analytical June 2000
1-3
NGA 2000 Paramagnetic Detector
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
I
NTRODUCTION
1-4
June 2000 Rosemount Analytical 748330-ENGA 2000 Paramagnetic Detector
N
OTES
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Rosemount NGA 2000 PMD O2 Analyzer Module SW 2.2-Rev E Owner's manual

Rosemount
Brand
Rosemount
Model
NGA 2000 PMD O2 Analyzer Module SW 2.2-Rev E
Type
Owner's manual
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