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Emerson NGA2000 TO2 manual

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Table of contents for the manual

  • Page 1

    Instruction Manual 748374-F March 2003 http://www.processanalytic.com Model NGA2000 TO2 Trace Oxygen Analyzer[...]

  • Page 2

    Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 e-mail: gas.csc@EmersonProcess.com http://www.processanalytic.com ESSENTIAL INSTRUCTIONS READ THIS PAGE BE FORE PROCEEDING! Rosemount Analytical designs, man ufactures and te sts its products to m[...]

  • Page 3

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Division of Emerson Process Management Contents i Model NGA2000 TO2 TABLE OF CONTENTS PREFACE........................................................................................................................ ................... P-1 Intended Use Statem ent .....................[...]

  • Page 4

    Instruction Manual 748374-F March 2003 ii Contents Rosemount Anal ytical Inc. A Division of Emerson Process Management Model NGA2000 TO2 4-0 MAINTENANCE AND TROUBLESHOO TING ..................................................................... 4-1 4-1 Overview .........................................................................................[...]

  • Page 5

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Division of Emerson Process Management Contents iii Model NGA2000 TO2 LIST OF ILLUSTRATIONS Figure 1-1. Trace Oxygen Detect or Techno logy ...................................................................... 1-2 Figure 1-2. Trace Oxygen Analyzer Module – Top View ...............[...]

  • Page 6

    Instruction Manual 748374-F March 2003 iv Contents Rosemount Anal ytical Inc. A Division of Emerson Process Management Model NGA2000 TO2[...]

  • Page 7

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-1 Model NGA2000 TO2 PREFACE INTENDED USE STATEMENT The purpose of this manual is to provide informati on concerning the components, functions, installation and maintenance of the Model NGA2000 TO2 and the System Accessor ies of the NG[...]

  • Page 8

    Instruction Manual 748374-F March 2003 P-2 Preface Rosemount An alytical Inc. A Division of Emerson Process Management Model NGA2000 TO2 SAFETY SUMMARY If this equipment is used in a manner not specifie d in these instructions, prot ectiv e system s may be im- paired. AUTHORIZED PERSONNEL To avoid explosion, loss of life, personal injury and damage[...]

  • Page 9

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3 Model NGA2000 TO2 NOTICE Software compatibility is necessary for all NGA2000 compon ents in y our system to work together. The version of your Platform's soft ware must be equal to or greater that th e version of any other modu[...]

  • Page 10

    Instruction Manual 748374-F March 2003 P-4 Preface Rosemount An alytical Inc. A Division of Emerson Process Management Model NGA2000 TO2 GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH PRESSURE GAS CYLINDERS Edited from selected paragraphs of the Compressed Ga s Association's "Handbook of Com- pressed Gases" published in 1981 Compr[...]

  • Page 11

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5 Model NGA2000 TO2 DOCUMENTATION The following NGA2000 Trace Oxygen Analyze r Mod ule instruction material s are available. Contact Cus- tomer Service Center (page 6-1 ). 748374 Instruction Manual (this do cument) COMPLIANCES This pr[...]

  • Page 12

    Instruction Manual 748374-F March 2003 P-6 Preface Rosemount An alytical Inc. A Division of Emerson Process Management Model NGA2000 TO2 GLOSSARY OF TERMS Analyzer Module The module that contains all senso r/det ector component s for development of a Primary Variable signal; in- cludes all signal conditioni ng and temperature control circuitry. Bac[...]

  • Page 13

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Divisi on of Emerson Process Management Description and Specifications 1-1 Model NGA2000 TO2 SECTION 1 DESCRIPTION AND SPECIFICATIONS 1-1 OVERVIEW This manual describes the Trace Oxyge n (TO2) Analyzer Module of Rosemount Analytical's NGA2000 Series of gas analysis components. [...]

  • Page 14

    Instruction Manual 748374-F March 2003 1-2 Description and Specifications Rosem ount Analytical Inc. A Divi sion of Emerson Process Management Model NGA2000 TO2 Figure 1-1. Trace Oxygen Detector Technology ELECTRO NICS SECON DARY AN ODE ( +) BI-ST R AT A™ DIFF USIO N BARRIER SAMPLE IN SAMPLE OUT O 2 SENSING CATHODE (-) SECONDARY CATHODE (-) O 2 S[...]

  • Page 15

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Divisi on of Emerson Process Management Description and Specifications 1-3 Model NGA2000 TO2 Figure 1-2. Trace Oxygen Analy zer Module – Top View Sensor Assembly Sensor Samp le Flo w Sensor Network/Power Module Computer Board Power Board[...]

  • Page 16

    Instruction Manual 748374-F March 2003 1-4 Description and Specifications Rosem ount Analytical Inc. A Divi sion of Emerson Process Management Model NGA2000 TO2 1-5 SPECIFICATIONS a. General Measurement Species ................... Trace Oxygen Ranges .......................................... 0 to 100 ppm (output scalable down to 0-2 ppm fullscale)[...]

  • Page 17

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1 Model NGA2000 TO2 SECTION 2 INSTALLATION 2-1 UNPACKIN G If the Trace Oxygen (TO2) Analyzer Mod ule is received as a separate unit, carefully examine the shipping carton and co ntents for signs of damage. Immediately notify the [...]

  • Page 18

    Instruction Manual 748374-F March 2003 2-2 Installation Rosemount Anal ytical Inc. A Division of Emerson Process Management Model NGA2000 TO2 with a clean, metallic diaphragm, two-stage regulator. A shutoff valve is recommended. Calibration Gases The TO2 module does not requi re routine zero calibration. The zero is factory set and does not experie[...]

  • Page 19

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3 Model NGA2000 TO2 Figure 2-2. Trace Oxygen Analy zer Outline and Mounting Dimensions 6.00 [152] 7.00 [178] 8.10 [206] 2.70 [68] 1.2 [31] .06 [1.5] DIA 8.25 [206] 11.00 [279] 12.00 [305] 18.56 [471] 10.15 [258] 6.62 [168] 7.75 [[...]

  • Page 20

    Instruction Manual 748374-F March 2003 2-4 Installation Rosemount Anal ytical Inc. A Division of Emerson Process Management Model NGA2000 TO2 Sample Inlet 1/4" Tube Sample Exhaust 1/4" Tube Figure 2-3. Trace Oxygen Analy zer Back Panel Connections CAUTION GAS OVERPRESSURE At no time should sample, zero or span gas inlet pressure exceed 69[...]

  • Page 21

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5 Model NGA2000 TO2 Network Connections Power Connection Fuse Power Indicator Light Figure 2-4. Trace Oxygen Analy zer Front Panel 2-5 ELECTRICAL CONNE CTIONS NOTE Electrical connnections must be made in compliance with National [...]

  • Page 22

    Instruction Manual 748374-F March 2003 2-6 Installation Rosemount Anal ytical Inc. A Division of Emerson Process Management Model NGA2000 TO2[...]

  • Page 23

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Division of Emerson Pr ocess Management Startup and Operation 3-1 Model NGA2000 TO2 SECTION 3 STARTUP AND OPERATION 3-1 OVERVIEW Prior to initial startup, the user should perform the leak test procedure outlined in Section 2. For the remainder of this section, Analyzer Module interc[...]

  • Page 24

    Instruction Manual 748374-F March 2003 3-2 Startup and Operation Rosemount Analyt ical Inc. A Division of Emerson Process Management Model NGA2000 TO2 From the Run Mode display, press the MENUS softkey to gain access to the Main Menu. The Basic controls menu i s as follo ws: Figure 3-3. Basic Controls Menu This menu allows the user to view the cur-[...]

  • Page 25

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Division of Emerson Pr ocess Management Startup and Operation 3-3 Model NGA2000 TO2 3-3 STARTUP PROCEDURE Establish sample or zero gas flow through the analyzer module at a nominal flow rate of 2 SCFH (1 l/min). Allow gas to flow for 15 to 30 seconds before applyin g p owe r. Apply [...]

  • Page 26

    Instruction Manual 748374-F March 2003 3-4 Startup and Operation Rosemount Analyt ical Inc. A Division of Emerson Process Management Model NGA2000 TO2 Introduce zero gas in to the SAMPLE INLET, and, after a stable reading is reach ed, do the following: 1. Move the cursor to Tech nical Level Configu- ration... and enter. Select Diagnostic Menus…, [...]

  • Page 27

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Division of Emerson Pr ocess Management Startup and Operation 3-5 Model NGA2000 TO2 3-8 ALARM INDICATI ON NGA analyzer modules co ntinuously monitor a number of internal parameters. It is possible to make the analyzer generat e certain kinds of alarm indications if these parameters&[...]

  • Page 28

    Instruction Manual 748374-F March 2003 3-6 Startup and Operation Rosemount Analyt ical Inc. A Division of Emerson Process Management Model NGA2000 TO2[...]

  • Page 29

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Divisi on of Emerson Process Management Maintenance and Troubleshooting 4-1 Model NGA2000 TO2 Sensor Cov er Indicat or, Elect rol y te Level Sensor Res erv oir Mounting S c rews (3 places) Enclos ure Back Wal l Mounting S c rews (2 places) Flow Sens or SIDE VIEW TOP VIEW SECTION 4 M[...]

  • Page 30

    Instruction Manual 748374-F March 2003 4-2 Maintenance and Troubleshooting Rosemount A nalytical Inc. A Division of Emerson Process Management Model NGA2000 TO2 a. Water Addition To add water: 1. Remove the top cover of t he analyzer module. 2. Unscrew the black sen sor cover. 3. Slide the cover ba ck ju st enough to al- low the neck of the fill bo[...]

  • Page 31

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Divi sion of Emerson Process Management Maintenance and Troubleshooting 4-3 Model NGA2000 TO2 Install replacement Sensor in reverse order. Check Sensor for leaks an d add electrolyte as described in Section 2-2a on pag e 2-1. Rein- stall Sensor Assembly in Analyzer Module and reconn[...]

  • Page 32

    Instruction Manual 748374-F March 2003 4-4 Maintenance and Troubleshooting Rosemount A nalytical Inc. A Division of Emerson Process Management Model NGA2000 TO2 sensor is a partial pressure measuring device, an increase in sample pressure will cause an increase in reading. If the reading drops with increased flow, conduct the leak che ck outlined i[...]

  • Page 33

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Divi sion of Emerson Process Management Replacement Parts 5-1 Model NGA2000 TO2 SECTION 5 REPLACEMENT PARTS WARNING PARTS INTEGRITY Tampering with or unauthorized substi- tution of components may adversely af- fect safety of this product. Use only factory-approv ed components for re[...]

  • Page 34

    Instruction Manual 748374-F March 2003 5-2 Replacement Parts Rosemount Analytical Inc. A Divi sion of Emerson Process Management Model NGA2000 TO2[...]

  • Page 35

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Divi sion of Emerson Process Management Return of Material 6-1 Model NGA2000 TO2 SECTION 6 RETURN OF MATERIAL 6-1 RETURN OF MATERIAL If factory repair of defective equipment is re- quired, proceed as follows: 1. Secure a return autho rization from a Rose- mount Analytical Inc. Sales[...]

  • Page 36

    Instruction Manual 748374-F March 2003 6-2 Return of Material Rosemount Analytical Inc. A Divi sion of Emerson Process Management Model NGA2000 TO2[...]

  • Page 37

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Divi sion of Emerson Process Management Appendix A. Menu Structure 7-1 Model NGA2000 TO2 SECTION 7 APPENDIX A. MENU STRUCTURE 7-1 NGA TO2 MENU STRU C TURE INTRODUCTION This Appendix contains a listing of the menu s belonging to the TO2 Analyzer Module. It also lists the available co[...]

  • Page 38

    Instruction Manual 748374-F March 2003 7-2 Appendix A. Menu Structure Rosemount Analytical Inc. A Divi sion of Emerson Process Management Model NGA2000 TO2 The Range Settings men u allows configuration of the upper and lower limit of the 4 ranges o n the Analyzer Module. The maximum and mini- mum range limits are shown an d adju stment beyond these[...]

  • Page 39

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Divi sion of Emerson Process Management Appendix A. Menu Structure 7-3 Model NGA2000 TO2 From the Analyzer Diagnostics m enu, all ana- lyzer health diagnostic information can be ac- cessed. Calibration cont rols are also acce ssible from this menu. The Primary Variable Parameters sc[...]

  • Page 40

    Instruction Manual 748374-F March 2003 7-4 Appendix A. Menu Structure Rosemount Analytical Inc. A Divi sion of Emerson Process Management Model NGA2000 TO2 The Load Factory Calibra tion scre ens allow the user to enter the factory calibration data unique to the sensor in the Analyzer Module. If the sensor is replaced, this data must be en- tered fr[...]

  • Page 41

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Divi sion of Emerson Process Management Appendix A. Menu Structure 7-5 Model NGA2000 TO2 Temperature Parameters… sele ct ion directs the user to the sensor temperature information. It is recommended that the user not co nd uct temperature calibration of the sensor in the field.[...]

  • Page 42

    Instruction Manual 748374-F March 2003 7-6 Appendix A. Menu Structure Rosemount Analytical Inc. A Divi sion of Emerson Process Management Model NGA2000 TO2[...]

  • Page 43

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Divi sion of Emerson Process Man agement Appendix B. User Interface Help 8-1 Model NGA2000 TO2 SECTION 8 APPENDIX B. USER INTERFACE HELP This section provides a mean s of rapidl y finding any desired function or configuratio n factor in the menu system. The NGA menu system is necess[...]

  • Page 44

    Instruction Manual 748374-F March 2003 8-2 Appendix B. User Interface Hel p Rosemount Analytical Inc. A Division of Emerson Process Management Model NGA2000 TO2 ITEM PATH NOTES Range number sel ec- tion Basic Range lower limits Expert - Analyzer module setup - Ran ge set- tings Range upper limits Expert - Analyzer module setup - Ran ge set- tings R[...]

  • Page 45

    Instruction Manual 748374-F March 2003 Rosemount Analytical Inc. A Divi sion of Emerson Process Management Index 9-1 Model NGA2000 TO2 SECTION 9 INDEX 2 24 V 5A DC power, 2-5 A alarm electrolyte, 4-1, 4-2 indications, 3-5 Analyzer Modu le electrical connections, 2-5 general operation of software, 3-4 leak test, 2-4 Applications, 1-1 automatic insta[...]

  • Page 46

    Instruction Manual 748374-F March 2003 9-2 Index Rosemount Analytical Inc. A Divi sion of Emerson Process Management Model NGA2000 TO2 R Return Authorization, 6-1 S sample connections, 2-2 flow rate, 2-2 inlet pressure, 2-2 security code s, 3-3 sensor electrolyte, 4-2 life, 3-3 load new calibration data, 4-3 maximum psig, 2-4 signal connector, 4-2 [...]

  • Page 47

    WARRANTY Goods and part(s) (excluding consu mables) manufac tured by Seller are warrant ed to be free fro m defects in workman ship and material under normal use and se rvice for a period of twelve (12) months from the date of shipment by Seller. Consumable s, glass electrode s, membranes, liquid junctions, electrolyte, o-rings, etc., are warra n t[...]

  • Page 48

    Instruction Manual 748374-F March 2003 © Rosemount Analytical Inc. 2003 Emerson Process Management Rosemount Analytical Inc. Process Analytic Division 1201 N. Main St. Orrville, OH 44667-0901 T (330) 682-9010 F (330) 684-4434 E gas.csc@emersonprocess.com ASIA - PACIFIC Fisher-Rosemount Singapore Private Ltd. 1 Pandan Crescent Singapore 128461 Repu[...]