Page 1 2101510– rev. AG NGC8206 Chromatograph User’s Manual...
Page 2 Intellectual Property & Copyright Notice © 2018 by ABB Inc., (“Owner”), Bartlesville, Oklahoma 74006, U.S.A. All rights reserved. Any and all derivatives of, including translations thereof, shall remain the sole property of the Owner, regardless of any circumstances. The original US English version of this manual shall be deemed the only valid version. Translated versions, in any other language, shall be maintained as accurately as possible.
Page 3: Table Of Contents
Typical Installation ..................2–1 Processing a Sample ................. 2–4 2.2.1 Hydrocarbons ....................2–4 Hardware System Specifications ..............2–5 2.3.1 NGC8206 Standard Hardware Features ............. 2–6 2.3.2 Recommended Spare Parts ................ 2–7 2.3.3 Cast Aluminum Enclosure ................2–7 2.3.4 Feed-through Assembly ................2–9 2.3.5...
Page 4 Calculating Lag Time ................2–23 2.8.1 Calculations ....................2–24 2.8.2 Calculating Using Actual Pressure............. 2–24 NGC8206 Standard Software Features ............ 2–25 2.9.1 Audit Quality Data ..................2–25 2.9.2 Tri-Level Security ..................2–25 2.9.3 Compressibility Options ................2–25 2.9.4 Calculation Options ..................2–26 2.9.5...
Page 5 3.1.2 Organization ....................3–1 3.1.3 Locating Area for Installation ............... 3–2 3.1.4 Installation ....................3–3 Unpacking and Inspection ................3–4 3.2.1 Shipping Carton ................... 3–4 3.2.2 Unpacking ....................3–5 3.2.3 Bill of Lading ....................3–5 3.2.4 Inspection ....................3–5 3.2.5 Damaged Components................
Page 6 3.15.1 Materials ..................... 3–25 3.15.2 Instructions ....................3–26 3.16 ENC82L Optional Pwr/Comm Outlet Box Assembly ......... 3–28 3.16.1 Materials ..................... 3–28 3.16.2 Customer-Supplied Materials ..............3–28 3.16.3 Instructions ....................3–28 3.17 Carrier/Calibration Bottle Rack Installation on Meter Run ......3–34 3.17.1 Instructions ....................
Page 7 Ethernet Installation and Setup ..............4–2 4.2.1 TCP/IP Network Connection ............... 4–2 4.2.2 TCP/IP Local Connection ................4–4 Connecting to the NGC8206 Local Port ............. 4–5 4.3.1 Communicate Instructions ................4–5 NGC Diagnostics ..................4–6 NGC Start-Up Wizard ................. 4–7 4.5.1...
Page 8 MAINTENANCE ..................5–1 Overview ....................5–1 5.1.1 Help ......................5–1 5.1.2 Maintaining Cleanliness ................5–1 5.1.3 How to Use This Chapter ................5–1 5.1.4 Returning Part(s) for Repair ................. 5–1 Spare Part Components ................5–2 5.2.1 Replacement Components ................5–2 5.2.2 Replacement Parts ..................
Page 9 5.18.1 Instructions ....................5–24 5.19 Replacing Frit Filters ................5–25 5.19.1 Instructions ....................5–25 5.20 Replacing Feed-through Interface Gasket ..........5–27 5.20.1 Instructions ....................5–27 5.21 Replacing Feed-through Manifold Gasket ..........5–27 5.21.1 Instructions ....................5–27 5.22 Replacing Termination Panel to Digital Controller Cable ......5–29 5.22.1 Instructions ....................
Page 10 Alarm Troubleshooting Tests ..............6–21 6.4.1 Sample Vent Pressure Test ............... 6–21 6.4.2 Column Vent Pressure Test ............... 6–21 6.4.3 Sample Pressure Test ................6–21 6.4.4 Feed-through Assembly Blockage Test ............. 6–22 6.4.5 Temperature Sensor Test ................6–22 6.4.6 Abnormal Calibration Gas Depletion............6–22 Power Troubleshooting ................
Page 11 Figure 2-2 Typical Multi-Stream Installation ..................2–3 Figure 2-3 Modular Design NGC8206 ....................2–6 Figure 2-4 NGC8206 Enclosure ......................2–8 Figure 2-5 NGC8206 Enclosure Left Side ..................2–8 Figure 2-6 NGC8206 Enclosure Right Side ..................2–9 Figure 2-7 NGC8206 Enclosure Underside ..................2–9 Figure 2-8 NGC Feed-through Assembly (2102026-xxx) ..............
Page 12 Figure 3-12 ENC82L–Pipe Mount installation ................... 3–13 Figure 3-13 ENC82L–Chain Retainer Lock ..................3–13 Figure 3-14 ENC82L–Optional support leg Overview ............... 3–14 Figure 3-15 ENC82S–Channel Tubing Installation ................3–16 Figure 3-16 ENC82S–Pipe Mount Split Brackets ................3–16 Figure 3-17 ENC82S– Pipe Mount Assembly ................... 3–17 Figure 3-18 ENC82S–Pipe Mounted ....................
Page 13 Figure 4-5 Typical Chromatograph for Chrom-1 (Heavies) .............. 4–11 Figure 4-6 Typical Chromatograph for Chrom-2 (Lights) ..............4–12 Figure 5-1 NGC8206 Overall View ..................... 5–3 Figure 5-2 Analytical Module, Exploded ..................... 5–4 Figure 5-3 Feed Through Assembly, Exploded .................. 5–4 Figure 5-4 Digital Controller Complete Assembly ................
Page 14 Figure 6-3 AC Charger/Power Supply Wiring ................... 6–28 Figure 6-4 Communication Troubleshooting Flowchart ..............6–30...
Page 15 LIST OF TABLES Table 2–1 Hydrocarbons ........................2–4 Table 2–2 System Specifications ....................... 2–5 Table 2–3 Calibration Gas Blend Recommended Components ............2–18 Table 2–4 12 VDC Battery Power Supply System Maximum Cable Lengths ........2–20 Table 2–5 AC Power Supply System Maximum Cable Lengths ............2–20 Table 2–6 Internal Volume of Commonly Used Sample Transport Tubing ........
Page 16: Introduction
INTRODUCTION This manual is written to provide an experienced chromatography technician with  the requirements necessary to install, set up and operate the Totalflow Model NGC8206 Natural Gas Chromatograph. 1.1 Chapter Descriptions The manual provides the following information: Chapter Name...
Page 17: Before Calling
1.2.1 Before calling • Know the Totalflow model and serial number. Serial numbers can be found on a plate located on each unit. • Be prepared to give the customer service representative a detailed description of the problem. • Note any alarms or messages as they appear. •...
Page 18: Safety First
• Only a properly trained technician should work on any equipment with power still applied. • When opening covers or removing parts, exercise extreme care as live parts or connections can be exposed. • Installation and maintenance must be performed by person(s) qualified for the type and area of installation according to national and local codes.
Page 19: Danger From Loss Of Ground
EU Directive 2012/19/EU - Waste Electrical and Electronic Equipment (WEEE) ABB Industrial Automation, Measurement and Analytics, is committed to actively protecting the environment. Do not dispose of WEEE as unsorted municipal waste. Collect WEEE separately. Participation in the management of WEEE is critical to the success of WEEE collection.
Page 20: System Description
Gathering and End User Gas Markets. 2.1.1 Framework Based on ABB Totalflow XSeries technology, the NGC features a common platform that combines the expandable framework of the XSeries equipment with the capabilities of a remote gas chromatograph. This expandability allows the NGC to run other applications such as AGA-3 and AGA-7, while simultaneously doing stream analysis.
Page 21: Figure 2-1 Typical Single Stream Installation
Figure 2-1 Typical Single Stream Installation Page 2–2 2101510 Rev. AG...
Page 22: Figure 2-2 Typical Multi-Stream Installation
Figure 2-2 Typical Multi-Stream Installation 2101510 Rev. AG Page 2–3...
Page 23: Processing A Sample
2.2 Processing a Sample A natural gas sample is extracted from the pipeline, processed for particulate removal and phase integrity by the sample conditioning module (optional as required), transported to the NGC and injected onto the chromatographic columns where component separation occurs. The NGC analyzes each sample, utilizing established chromatographic techniques.
Page 24: Hardware System Specifications
2.3 Hardware System Specifications Table 2–2 System Specifications 12 VDC 24 VDC No. Aux. With Aux. Heater No Aux. Heater With Aux. Heater Heater Supply Voltage 10.5–16 VDC 10.5–16 VDC 21–28 VDC 21–28 VDC Recommended AC Power Supply 14.5V 14.5V Maximum Instantaneous Current...
Page 25: Ngc8206 Standard Hardware Features
 Dual digital carrier pressure regulation  Digital temperature control  Digital detector electronics  Low EMI/RFI Design  Operates on Windows CE • Auto-start with diagnostics • Factory calibrated Figure 2-3 Modular Design NGC8206 Page 2–6 2101510 Rev. AG...
Page 26: Recommended Spare Parts
2.3.2 Recommended Spare Parts Totalflow has provided a recommended spare parts list for the NGC8206 product line. Consideration was given to the cost of the repair time and the cost of stocking repair parts. The NGC8206 modular design is uniquely suited to quick repair times.
Page 27: Figure 2-4 Ngc8206 Enclosure
Figure 2-4 NGC8206 Enclosure Figure 2-5 NGC8206 Enclosure Left Side Page 2–8 2101510 Rev. AG...
Page 28: Feed-Through Assembly
Figure 2-6 NGC8206 Enclosure Right Side Figure 2-7 NGC8206 Enclosure Underside 2.3.4 Feed-through Assembly Independent sample streams are connected to the NGC directly to the feed- through assembly (see Figure 2-8), or through an optionally installed sample conditioning module. The feed-through assembly also serves as the connection 2101510 Rev.
Page 29: Analytical Module
for carrier gas and calibration streams, and contains the vents for sample and column gases. The feed-through assembly comes in three configurations: • Without auxiliary heater • With 12 VDC auxiliary heater • With 24 VDC auxiliary heater Assemblies with the auxiliary heater feature a heater with a temperature sensor cable which makes connection to the analytical module and is replaceable.
Page 30: Figure 2-9 Analytical Module
Of the subassemblies that comprise the analytical module, GC module and manifold assembly come in two configurations: 12 VDC and 24 VDC. Figure 2-9 shows the analytical module assembly removed from the enclosure. 2.3.5.1 Features • High-speed serial interface to digital controller board •...
Page 31: Figure 2-10 Manifold Assembly
Figure 2-10 Manifold Assembly 2.3.5.3 Analytical Processor Assembly The analytical processor board provides real-time system control and measurement of the analytical processes within the NGC. It does this by interfacing with all of the sensors in the GC module (and optional feed-through temperature sensor) as well as controlling the carrier pressure regulator valves, sample stream valves, the pilot valve and the heaters.
Page 32: Figure 2-11 Analytical Processor Assembly
Figure 2-11 Analytical Processor Assembly 2.3.5.4 GC Module The GC module is comprised of three parts: columns, chromatographic valve and GC module circuit board. The valve controls the flow of gas within the system. The columns perform the separation of the gas into component parts for analysis. The GC module circuit board contains the sensors for the carrier pressure regulators, the sample pressure sensor and the thermal conductivity detectors (TCDs) which detect the different gas components as they leave the GC columns.
Page 33: Digital Controller Assembly With Vga Display
2.3.6 Digital Controller Assembly with VGA Display This assembly (see Figure 2-13) contains the digital electronic board, mounting assembly and a VGA display. The digital controller board provides control parameters to the analytical processor board and stores and processes the data sent from the analytical processor board.
Page 34: Figure 2-14 Ngc Vga Display Screen
Totalflow Measurement and Control Systems www.abb.com/totalflow 12/19/05 16:49:21 USER Alarm Mode Stream Time Normal NGC Menu Analyzer Chrom Control Results Display Analyzer ID: TOTALFLOW Commands: Streams: Stream Current Abort Alarms BACK Results Hold Stream 2 User Definable Screen Stream 3...
Page 35: Termination Panel
2.3.7 Termination Panel The NGC8206 termination panel acts as a connection to the outside world (see Figure 2-15). It features transient protection, a voltage regulator for digital controller, positive temperature co-efficient fuses (PTC) and many other safeguards to protect the remainder of the system from electrical damage. All outside communications and I/O are channeled through this board.
Page 36: Grounding The Ngc
2.4 Grounding the NGC The NGC8206 must be properly grounded. The NGC has a grounding lug on the mounting neck of the enclosure. This lug should be tied to a good earth ground with no smaller than 12 AWG wire. The NGC8206 cannot be connected to any pipeline where cathodic protection exists.
Page 37: Power Supply
In an office environment, insure that a good earth ground is established to the NGC8206. In an office situation, it is easy to not have the NGC well grounded. Often the third pin (ground) on the power cable is missing or has been removed.
Page 38: Operating Voltages And Cable Lengths
Component Abbreviation Mol % Component Abbreviation Mol % Name Name Hexanes and Propane 1.000 0.030 Heavier Iso Butane 0.300 2.6 Operating Voltages and Cable Lengths The NGC is designed for connection to a 12 VDC or 24 VDC power source. The 12 volt power source must provide a minimum of 10.5 VDC to a maximum of 16 VDC at 4 amps minimum, and the 24 volt must provide a minimum of 21 VDC to a maximum of 28 VDC at 2.2 amps.
Page 39: Table 2-4 12 Vdc Battery Power Supply System Maximum Cable Lengths
Table 2–4 12 VDC Battery Power Supply System Maximum Cable Lengths Min. Batt Model Voltage Units 12 AWG 14 AWG 16 AWG 6 mm^2 4 mm^2 2.5 mm^2 1.5 mm^2 10 AWG /Option (ft) 78.28 49.44 30.97 19.43 90.03 60.17 37.42 22.92 12 VDC NGC w/o...
Page 40: Sample Transport Tubing Design
2.7 Sample Transport Tubing Design Information in this section enables the user to design the sample transport tubing connected between the TCR sample probe and the installed NGC. Minimizing transport lag time and maintaining a single vapor phase sample are important factors to consider when selecting transport tubing.
Page 41: Gas Volume In Transit Tubing
Table 2–6 Internal Volume of Commonly Used Sample Transport Tubing Tube Outside Diameter Tube Wall Thickness (in.) Volume per Foot (cc) (in.) 0.02 0.035 0.035 0.035 2.7.5 Gas Volume in Transit Tubing Gases are compressible, and the volume of gas in transport tubing for standard conditions (atmospheric pressure and 70°F [21.1°C]), is a function of gas pressure and temperature within tubing.
Page 42: Heat Tracing Sample Lines
2.7.8 Heat Tracing Sample Lines If there is a possibility that vapor samples could condense in the sample transport line, heat tracing the sample line should be considered. This could occur at ambient temperatures or when a liquid has to be kept warm for transporting or to keep it from freezing (see Figure 2-17).
Page 43: Calculations
NGC8200 HEATED CABINET LIQUID DRAIN RM-2 RM-3 RM-1 ANALYZER 10 cc/min. HV-3 BYPASS RM-4 RM-5 By-Pass Flow HV-1 HV-2 800 cm/min Typical HV-4 STREAM 1 STREAM 2 HV-5 115 VAC 60 HZ HEATER HV-8 125 WATT HV-7 LIQUID DRAIN HV-6 STANDARD Figure 2-18 Typical Sample Installation Diagram 2.8.1...
Page 44: Ngc8206 Standard Software Features
Care should be taken to assure that enough pressure is available to keep sample flowing throughout the analysis system. 2.9 NGC8206 Standard Software Features Totalflow’s on-board and host software work together to provide many key features that enable the user to access, control and share data. The user-friendly interface allows multi-faceted report and communication capabilities without compromising the integrity of the system or the data.
Page 45: Calculation Options
2.9.4 Calculation Options During Stream Setup, the user may select from several calculation files. Selection of a suitable file automatically sets up other factors such as concentration/Btu basis and saturated gas treatment (see Table 2–7). For additional information, refer to the PCCU Help files. Table 2–7 Calculation File Settings Calculation File Agency...
Page 46: Ngc Start-Up Diagnostics
1.5 Minutes 2.11 NGC Start-Up Diagnostics The Totalflow NGC8206 has an extensive built-in list of tests which are performed each time the unit is started. This start-up testing may be disabled, but Totalflow recommends that it be left enabled. These diagnostics consist of four areas of testing: •...
Page 47: Start-Up Wizard
2.12 Start-Up Wizard The NGC8206 Start-up Wizard is designed to walk the technician through procedures required for setting up the unit. Following installation and connection to the NGC, the Startup Wizard begins automatically. This only happens the first time the user connects to the unit or upon start-up each time the user reconnects to the system until the unit setup is completed.
Page 48: Audit Logs
Table 2–9 to ensure the correct sample probe for installation. The length of the sample probe is dependent on the diameter of the meter run. ABB Totalflow recommends that a TCR be installed with the NGC. Refer to Figure 2-19.
Page 49: Location
2.14.1 Location • Locate the pipeline coupling on the gas meter run in close proximity to the NGC. This allows the stainless steel sample line from sample probe to Chromatograph to be as short as possible. • The coupling should be mounted so the probe can be installed horizontally or vertically on the meter run pipe.
Page 50: Figure 2-20 Enc82L Environmental Enclosure With Electric Heater
depending upon site requirements. The large enclosure (ENC82L) will hold a single or dual unit NGC and features a large foot print (38” w x 31”d x 30.5” h) See Figure 2-20 Figure 2-21. The small enclosure (ENC82S) is designed for a single NGC unit and features a smaller foot print (24”...
Page 51: Figure 2-21 Enc82L Environmental Enclosure With Catalytic Heater
CATALYTIC HEATER OPTION BOTTLE RACK OPTION POWER SWITCH THERMOSTAT PWR/COMM OUTLET BOX CALIBRATION BLEND INSULATED ENCLOSURE WALL Figure 2-21 ENC82L Environmental Enclosure with Catalytic Heater HEATER KIT: THERMOSTAT VARITHERM 120 VAC, 400 WATT INSULATED ENCLOSURE WALL CALIBRATION BLEND BOTTLE BOTTLE RACK OPTION CYLINDER: M009 FITTINGS: CGA180 Figure 2-22: ENC82S Environmental Enclosure with Electric Heater...
Page 52: Optional Features
CATALYTIC HEATER OPTION BOTTLE RACK OPTION CALIBRATION BLEND THERMOSTAT INSULATED ENCLOSURE WALL Figure 2-23 ENC82S Environmental Enclosure with Catalytic Heater 2.15.1.2 Mounting Options The ENC82 may be mounted directly on the pipe run, with or without the sample probe enclosed. Optional support legs are available for added support when mounted on the pipe run.
Page 53: Gas Types
2.16.1 Gas Types The user can select from one of four sample conditioning modules for installations whose gas samples do not meet the ideal clean and dry conditions. The following definitions define what is meant by the condition of natural gas to be sampled. •...
Page 54: Mounting Brackets
Part Number Description • Particulate/coalescing filter • Liquid/vapor separator Designed to remove condensing sample line liquid or water that has penetrated the sample probe. The system expels the liquid or water downward into the bottom of the Armstrong trap drainer via inertial separation. Sample gas is extracted from the fitting at the top of the Armstrong accumulator.
Page 55: Figure 2-26 Single Stream Conditioning Module Dimensions
Figure 2-26 Single Stream Conditioning Module Dimensions Figure 2-27 Multiple Stream Conditioning Module Dimensions Page 2–36 2101510 Rev. AG...
Page 56: Security Seal (Optional Equipment)
2.17 Security Seal (Optional Equipment) For some NGC installations, it may be desirable to attach a Security Seal on the enclosure front and rear End Caps. To accommodate seal, please note the holes located in the tab located on each End Cap (See Figure 2-28).
Page 57: 6200 Optional Equipment Enclosure
115/230 VAC UPS Power Option (24 VDC Systems Only)  2 ea. 40–110 Ah Batteries 2.19 Power Supply Options (Optional Equipment) Power supply options available for the NGC8206 are as follows: • 110/240 VAC to 12/24 VDC • 115/230 VAC to 12 VDC (explosion-proof) •...
Page 58: 115/230 Vac Ups Power Option (24 Vdc Systems Only)
disconnects batteries when the voltage drops below the minimum recharge level. Minimum configuration consists of dual 50 W solar panels. System is designed to accommodate dual 110 W solar panels as a maximum. Auxiliary fusing is not available when using the optional heater.
Page 59: Explosion-Proof Power Supply (Optional Equipment)
OUTPUT INPUT OUTPUT BATTERY Figure 2-31 6800 Enclosure with 115/230 VAC UPS Power Option 2.19.3 Explosion-Proof Power Supply (Optional Equipment) For installations requiring an explosion-proof power supply, Totalflow provides two power supplies (115 VAC and 230 VAC to 12 VDC) that meet these requirements and are housed in explosion-proof enclosures.
Page 60: Figure 2-32 Explosion-Proof Ac Power Supply
hex socket set screw on cap. Figure 2-32 Explosion-Proof AC Power Supply 2101510 Rev. AG Page 2–41...
Page 61: Installation
INSTALLATION 3.1 Overview This chapter provides information for field installation of the NGC and optional equipment. After completing the procedures within this chapter, the NGC is ready for start-up. The following procedures, unless otherwise stated, are applicable to all NGC units.
Page 62: Locating Area For Installation
NGC8200 SAMPLE PROBE CALIBRATION GAS CARRIER GAS Figure 3-1 Basic Meter Run Installation MOUNTING PLATE FLANGE WALL SHELF Figure 3-2 Typical Wall Shelf Mount Installation 3.1.3 Locating Area for Installation The NGC is designed for mounting on main gas lines, 2-inch to 12-inch pipe sizes. Each type of installation is described within this chapter.
Page 63: Installation
Be certain the installation site is clean and free of foreign debris that could affect NGC operation. The NGC should be located as close as possible to the sample probe installation point. This prevents the need for high gas flow rates through sample lines to assure the analysis accuracy of the current sample.
Page 64: Unpacking And Inspection
Installation Instructions • ENC82L Optional Pwr/Comm Outlet Box Assembly 2.16 • • • Carrier/Calibration Bottle Rack Installation on Meter Run 2.17 • • ENC82 Carrier Gas Bottle Rack Installation 2.18 • • • • • Carrier Gas Regulator Installation 2.19 •...
Page 65: Unpacking
3.2.2 Unpacking The NGC is shipped in specially designed shipping cartons which contains the unit, mounting brackets, parts list and wiring and interconnect diagrams. Optional equipment is shipped in a separate carton. Carefully remove all internal and external packing material. Carefully remove all items from the box.
Page 66: Stand Alone Installation
6) Insert gas probe into pipeline coupling (see Figure 3-4). 7) Using the correct tool, tighten probe. Securely tighten so there is no gas leakage. Do not over-tighten. 8) Install shut-off valve on secondary side of sample probe, if desired. PRESSURE RELIEF VALVE 1/4"...
Page 67: Material Required
3.4.1 Material required • One 2 inch pipe with flange • One 2 inch pipe coupling • One 2 inch mounting pipe (installed). Length dependent upon final overall NGC desired height. Optional equipment may be ordered from Totalflow. 3.4.2 Instructions 1) Select a location to install the mounting pipe that allows easy access and is close to the sample probe.
Page 68: Figure 3-5 Enc82L-Enclosure Stand Installation
57.00" 84.00" 55.50" 4.00" 27.00" 21.50" 34.00" 24.00" 38.00" Figure 3-5 ENC82L–Enclosure Stand Installation 3) Place a split washer, then a flat washer on one of the 1 ¼” bolts and insert through bolt hole located in the angle iron into the outermost corner of the enclosure (see Figure 3-6).
Page 69: Small Free-Standing Environmental Enclosure Installation
Figure 3-6 ENC82L–Enclosure Mounting Hardware 5) Repeat for all other corners. 6) Position enclosure on stand, centering stand underneath, or offset as desired, and tighten all bolts. 7) Foot plate mounting holes are pre-drilled for mounting to a pad. Hardware is to be supplied by the customer.
Page 70: Figure 3-7 Enc82S-Enclosure Installation
24.00" 22.63" 67.51" 53.00" (4) Holes for attaching Bottle Rack Option 30.38" 13.25" 20.5" O.C. 17.25" 22.50" 19.00" 9/16 X 1 1/4 Slotted Holes Figure 3-7 ENC82S–Enclosure Installation Existing Channel Tubing Spring Nut (4 places) Stand Screw, Lock Washer & Washer (4 places) Figure 3-8 ENC82S–Enclosure Mounting Hardware...
Page 71: Large Pipe-Mounted Environmental Enclosure Mounting Kit
6) Position the enclosure on the stand, centering the stand underneath or offset as desired and tighten all bolts. 7) Foot plate mounting holes are pre-drilled for mounting to a pad. Hardware is to be supplied by the customer. 3.7 Large Pipe-Mounted Environmental Enclosure Mounting Kit If the installation includes a pipe-mounted environmental enclosure, follow these instructions as well as the optional support leg instructions, if applicable.
Page 72: Figure 3-9 Enc82L-Mounting Brackets
BOLT HOLES CHAIN HOLE 43.00 4.12 34.000 (2 1/2) 1.25 ADJUSTMENT 1.00 CHAIN RETAINER ASSEMBLY HOLE MOUNTING HOLE 1.12 Figure 3-9 ENC82L–Mounting Brackets (31.00) Figure 3-10 ENC82L–Mounting Hardware Installation TIGHTENING CHAIN LENGTHS -001 13.00" .75 FLAT WASHER .75 SPLIT WASHER -002 19.00"...
Page 73: Figure 3-12 Enc82L-Pipe Mount Installation
10) Screw nut onto all-thread until top of nut is level with top of all-thread. Final tightening may be done after mounting chain is in place. Lift enclosure above meter run, allowing enough clearance to clear the pipe. 11) Set the enclosure on top of the pipe in-between the angle iron mounting brackets.
Page 74: Materials
3.8 Optional Support Leg Kit Installation If the installation includes a pipe-mounted environmental enclosure and requires an optional support leg, follow these instructions. Otherwise, continue to the next applicable set of instructions. 3.8.1 Materials • 2 ea. ½-13 x 1 ¼ SST bolt •...
Page 75: Materials
6) Loosen adjustment handle and drop leg foot down and retighten adjustment handle. 7) Foot plate mounting holes are pre-drilled for mounting to a pad. Hardware is to be supplied by the customer. 3.9 Small Pipe-Mounted Environmental Enclosure Mounting Kit If the installation includes a pipe-mounted environmental enclosure, follow these instructions if applicable.
Page 76: Figure 3-15 Enc82S-Channel Tubing Installation
Spring Nut Existing Channel Tubing Spring Nut Screw, Lock Washer & Washer Screw, Lock Washer & Washer Figure 3-15 ENC82S–Channel Tubing Installation Figure 3-16 ENC82S–Pipe Mount Split Brackets Page 3–16 2101510 Rev. AG...
Page 77: Figure 3-17 Enc82S- Pipe Mount Assembly
Screw & Nut Asm Unassemble to fit on pipe Figure 3-17 ENC82S– Pipe Mount Assembly Pipe Reassemble Figure 3-18 ENC82S–Pipe Mounted 2101510 Rev. AG Page 3–17...
Page 78: Pipe Saddle Installation
3.10 Pipe Saddle Installation If installing an NGC using the pipe saddle mounting kit, use this procedure to install the pipe saddle. Before beginning, review the procedure and the materials required for installation. The optional pipe with flange may be used in installations requiring additional stability.
Page 79: Shelf Installation
3.11 Shelf Installation If the installation calls for the NGC shelf mounting kit, use this procedure to mount the shelf. Otherwise, continue to the next applicable instructions. Before beginning, review the procedure and the materials required for installation. 3.11.1 Materials •...
Page 80: Ngc Installation
OPTIONAL MOUNTING FLANGE PIPE 2" PIPE COUPLING WALL SHELF Figure 3-20 Shelf Installation 3.12 NGC Installation Once the mounting system has been installed, regardless of the type used, follow these instructions to install the NGC onto the mounting pipe. Both the large and small environmental enclosures are shipped with the NGC mounting system installed inside the environmental enclosure.
Page 81: Sample Conditioning Module Installation
to the feed-through assembly and the termination panel located in the rear of the housing. • For the shelf-mounted units, the unit would be oriented with the feed- through assembly also facing forward. Sufficient clearance is required when mounted near an inside corner. •...
Page 82: Mounting Kits
• Single or multiple module mounting kit (see Figure 3-23) • 1 ea. .312 x 2.5 x 3.62 x 1.5 U-bolt • 2 ea. 5/16” SST split washer • 2 ea. 5/16” SST flat washer • 2 ea. 5/16-18 SST lock nut •...
Page 83: Sample Line Connections
8) Tighten both nuts. Single and Multiple Stream Sample Conditioning Assemblies Figure 3-24 3.14 Sample Line Connections Following the installation of the sample conditioning module(s), install the sample tubing from the sample probe to the sample conditioning system and NGC feed- through assembly.
Page 84: Figure 3-25 Sample Conditioning Module Line Connections
1) Locate the sample input fitting on the sample conditioning module (see Figure 3-25). 2) Locate the sample output fitting on the installed sample probe. 3) Measure and cut the SST tubing to the required length. 4) Make the necessary bends in the tubing to ease installation of the ferrule and nut into the sample conditioning module input port.
Page 85: Sample Line(S) To Ngc Inside Of Enc82
9) Insert the ferrule into the sample conditioning module input fitting. Move the nut down onto the ferrule, screw onto fitting and tighten. 10) Locate the sample output fitting on the sample conditioning module. 11) Locate the sample input on the NGC feed-through assembly and remove the sealing screw.
Page 86: Instructions
3.15.2 Instructions Be certain that the ends of stainless steel tubing are open and not restricted. 1) Locate the sample input fitting on sample conditioning module (see Figure 3-26) and sample output fitting on installed sample probe.. 2) Locate the sample boot on side of environmental enclosure. Sample lines must feed through the sample boot located on the side of the enclosure.
Page 87: Figure 3-27 Enc82S-Environmental Enclosure Sample Boot
Sample Boot Figure 3-27 ENC82S–Environmental enclosure Sample Boot 4) If necessary, install reducer into sample probe output fitting. 5) Install ferrule and nut onto one end of the sample tubing. 6) Insert tubing with ferrule into reducer/sample probe output fitting. Move nut down onto ferrule, screw onto fitting and tighten.
Page 88: Enc82L Optional Pwr/Comm Outlet Box Assembly
15) Insert the tubing with the ferrule into the corresponding input port located on the NGC feed-through assembly. Move the Valco nut down onto the ferrule, screw into the port and tighten. 16) Repeat for each additional sample stream. Do not over-tighten. After securing the tubing, check for gas leaks.
Page 89: Figure 3-28 Power Communication Outlet Box Assembly
DC POWER SWITCH INTERNAL NGC CONNECTION ASSEMBLY OUTLET BOX ASSEMBLY FLEXIBLE CABLE ASSEMBLY Figure 3-28 Power Communication Outlet Box Assembly 4) Moving the assembly clockwise, screw the nipple fitting into the hub until the assembly is tight and hanging straight down at a 180˚. 5) Feed the other end of the wire bundle through the flexible cable assembly, beginning at end with the sealing gasket, until threads meet the conduit seal.
Page 90: Figure 3-29 Enc82L Large Enclosure
15) Repeat steps 13 through 15 for the second screw. INTERNAL CONNECTION ASSY FLEXABLE CABLE OUTLET BOX ASSY DC POWER SWITCH Figure 3-29 ENC82L Large Enclosure 16) Locate the support bracket mounting holes on the enclosure. 17) Place the split washer, then a flat washer on the end of each screw. 18) Insert the screw through the mounting bracket and into the hole on the side of the enclosure.
Page 91: Figure 3-30 Assembled Power/Communication Assembly
INSULATED ENCLSOSURE WALL DC POWER SWITCH FLEXABLE CABLE ASSEMBLY NGC8200 MOUNTING BRACKET CONDUIT SEAL-TO BE COMPLETED BY CUSTOMER OUTLET BOX ASSEMBLY Figure 3-30 Assembled Power/Communication Assembly 23) At the NGC termination panel, trim and strip the wire ends. 24) Remove the power field termination J1 connector from the termination panel. 25) Using the wiring instructions in Figure 3-31, install each wire into the correct...
Page 92: Figure 3-31 Power Wiring Diagram
POWER Figure 3-31 Power Wiring Diagram 35) Feed the excess wire through the 6” nipple fitting, conduit seal, 5” nipple fitting and out into outlet box opening. Pull sufficient wire to complete field wiring. 36) Remove the power field termination J4 connector from the outlet box panel. 37) Using the wiring instructions in Figure 3-31, install power (+) and power (-) wires...
Page 93: Figure 3-32 Suggested Rs-232 Wiring Instructions
Communication wiring terminations inside the power/communication outlet box assembly are pass-through connections, meaning that J1-pin 1 is associated with J2-pin 1. Therefore, pinouts may be user-defined and wiring instructions for this assembly are only suggestions. External wiring and connections should be performed by an experienced technician and follow requirements of national and local codes.
Page 94: Carrier/Calibration Bottle Rack Installation On Meter Run
NGC 8200 TERMINATION BOARD 2102080-XXX 1 2 3 1 2 3 SW PWR RRTS BUS+ BUS- SW PWR RRTS 10 10 BUS+ J8 COMM PORT 1 J10 COMM PORT 2 BUS- 11 11 12 12 Figure 3-33 Suggested RS-485 Wiring Instructions NGC 8200 TERMINATION BOARD 2102080-XXX...
Page 95: Instructions
3.17.1 Instructions 1) Position the bottle rack in close proximity to the NGC. 2) Secure the rack to the pipe meter run with the provided mounting hardware. 3) Install both the carrier and calibration gas bottles in the rack. 4) Strap both bottles in the rack to prevent falling. CARRIER CALIBRATION TO NGC...
Page 96: Figure 3-36 Dual Bottle Rack Assembly
Enclosure hole contains a captive nut. Figure 3-36 Dual Bottle Rack Assembly 3) Screw the bolt into the captive nut on the large enclosure or nut provided with small enclosure kit, tighten. 4) Repeat for second bolt. 5) Install carrier gas bottle in bottle rack. 6) Using chains, strap the bottle(s) to the rack by attaching a bolt snap to one of the center chains.
Page 97: Figure 3-38 Enc82S-Dual Bottle Rack Installation
Large Environmental Enclosure Back Side Bracket Figure 3-37 ENC82L–Dual Bottle Rack Installation Bottle Rack Option P/N: 2101076 Note: This option mounts to the side of the stand and not to the Enclosure Insert Bolt through split and flat washer. Feed through stand mounting holes into nut.
Page 98: Carrier Gas Regulator Installation
3.19 Carrier Gas Regulator Installation The following instructions are valid for all installations. 3.19.1 Materials • Carrier regulator assembly with low pressure switch (see Figure 3-39) • Installed carrier gas bottle These instructions assume that the carrier gas bottle has been installed.
Page 99: Enc82L Calibration Gas Bottle Installation
BARRIER REQUIRED FOR ALL INSTALLATIONS OTHER THAN NON-HAZARDOUS REGULATOR CARRIER INPUTS OUTPUTS ASSY DIGITAL I/0 CYLINDER NGC TERMINATION BOARD Figure 3-40 Carrier Gas Low Pressure Switch Wiring Instruction 5) Using a small flat blade screw driver, loosen DI2 pins 3 and 4. 6) Insert the red wire into the (+) terminal (pin 3).
Page 100: Enc82S Calibration Gas Bottle Installation
NGC8200 CAL BLEND REGULATOR ASSY CAL BLEND CYLINDER WORM GEAR CLAMP RIGHT SIDE CUT-AWAY VIEW Figure 3-41 Calibration Bottle Location 3.21 ENC82S Calibration Gas Bottle Installation The calibration gas bottle mounting rack is used to hold the calibration gas bottle when located inside of the small environmental enclosure.
Page 101: Calibration Gas Regulator Installation
CALIBRATION BLEND BOTTLE CYLINDER: M009 FITTINGS: CGA180 Figure 3-42 Calibration Bottle Location 3.22 Calibration Gas Regulator Installation The following instructions are valid for all installations. 3.22.1 Materials • Calibration blend regulator assembly with low pressure switch (see Figure 3-43) • Installed calibration gas bottle These instructions assume that the carrier gas bottle has been installed.
Page 102: Figure 3-43 Calibration Gas Pressure Regulator With Relief Valve
9) Insert the black wire into the (-) terminal (pin 4). 10) Retighten pin 4. 11) Replace the termination connector in the J2 board connector. Figure 3-43 Calibration Gas Pressure Regulator with Relief Valve BARRIER REQUIRED FOR ALL INSTALLATIONS OTHER THAN NON-HAZARDOUS REGULATOR INPUTS...
Page 103: Carrier Gas And Calibration Gas Connections
3.23 Carrier Gas and Calibration Gas Connections The following procedures describe the steps for connecting the external carrier gas and calibration gas lines from the respective regulators to the feed-through assembly on the NGC. They are applicable for both a meter run and an environmental enclosure installation.
Page 104 Tube, ferrule and nut should always enter the connection at a right angle. 5) Install the reducer into the carrier gas regulator. 6) Insert the tube with the ferrule into the reducer/pressure regulator output fitting. Move the nut down onto the ferrule, screw onto fitting, tighten. 7) Carrier gas pressure should be set at 90 PSIG.
Page 105: Vent Lines Connections
3.24 Vent Lines Connections The following procedure provides general steps for connecting the external vent lines from the respective output ports on the feed-through assembly. When the NGC is installed in the environmental enclosure, the sample vent line must vent outside of the enclosure.
Page 106: Enc82L Optional Catalytic Heater Installation
3.25 ENC82L Optional Catalytic Heater Installation The following procedures describe the steps for installing a catalytic heater for the environmental enclosure. Verify the heater and fittings are approved for the classification rating of the area of installation. These instructions are only applicable to the large environmental enclosure.
Page 107: Figure 3-47 Catalytic Heater Option In Environmental Enclosure
Figure 3-47 Catalytic Heater Option in Environmental Enclosure 1/4 NPT PLUG MALE, 3/8 x 1/4 NPT 3/8" TUBBING MALE, 3/8 x 1/4 NPT W/ FERRULES AND NUT TUBING T ASSEMBLY THERMOSTAT REGULATOR TEMPERATURE PROBE REGULATOR SERVICE COCK FILTER/DRAIN ASSEMBLY MALE, 3/8 x 1/4 NPT THERMOSTAT ASSEMBLY REGULATOR ASSEMBLY Figure 3-48 Catalytic Heater Assemblies...
Page 108: Figure 3-49 Thermostat Assembly Installed
FILTER/DRAIN ASSEMBLIES Figure 3-49 Thermostat Assembly Installed 5) Screw the threaded end of the T assembly into the ¼” female fitting located on the factory-installed Catalytic heater, by turning the entire assembly clockwise until tight (see Figure 3-50). ® 6) Remove ferrules and nut from the bottom of the T assembly. Apply Teflon tape to threads.
Page 109: Figure 3-51 Temperature Probe Installation
8) Place the nut, front ferrule and back ferrule onto the opposite end of the tubing and position so that the ferrules and nut screw onto the bottom of T assembly. Screw nut until tight. 9) Remove ferrules and nut from the thermostat end of the thermostat assembly. ®...
Page 110: Enc82S Optional Catalytic Heater Installation
The technician responsible for installing the gas supply must follow local and national codes. 21) Using the regulator manufacturer's instructions supplied with the regulator, make external gas connections. The technician responsible for installing the power supply must follow local and national codes. 22) Using the wiring instructions shown in Figure 3-52 and the manufacturer's...
Page 111: Instructions
3.26.2 Instructions The technician responsible for installing the gas supply must follow local and national codes. 1) Using the manufacturer's instructions supplied with the regulator, make external gas connections. ® 2) Apply Teflon tape to the port one nipple on the filter/drain assembly. 3) Insert the port one nipple on the filter/drain assembly into the output port on the regulator and tighten the nut (see Figure...
Page 112: Enc82 Optional Electric Heater Installation
Catalytic Heater Option From Customer-supplied 12V DC Power Source Figure 3-54 ENC82S Catalytic Heater Pre-Heat Wiring 3.27 ENC82 Optional Electric Heater Installation The following procedures describe the steps for wiring an electric heater for the environmental enclosure. Verify the heater and fittings are approved for the classification rating of the area of installation.
Page 113: Instructions
BOTTLE RACK OPTION ELECTRIC HEATER OPTION POWER SWITCH THERMOSTAT PWR/COMM OUTLET BOX CALIBRATION INSULATED BLEND ENCLOSURE WALL Figure 3-55 ENC82L Electric Heater Installed in Enclosure THERMOSTAT HEATER KIT: VARITHERM 120 VAC, 400 WATT INSULATED ENCLOSURE WALL CALIBRATION BLEND BOTTLE CYLINDER: M009 FITTINGS: CGA180 Figure 3-56 ENC82S Electric Heater Installed in Enclosure 3.27.2 Instructions...
Page 114: Figure 3-57 Electric Heater Option Wiring Instructions
ENVIRONMENTAL ENCLOSURE JUNCTION BOX Thermostat TO AC YEL/GRN Figure 3-57 Electric Heater Option Wiring Instructions To Customer-supplied 120V AC Power Source Electrical Junction Box Heater 120V AC, 120 WATT, Class 1, Div 1 Figure 3-58 ENC82S Electric Heater Option Wiring Instructions Page 3–54 2101510 Rev.
Page 115: Sealing Environmental Enclosure
NGC, communication equipment, solar power charger and additional I/O. Three enclosures are commonly used for the NGC8206 installations: the 6200, 6700 and 6800 enclosure. The unit may be mounted on a 2” pipe or mounted on a flat surface such as a wall.
Page 116: 6800 Enclosure
 1 each 26/30 AH battery • Communications kit The 6700 enclosure supports battery-backed operation for the NGC. The XFC/XRC electronic board provides a battery charger/regulator for the system. 3.29.3 6800 Enclosure The 6800 enclosure can accommodate the following : •...
Page 117: Figure 3-59 6200 Enclosure Pipe-Mounting Installation
Figure 3-59 6200 Enclosure Pipe-Mounting Installation 2.00 PIPE (2.38 O.D.) Figure 3-60 6700 Enclosure Pipe Mounting Installation 2101510 Rev. AG Page 3–57...
Page 118: Wall Mount Instructions
Enclosure mounting brackets and fastening hardware are supplied with the unit. 1) When the unit is received, unpack and inspect all components for evidence of damage. Report damage to the shipping carrier and to the ABB Totalflow service department. 2) Using instructions supplied with the mounting kit, attach the bracket to the back of the enclosure unit.
Page 119: Figure 3-62 6200 Enclosure Wall Mounted Installation
MOUNTING BRACKET Figure 3-62 6200 Enclosure Wall Mounted Installation MOUNTING BRACKET Figure 3-63 6700 Enclosure Wall Mounted Installation 2101510 Rev. AG Page 3–59...
Page 120: 115/230 Vac Ups Power Supply (24 Vdc Systems)
Wall Mount Instructions 1) When the unit is received, unpack and inspect all components for evidence of damage. Report damage to the shipping carrier and to the ABB Totalflow service department. 2) Using instructions supplied with the mounting kit, attach the bracket to the back of the enclosure unit.
Page 121: Instructions
3.30.1 Instructions 1) If configured, the optional equipment unit should contain an installed power supply. The Optional Equipment Enclosure Installation should be installed using instructions shown previously in this chapter. 2) Remove the necessary plugs from the side of the enclosure to install the rigid conduit.
Page 122: 115/230 Vac To 12 Vdc Explosion-Proof Power Supply Installation
Figure 3-65 115/230 VAC UPS Power Supply Option 3.31 115/230 VAC to 12 VDC Explosion-Proof Power Supply Installation Before beginning, review the procedure and the materials required for installation. Page 3–62 2101510 Rev. AG...
Page 123: Customer Supplied Materials
The AC/DC power supply may be approved for classified hazardous locations or potentially explosive atmospheres. Verify the rating listed on the unit tag and install per the referenced control drawing. Be sure to follow the requirements of national and local codes when installing the power supply. Installation must be performed by person(s) qualified for the type and area of installation, according to national and local codes.
Page 124: Instructions
1) The AC power supply is shipped separately. When the unit is received, unpack and inspect all components for evidence of damage. Report damage to the shipping carrier and to the ABB Totalflow service department. 2) Mount the explosion-proof enclosure on a nearby wall or panel. Make sure that the rigid explosion-proof conduit or appropriate flexible conduit can be installed between the power supply’s explosion-proof enclosure and the NGC.
Page 125: 110/240 Vac To 12/24 Vdc Power Supply Installation
Explosion-Proof Enclosure DIGITAL I/O POWER (+) (-) (+) (-) (+) (-) (+) (-) (+) (-) PWR IN INPUTS OUTPUTS 5VDC TERM TERM NO TERM NO TERM 13 14 Output DC 12V 10A SERIAL PORT 1 SERIAL PORT 2 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 PHOENIX CONTACT...
Page 126: Figure 3-69 6200 Optional Equipment Enclosure With Power Supply
DC OK Adjust 11.5-18VDC Figure 3-69 6200 Optional Equipment Enclosure with Power Supply Communication Shelf PHOENIX CONTACT DC OK Adjust 11.5-18VDC Figure 3-70 6700 Optional Equipment Enclosure with Power Supply Page 3–66 2101510 Rev. AG...
Page 127: Instructions
The AC/DC power supply may be approved for classified hazardous locations or potentially explosive atmospheres. Verify the rating listed on the unit tag, and install per the referenced control drawing. Be sure to follow the requirements of national and local codes when installing the power supply. Installation must be performed by person(s) qualified for the type and area of installation, according to national and local codes.
Page 128: Vdc To 12 Vdc Power Converter
3.33 24 VDC to 12 VDC Power Converter Before beginning, review the procedure and the materials required for installation. This power converter is not applicable for NGC systems with optional auxiliary feed-through heater. The DC/DC power converter may be approved for classified hazardous locations or potentially explosive atmospheres.
Page 129: Battery Pack Installation
Power Supply 6470/6770 Enclosure IPS, Inc. P/N 2015440-005 NGC8200 TERMINATION PANEL DIGITAL I/O POWER (+) (-) (+) (-) (+) (-) (+) (-) INPUTS OUTPUTS DC+ IN DC- IN TERM TERM 24V DC Input SERIAL PORT 1 SERIAL PORT 2 RESET POWER SUPPLY (ROTATED FOR CLARITY) Figure 3-72 24 VDC/12 VDC Power Supply Converter 3.34 Battery Pack Installation...
Page 130: Instructions
Figure 3-73 Optional 6800 Enclosure with Battery Pack BATTERY 2 BATTERY 1 Figure 3-74 12/24 VDC Dual Battery Pack Cable 3.34.1 Instructions 1) Insert the battery(s) into the battery compartment with the terminals facing up (see Figure 3-73). 2) For the 12/24 VDC solar power system or the 24 VDC UPS power system, a dual battery cable is provided with the unit (see Figure 3-74).
Page 131: Figure 3-75 Battery Pack With Dc Power Supply Wiring Instructions
6870 Enclosure To NGC (Supplied by customer) 1 2 3 4 (-) BLK (-) BLK (+) RED Cable (+) RED Dual 110AH Battery Kit P/N 2018359-008 P/N 2104054-002 Figure 3-75 Battery Pack with DC Power Supply Wiring Instructions 3) For AC charging systems containing one or two batteries (see Figure 3-76), connect the battery cable to the prewired power supply cable(s).
Page 132: Solar Panel Installation
( SELECT EITHER ) 6770 ENCLOSURE BATT J18 I/ O EXP CHARGER INPUT J10 J7 COMM2 COMM 1 3- WAY CONNECTOR P/ N 2012907 - 001 DIGITAL I / O ( - ) ( + ) KEYPAD SECURITY XFC/ XRC Bd . NGC 8201 TERMINATION PANEL BATTERY (BT1) AUXPWR OUTPUT...
Page 133: Instructions
• One 9-inch extension of 2-inch pipe or other suitable length of pipe, threaded on one end. • One 2-inch coupling. Exercise caution when installing the solar panel so as not to damage it. When mounted, solar panel will face up from horizon at 50°...
Page 134: Instructions
3 and 4. Review the Grounding the NGC8206 section in, System Description, before making power connections. 3) Pipe the conduit and associated DC wiring from the NGC8206 into the power supply enclosure. See Table 2–4 for wire sizes.
Page 135: Figure 3-78 12 Vdc Battery Pack/Solar Panel Wiring Instructions
Figure 3-78 12 VDC Battery Pack/Solar Panel Wiring Instructions 2101510 Rev. AG Page 3–75...
Page 136: Figure 3-79 24 Vdc Battery Pack/Solar Panel Wiring Instructions
Figure 3-79 24 VDC Battery Pack/Solar Panel Wiring Instructions Page 3–76 2101510 Rev. AG...
Page 137: Dc Power Installation
5) If the NGC8200 has the optional VGA screen, the unit will show “Totalflow Boot Loader” followed by the navigational screen, when functional. 6) Unit will begin Start-up Diagnostics and oven stabilization. This completes the hardware installation. Proceed to the next chapter, NGC8206 STartup, to begin unit setup and operation. 3.38 Remote Communication Installation As remote communication installation is specific to the communication transceiver, only basic information is supplied here.
Page 138 RS-232 RS-485 RS-422 Switched Switched Switched Power Power Out Power Out Operate Operate Operate Not Used RRTS Request To Transmit Bus + Send Bus + Transmit Transmit Data Bus - Bus - Receive Receive Data Connection Bus + Clear To Send Receive (CTS) Connection...
Page 139: Ngc8206 Startup
NGC8206 STARTUP This chapter describes the minimum requirements to start up a newly installed NGC system. Specific details to further customize the NGC are discussed in the PCCU32 help files. Do not open or remove covers, including the PCCU local communications cover, unless the area is known to be non- hazardous, including the internal volume of the enclosure.
Page 140: Ethernet Installation And Setup
4.2 Ethernet Installation and Setup Installation of an NGC in a network environment may be implemented using the following instructions. Some decisions may require input from the network administrator. PCCU32 communication with the NGC over an Ethernet connection (TCP/IP) requires the use of a hub, switch or router (see Figure 4-1).
Page 141: Figure 4-2 Ethernet Cable-Typical
• At the command prompt, type ipconfig /all (space after ipconfig). • Record the PC and LAN settings displayed for later use. 2) Make local connection to the NGC using either the USB or RS-232 cable to do initial setup of the parameters. 3) From the Analyzer Operation screen in PCCU, click Show Tree View in the upper left corner of the screen.
Page 142: Tcp/Ip Local Connection
4.2.2 TCP/IP Local Connection Material Required: • Ethernet Cross-Over Cable (see Figure 4-3). 4.2.2.1 Instructions 1) Make local connection to the NGC using either a USB or RS-232 cable to set up the initial parameters. End View Crossed-Over Cable Brown Brown Brown/White Brown/White...
Page 143: Connecting To The Ngc8206 Local Port
The VPN may need to be disconnected before a local Ethernet connection is possible. 4.3 Connecting to the NGC8206 Local Port The laptop computer connects to the local port via USB or RS-232 using one of two cables (See Figure 4-4).
Page 144: Ngc Diagnostics
RS-232 Cable USB Cable P/N 2015240-xxx P/N 180 1800-xxx Figure 4-4 MMI Communication Cables 4) If the unit has already been set up, the Local Connect screen displays two buttons: Entry Setup and Collect Historical Data. Clicking on Entry Setup will takes the user to the Analyzer Operation screen which has links to other operations.
Page 145: Ngc Start-Up Wizard
Additionally, part of the processor control test is testing the amount of effort the oven controller takes to keep the oven at its set point of 60° C. Based on ambient temperatures, this could take up to an hour. During this time, the user can be entering information via the Startup Wizard.
Page 146: Stream Setup Instructions
Location Enter information regarding meter location (24 alphanumeric digits). Date/Time Shows current unit Date/Time Set Device with PCCU Date/Time Resets device date and time to match PC 4.5.2 Stream Setup Instructions 1) Enter the Stream ID, Location, Contract Settings and Calculation Settings (see Table 4–2).
Page 147: Diagnostics
2) To make changes to the calibration stream for each process stream, use the Back button to return to the setup for the stream and make changes. 3) Change Calibration Cycles Average and Purge Cycles, if required. Default Calibration Cycles Average is 3 and Purge Cycles is 2. 4) Make changes to the concentrations in the % BLEND column insuring that the Total Mole % equals 100%.
Page 148: Start-Up Completion
4) Compare normalized % for each component to the component and percent listed on the calibration blend bottle. Component percentages should be relatively similar. There will not be any comparisons for C6+ individual components. There may be values in the Normalized column for hexane through Decane, but this is based on the C6+ configuration entered in Stream Setup.
Page 149: Figure 4-5 Typical Chromatograph For Chrom-1 (Heavies)
2) When the current cycle completes, the unit should begin a calibration on the designated cal stream (stream 4 default). 3) When the calibration is complete, the unit should move to the designated next mode. View results on the Analyzer Operation screen. 4) The calibration stream’s Un-Normalized total should be 6.5% (between 99.5% and 100.5%).
Page 150: Security System
Figure 4-6 Typical Chromatograph for Chrom-2 (Lights) 4.7 Security System The NGC Board has a bi-level security system built in. For the purpose of this manual, this is referred to as hardware security. When the NGC is accessed through PCCU32 or WINCCU Host software packages, either remotely or locally, there is a third level of security included.
Page 151: Alarm Definitions
software users. These privileges include being able to instantiate applications and make changes to the functionality of the NGC. A second level of user access includes application editing and downloading files to a device. User access by default is restricted from modifying and downloading the application table or from downloading files to the device’s TFData and TFCold drives but has all other user-type privileges.
Page 152 Alarm Descriptions Logic Type Threshold Severity Default System Memory Available 500000 Warning Ram File Available 1000000 Warning Flash File Available 1000000 Warning Missing Peak-Cal Not Used 0.0000 Warning Stream Un-Normalized Total 0.000 Warning Page 4–14 2101510 Rev. AG...
Page 153: Maintenance
5.1.1 Help If technical assistance is required during performance of maintenance functions or if returning parts, contact ABB Totalflow customer service department at the following phone number: USA: (800) 442-3097 or International: 1-918-338-4880 5.1.2...
Page 154: Spare Part Components
Parts shipments must be prepaid by the customer. Any part, not covered by original system warranty, will be shipped to the customer, F.O.B. When removing the front or rear end caps, hands can become coated with a black thread lubricant. If this happens, wash hands before performing maintenance functions, using Go-Jo or an equivalent type hand cleanser.
Page 155: Figure 5-1 Ngc8206 Overall View
Figure 5-1 NGC8206 Overall View 2101510 Rev. AG Page 5–3...
Page 156: Figure 5-2 Analytical Module, Exploded
Cable Asm Analytical Proc to Term Bd Cable Asm Temp Sensor, GC Module GC Valve Asm Screw, 8-32 X ½ Soc Hd; SST [This is a captive screw inside the assembly that bolts to the Manifold Heater Plate] Analytical Proc Asm Manifold Asm Figure 5-2 Analytical Module, Exploded Cable Asm, Heater...
Page 157: Repair Time
Consideration was given to the cost of the repair time and the cost of stocking the repair parts. The NGC8206 modular design is uniquely suited for quick repair times. Below are four categories of repair times and the spares required to achieve those various repair times.
Page 158: Field Tool Kit
Table 5–3 Tool Requirements -001 -002 Part Number Description   2102304-001 Bag, ABB Nylon 11” x 6” Tool  1800683-001 Cutter, 1/16” Tubing   1801690-001 Extractor Tool, IC 8-24 Pin ...
Page 159: Backing Up Configuration Files (Save)
• Pipe or wall mounting: The unit must be in a vertical position and the mounting brackets tightened on the pipe. The wall mounting bracket must be securely affixed to the mounting wall. • Carrier gas bottle mounting rack: The mounting rack should be tilted backward slightly to keep the bottles from falling forward.
Page 160: Reset Procedures
function uploads these files into the NGC TFCold drive. This safeguards the data and allows for a re-start of the unit without the problems of re-configuring the NGC should anything arise. 5.6.1 Instructions 1) While in PCCU, use the Save and Restore Utility found under File Utilities in the Operate drop down menu or by clicking Save and Restore Utility on the toolbar.
Page 161: Restore Factory Defaults
2) Gain access to digital controller assembly by loosening the countersunk hex socket locking set screw in the front end cap using a 1/16” hex wrench and then unscrewing the end cap. 3) Gain access to rear termination panel on the NGC by loosening the countersunk hex socket locking set screw in the rear end cap using a 1/16”...
Page 162: Instructions
This procedure will require the user to delete both the TFData folder (current setup data being used to operate the NGC) and tfCold folder (non-volatile backup of the setup data). This procedure should not be a normal operation. It should only be used when all other setup and troubleshooting options have been exhausted or used when a Totalflow technical specialist recommends this procedure.
Page 163: Changing Ngc Clock
4) If Lithium Battery Status reads “Low Voltage" or "Not Connected”, then the lithium battery should be connected or replaced prior to removing power from the unit. See instructions later in the chapter, Replacing Lithium Battery. 5.10 Changing NGC Clock When measurement streams are instantiated on the PGC, changing the clock could affect the time when log period entries are made.
Page 164: Removing Digital Controller Assembly
5.11.1 Instructions 1) On the Analyzer Operation screen, click Hold under Next Mode. When the unit completes the current cycle and enters hold, continue to the next step. 2) Turn off the calibration and/or carrier gas at the bottle. 3) Remove the regulator from the bottle. 4) Exchange the bottle with the full bottle.
Page 165: Replacing Digital Controller Complete Assembly
Do not remove the NGC board-mounted lithium battery or the termination panel cable at this time. Removing the lithium battery will cause a cold start and that may not be desirable. When replacing the lithium battery, the termination panel cable must remain connected to power the digital controller assembly;...
Page 166: Figure 5-5 Digital Controller Board
PRIMARY COMPONENT SIDE SECONDARY COMPONENT SIDE SECURE DIGITAL CARD DRIVE LCD INTERFACE 40 PIN CONNECTOR JTAG INTERFACE 14 PIN HEADER AUXILIARY INTERFACE 32 PIN CONNECTOR BOOT MODE NOT USER CONFIGURABLE LITHIUM BATTER 3 PIN HEADER TERMINATION INTERFACE 50 PIN CONNECTOR Figure 5-5 Digital Controller Board 8) To reassemble using the replacement assembly, perform steps 6–7 in reverse order, being careful to align the display screen before tightening.
Page 167: Replacing Analytical Module
5.14 Replacing Analytical Module This section presents the procedures for removal and installation of the analytical module. The module is a completely self-contained unit and is part of the NGC8200. Read through all procedural steps before beginning disassembly. Verify before beginning the procedure that the module is appropriately rated for the system voltage.
Page 168: Figure 5-6 Analytical Module
11) Detach the analytical module rear face jack J1 and J4, if the auxiliary heater is installed (see Figure 5-7). 12) Set module on a clean, lint-free surface. 13) Verify that the gasket on the feed-through assembly manifold interface is in place, in good condition and free from metal filings or other contamination.
Page 169: Replacing Gc Module
16) Holding the new analytical module at the opening of the enclosure, reconnect jack J1 and J4, if the auxiliary heater is installed (see Figure 5-7). 17) Carefully insert the module into the enclosure, rotating the module to ensure the rear components clear the manifold interface on the inside area of the feed- through assembly.
Page 170: Instructions
When the GC module is removed, the module should be placed on a clean, dirt-free work surface. It is important that the bottom surface of the module be placed on a clean, lint free cloth to prevent its base from being scratched or damaged.
Page 171: Figure 5-8 Gc Module, Exploded View
Figure 5-8 GC Module, Exploded View 12) Using the extraction tool, remove the cable connectors from J1, J2 and J3 jacks. Do not pull the connectors from the board by the wires. 13) Using a 9/64” hex wrench, loosen the mounting screw inside the center of the assembly.
Page 172: Replacing Termination Panel
23) Turn on all sample streams, calibration gas and carrier gas. 24) Once the unit is reassembled, apply power to the NGC (Step 6). To return the assembly to Totalflow service for warranty or repair, please contact Totalflow customer service for an RA number.
Page 173: Figure 5-9 Termination Panel
Note that the termination panel to the digital controller ribbon cable pin 1 wire is not red. On the termination panel, the red edge (pin 1) of cable should plug onto pin 50, the right side of the plug. The plug is keyed; do not force plug into the connector.
Page 174: Replacing Feed-Through Assembly
5.17 Replacing Feed-through Assembly This section presents the procedures for the removal and installation of the feed- through assembly. This assembly is located on the side of the NGC. Read through all the procedural steps before removing the assembly. Verify before beginning the procedure that the module is appropriately rated for the system voltage.
Page 175: Figure 5-10 Feed-Through Assembly
Figure 5-10 Feed-Through Assembly 18) Insert the replacement feed-through assembly through the opening and screw in clockwise until completely screwed in but not tight. 19) If the flat surface, when screwed all the way in, is over 180 degrees past the top, reverse the Feed-Through Assembly counter clockwise until the flat surface is on top and horizontal.
Page 176: Replacing Lithium Battery
Note that since the power was removed from this unit, the NGC will perform start-up diagnostics and stabilize. If the user has disabled the start-up diagnostics, they should be enabled and power cycled to the unit. If the power has been withheld from the unit for an unknown or lengthy period of time, a complete start-up should be performed.
Page 177: Replacing Frit Filters
SECURE DIGITAL CARD DRIVE LCD INTERFACE 40 PIN CONNECTOR JTAG INTERFACE 14 PIN HEADER BOOT MODE NOT USER CONFIGURABLE LITHIUM BATTER 3 PIN HEADER TERMINATION INTERFACE 50 PIN CONNECTOR Figure 5-11 Primary Component Side Digital Controller Board 5.19 Replacing Frit Filters Several reasons exist for replacing the frit filters from a scheduled maintenance procedure to decrease sample pressure due to clogged filters.
Page 178: Figure 5-12 Feed-Through Assembly, Exploded View
OPTIONAL FEED-THROUGH HEATER CABLE INTERNAL PLATE FEED-THROUGH MANIFOLD GASKET FEED-THROUGH INTERFACE GASKET EXTERNAL PLATE SILICONE O-RING .5 MICRON INPUT FRIT FILTERS MOUNTING HOLES FOR 1/4" SST HEX SOCKET SCREWS Figure 5-12 Feed-through Assembly, Exploded View 7) If the filters appear soiled, it will be necessary to remount the external plate, and remove the input lines.
Page 179: Replacing Feed-Through Interface Gasket
5.20 Replacing Feed-through Interface Gasket Should the feed-through interface gasket require replacement (see Figure 5-12), follow these instructions. Typically, the user would change the gasket while performing another procedure, but for the purposes of this manual, the instructions will start and finish as a complete procedure. 5.20.1 Instructions 1) On the Analyzer Operation screen, click Hold under Next Mode.
Page 180 3) Back up the configuration files, following the instructions detailed previously in the section, Backing Up Configuration Files (Save). 4) Using the Lithium Battery Status instructions, verify that the battery status is ok before proceeding. 5) Turn off all the sample streams, calibration gas and carrier gas. 6) Disconnect or remove power from the NGC unit externally, or remove the J1 connector from termination panel.
Page 181: Replacing Termination Panel To Digital Controller Cable
21) Once the unit is reassembled, apply power to the NGC8201 (Step 6). 22) Reinstall the front and rear end caps. Note that since power was removed from this unit, the NGC8201 will perform startup diagnostics and stabilize. If the user has disabled the startup diagnostics, it should be enabled and power cycled to the unit.
Page 182: Replacing Analytical Processor To Termination Panel Cable
12) Reach into the enclosure through the front opening, and unplug the ribbon cable from the rear of the termination panel J4. 13) On the replacement cable, verify the orientation by viewing the keyed receptacle on the termination panel and cable. Insert the plug into the J4 connector. 14) Verify that the gasket on the feed-through assembly manifold interface is in place and in good condition.
Page 183 4) Using the Lithium Battery Status instructions, verify the battery status is ok before proceeding. 5) Disconnect or remove the power from the NGC unit externally, or remove the J1 connector from the termination panel. As with all the electronic components, caution should be used when handling boards.
Page 184: Troubleshooting
TROUBLESHOOTING 6.1 Overview As an aid to troubleshooting the NGC, this chapter will provide troubleshooting guidelines for the various subsystems of the NGC. Some of these procedures will differ slightly from other Totalflow products because the communications, power charger/source and other I/O are contained in a separate enclosure rather than within the NGC enclosure.
Page 185: Start-Up Diagnostic Troubleshooting
START Go To Startup During Receive Return to Diagnostics Startup? Alarm? Start Go To Troubleshooting Return to Alarm Start Go To Power Supply Batteries Troubleshooting Return to Chart Dead? Start Go To COMM COMM Troublelshooting Return to Trouble? Chart Start Call Totalflow Still Having Technical...
Page 186: Status
Totalflow has performed extensive testing on each NGC8200 prior to shipment, and each unit is factory- calibrated using our standard calibration blend. During the stream test, streams with no gas pressure will fail, and they will be disabled in the stream sequence. To enable these streams, click Stream Setup on the Analyzer Operation screen.
Page 187: Oven Temperature Test
Status Description The flow test is in progress. The flow test is initiated when a blockage is sensed. The flow test will raise the Flow Test pressure in an attempt to blow the plug out through the vent. If unsuccessful, the flow blocked status will be display The additional tests can not prove with certainty but Failed...
Page 188: Processor Control Test
3) Using the Replacing Analytical Module Assembly instructions in Maintenance, replace the analytical module assembly. Totalflow recommends that a replacement analytical module be installed at this point, and additional steps be performed in a clean, lint free atmosphere. The Totalflow repair department offers a range of services for troubleshooting and repairing/replacing the non- functioning parts.
Page 189: Troubleshooting Alarms
6.2.5.1 Status The following descriptive status and definitions are applicable for only the stream test and are in addition to those defined for all start-up diagnostics. Status Description Failed Initial Pressure Failed the Initial Pressure test. Failed Resting Pressure Failed the Resting Pressure test. Failed No Pressure Failed the Maximum Pressure test.
Page 190: Operators
Additionally, component high/low concentration, component peak not found, and component RF limit exceeded alarms are available but disabled. These alarms may be enabled by the user, but are not included here for the purposes of troubleshooting. See the PCCU32 help files for more information.
Page 191: Alarm Severity
• Plus = In addition to • Minus = Not Included or subtract from 6.3.2 Alarm Severity Table 6–2 Alarm Severity Type Definition Indicates that an alarm exists, but that it is not critical to the operation of the unit. Use General general when testing for some condition that may occur from time to time and want to know when it happens.
Page 192: Sample Pressure Alarm
8) Perform the Column Vent Pressure Test procedure, found in this chapter, for both column vent 1 and column vent 2. If either test failed, proceed to the next step. 9) Perform the Feed-through Assembly Blockage Test procedure, found in this chapter, on column vent 1 (CV1) and column vent 2 (CV2).
Page 193: Oven Temperature Error Alarm
6) Perform the Feed-through Assembly Blockage Test found in this chapter, on the sample vent (SV). If the test fails, replace the feed-through assembly. Otherwise, continue to next step. 7) Check the sampling system for leaks and tubing restrictions. Repair the leak or restriction, if found.
Page 194: No Stream Valve Selected
The information provided for troubleshooting this alarm is only intended to cover basic steps that can be performed in the field. On occasion, additional troubleshooting steps may be provided by Totalflow technical support in an effort to reduce down time. Additionally, it may be desirable to return a module to Totalflow for comprehensive testing and/or repair.
Page 195: Calculation Error Alarm
If the alarms continue to register, call Totalflow technical support. The information provided for troubleshooting this alarm is only intended to cover basic steps that can be performed in the field. On occasion, additional troubleshooting steps may be provided by Totalflow technical support in an effort to reduce down time.
Page 196: Stream Sequence Error Alarm
2) Verify the calibration blend concentrations to calibration blend concentrations listed on the Calibration Setup screen. If an error exists, make corrections and send the setup when complete. 3) Under Stream Setup, Alarm Definitions, locate the calibration un-normalized error alarm and set alarm enable to No. Send change. Repeat for any additional streams with this alarm.
Page 197: Calibration Rf Percent Error Alarm
6.3.11.1 Description These alarms are indicative of a change to the CV Percent of sufficient percentage to activate the alarm. This alarm will discontinue a scheduled calibration and will need to be disabled prior to calibrating the unit. 6.3.11.2 Instructions 1) On the Analyzer Operation screen, click Hold under Next Mode.
Page 198: Enclosure Temperature Alarm
5) Verify that the peaks are correctly labeled and integrated. If the peaks are correctly labeled and integrated, return the unit to operation. 6) Allow unit to cycle 3-4 times. 7) Following the Calibrating the NGC instructions in Startup, perform a calibration ensuring that the Next Mode is set to Hold.
Page 199: Low Carrier Gas Bottle (Di1) Alarm
6.3.14.2 Instruction 1) Check the power supply to the termination panel, following instructions later in this chapter, Termination Panel Supply Voltage Test. If the test fails, restore the power supply to proper working specifications; otherwise, continue to the next step. 2) Following the Cable Replacement instructions in Chapter 4, Maintenance, check the analytical processor to termination panel cable for damage.
Page 200: Gcm Processing Error Alarm
4) Perform the Abnormal Calibration Gas Depletion procedure, found in this chapter. If the procedure fails to locate the problem, contact Totalflow technical support following the procedure in the Introduction section of this manual. 6.3.17 GCM Processing Error Alarm If the GCM Chrom Process alarm is in warning status, the following procedure will step the user through the troubleshooting process.
Page 201: Sample Flow Detection Alarm
6.3.20 Sample Flow Detection Alarm If the Sample Flow Detection alarm is in fault status, the following procedure will step the user through the troubleshooting process. On occasion, these instructions may detour the user to other procedures, and, when complete, they should return to these procedures to continue.
Page 202: Ram File Available Alarm
4) Reducing the number of instantiated applications may be required. Contact Totalflow technical support for assistance. 6.3.23 RAM File Available Alarm If the RAM File Available alarm is in warning status, the following procedure will step the user through the troubleshooting process. On occasion, these instructions may detour the user to other procedures, and, when complete, they should return to these procedures to continue.
Page 203: Stream Un-Normalized Total
6.3.25.2 Instructions 1) Verify the calibration blend concentrations to the calibration blend concentrations listed on the Calibration Setup screen. If errors exist, make corrections and send the setup when complete. 2) On the Analyzer Operation screen, click Hold under Next Mode. When the unit completes the current cycle and enters hold, continue to the next step.
Page 204: Alarm Troubleshooting Tests
6.4 Alarm Troubleshooting Tests 6.4.1 Sample Vent Pressure Test 6.4.1.1 Instructions 1) Attach a flowmeter to the sample valve. 2) From the Analyzer Operation screen, click Diagnostics. 3) Select the Manual Operation tab. 4) Under Manual Control, open the sample shutoff valve. 5) When opened, the SV should measure a spike to 15 sccm.
Page 205: Feed-Through Assembly Blockage Test
6.4.4 Feed-through Assembly Blockage Test 1) Remove the feed-through assembly from the NGC following Replacing Feed- through Assembly instructions in Maintenance. 2) If testing from the pressure regulator 1 or 2 alarms, continue to steps 3 and 4. If testing from the stream test in the start-up diagnostics or from the sample pressure alarm, skip to step 5.
Page 206: Power Supply Voltage Test
(see Figure 6-2) takes the user through several tests, but also directs them to the communication troubleshooting flowchart located later in this chapter. START Go To Charger Circuit Batteries Test Dead? Go To Power Supply Voltage Test RETURN Power Issue Located? Perform Tests Sequentially...
Page 207: Equipment Isolation Test
6.5.2 Power Supply Voltage Test This test assumes a power supply is in good working order and has previously been tested and qualified to power an NGC. If the power supply is under suspicion, it is recommended that it be replaced with a known good power supply before conducting these tests.
Page 208: Ngc Module Isolation Test
The NGC uses pulse width modulation technology to drive its heaters and valves. Due to this feature, a DMM may not show the voltage present at the NGC termination panel accurately. However, in no case, even under load, should the DMM indicate a voltage less than 11.5 VDC (or 22 VDC for 24 VDC system) if the proper cables are used.
Page 209: Charger Circuit Test
If the drop is less than 0.1 V, check the termination panel to the analytical processor cable for pinched or exposed insulation. Also, check the feed- through auxiliary heater cable for similar damage. 8) Was the damaged cable found? If yes, replace the appropriate cable using instructions in Maintenance.
Page 210: Solar Panel Troubleshooting Test
Table 6–3 Specifications for Solar Panels Panel Volts at P Open Circuit Load Resistance Loaded Voltage 5 Ω 100 W 54 W 17.4 V 21.7 V 16–18 VDC 5 Ω 100 W 87 W 17.4 V 21.7 V 16–18 VDC 6.5.6 Solar Panel Troubleshooting Test If the system setup includes a solar panel connected to the optional equipment...
Page 211: Ac Charger/Power Supply Troubleshooting Test
6.5.7 AC Charger/Power Supply Troubleshooting Test If the system setup includes an AC charger/power supply connected to the optional equipment enclosure, and it is not supplying the required voltage to the NGC unit, test the AC charger/power supply. 6.5.7.1 Instructions 1) Check the input AC voltage to the enclosure power supply.
Page 212: Communication
When switching the power to a radio with inhibit (SLEEP) mode, the serial port 1 or 2 switched power line will go to the radio's inhibit (SLEEP) mode input. Power out will go to the radio's power input. 6.6.1 Communication Troubleshooting the communications for this unit requires that equipment in two areas be tested: the NGC Comm Ports and the external Communication device.
Page 213 START Verify unit ID#, Security Code and Protocol are Correct. Verify jumper and terminal & pin wiring are correct. Transceiver Does Unit Transceiver Investigate Respond to Host Supply voltage Supply voltage Transceiver Test Comm Request? within Specs? Issues Communication Investigate Voltage supply Supply Voltage Power Supply...
Page 214: Transceiver Supply Voltage Test
When the communication equipment is powered/switched on, the NGC displays the communication icon after it recognizes the NGC ID and is responding. Check the baud rate of the NGC transmission and the listen time settings. The baud rate and time settings can be changed by entering the Station Setup screen from the Analyzer Operation screen.
Page 215: Transceiver Check
6.6.5 Transceiver Check 6.6.5.1 Instructions 1) If available, use a wattmeter to check the transceiver output power. Refer to the manufacturer’s documentation for measuring instructions. 2) If available, use two (2) hand-held transceivers and verify the communication path between the master and remote sites. Voice-activated interface can be used, if available.
Page 216: Communications
6.6.6.1 Instructions Voltage on the following steps may be hard to see using a digital multimeter. If available, an oscilloscope will provide a more accurate reading. To verify, the host software must be continuously polling the NGC. Generally speaking, these tests performed on the terminal board will only verify incorrect or damaged wiring.
Page 217: Communication Test
Table 6–5 RS-485 Terminations Serial Comm Port Jumper First or Intermediate Unit pins 2–3 pins 2–3 Last or Only Unit pins 1–2 pins 1–2 6.6.8 RS-485 Communication Test Before performing this test on the termination panel located inside the rear end cap, verify that the wiring is correct (see Table 6–6).
Page 218 When the unit is transmitting data, the voltage should vary between +5 VDC and 0 VDC. This would indicate that the RRTS is working correctly. 3) If any inaccuracy exists, investigate the wiring errors or damaged wires. If a communication problem still exists and the unit has passed the tests in steps 1 and 2, additional testing will be required.
Page 219: Appendix Amodbus Registers
APPENDIX A MODBUS REGISTERS The table below lists the Modbus register assignments for the NGC. The 32-Bit and 16-Bit Register Format columns relate to the Register Format setup in a communication port setup. 32-Bit registers are transferred as a single 32-bit register. 16-Bit registers are transferred as 32-bits via two consecutive 16-bit registers.
Page 220 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 3031 3031 51.200.14 Component Table #2, Component Register #15 available 3032 3032 51.200.15 Component Table #2, Component Register #16 available 3033 3033 51.201.1 Analysis Time (in1/30ths of 1 second) un-available 3034 3034...
Page 221 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 3073 3073 51.201.27 Cal. Bottle Low (DI2) (1 = closed, 0 = open) available 3074 3074 51.201.1 Manual Update Response Factors un-available 3075 3075 51.201.1 Auto Update Response Factors un-available 3076 3076...
Page 222 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7007 7013 51.203.6 Mole % - Component #7 available 7008 7015 51.203.7 Mole % - Component #8 available 7009 7017 51.203.8 Mole % - Component #9 available 7010 7019 51.203.9 Mole % - Component #10...
Page 223 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7049 7097 51.241.4 Rolling Average for Component #5 available 7050 7099 51.241.5 Rolling Average for Component #6 available 7051 7101 51.241.6 Rolling Average for Component #7 available 7052 7103 51.241.7 Rolling Average for Component #8...
Page 224 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7091 7181 51.207.14 Previous 24 Hr Average for Component #15 available 7092 7183 51.207.15 Previous 24 Hr Average for Component #16 available 7093 7185 51.244.44 Rolling Average BTU - Dry available 7094 7187...
Page 225 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7211 7421 51.233.2 Calibration Standard - Component #3 available 7212 7423 51.233.3 Calibration Standard - Component #4 available 7213 7425 51.233.4 Calibration Standard - Component #5 available 7214 7427 51.233.5 Calibration Standard - Component #6...
Page 226 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7253 7505 51.239.12 Alt Calibration Standard - Component #13 available 7254 7507 51.239.13 Alt Calibration Standard - Component #14 available 7255 7509 51.239.14 Alt Calibration Standard - Component #15 available 7256 7511...
Page 227 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7417 7833 51.211.0 GPM % - Component #1 available 7418 7835 51.211.1 GPM % - Component #2 available 7419 7837 51.211.2 GPM % - Component #3 available 7420 7839 51.211.3 GPM % - Component #4...
Page 228 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7459 7917 51.235.14 Rolling Average for Component #15 available 7460 7919 51.235.15 Rolling Average for Component #16 available 7461 7921 51.212.0 24 Hr Average for Component #1 available 7462 7923 51.212.1...
Page 229 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7501 8001 51.247.46 Rolling Average Density Normal available 7502 8003 51.248.44 24 Hr Average for BTU - Dry available 7503 8005 51.248.39 24 Hr Average for BTU - Sat available 7504 8007...
Page 230 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7621 8241 51.216.4 GPM % - Component #5 available 7622 8243 51.216.5 GPM % - Component #6 available 7623 8245 51.216.6 GPM % - Component #7 available 7624 8247 51.216.7 GPM % - Component #8...
Page 231 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7663 8325 51.217.2 24 Hour Average for Component #3 available 7664 8327 51.217.3 24 Hour Average for Component #4 available 7665 8329 51.217.4 24 Hour Average for Component #5 available 7666 8331...
Page 232 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7705 8409 51.248.140 24 Hr Average for Compressibility available 7706 8411 51.248.141 24 Hr Average for Superior Wobbe available 7707 8413 51.248.147 24 Hr Average for Total Un-Normalized Mole % available 7708 8415...
Page 233 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7826 8651 51.221.9 GPM % - Component #10 available 7827 8653 51.221.10 GPM % - Component #11 available 7828 8655 51.221.11 GPM % - Component #12 available 7829 8657 51.221.12 GPM % - Component #13...
Page 234 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7868 8735 51.222.7 24 Hr Average for Component #8 available 7869 8737 51.222.8 24 Hr Average for Component #9 available 7870 8739 51.222.9 24 Hr Average for Component #10 available 7871 8741...
Page 235 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 7910 8819 51.248.246 24 Hr Average for Density Normal available 7911 8821 51.249.244 Previous 24 Hr Average for BTU - Dry available 7912 8823 51.249.239 Previous 24 Hr Average for BTU - Sat available 7913 8825...
Page 236 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 8031 9061 51.226.14 GPM % - Component #15 available 8032 9063 51.226.15 GPM % - Component #16 available 8033 9065 51.224.0 BTU - Dry available 8034 9067 51.224.1 BTU - Saturated available 8035...
Page 237 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 8073 9145 51.227.12 24 Hr Average for Component #13 available 8074 9147 51.227.13 24 Hr Average for Component #14 available 8075 9149 51.227.14 24 Hr Average for Component #15 available 8076 9151...
Page 238 32 Bit 16 Bit Register Register Format Format NGC Address Description Status 8115 9229 51.249.341 Previous 24 Hr Average for Superior Wobbe available 8116 9231 51.249.347 Previous 24 Hr Avg for Total Un-Normalized Mole % available 8117 9233 51.249.348 Previous 24 Hr Average for Total GPM available 8118 9235...
Page 239: Contact Us
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ABB NGC8206 User Manual

1 Introduction

2 System Description

3 Installation

Quick Links

Troubleshooting

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Summary of Contents for ABB NGC8206