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R OSEMOUNT A NALYTICAL NGA2000
C
HEMILUMINESCENSE
D
ETECTOR
A
NALYZER
M
ODULE
748410-A
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.
Teflon is a Registered Trademark of E.I. duPont de Nemours and Co., Inc.
Kynar is a Registered Trademark of Atochem North America, Inc.
Manual Part Number 748410-A
August 1999
Printed in U.S.A.
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
C ONTENTS
P
REFACE
Purpose/Safety Summary.................................................................................P1
Glossary ....................................................................................................P5
Specifications - General....................................................................................P7
Specifications - Physical ...................................................................................P7
Specifications - Sample ....................................................................................P8
Specifications - Gas Connections.....................................................................P8
Customer Service, Technical Assistance and Field Service .............................P9
Returning Parts to the Factory ..........................................................................P9
Training ....................................................................................................P9
Documentation..................................................................................................P10
Compliances ....................................................................................................P10
S
ECTION
1. I
NTRODUCTION
1.1 Overview....................................................................................................1
1.2 Typical Applications ...................................................................................1
1.3 Theory of Technology ................................................................................1
1.4 Features ....................................................................................................2
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000 i
C ONTENTS
S
ECTION
2. I
NSTALLATION
2.1 Unpacking ................................................................................................. 5
2.2 Assembly................................................................................................... 5
2.3 Location .................................................................................................... 5
2.4 Gases .................................................................................................... 6
2.4.1 Overview ...................................................................................... 6
2.4.2 Connections................................................................................... 6
2.4.3 Specifications ................................................................................ 8
2.5 Electrical Connections............................................................................... 9
S
ECTION
3. S
TARTUP AND
O
PERATION
3.1 OVERVIEW............................................................................................... 13
3.2 Displays .................................................................................................... 13
3.2.1 Run Mode Display ......................................................................... 13
3.2.2 Menu Displays ............................................................................... 13
3.2.3 Help Displays................................................................................. 14
3.3 Startup Procedure ..................................................................................... 14
3.4 Binding .................................................................................................... 15
3.5 Calibration ................................................................................................. 17
3.6 Converter Temperature Adjustment Procedure ........................................ 18
3.7 Measurement of Converter Efficiency ....................................................... 20
3.7.1 Test Setup for Measurement of Conversion Efficiency.................. 20
3.7.2 Test Procedure .............................................................................. 20
3.7.3 Subnormal Conversion Efficiency.................................................. 22
3.7.4 Replacement of Converter............................................................. 24
3.7.5 Capillaries...................................................................................... 24
3.7.6 TEA Scrubber ................................................................................ 24
3.8 Routine Operation ..................................................................................... 25 ii
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
C ONTENTS
S
ECTION
4. M
AINTENANCE AND
T
ROUBLESHOOTING
4.1 Overview....................................................................................................27
4.2 Fuses ....................................................................................................27
4.3 Fans ....................................................................................................29
4.4 Converter ...................................................................................................29
4.5 Ozonator ....................................................................................................30
4.6 Printed Circuit Boards................................................................................30
4.7 Detector Disassembly................................................................................30
S
ECTION
5. R
EPLACEMENT
P
ARTS
5.1 Replacement Parts ....................................................................................35
A
PPENDIX
A. CLD I
DENTIFICATION
M
ATRIX
General Precautions for Handling an d Storing High Pressure Cylinders
Warranty
Field Service and Repair Facilities
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000 iii
C ONTENTS
F
IGURES
1-1 CLD Analyzer Module Flow Diagram .......................................................... 3
1-2 CLD Analyzer Module - Top View .............................................................. 4
2-1 Analyzer Module Installation into Instrument Platform ............................... 6
2-2 CLD Rear Panel Connections .................................................................... 7
2-3 Front Panel Controls and Electrical Connections....................................... 10
2-4 CLD Wiring Diagram .................................................................................. 11
2-5 Outline and Mounting Dimensions ............................................................. 12
3-1 Run Mode Display...................................................................................... 15
3-2 Main Menu Display..................................................................................... 15
3-3 Basic Controls Menu .................................................................................. 16
3-4 Expert Controls and Setup Menu ............................................................... 16
3-5 Technical Level Configuration Menu .......................................................... 16
3-6 Typical Help Screen ................................................................................... 17
3-7 Measuring Efficiency of NO2 to NO Converter........................................... 23
3-8 Conversion Efficiency as a Function of Converter Temperature................ 24
4-1 CLD Module Assembly............................................................................... 28
4-2 Converter Assembly................................................................................... 29
4-3 Detector Assembly ..................................................................................... 33
T
ABLES
2-1 Gas Specifications ...................................................................................... 7
3-1 CLD Analyzer Module Alarms ..................................................................... 14 iv
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
P REFACE
P
URPOSE
/S
AFETY
S
UMMARY
The purpose of this manual is to provide the procedures for the installation, operation and maintenance of the Platform and the System Accessories of the NGA 2000 System.
Read this instruction manual completely before attempting to install any components into the NGA 200 System.
WARNING: AUTHORIZED PERSONNEL
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 doors and 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.
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
P1
P REFACE
WARNING: TOXIC AND OXIDIZING GAS
This module generates ozone which is toxic by inhalation and is a strong irritant to throat and lungs. Ozone is also a strong oxidizing agent. Its presence is detected by a characteristic pungent odor.
The module's exhaust contains both ozone and nitrogen dioxide, both toxic by inhalation, and may contain other constituents of the sample gas which may be toxic. Such gases include various oxides of nitrogen, unburned hydrocarbons, carbon monoxide and other products of combustion reactions. Carbon monoxide is highly toxic and can cause headache, nausea, loss of consciousness, and death.
Avoid inhalation of the ozone produced within the module, and avoid inhalation of the sample and exhaust products transported within the module. Avoid inhalation of the combined exhaust products at the exhaust fitting.
Keep all tube fittings tight to avoid leaks. See section 2.4.3, page 9, for leak test information.
Connect rear exhaust outlet to outside vent with stainless steel or Teflon line.
Check vent line and connections for leakage.
WARNING: PARTS INTEGRITY
Tampering or unauthorized substitution of components may adversely affect safety of this product. Use only factory documented components for repair.
CAUTION: PRESSURIZED GAS
This module requires periodic use of pressurized gas. See General Precautions for Handling and Storing High Pressure Gas Cylinders at the rear of this manual
WARNING: OVERBALANCE HAZARD
This analyzer module may tip instrument over if it is pulled out too far and the
Platform is not properly supported.
P2
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
P REFACE
WARNING: INTERNAL ULTRAVIOLET LIGHT
Ultraviolet light from the ozone generator can cause permanent eye damage.
Do not look directly at the ultraviolet source. Use of ultraviolet filtering glasses is recommended.
WARNING: TOXIC CHEMICAL HAZARD
The ozone generator lamp contains mercury. Lamp breakage could result in mercury exposure. Mercury is highly toxic if absorbed through the skin or ingested, or if vapors are inhaled.
Handle lamp assembly with extreme care. If the lamp is broken, avoid skin contact and inhalation in the area of the lamp or the mercury spill.
Immediately clean up and dispose of the mercury spill and lamp residue as follows:
•
Wearing rubber gloves and goggles, collect all droplets of mercury by means of a suction pump and aspirator bottle with a long capillary tube. (Alternately, a commercially available mercury spill clean-up kit, such as J.T. Baker product
No. 4439-01, is recommended.)
•
Carefully sweep any remaining mercury and lamp debris into a dust pan.
Carefully transfer all mercury, lamp residue and debris into a plastic bottle which cab be tightly capped.
•
Label and return to hazardous material reclamation center. Do not place in the trash, incinerate or flush down the sewer.
•
Cover any fine droplets of mercury in non-accessible crevices with calcium polysulfide and sulfur dust
WARNING: HAND INJURY HAZARD
Do not place hands or fingers in the Platform front handles when front panel is open. Dropping the front panel of the Platform while hand or fingers are inside either handle can cause serious injury.
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
P3
P REFACE
WARNING: POSSIBLE EXPLOSION HAZARD
Ensure that all gas connections are made as labeled and are leak free.
Improper gas connections could result in explosion or death.
CAUTION: OVER-VOLTAGE SPIKING
If this analyzer module is used with a non-Rosemount Analytical power supply, adding Rosemount Analytical PN 903341 Current Protector in series with the 24V positive power line will prevent over-voltage spiking and resultant fuse blowing when powering up the instrument.
WARNING: POSSIBLE EXPLOSION HAZARD
This equipment is not designed and should not be used in the analysis of flammable samples. Use of this equipment in this way could result in explosion or death.
CAUTION: EXTERNALLY RESTRICT SAMPLE FLOW TO LESS THAN
2200 CC/MIN.
No restrictor is provided in the sample inlet of this module. For those users who cannot externally limit sample flow, accessory restrictor PN 657300 is available from Rosemount Analytical.
To obtain this accessory, call 800-441-7245.
P4
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
P REFACE
G
LOSSARY
Analyzer Module
The module that contains all sensor/detector components for development of a Primary
Variable signal; includes all signal conditioning and temperature control circuitry.
Backplane
The interconnect circuit board which the Controller Board, Power Supply, Analyzer Module power and network cables, I/O Modules and Expansion Modules plug into.
Control Module
The Operator Interface plus the Controller Board.
Controller Board
The computer board that serves as the Network Manager and operates the Display and
Keypad.
Distribution Assembly
The Backplane and the card cages that hold I/O and Expansion Modules.
Expansion Module
A circuit board that plugs into the Backplane from the front of the Platform and performs special features not related to I/O functions.
I/O Module
A circuit board that plugs into the Backplane from the rear of the Platform. Has a connector terminal for communication with external data acquisition devices and provides an input/output function.
Operator Interface
The Display and Keyboard.
Platform
Any workable collection of the following: Controller Board, Power Supply, Distribution
Assembly, Enclosure and Operator Interface.
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
P5
P REFACE
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.
Primary Variable
The measured species concentration value from an Analyzer Module.
Secondary Variable
Data placed on the network by a module regarding current status, e.g., sample flow, source voltage and other diagnostic information.
Softkeys
The five function keys located below the front panel display; they assume the function displayed directly above each on the display, a function dictated by software.
System
Any collection of Analyzer Module(s), Platform(s), I/O Module(s) and Expansion Module(s).
P6
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
P REFACE
S
PECIFICATIONS
- G
ENERAL
M
R
R
EASUREMENT
ANGES :
EPEATABILITY :
S
M IN . D ETECTABLE L EVEL :
N OISE :
L INEARITY :
R ESPONSE T IME :
PECIES :
NO, NOx
0 to 10 ppm through 0 to 10,000 ppm NO, NOx
±
0.5% of fullscale (at constant temperature)
0.1 ppm
<1% of fullscale, peak to peak
±
1% of fullscale
<1 sec. for 90% of fullscale for ranges of 25 ppm or greater
<3 sec. for 90% of fullscale for ranges of less than
25 ppm
<
±
1% of fullscale/24 hours, <
±
2% of fullscale/week Z ERO D RIFT :
( AT CONSTANT TEMPERATURE )
S PAN D RIFT :
( AT CONSTANT TEMPERATURE )
E FFECT OF T EMPERATURE :
A
P
MBIENT
OWER R
T EMPERATURE
EQUIREMENTS :
:
<
±
1% of fullscale/24 hours, <
±
3% of fullscale/week
<2% of fullscale (over any 10
°
C ambient temperature variation interval for a rate of change no greater than 10
°
C/hour)
0
°
C to 45
°
C (32
°
F to 113
°
F)
24V DC 120W
S
PECIFICATIONS
- P
HYSICAL
C ASE C LASSIFICATION :
D IMENSIONS :
W EIGHT :
M OUNTING :
M AX . L ENGTH OF LON
C ABLE :
General purpose for installation in weatherprotected area
See Outline and Mounting Dimensions, Figure 2-4
8.1 kg (18 lbs.)
Inside a Platform or custom-installed in a panel
1600m (1 mile) between Analyzer Module and
Platform
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
P7
P REFACE
S
PECIFICATIONS
- S
AMPLE
T EMPERATURE :
T OTAL F LOW RATE :
P ARTICLES :
D EWPOINT :
M ATERIALS IN CONTACT
WITH S AMPLE :
O ZONATOR G AS :
0
°
C to 55
°
C (32
°
F to 131
°
F)
(Externally measured) 900 to 2200 cc/min. with backpressure regulator pressure adjusted to 344 hPa
(5 psig)
Filtered to <2 microns
5.5
°
C below ambient temperature, no entrained liquid
Stainless steel, Teflon, glass, brass and neoprene
Optional: Stainless steel, Teflon, glass and Kynar
Clean, dry air or oxygen; flow rate: 1 L/min. maximum; pressure: 689 hPa to 1034 hPa-gauge (10 to 15 psig); maintain a constant pressure
±
34 hPa (
±
0.5 psig)
S
PECIFICATIONS
- G
AS
C
ONNECTIONS
O ZONE A IR :
E XHAUST :
S AMPLE I N :
1/4” O.D. tube fitting, brass
1/4” O.D. tube fitting, stainless steel
1/4” O.D. tube fitting, stainless steel
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).
P8
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
P REFACE
C
USTOMER
S
ERVICE
, T
ECHNICAL
A
SSISTANCE AND
F
IELD
S
ERVICE
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
R
ETURNING
P
ARTS TO THE
F
ACTORY
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
T
RAINING
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
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
P9
P REFACE
D
OCUMENTATION
The following Chemiluminescense Detector Analyzer Module instruction materials are available. Contact Customer Service or the local representative to order.
748410 Instruction Manual (this document)
C
OMPLIANCES
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.
FM
APPROVED
NRTL /C
®
97-C219
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).
NAMUR
This product satisfies all obligations of all relevant standards of the EMC framework in
Australia and New Zealand.
N96
P10
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
I NTRODUCTION
1
1.1 O
VERVIEW
This manual describes the Chemiluminescence (CLD) Analyzer Module of Rosemount
Analytical's NGA 2000 Series of gas analysis components (See Figures 1-1 and 1-2).
The CLD Analyzer Module is designed to continuously determine the concentration of nitric oxide and oxides of nitrogen (NO plus nitrogen dioxide [NO2]) in a flowing gaseous mixture.
The concentration is expressed in parts-per-million.
The CLD 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 T
YPICAL
A
PPLICATIONS
The CLD Analyzer Module has specific applications in the following areas:
•
Oxides of nitrogen emissions from the combustion of fossil fuels in:
•
Vehicle exhaust
•
Incinerators
•
Boilers
•
Gas
•
Turbine
Nitric acid plant emissions
De-NOx control system
Nitric oxide emissions from decaying organic material (e.g., landfills).
1.3 T
HEORY OF
T
ECHNOLOGY
The CLD Analyzer Module uses the chemiluminescence method of detection. This technology is based on NO's reaction with ozone (O
3
) to produce NO
2 and oxygen (O
2
).
Some of the NO
2
molecules thus produced are in an electronically excited state ((NO
2
* - the
"*" refers to the excitation)). These revert immediately to the ground state, with emission of photons (essentially, red light). The reactions involved are:
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
1
1
I NTRODUCTION
NO + O
3
→
NO2* + O
2
NO
2
*
→
NO
2
+ red light
As NO and O3 mix in the reaction chamber, the intensity of the emitted red light is measured by a photodiode and is proportional to the concentration of NO in the original gas sample.
To measure NOx (NO + NO
2
), any NO
2
in the sample is reduced to NO (at <95% efficiency) by being continuously passed through a heated bed of vitreous carbon (this occurs before the sample gas is presented to the ozone). Any NO initially present in the sample passes through this converter stage unchanged before being routed to the reaction chamber.
The photodiode generates a DC current, which is then amplified, conditioned and expressed on the network as the Primary Variable.
1.4 F
EATURES
Among the features included in the CLD Analyzer Module are: 1) ozonator air loss shutoff and 2) NO/NOx mode capability.
2
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
I NTRODUCTION
1
AIR RESTRICTOR
430cc/min @ 12 PSIG
BULKHEAD REDUCER
1/4T - 1/8T BRS
OZONE AIR
CROSS
1/8T BRS
MALE CONNECTOR
1/8T-3/8NPT BRS
ELBOW
116 ID VITON BLK
PRESSURE
SWITCH
PRESSURE SENSOR
30 PSIG AIR
CONNECTOR,
GLASS BLUE
1/8T-1/8MPT KYNAR
BYPASS
FLOW
SENSOR
TOP
NOx TO NO
CONVERTER
VALVE
NC NO
ELBOW
1/8T-1/8MPT
KYNAR
C
TEE 1/8T
KYNAR
FLOW
BALANCE
VALVE
CONNECTOR
1/8T-1/8NPT BRS
MALE CONNECTOR
1/8T-3/8NPT BRS
TEE ASSEMBLY
1/8T-1/4MPT
SAMPLE
BULKHEAD REDUCER
1/4T - 1/8T SS
TEE
1/4T - 1/8FPT SS
EXHAUST
BULKHEAD
1/4T SS
CONNECTOR
1/4T SS
ELBOW
1/8T - 1/8MPT
SS
1 70 cc/min. 5 psig Capillary: PN 659657
200 cc/min. 5 psig Capillary: PN 659658
BACK
PRESSURE
REGULATOR
REDUCER
1/4T - 1/8T SS
ELBOW
1/8T-1/4MPT
SS
TEE 1/8T
KYNAR
OZONE GENERATOR
CONNECTOR,GLASS
BLUE
VENT CAPILLARY
70cc/min 4 PSIG
CROSS
1/8T SS
PUMP CAPILLARY
1/8 OD TEFLON
TEE
1/8T
KYNAR
SAMPLE
PRESSURE
SENSOR
15 PSIG
CONNECTOR, MALE
1/8T-3/8MPT SS
ELBOW 1/8T
SS
1/8 OD SS
ELBOW 1/8T
SS
1/8 OD SS
REACTION
CHAMBER
OZONE
EXHAUST
1
REDUCING UNION
1/8T - 1/16T SS
SAMPLE
F IGURE 1-1. CLD A NALYZER M ODULE F LOW D IAGRAM
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
3
1
I NTRODUCTION
INLET/OUTLET
FITTINGS
FANS
NO2 TO NO
CONVERTER
DRIVER BOARD
OZONE
GENERATOR
3-WAY
SOLENOID VALVE
DETECTOR
SAMPLE
CAPILLARY
FLOW SENSOR
POWER SUPPLY
BOARD
FUSE
SIGNAL
BOARD
FLOW BALANCE
NEEDLE VALVE
COMPUTER
BOARD
NETWORK/POWER
CONNECTOR
SAMPLE BACKPRESSURE REGULATOR
F IGURE 1-2. CLD A NALYZER M ODULE - T OP V IEW
4
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
I NSTALLATION
2
2.1 U
NPACKING
If the Chemiluminescence (CLD) 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 CLD Analyzer Module are operational.
2.2 A
SSEMBLY
If the CLD Analyzer Module requires assembly with other components (e.g., the Platform and associated I/O Modules), do so at this time. Following the guides on the bottom left and bottom center of the Platform, carefully slide the Analyzer Module halfway into place.
CAUTION: HAND INJURY HAZARD
Do not place hands or fingers in the Platform front handles when front panel is open. Dropping the front panel of the Platform while hand or fingers are inside either handle can cause serious injury.
Lift the spring-loaded pins on the front of the Analyzer Module, and carefully slide it the rest of the distance. 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). 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.
Refer to Section 2-4 for electrical connections.
Install I/O Module(s) according to guidelines in the I/O manual. After startup and calibration have been performed, secure the front panel with the six screws provided.
2.3 L
OCATION
Install the CLD Analyzer Module in a clean, weather-protected, vibration-free location free from extreme temperature variations and moisture. For best results, install the instrument near the sample stream to minimize sample transport time.
The analyzer should be installed within
±
15
°
of horizontal.
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
5
2
I NSTALLATION
ANALYZER MODULE GUIDES
PIN SEATS
DISENGAGED FRONT PANEL
F IGURE 2-1. A NALYZER M ODULE I NSTALLATION INTO I NSTRUMENT P LATFORM
NOTE
Unrestricted air flow to the rear of the Analyzer Module is critical to its performance and reliability.
Operating ambient temperature is 0 o
C to 45 o
C (32 o
F to 113 o
F). Temperature change should not exceed 10 o
C (18 o
F) per hour. The same temperature range restrictions apply to the location of the air and span gas cylinders.
2.4 G
ASES
2.4.1 O VERVIEW
See Table 2-1. The CLD Analyzer Module requires two cylinder gases: 1) breathing grade air or oxygen and 2) a standard of accurately known composition for use as a span gas.
Each gas should be supplied from a cylinder equipped with a clean, non-corrosive, two-stage regulator. A shutoff valve is recommended.
2.4.2 C ONNECTIONS
(See Figure 2-2.) Connect inlet and outlet lines for sample, air, and exhaust to appropriately labeled fittings on the rear panel, each of which is a 1/4-inch ferrule-type compression fitting.
Stainless steel or Teflon tubing is recommended for the sample line. Exhaust tubing should be 1/4 inch (6.3 mm) or larger, and made of stainless steel or Teflon.
6
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
I NSTALLATION
2
MAXIMUM NOX
LEVEL IN PARTS
PER MILLION
800
2,500
10,000
GAS SUPPLIED TO
REAR PANEL AIR
INLET
Air
Air
Oxygen
SETTING ON OZONE
PRESSURE GAUGE
(PRESSURE VALUES:
GAUGE)
690 hPa (10 psig); provides flow of approximately 500 cc/min. to ozone generator
690 hPa (10 psig); provides flow of approximately 1000 cc/min. to ozone generator.
1035 hPa (15 psig); provides flow of approximately 1000 cc/min to ozone generator.
SETTING ON SAMPLE
PRESSURE GAUGE
(PRESSURE VALUES:
GAUGE)
344 hPa (5 psig); provides flow of approximately 200 cc/min. to reaction chamber
344 hPa (5 psig); provides flow of approximately 70 cc/min to reaction chamber.
103 hPa (1.5 psig); provides flow of approximately 20 cc/min.
to reaction chamber.
CAUTION: EXTERNALLY LIMIT SAMPLE FLOW RATE TO LESS THAN 2200 CC/MIN.
T ABLE 2-1. G AS S PECIFICATIONS
EXHAUST OZONATOR AIR
EXHAUST FAN SAMPLE IN
F IGURE 2-2. CLD R EAR P ANEL C ONNECTIONS
INTAKE FAN
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2
I NSTALLATION
2.4.3 S PECIFICATIONS
Calibration Gases
Either U.S.P. breathing grade air or nitrogen is recommended for use as zero gas. A mixture of NO or NO
2
in a background of nitrogen is recommended as span gas. For maximum accuracy, the concentration of NO in the span gas should be about the same as that in the expected sample stream.
Ozonator Source Gas
For analyzers with ranges less than 0 to 2,500 ppm, U.S.P. breathing grade air should be used for generation of the ozone required for the chemiluminescence reaction. For ranges greater than 0 to 2,500 ppm, breathing grade oxygen is required.
Sample
The sample must be clean and dry before entering the Analyzer Module. Sample should be filtered for particulates down to two microns, and should have a dew point 5 o
C (13 o
F) below coldest ambient temperature.
NOTE components may occur if this flow level is exceeded.
CAUTION: EXTERNALLY RESTRICT SAMPLE FLOW TO LESS THAN
2200 CC/MIN.
No restrictor is provided in the sample inlet of this module. For those users who cannot externally limit sample flow, accessory restrictor PN 657300 is available from Rosemount Analytical.
To obtain this accessory, call 800-441-7245.
Pressure
Between 690 and 1035 hPa-gauge (10 and 15 psig) of ozonator air (or oxygen, if appropriate) should be present at the rear panel of the module. Bypass sample gas flow rate should be between 700 and 2000 cc/min. with backpressure regulator pressure (see
Capillary Pressure in Current Measurement Parameters menu, which can be viewed by selecting the PARMS softkey in Main Menu) adjusted to 344 hPa (5 psig).
Zero/span gases should be introduced at the SAMPLE IN fitting at normal sample inlet flow rate.
8
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
I NSTALLATION
2
NOTE
At no time should ozonator gas pressure exceed 2070 hPa-gauge (30 psig).
Damage to internal components may occur if this pressure level is exceeded.
Leak Test
The CLD Analyzer Module is completely tested at the factory for gas leakage. The user is responsible for testing for leakage only at the inlet and outlet fittings on the rear panel.
Periodically, the user should do an internal leak test (with a test procedure chosen by the user).
Contaminants
White crystal deposits on the windows of the reaction chamber, and the clogging of capillaries and vent are usually due to sample contaminates such as ammonia reacting with the high ozone levels and NO components.
To eliminate the contaminates, the sampling system should be reworked or a preventive maintenance program developed (if dropout is not excessive). Another source of crystalline formation is contaminated air.
2.5 E
LECTRICAL
C
ONNECTIONS
NOTE
Electrical installation must be in compliance with National Electrical Code
(ANSI/NFPA 70) and/or any applicable national or local codes.
Refer to Figure 2-3. 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. Interconnection with the Backplane of the Platform. (See instruction manual for the NGA
2000 Platform).
2. "Daisy-chaining" with other NGA 2000 components.
Connect Analyzer Module POWER to 24 VDC, 120 Watt power source, either the Platform or external power source.
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2
I NSTALLATION
Regulator Adjust
Slot
Metering Valve
Sample
Regulator
Flow
LON
1
CLD
Balance
LON
2
1 +
2 -
24V
3 GND
T 6A
250 V
Network1 Connection
Network2 Connection
Power Connection
Fuse
F IGURE 2-3. F RONT P ANEL C ONTROLS AND E LECTRICAL C ONNECTIONS
10
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
I NSTALLATION
2
POWER SUPPLY BOARD-LON/POWER
MODULE ASSEMBLY 657510
J1 J2
J5
LON/PWR MODULE
656761
3 2 1
J3
E2
E3
E1
RED
HARNESS, EXPANSION I/O 655249
NC
1
J1
1
1
J4
1
J2
1
J3
J5
1
J6
COMPUTER ANALYSIS BOARD 655520
J7
1
2
3
RED
CABLE, INTERNAL NETWORK 903035
HARNESS, SIGNAL POWER 655252
J3
J5
BLK
WHT
J6
3
2
5
4
1
J8
SIGNAL BOARD 655580
J9
J1
J13 1 2 3 4 5 6 7 8 9
*COAX
CABLE
CABLE, CONTROLLER PWR 903034
7
1
NC
J6
1
1 2
2
J13
8
2
J1
9
10
12
POWER SUPPLY
BOARD 657520
3
J2
1
2
3
J11
BLK
GRN
ORN
7
1
10
J3
6
1
12
CABLE, FLOW SENSOR 655384
RED
FLOW
SENSOR
902931
PRESSURE
SWITCH
(NO) 8 PSIG
655215
WHT BLK
SAMPLE
PRESSURE
SENSOR
655253
SAMPLE
PRESSURE
SENSOR
655254
J4 J11
1 4 5 6 1 2 3 6
J7
8 7 6 1
J2
HARNESS, DRIVER POWER 655243
HEATER/THERMOSTAT ASSEMBLY 655235
RED WHT
HEATERS
DETECTOR
658160
THERMOSTAT
NO/NOx
SOLENOID
655263
WHT
CONVERTER TEMPERATURE
SENSOR 655282
THERMOSTAT
657298
OZONATOR
POWER
SUPPLY
657716
JUMPER
657162
CONVERTER
655250
SHLD
OZONATOR
659494
TRANSISTOR
2SD1308
655264
E
C
B
B = YEL
C = RED
E = BLU
4 3 1
J10
BLK
RED
2
1
2
1
4
3
BLK
RED
3
4
3
2
1
J2
J1
WHT 2 1
WHT
BRN
BRN
2 1
ORN
ORN
4
3
2
1
RED
WHT
BLU
RED
YEL
3
2
5
4
1
BRN
YEL
4
3
2
1
12
3
4
5
1
2
6
7
8
J9
J5
J4
J3
J8
J12
3
DRIVER BOARD
655620
10
1
2
1
J11
J2 10 2 J6 24
FAN 655245 FAN 655245
F IGURE 2-4. CLD W IRING D IAGRAM
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Rosemount Analytical NGA 2000
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2
I NSTALLATION
4.3
[109]
2.5
[64]
1.5
[38]
4.1
[104]
8.4
[213]
8.2
[208]
6.1
[155]
.4
[10]
.7
[18]
.8
[20]
2.8
[71]
1.1
[28]
6.0
[152]
17.5
[445]
.5
[13]
[104]
Dimensions:
INCHES
[MM]
1.3
[33]
.9
[23]
.9
[23]
F IGURE 2-5. O UTLINE AND M OUNTING D IMENSIONS
12
Chemiluminescense Detector Analyzer Module
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1.3
[33]
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3.1 OVERVIEW
Prior to initial startup, the user should leak test the module as outlined in Section 2.
For the remainder of this section, Analyzer Module interconnection with a Platform or some interfacing component will be assumed. Display and Keypad information shall refer to that which the user can expect to see and do with regard to the Front Panel of the Platform. (For a complete description of Platform Front Panel controls and indicators, see Section 1 of the
Platform Components instruction manual.)
3.2 D
ISPLAYS
Three kinds of Display screens are available to the user (see Figures 3-1 through 3-6.):
•
Run
•
Menu
•
Help
3.2.1 R UN M ODE D ISPLAY
The Run Mode is the normal mode of operation. In this mode, the Display will show current gas measurement, the component of interest, the current operations of the softkeys, and a graphic bar representing the displayed concentration as a percent of fullscale.
3.2.2 M ENU D ISPLAYS
The Menu structure enables the user to access data and functions, and put information onto the network. From the Run Mode display, press the MENUS softkey to gain access to the
Main Menu.
The Main Menu (see Figure 3-2) is subdivided into three levels of control based generally on which personnel is likely to use it: Basic Controls, Expert Controls and Setup, and Technical
Controls. (See Figures 3-3 through 3-5.) Many layers of the menu structure are described at appropriate places throughout this manual.
From the Run Mode display, press the MENUS softkey to gain access to the Main Menu.
(See Figure 3-2.)
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DISPLAY MESSAGE
BAROMETER
BLOCK FET
BLOCK THRESH
BLOK TEMP
CONV FET
CONV TEMP
CRUDE NOISE
LIN ERROR
N15 VOLTS
OZON PRES
P10 VOLTS
P12 VOLTS
P15 VOLTS
P24 VOLTS
P5 VOLTS
RAW SIGNAL
SAMP PRES
SVFLOW
PELT TEMP
SW ERROR
DESCRIPTION
System Barometer
Heater Current
CLD Threshold Temperature
Block Temperature
Converter Heater Temperature
Converter Temperature
Calculated Noise
Linearizer Error
Power Supply, -15V
CLD Ozone Supply Pressure
Power Supply, +10V Ref
Power Supply, +12V
Power Supply, +15V
Power Supply, +24V
Power Supply, +5V
Raw Signal
Sample Pressure
Sample Bypass Flow
CLD Peltier Cooler Temperature
Software Error
T ABLE 3-1. CLD A NALYZER M ODULE A LARMS
TYPE
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
FAILURE
FAILURE
3.2.3 H ELP D ISPLAYS
The Help structure is on-line "tutorial," context-sensitive and topic-interconnected, so that the user can practically operate NGA 2000 without need of an instruction manual. Press the
INFO softkey for help. (See Figure 3-6.)
3.3 S
TARTUP
P
ROCEDURE
Apply power to the CLD 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 CLD Analyzer Module will be energized.
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.
14
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After the warm-up period (about one hour for the CLD Analyzer Module), all modules are completely functional. Establish that correct ozonator air pressure and sample flow rate are within specifications (see the Specifications page in the Preface section of this manual).
Calibrate and adjust converter efficiency, and begin routine operation as the following sections indicate.
3.4 B
INDING
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.
Analyzer PQ 322-14
23.2 ppm NO
0 ppm
Secondary Variable: XXXX
Secondary Variable: XXX
Secondary Variable: XXXX
Secondary Variable: XXXX
50
Display Parms. Menu Dual Info
F1 F2 F3 F4 F5
F IGURE 3-1. R UN M ODE D ISPLAY
23.2 ppm NO Analyzer XXXXXXXX
Main Menu
Basic Controls
Expert controls and setup ...
(Operational configuration)
Technical level configuration ...
(Diagnostic and manufacturing/service)
Delete alarm message!
Display Parms. Info
F1 F2 F3 F4 F5
F IGURE 3-2. M AIN M ENU D ISPLAY
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Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
15
3
S TARTUP AND O PERATION
23.2 ppm NO Analyzer XXXXXXXX
Basic Controls
Measurement range Numbers:
Range upper limit: 10 ppm
Range and functional control: Local
Calibration…
Measurement mode: NO
Ozonator status: Powered
Status: Ready
Home NO/NOx Zero Span Info
F1 F2 F3 F4 F5
F IGURE 3-3. B ASIC C ONTROLS M ENU
23.2 ppm NO Analyzer XXXXXXXX
Expert controls and setup
Expert analyzer controls ...
Auxiliary module controls ...
System set up ...
Analyzer module set up ...
Auxiliary module set up ...
Home Escape Info
F1 F2 F3 F4 F5
F IGURE 3-4. E XPERT C ONTROLS AND S ETUP M ENU
23.2 ppm NO Analyzer XXXXXXXX
Technical configuration menu
System set up ...
Service menus...
Diagnostic menus...
Other module diagnostic menus...
listing of all modules...
Status: normal
Home Info
F1 F2 F3 F4 F5
F IGURE 3-5. T ECHNICAL L EVEL C ONFIGURATION M ENU
16
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
S TARTUP AND O PERATION
3
23.2 ppm NO Analyzer XXXXXXXX
Main Menu Help
The Main Menu for the analyzer system.
Note that this menu refers to the particular analyzer selected from the run screen, when used in a system. The softkey marked “HOME” will always return you to this screen.
Help menu system...
Help on help...
Keyboard controls...
Editing controls...
Home Escape Map
F1 F2 F3 F4 F5
F IGURE 3-6. T YPICAL H ELP S CREEN
3.5 C
ALIBRATION
Under the Expert Controls and Setup menu, use the
↓
arrow key to select Analyzer Module
Setup, then select Calibration Gas List. Input appropriate data here.
Under the Expert Controls and Setup menu, select Expert Analyzer Controls and then
Range Settings. Select the range that will be used during sample analysis.
Introduce zero gas into the SAMPLE INLET, and, after a stable reading is reached, do the following:
1. If the multi-Analyzer Module, split Run Mode display is shown, use the arrow keys to highlight the Analyzer Module to be calibrated and press the select key. The desired
Analyzer Module's Run Mode display is then shown.
2. Press the MENUS softkey to enter the Main Menu.
3. Make the following selections from the Main Menu: Expert Controls and Setup, Expert
Analyzer Controls, and Zero/Span Calibration.
4. Press the ZERO softkey to enter the Analyzer Zero menu.
5. Press the ZERO softkey and wait.
6. Introduce a suitable span gas into the SAMPLE INLET.
7. Press the SPAN to enter the Analyzer Span menu, press SPAN again and wait.
8. Press the HOME softkey to re-enter the Main Menu.
9. Press DISPLAY softkey for the Run Mode display.
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Chemiluminescense Detector Analyzer Module
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3
S TARTUP AND O PERATION
It is recommended, after initial startup, that the CLD Analyzer Module is calibrated at least once every eight hours. This practice should continue until experience indicates that some other interval is more appropriate depending on the analytical accuracy required.
If the user is unable to calibrate the Analyzer Module (i.e., when ZERO or SPAN is initiated, nothing happens), a possible 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.
To remedy the problem, do the following:
1. Select the following from the Main Menu: Expert Controls and Setup, Analyzer Module
Set Up, and Calibration Parameters.
2. Using the
↓
arrow, select Zero Ranges, press ENTER and, using the up/down arrows, toggle to SEPARATE. Do the same for the Span Ranges selection. Do not press
ESCAPE at any time unless retention of prior settings is desired.
3. Return to the Main Menu and make the following selections: Expert Controls and Setup,
Expert Analyzer Controls, Zero/Span Calibration, FACTORS softkey, and Range 1 (2, 3,
4) Factors (do Steps 4 and 5 for each range).
4. Select Zero Offset, press ENTER, adjust the value to 32700 with the
↑
and
↓
arrow keys, and press ENTER. Do not press ESCAPE at any time unless retention of prior settings is desired.
5. Select Span Factor, press ENTER, adjust the value to 0.00015 with the
↑
and
↓
arrow keys, and press ENTER. Do not press ESCAPE unless retention of prior settings is desired.
6. Attempt to recalibrate the Analyzer Module according to the procedure outlined at the beginning of Section 3.4. If recalibration fails, return to the Range Factors menu, readjust
Zero Offset and Span Factor values, and try calibrating again.
3.6 C
ONVERTER
T
EMPERATURE
A
DJUSTMENT
P
ROCEDURE
18
The vitreous carbon converter used in this analyzer module must be checked periodically to assure that it is working at peak efficiency. The efficiency of the converter is typically 95% to
98%, that is, 95% to 98% of the nitrogen dioxide introduced to the module is reduced to nitric oxide. That is well above the 90% minimum required by the Environmental Protection
Agency. (Refer to 40 CFR 60, App. A, Method 20, Paragraph 5.6.)
Two conditions reduce the efficiency of the converter:
•
the converter is operating at too low a temperature and the efficiency drops or
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
S TARTUP AND O PERATION
3
•
the converter is operating at too high a temperature and the nitrogen dioxide is reduced to nitrogen, which is not detectable by the chemiluminescence reaction.
Initially, an interval of one week between converter efficiency checks is recommended because high temperature operation changes conditions inside the converter. The active surface area of the vitreous carbon increases through use. Initially, when the surface area is low, the temperature at which converter efficiency peaks is relatively high. This peak temperature moves downscale as surface area increases, and less external energy is required to cause adequate conversion.
The nominal range of converter operational temperatures is 300
°
C to 400
°
C (572
°
F to
752
°
F). The current converter temperature can be located in the Physical Measurement menu by selecting the following from the Main Menu: Expert Controls and Setup, Analyzer
Module Setup and Physical Measurement Parameters.
Follow this procedure to optimize the operating temperature of the converter:
1. Power up the module and allow it to stabilize at operating temperature (about one hour).
2. Check the Converter Temperature in the Physical Measurements menu (as noted above). Note the value for future reference.
3. Introduce a calibration gas of known (NO
2
) concentration into the analyzer and note the concentration value determined when the full response has been achieved.
4. Change Converter Setpoint in the Temperature Control menu to 300
°
C by selecting the following from the Main Menu: Technical Configuration Menu, Diagnostic Menus,
Analyzer Module Diagnostics, Temperature Control Parameters. Allow module 15 minutes to stabilize, recheck the concentration value and note the value for later use.
5. Increase the Converter Setpoint value by 20
°
C, wait 15 minutes, and note the concentration value. Repeat this step until either a converter efficiency of between 95% and 98% is obtained or the final 20
°
C increment produces an efficiency increase of less than one percent.
6. Decrease the Converter Setpoint value by 5
°
C, which places the converter at a temperature suitable for low ammonia interference and efficient NO
2
conversion.
7. Recheck the Converter Temperature value in the Physical Measurements menu, and compare it to the initially recorded value.
NOTE
Converter temperature is not a direct measure of converter efficiency.
Temperature measurement is for reference purposes only.
748410-A
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Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
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3
S TARTUP AND O PERATION
3.7 M
EASUREMENT OF
C
ONVERTER
E
FFICIENCY
It is the responsibility of the user to measure efficiency of the NO
2
-to-NO converter during initial startup and thereafter at intervals appropriate to the application (normally once a month).
The reactant material used in the converter provides the optimum combination of high conversion efficiency and low ammonia interference. Unlike most competitive analyzers, the
NGA 2000 CLD Analyzer Module utilizes a reactant material that gradually becomes more efficient at a given temperature. Thus, after a period of use, operation at a lower temperature setpoint than initially required is certain.
3.7.1 T EST S ETUP FOR M EASUREMENT OF C ONVERSION E FFICIENCY
A typical setup for measurement of conversion efficiency is shown in Figure 3-7. The test setup includes:
A cylinder of nitric oxide standard gas consisting of NO in N
2
The concentration of NO in the standard gas should be about the fullscale value of the range under test. The test sample supplied to the analyzer should contain a concentration of
NO comparable to that in the samples that are to be analyzed. Alternatively, a higher concentration NO standard may be used if the test setup includes provision for diluting it appropriately with zero air. Suitable standard gases are available from various suppliers.
Stainless steel cylinders are commonly used, but specially treated aluminum is preferred for low parts-per-million NO samples.
20
An ozone generator utilizing an ultraviolet lamp, not a corona discharge
A corona discharge ozone generator is undesirable because it may produce oxygen atoms, which can then combine with atmospheric nitrogen to form NO. The result can be an erroneously high value for the measured conversion efficiency.
3.7.2 T EST P ROCEDURE
1. Measure converter temperature in the sub-menu structure as described in Section 3.6.
Note present reading as a reference for comparison with subsequent readings.
2. Lower converter temperature to 300
°
C as described in Section 3.5, Step 4, and wait 15 minutes for temperature equilibration.
3. (See Figure 3-7) Connect the Model 958 Converter Efficiency Tester to the CLD Module, and follow Steps 4 through 17 below (as adapted from 40 CFR 60):
4. Attach the NO/N
2
supply to C2, the air supply to C1, and the CLD Module inlet fitting to
C3.
5. With the variable transformer off, switch the CLD Module to NO mode, and close valve
MV1.
Chemiluminescense Detector Analyzer Module
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S TARTUP AND O PERATION
3
6. Open valve MV2 until the CLD Module SAMPLE Pressure Gauge reaches operating pressure and the BYPASS flowmeter indicates some bypass flow. Wait until stable readings are obtained by the CLD Module.
7. Zero and span the Analyzer output to indicate the value of the NO concentration being used. This value should be about 80% of fullscale. Record this concentration.
8. Open valve MV1 (air supply metering valve) and adjust to blend enough air to lower the
NO concentration (as noted above) about 10%. Record this concentration.
9. Power up the ozonator, and increase its supply voltage until the NO concentration noted in Step 8 is reduced to about 20 percent of the concentration noted in Step 7. Wait for stabilization. NO
2
is now being formed from the NO + O
3
reaction. There must always be at least 10 percent unreacted NO at this point. Record this concentration.
10. Switch the CLD Module to NOx mode. Total NOx concentration is now output to the network for display. Record this concentration.
concentration of the dilute NO span gas initially used is displayed. Record this concentration.
12. Close valve MV1. The NO concentration should be equal to or greater than the reading in Step 7. This indicates whether the NO contains any NO
2
.
13. Calculate the efficiency of the NO converter by substituting the concen-trations obtained during the test in the equation below: a - b
% Efficiency = 1 + 100 c - d
Where: a = recorded concentration in Step 10 b = recorded concentration in Step 11 c = recorded concentration in Step 8 d = recorded concentration in Step 9
In the example in Figure 3-7B, the following calculations would apply:
80 - 85
% Efficiency = 1 + 100 = 92%
80 - 20
Efficiency checks should be made on each analyzer range, using an NO span gas concentration appropriate to the instrument range.
748410-A
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NOTE
In the initial measurement, after lowering the temperature setpoint in Step 2, the efficiency will normally be less than 92%.
14. Reset converter temperature setpoint 20
°
C higher, wait 15 minutes for temperature equilibration, and measure conversion efficiency by repeating Steps 3 through 13.
Conversion efficiency should be improved.
15. Repeat Step 14 until: a) 95% to 98% efficiency is attained or b) the final 20
°
C converter temperature adjustment yields an increase in efficiency of less than 1%.
16. Reset converter temperature setpoint 5
°
C lower. Converter temperature is now set to the front edge of the plateau on the efficiency-vs.-temperature curve. (See Figure 3-8.) This setting should provide the optimum combination of high conversion efficiency and low ammonia interference.
Compare present temperature with original value. Normally, converter temperature should be in the range of 300
°
C to 400
°
C (572
°
F to 752
°
F).
3.7.3 S UBNORMAL C ONVERSION E FFICIENCY
If a measured conversion efficiency of between 95% and 98% is unobtainable within the normal temperature range, the most probable cause is depletion of the catalytic material within the converter.
However, before concluding that the converter is defective, ensure that the conversion efficiency measurement is accurate. Though the measured efficiency is less than the 95% to
98% range, the actual efficiency may be somewhat higher.
An apparent subnormal efficiency can be due to a problem external to the Analyzer Module, perhaps located either within the test setup or between it and the Analyzer Module. Check the following:
1. Leakage.
2. Loss of NO
2
between test setup and Analyzer Module. Such loss can occur by reaction with a rubber diaphragm in a pressure regulator or flow controller. Stainless steel diaphragms are preferred. Loss can also occur during passage through filter media.
22
Chemiluminescense Detector Analyzer Module
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748410-A
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3
A. TYPICAL TEST SETUP
FLOWMETER
FM2
METERING
VALVE MV2
115
VAC
ON
OFF
T1
VARIABLE
TRANSFORMER
CONNECTOR
C2
OZONATOR
UTILIZING
ULTRAVIOLET
LAMP
CONNECTOR C3
TO SAMPLE
INLET OF
CLD ANALYZER
MODULE
FLOW APPROXIMATELY
3 LITERS PER MINUTE
FLOWMETER
FM1
METERING
VALVE MV1
CONNECTOR
C2
STANDARD GAS:
NO IN N
2
BACKGROUND
CONNECTOR
C1
ZERO AIR
CAUTION: Externally limit sample flow rate to less than 2200 cc/min.
ALL LINES AND FITTINGS STAINLESS STEEL OR TEFLON
B. TYPICAL TEST RESULTS
90
85
80
NO in
N
2
AIR ADDED
OZONATOR OFF a-b
OZONATOR
ON c c-d a b
% Efficiency = 100
((((
1+
)))) c - d
20 d
TO NO
X
MODE
0
NO Mode NOx Mode
F IGURE 3-7. M EASURING E FFICIENCY OF NO
2 TO NO C ONVERTER
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3
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About 97%
Final 2 degree higher adjustment
Final 1 degree lower adjustment
Converter
Efficiency
Converter Temperature
F
IGURE
3-8. C
ONVERSION
E
FFICIENCY AS A
F
UNCTION OF
C
ONVERTER
T
EMPERATURE
3.7.4 R EPLACEMENT OF C ONVERTER
If the subnormal conversion efficiency is real, and not due to measurement error introduced by the test setup, the converter must be replaced. See Section 4.
The usual cause of converter failure is destruction of a large part of the catalytic material by excessive heat. This is due either to an excessively high temperature setpoint or failure of the converter temperature control circuitry.
3.7.5 C APILLARIES
Replacement vent and pump capillaries should be installed finger-tight. Use of a wrench can constrict capillaries, thus changing flow rate. Sample capillary is metal; use a wrench for tightening.
3.7.6 TEA S CRUBBER
The presence of NO
2
in the NO cylinders can cause inaccurate converter efficiency values.
The TEA Scrubber accessory (P/N NL635741) can be used to remove residual NO
2
from the NO cylinders. Use of this accessory allows an NO
2
-free NO calibration gas.
24
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
S TARTUP AND O PERATION
3
3.8 R
OUTINE
O
PERATION
The CLD Analyzer Module is designed to continuously analyze the sample stream.
Normally, it is never powered off except for servicing or for a prolonged shutdown.
Maximum permissible interval between calibrations depends on the analytical accuracy required, and therefore cannot be specified. Initially, the instrument should be calibrated at least once every eight hours. This practice should continue until experience indicates that some other interval is more appropriate.
The Analyzer Module will not allow the user to increase the upper limit of a range beyond the maximum range software setting. To change the Maximum Range value, select the following from the Main Menu: Technical Configuration Menu, Service Menu, Manufacturing
Data, and Analyzer Module Data. Select Maximum Range, and use the arrow keys to scroll the indicated value. The same applies for the Minimum Range value.
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
25
3
S TARTUP AND O PERATION
N
OTES
26
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
M AINTENANCE AND T ROUBLESHOOTING
4
WARNING: ELECTRICAL SHOCK HAZARD
Disconnect power to the module(s) prior to replacing components.
This equipment should not be adjusted or repaired by anyone except properly qualified service personnel.
4.1 OVERVIEW
The CLD Analyzer Module requires very little maintenance during normal operation.
Occasionally, the intake fan screen may require cleaning, refer to Section 4.3.
Also, the detector's reaction chamber and sapphire window may require cleaning, refer to
Section 4.7.
White crystal deposits on the windows of the reaction chamber and plugging of capillaries and vent are usually due to sample contaminates such as ammonia reacting with the high ozone levels and NO components. To eliminate the contaminates, the sampling system should be reworked or a preventive maintenance program developed (if dropout is not excessive). Another source of crystalline formation is contaminated air.
Several components may require replacement. These are discussed in the following sections.
4.2 F
USES
The main power fuse may require replacement.
NOTE Before replacing the fuse, remove power to the Analyzer Module.
See Figure 1-2 for the location of the Power Supply Board main power fuse, which protects
24 VDC input to the module.
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
27
4
M AINTENANCE AND T ROUBLESHOOTING
Ozonator
659494
NO/NOx Solenoid
655263
Thermostat
657298
Converter Assembly 655250
See Figure 4-2
PCB Insulators
Transistor
655264
Driver
Board
655620
Signal
Board
655580
Insulator
Computer Analysis
Board 655520
Sample
Pressure
Sensor
655253
Ozone
Pressure
3
Sensor
655254
Flow Sensor
902931
Glass Tube
Connectors
1
Fan Guard
Pressure Switch 655215
Ozonator Power Supply
657716
Fan Guard
Fan
655245
2
EMI Shield
Detector Assembly 658160
See Figure 4-3
Detector Case
Insulator
Power Supply
Board 657520
Flow Balance
Metering Valve
903207
Sample
Regulator
655269
Fuse, Power
903347
LON/Power
Module
3 Ground wires from ozonator shown.
2 Flow direction of intake fan (shown) is into case. Flow direction of exhaust fan is out of case.
1
Fan guard between fan and EMI filter is on the intake fan only (shown).
F IGURE 4-1. CLD M ODULE A SSEMBLY
28
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
M AINTENANCE AND T ROUBLESHOOTING
4
4.3 F
ANS
Refer to Figure 4-1. To replace either rear panel fan, remove the cover of the Analyzer
Module and then the rear panel. Disconnect connectors and remove screws. Assemble in reverse order.
4.4 C
ONVERTER
Refer to Figures 4-1 and 4-2. To replace the converter or sensor, disconnect the two pneumatic tubes and two electrical connections. Unlace the heater blanket, and remove the converter. Reassemble in reverse order, ensuring that the converter is oriented with the glass cloth at the bottom and the sensor is oriented correctly inside the heater jacket.
ASSEMBLED SIDE VIEW
Sensor
Heater
Jacket
655228
Converter
Tube 655227
Glass
Cloth
Wrap with aluminum foil
F IGURE 4-2. C ONVERTER A SSEMBLY
Sensor
655282
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
29
4
M AINTENANCE AND T ROUBLESHOOTING
4.5 O
ZONATOR
Refer to Figure 4-1.To replace the ozonator, remove the two large straps and all tie-wraps, and disconnect the one electrical connection. Reassemble in reverse order.
4.6 P
RINTED
C
IRCUIT
B
OARDS
All four printed circuit boards can be replaced, if necessary. Refer to Figure 4-1 for location of the Driver, Power Supply, Signal and Computer Boards.
To remove any PCB (except the Computer Board), disassemble the enclosure side first.
Ribbon and other cables are long enough to allow the entire side to be folded out from the remainder of the components. This makes PCB removal much simpler.
Tag each connector and its location before disconnecting any wiring. This helps in reassembly.
4.7 D
ETECTOR
D
ISASSEMBLY
Refer to Figure 4-3.
Reaction Chamber Removal
Disconnect the stainless steel tubing lines at the Gyrolok fittings. Remove the (4) nuts holding the Detector Assembly to the chassis. Disconnect the plug from connector J1 on the Signal Board and remove the assembly from the chassis.
NOTE
Care should be taken to avoid getting heatsink compound on optical surfaces.
If this substance is removed during the disassembly process, a zinc-oxide-filled, silicone grease (e.g., Dow Corning 340 or EG&G Wakefield
Engineering's Series 120 Thermal Joint Compound) be reapplied in the reassembly of this component.
Although the heater and thermostat can be removed to facilitate handling, contact with the white heatsink compound can be minimized by leaving these items in place. Remove the (2) screws holding the top plate of the Detector , and move the plate along the wires and away from the Detector .
Remove the (2) screws holding the tube assembly in place. Hold the tubing with one hand while inverting the Detector Housing with the other, allowing the Reaction Chamber O-ring and window to be removed from below.
30
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
M AINTENANCE AND T ROUBLESHOOTING
4
Reaction Chamber Installation
To reinstall, hold the housing in the inverted position while sliding the Reaction Chamber
O-ring and window into position and the tubing into the slot in the housing. Hold the
Reaction Chamber in place while rotating the housing upright. Replace the hold-down screws.
NOTE
The procedure described above is for the purpose of maintaining the relative positions of windows and O-ring to the Reaction Chamber during installation.
Replace the top cap and screws. Reverse the removal procedure to reinstall the Detector
Assembly into the Analyzer Module.
Photodiode Removal
Remove the Detector Assembly as described above. Invert the housing to access the mounting bracket. Remove the (3) screws and shoulder washers from the bracket. Remove the bracket, insulating disk and bottom plate as a unit to minimize the spread of the heatsink compound.
Remove the (2) screws holding the lower section of the Detector Housing, then slide the section along the cable and remove.
Remove the (2) screws holding the socket, thermistor and photodiode in place, being careful not to lose the washers that are used as shims.
Grasp the socket and photodiode base while slowly rotating to separate the photodiode from the housing. Some friction will be felt as an O-ring is used around the photodiode as a seal.
Photodiode Installation
To replace the photodiode, carefully remove the diode from the green socket, and replace with a new one. Before mounting the new diode, the top cap of the enclosure should be temporarily removed and the (2) screws holding the Reaction Chamber loosened about two turns. This allows air which is trapped between the O-ring seals to escape when the diode is inserted. It also maintains the position of the O-ring and window in the upper compartment.
The new photodiode should be slowly inserted into the housing while gradually rotating the body. This allows the O-ring to properly seat. Continue replacing screws, washers, thermistors, etc., with the thicker shim (washer) on the opposite side of the socket from the thermistor.
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
31
4
M AINTENANCE AND T ROUBLESHOOTING
Replace the lower section of the housing, then the bottom cover, insulator and bracket with the shoulder washers and screws.
Re-tighten the screws in the Reaction Chamber (upper section). Replace the top cap and its screws.
To reinstall in the Analyzer Module, reverse the procedure for removal as indicated above.
32
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
M AINTENANCE AND T ROUBLESHOOTING
4
Photodiode
Sapphire
Window
Reaction
Chamber
Thermistor
Assembly
Sample
Ozone
Exhaust
Heater *
M3X0.5 x 16mm Screw (2)
3mm Spring Washer (2)
Photodiode Socket
Assembly
Detector Mounting
Bracket
Heater *
Thermostat *
Tubing Cover
Detector Header
M3X0.5 x 25mm Screw (2)
3mm Spring Washer (2)
Retainer Gasket
Reaction Chamber
O-Ring 854540
Sapphire Window
Cushioning Gasket
Photodiode
Cable
Insulator
(between Lower Cover and Mounting Bracket)
Photodiode Case
Ground
Lower Cover
Nylon Shoulder
Washers (3)
M3X0.5 x 16mm
Screw (3)
O-Ring 876478
Photodiode Assembly
(see detail below)
M3X0.5 x 20mm Screw (2)
3mm Spring Washer (2)
Detector Cover
M3X0.5 x 16mm Screw (2)
3mm Spring Washer (2)
* Heater/Thermostat Assembly 655235.
Photodiode
655258
Thermistor
655216 Thermistor Spacer
Thermistor Shim
Photodiode Socket Assembly
No. 6 Flat Washer (2)
Assembly of Photodiode
F IGURE 4-3. D ETECTOR A SSEMBLY
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
33
4
M AINTENANCE AND T ROUBLESHOOTING
N
OTES
34
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
R EPLACEMENT P ARTS
5
CAUTION: PARTS INTEGRITY
Tampering with or unauthorized substitution of components may adversely affect safety of this product. Use only factory-approved components for repair.
NL655215
NL655245
NL655250
NL655253
NL655254
NL655263
NL655264
NL655269
NL659063
NL655287
NL655520
NL655580
NL655620
NL657298
NL657473
NL657520
NL657716
NL659494
NL658157
NL659657
NL659658
NL659753
NL659754
NL902931
NL903207
NL903347
5.1 REPLACEMENT PARTS
Pressure Switch
Fan (Exhaust and Intake)
Converter (see below)
Sample Pressure Sensor
Ozone Pressure Sensor
NO/NOx Solenoid
Transistor Assembly
Regulator, Back Pressure – Brass/Neoprene
Regulator, Back Pressure – Stainless Steel/Viton
Prom
Computer Board
Signal Board
Driver Board
Thermostat 80
°
C
Pump Capillary
Power Supply Board
Ozonator Power Supply
Ozone Generator
Air Restrictor 430 cc/min 12 psig
Sample Capillary 70 cc/min. 5 psig
Sample Capillary 200 cc/min. 5 psig
Detector 70 cc/min.
Detector 200 cc/min.
Flow Sensor
Metering Valve
Fuse, Main Power 6A 250V
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
35
5
R EPLACEMENT P ARTS
655250 CONVERTER REPLACEMENT PARTS
NL655228 Heater Jacket
NL655227 Tube, Aged
NL655282 Temperature Sensor
659753, 659754 DETECTOR REPLACEMENT PARTS
NL655235 Heater/Thermostat Assembly
NL655216 Thermistor
NL655258 Photodiode
NL854540 O-Ring, Viton .739ID .875OD
NL876478 O-Ring, Viton .737ID .943OD
36
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
CLD I DENTIFICATION M ATRIX
A
Each analyzer is configured per the customer sales order. Below is the CLD sales matrix which lists the various configurations available.
To identify the configuration of an analyzer, locate the analyzer name-rating plate. The 12position sales matrix identifier number appears on the analyzer name-rating plate.
C CHEMILUMINESCENCE NO/NOx ANALYZER - CLD
Code Language
A English
X Special
Code Configuration Identifier
A10 Calibrated Low Ranges: 0-10, 0-25, 0-100, 0-250 ppm
A20 Calibrated High Ranges: 0-250, 0-1000, 0-2500, 0-10000
B10 Calibrated Low Ranges: 0-10, 0-30, 0-100, 0-300 ppm
B20 Calibrated High Ranges: 0-300, 0-1000, 0-3000, 0-10000 ppm
C10 Calibrated Low Ranges: 0-10, 0-50, 0-100, 0-500 ppm
C20 Calibrated High Ranges: 0-500, 0-1000, 0-5000, 0-10000 ppm
Code Materials
A00 Brass and Neoprene Back Pressure Regulator
B00 Stainless Steel and Viton Back Pressure Regulator
C00
D00
Brass and Neoprene Back Pressure Regulator with
Sample Inlet
Restrictor (Recommended if External Flow Control Device is not used.)
Stainless Steel and Viton Back Pressure Regulator with
Sample Inlet
Restrictor (Recommended if External Flow Control Device is not used.)
C A
ZZZZ No Selection
A10 A00 ZZZZ Example
748410-A
August 1999
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
A1
A
CLD I DENTIFICATION M ATRIX
N
OTES
A2
Chemiluminescense Detector Analyzer Module
Rosemount Analytical NGA 2000
748410-A
August 1999
G
ENERAL
P
RECAUTIONS FOR
H
ANDLING AND
S
TORING
H
IGH
P
RESSURE
G
AS
C
YLINDERS
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 125
°
F (52
°
C). 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.
Rosemount Analytical Inc.
4125 E AST L A P ALMA A VENUE • A NAHEIM , C ALIFORNIA 92807-1802 • 714-986-7600 • FAX 714-577-8006
J ULY 1997 • 748525-C • P RINTED IN USA
(blank)
W
ARRANTY
Goods and part(s) (excluding consumables) manufactured by Seller are warranted to be free from defects in workmanship and material under normal use and service for a period of twelve (12) months from the date of shipment by Seller. Consumables, glass electrodes, membranes, liquid junctions, electrolyte, o-rings, etc., are warranted to be free from defects in workmanship and material under normal use and service for a period of ninety (90) days from date of shipment by
Seller. Goods, part(s) and consumables proven by Seller to be defective in workmanship and/or material shall be replaced or repaired, free of charge, F.O.B. Seller's factory provided that the goods, part(s) or consumables are returned to Seller's designated factory, transportation charges prepaid, within the twelve (12) month period of warranty in the case of goods and part(s), and in the case of consumables, within the ninety (90) day period of warranty. This warranty shall be in effect for replacement or repaired goods, part(s) and the remaining portion of the ninety (90) day warranty in the case of consumables. A defect in goods, part(s) and consumables of the commercial unit shall not operate to condemn such commercial unit when such goods, part(s) and consumables are capable of being renewed, repaired or replaced.
The Seller shall not be liable to the Buyer, or to any other person, for the loss or damage directly or indirectly, arising from the use of the equipment or goods, from breach of any warranty, or from any other cause. All other warranties, expressed or implied are hereby excluded.
IN CONSIDERATION OF THE HEREIN STATED PURCHASE PRICE OF THE GOODS, SELLER
GRANTS ONLY THE ABOVE STATED EXPRESS WARRANTY. NO OTHER WARRANTIES ARE
GRANTED INCLUDING, BUT NOT LIMITED TO, EXPRESS AND IMPLIED WARRANTIES OR
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Limitations of Remedy. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN
PERFORMANCE. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF WARRANTY SHALL
BE LIMITED TO REPAIR OR REPLACEMENT UNDER THE STANDARD WARRANTY CLAUSE. IN
NO CASE, REGARDLESS OF THE FORM OF THE CAUSE OF ACTION, SHALL SELLER'S
LIABILITY EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED BY
SELLER GIVING RISE TO THE CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT
SHALL SELLER'S LIABILITY EXTEND TO INCLUDE INCIDENTAL OR CONSEQUENTIAL
DAMAGES. CONSEQUENTIAL DAMAGES SHALL INCLUDE, BUT ARE NOT LIMITED TO, LOSS
OF ANTICIPATED PROFITS, LOSS OF USE, LOSS OF REVENUE, COST OF CAPITAL AND
DAMAGE OR LOSS OF OTHER PROPERTY OR EQUIPMENT. IN NO EVENT SHALL SELLER BE
OBLIGATED TO INDEMNIFY BUYER IN ANY MANNER NOR SHALL SELLER BE LIABLE FOR
PROPERTY DAMAGE AND/OR THIRD PARTY CLAIMS COVERED BY UMBRELLA INSURANCE
AND/OR INDEMNITY COVERAGE PROVIDED TO BUYER, ITS ASSIGNS, AND EACH
SUCCESSOR INTEREST TO THE GOODS PROVIDED HEREUNDER.
Force Majeure. Seller shall not be liable for failure to perform due to labor strikes or acts beyond
Seller's direct control.
Rosemount Analytical
Rosemount Analytical Inc.
4125 E AST L A P ALMA A VENUE • A NAHEIM , C ALIFORNIA 92807-1802 • 714-986-7600 • FAX 714-577-8006
F EBRUARY 1997 • 7485189-C • P RINTED IN USA
(blank)
F
IELD
S
ERVICE AND
R
EPAIR
F
ACILITIES
Field service and repair facilities are located worldwide.
U.S.A.
To obtain field service on-site or assistance with a service problem, contact (24 hours, 7 days a week):
National Response Center
1-800-654-7768
I
NTERNATIONAL
Contact your local Rosemount Sales and Service office for service support.
F
ACTORY
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
R
ETURNING
P
ARTS TO THE
F
ACTORY
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
Rosemount Analytical Inc.
4125 E AST L A P ALMA A VENUE • A NAHEIM , C ALIFORNIA 92807-1802 • 714-986-7600 • FAX 714-577-8006
J ULY 1997 • 748190-G • P RINTED IN USA
(blank)
I NSTRUCTIONS 015-748335-B
Rosemount Analytical
SAMPLE INLET FLOW RATE RESTRICTION
FOR NGA 2000 CLD ANALYZER MODULE
NOTICE
CAUTION
EXTERNALLY RESTRICT SAMPLE FLOW TO LESS THAN 2200 CC/MIN.
N O RESTRICTOR IS PROVIDED IN THE SAMPLE INLET OF THIS MODULE . F OR THOSE
USERS WHO CANNOT EXTERNALLY LIMIT SAMPLE FLOW , ACCESSORY RESTRICTOR PN
657300 IS AVAILABLE FROM R OSEMOUNT A NALYTICAL . T O OBTAIN THIS
ACCESSORY , CALL 800-441-7245.
Rosemount Analytical Inc.
4125 East La Palma Avenue • Anaheim, California 92807-1802 • (714) 986-7600 • FAX (714) 577-8006
June 1997 015-748335-B Printed in U.S.A.
(blank)
Rosemount Analytical
I NSTRUCTIONS 015-748430-A
ADDENDUM
CLD I NSTRUCTION M ANUAL 748410
This addendum serves as an amendment to the CLD Instruction Manual 748410. The following information should be considered part of the manual, and supersedes any conflicting information in the body of the manual.
Read this information and note the conflicts.
M
ENU
D
ISPLAYS
Menu: 0 MAIN
Menu: 1 ANALSET
Rosemount Analytical Inc.
4125 E AST L A P ALMA A VENUE
•
A NAHEIM , C ALIFORNIA 92807-1802
•
(714) 986-7600
•
FAX: (714) 577-8006
A UGUST 1999
•
015-748430-A
•
P RINTED IN USA
ADDENDUM
Menu: 2 FLOCHEK
Menu: 3 ZEROI1
Menu: 4 FLOCHEKI1
2 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 5 ANALOPI1
Menu: 6 ACALSET
Menu: 7 APARLST
748430-A August 1999 Rosemount Analytical 3 of 44
ADDENDUM
Menu: 8 ANALSETI1
Menu: 9 CALLIST
Menu: 10 CALLISTI1
4 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 11 ACALSETI1
Menu: 12 APARLSTI1
Menu: 13 AMMAN
748430-A August 1999 Rosemount Analytical 5 of 44
ADDENDUM
Menu: 14 AMMANI1
Menu: 15 AMSVC
Menu: 16 AMSVCI1
6 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 17 ADIAG
Menu: 18 AMPWR
Menu: 19 AM1V
748430-A August 1999 Rosemount Analytical 7 of 44
ADDENDUM
Menu: 20 AMTEMP
Menu: 21 AMMISC
Menu: 22 AMTREND
8 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 23 ADIAGI1
Menu: 24 RANGESETAM
Menu: 25 RANGESSETI1
748430-A August 1999 Rosemount Analytical 9 of 44
ADDENDUM
Menu: 26 LINRANGE1
Menu: 27 LINRANGE2
Menu: 28 LINRANGE3
10 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 29 LINRANGE4
Menu: 30 LINRANGE0
Menu: 31 AMPWRI1
748430-A August 1999 Rosemount Analytical 11 of 44
ADDENDUM
Menu: 32 FLOCHEK1I1
Menu: 33 FILTER
Menu: 34 NONOXEFFIC
12 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 35 AM1VI1
Menu: 36 AMTEMPI1
Menu: 37 AM2VA
748430-A August 1999 Rosemount Analytical 13 of 44
ADDENDUM
Menu: 38 PLIMITSA
Menu: 39 TLIMITSA
Menu: 40 AMMISCI1
14 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 41 NONOXEFFICI1
Menu: 42 ANALSIMPLE
Menu: 43 FILTERI1
748430-A August 1999 Rosemount Analytical 15 of 44
ADDENDUM
Menu: 44 LINRANGE0I1
Menu: 45 PLIMITSAI1
Menu: 46 CALFACTORS
16 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 47 AMHELPINDEX
Menu: 48 LINRANGE1I1
Menu: 49 CALFACTORSI1
748430-A August 1999 Rosemount Analytical 17 of 44
ADDENDUM
Menu: 50 CALLIST2
Menu: 51 APARLST2
Menu: 52 APARLST4
18 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 53 APARLST5
Menu: 54 APARLST6
Menu: 55 APARLST7
748430-A August 1999 Rosemount Analytical 19 of 44
ADDENDUM
Menu: 56 LISTNOTES
Menu: 57 AMMISC2
Menu: 58 AMMISCI2
20 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 59 MPARMS
Menu: 60 MPARMS2
Menu: 61 DISPLAY
748430-A August 1999 Rosemount Analytical 21 of 44
ADDENDUM
Menu: 62 ANALSET2
Menu: 63 AMHELPINDEX2
Menu: 64 MPARMSI1
22 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 65 AMPWR2
Menu: 66 ANALSETI2
Menu: 67 AMMISC3
748430-A August 1999 Rosemount Analytical 23 of 44
ADDENDUM
Menu: 68 SOFT_DIAGS
Menu: 69 CALI1
Menu: 70 AM2VB
24 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 71 LINFUNCT
Menu: 72 POLYSETUP
Menu: 73 MIDPOINT1
748430-A August 1999 Rosemount Analytical 25 of 44
ADDENDUM
Menu: 74 POLYGAS1
Menu: 75 POLYSETI1
Menu: 76 POLYGAS2
26 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 77 POLYGAS3
Menu: 78 POLYGAS4
Menu: 79 POLYGAS5
748430-A August 1999 Rosemount Analytical 27 of 44
ADDENDUM
Menu: 80 POLYGAS6
Menu: 81 POLYGAS7
Menu: 82 POLYGAS8
28 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 83 POLYGAS9
Menu: 84 POLYGAS0
Menu: 85 MIDPOINT2
748430-A August 1999 Rosemount Analytical 29 of 44
ADDENDUM
Menu: 86 MIDPOINT3
Menu: 87 MIDPOINT4
Menu: 88 EXP_CAL
30 of 44 Rosemount Analytical August 1999 748430-A
ADDENDUM
Menu: 89 EXP_CAL_DAT
Menu: 90 EXP_CAL_DATI
Menu: 91 UNITS
748430-A August 1999 Rosemount Analytical 31 of 44
ADDENDUM
Menu: 92 UNITSI1
Menu: 93 POLYSETI2
Menu: 94 POLYSETI3
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Menu: 95 ZEROI3
Menu: 96 TWEAKI1
Menu: 97 ANALSETI3
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Menu: 98 RESET
Menu: 99 STORE
Menu: 100 INIT
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Menu: 101 RFACTORSI
Menu: 102 RFHIST
Menu: 103 RFHIST2
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Menu: 104 RFACTORS
Menu: 105 R2FACTORS
Menu: 106 RN3FACTORS
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Menu: 107 RFHIST3
Menu: 108 RFHIST4
Menu: 109 RN4FACTORS
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Menu: 110 STOREPVA
Menu: 111 ZERO_NOW2
Menu: 112 SPAN_NOW2
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Menu: 113 NEW_CONV
Menu: 114 FLOWBALANCE
Menu: 115 FLOWBALCALC1
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Menu: 116 FLOWBALCALC2
Menu: 117 FLOWBALI1
Menu: 118 FLOWBALI2
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Menu: 119 DIAG_VOLTS_
Menu: 120 AMPWR_CLD2
Menu: 121 AMPWRI1_CLD2
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Menu: 122 AM2VA2
Menu: 123 ALARM1
Menu: 124 ABOUT
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Menu: 125 ABOUT1
Menu: 126 MANDATA
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N
OTES
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Table of contents
- 7 Purpose/Safety Summary
- 13 Specifications - General
- 13 Specifications - Physical
- 14 Specifications - Sample
- 14 Specifications - Gas Connections
- 15 Customer Service, Technical Assistance and Field Service
- 15 Returning Parts to the Factory
- 16 Documentation
- 16 Compliances
- 17 1.1 Overview
- 17 1.2 Typical Applications
- 17 1.3 Theory of Technology
- 18 1.4 Features
- 21 2.1 Unpacking
- 21 2.2 Assembly
- 21 2.3 Location
- 22 2.4.1 Overview
- 22 2.4.2 Connections
- 24 2.4.3 Specifications
- 25 2.5 Electrical Connections
- 29 3.1 OVERVIEW
- 29 3.2 Displays
- 29 3.2.1 Run Mode Display
- 29 3.2.2 Menu Displays
- 30 3.2.3 Help Displays
- 30 3.3 Startup Procedure
- 31 3.4 Binding
- 33 3.5 Calibration
- 34 3.6 Converter Temperature Adjustment Procedure
- 36 3.7 Measurement of Converter Efficiency
- 36 3.7.1 Test Setup for Measurement of Conversion Efficiency
- 36 3.7.2 Test Procedure
- 38 3.7.3 Subnormal Conversion Efficiency
- 40 3.7.4 Replacement of Converter
- 40 3.7.5 Capillaries
- 40 3.7.6 TEA Scrubber
- 41 3.8 Routine Operation
- 43 4.1 Overview
- 45 4.4 Converter
- 46 4.5 Ozonator
- 46 4.6 Printed Circuit Boards
- 46 4.7 Detector Disassembly
- 51 5.1 Replacement Parts