NGA 2000
TRACE OXYGEN
ANALYZER MODULE
Rosemount Analytical
748374-E
OTICE
N
The information contained in this document is subject to change without notice.
Rosemount Analytical's NGA 2000 system of Modular Gas Analyzers and Controllers are patented, under U.S. Patent
5.787.015.
Teflon® is a registered trademark of E.I. duPont de Nemours and Co., Inc.
SNOOP
Waferpure™ is a trademark of Millipore Corp.
Nanochem
®
is a registered trademark of NUPRO Co.
®
is a registered trademark of Semigas Corp.
Manual Part Number 748374-E
September 2000
Printed in U.S.A.
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
C
P
REFACE
PURPOSE/SAFETY SUMMARY........................................................................P1
GLOSSARY ......................................................................................................P3
SPECIFICATIONS - GENERAL .........................................................................P5
SPECIFICATIONS - SAMPLE............................................................................P5
SPECIFICATIONS - PHYSICAL.........................................................................P5
SPECIFICATIONS - GAS CONNECTIONS........................................................P6
CUSTOMER SERVICE, TECHNICAL ASSISTANCE AND FIELD SERVICE....P7
RETURNING PARTS TO THE FACTORY.........................................................P7
TRAINING ......................................................................................................P7
ONTENTS
DOCUMENTATION............................................................................................P7
COMPLIANCES .................................................................................................P8
S
ECTION
1.1 OVERVIEW...............................................................................................1-1
1.2 TYPICAL APPLICATIONS.........................................................................1-1
1.3 THEORY OF TECHNOLOGY....................................................................1-1
1.4 FEATURES ...............................................................................................1-2
1. I
NTRODUCTION
748374-E Rosemount Analytical September 2000
NGA 2000 Trace Oxygen Analyzer
I
ONTENTS
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SECTION 2. INSTALLATION
2.1 UNPACKING............................................................................................. 2-1
2.2 ASSEMBLY............................................................................................... 2-1
2.2.1 Electrolyte Addition...................................................................... 2-1
2.3 LOCATION................................................................................................ 2-2
2.4 GASES...................................................................................................... 2-2
2.4.1 Requirements.............................................................................. 2-2
2.4.2 Connections ................................................................................ 2-3
2.4.3 Leak Test..................................................................................... 2-5
2.5 ELECTRICAL CONNECTIONS................................................................. 2-6
SECTION 3. STARTUP AND OPERATION
3.1 OVERVIEW............................................................................................... 3-1
3.2 DISPLAYS................................................................................................. 3-1
3.2.1 Run Mode Display....................................................................... 3-1
3.2.2 Menu Displays............................................................................. 3-2
3.2.3 Help Displays .............................................................................. 3-4
3.3 STARTUP PROCEDURE..........................................................................3-5
3.4 QUICK START FEATURE........................................................................ 3-5
3.5 GAS SCALE FACTOR (GSF)................................................................... 3-5
3.6 CALIBRATION.......................................................................................... 3-6
3.7 ROUTINE OPERATION............................................................................ 3-8
3.8 ALARM INDICATION................................................................................ 3-8
SECTION 4. MAINTENANCE AND TROUBLESHOOTING
4.1 OVERVIEW............................................................................................... 4-1
4.1.1 Water Addition............................................................................. 4-2
4.2 FUSES...................................................................................................... 4-3
4.3 ELECTROLYTE REPLACEMENT............................................................ 4-3
4.4 SENSOR REPLACEMENT....................................................................... 4-4
4.5 FLOW SENSOR REPLACEMENT............................................................ 4-4
4.6 PRINTED CIRCUIT BOARDS................................................................... 4-5
4.7 TROUBLESHOOTING.............................................................................. 4-5
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September 2000 Rosemount Analytical 748374-ENGA 2000 Trace Oxygen Analyzer
ONTENTS
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S
ECTION
5.1 REPLACEMENT PARTS..........................................................................5-1
5. R
EPLACEMENT PARTS
APPENDIX A. NGA TO2 MENU STRUCTURE
APPENDIX B. USER INTERFACE HELP
A
PPENDIX
ACTORY CALIBRATION DATA SHEET
F
ATERIAL SAFETY DATA SHEET
M
G
ENERAL PRECAUTIONS FOR HANDLING
ARRANTY
W
IELD SERVICE AND REPAIR FACILITIES
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C. TO2 I
DENTIFICATION MATRIX
PN 748377 (S
& S
ENSOR ELECTROLYTE
TORING HIGH PRESSURE CYLINDERS
)
748374-E Rosemount Analytical September 2000
NGA 2000 Trace Oxygen Analyzer
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ONTENTS
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FIGURES
1-1 Trace Oxygen Detector Technology ......................................................... 1-2
1-2 Trace Oxygen Analyzer Module - Top View.............................................. 1-3
2-1 Analyzer Module Interconnection with Instrument Platform ......................2-3
2-2 Outline and Mounting Dimensions............................................................ 2-4
2-3 Back Panel Connections........................................................................... 2-5
2-4 Trace Oxygen Analyzer Front Panel......................................................... 2-6
3-1 Run Mode Display..................................................................................... 3-2
3-2 Main Menu................................................................................................ 3-2
3-3 Basic Controls Menu................................................................................. 3-3
3-4 Expert Controls Menu............................................................................... 3-3
3-5 Analyzer Module Setup Menu................................................................... 3-4
3-6 Typical Help Menu (shown is Zero/Span Calibration Help)....................... 3-4
4-1 Trace Oxygen Analyzer Sensor Assembly................................................ 4-2
4-2 Load Factory Calibration Data Menu ........................................................ 4-4
TABLES
3-1 Trace Oxygen Analyzer Module Alarms.................................................... 3-8
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September 2000 Rosemount Analytical 748374-ENGA 2000 Trace Oxygen Analyzer
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REFACE
PURPOSE/SAFETY SUMMARY
The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of this particular NGA 2000 module.
Some sections may describe equipment not used in your configuration. The user
should become thoroughly familiar with the operation of this module before operating
it. Read this instruction manual completely.
To avoid explosion, loss of life, personal injury and damage to this equipment
and on-site property, all personnel authorized to install, operate and service this
equipment should be thoroughly familiar with and strictly follow the instructions
in this manual. Save these instructions.
If this equipment is used in a manner not specified in these instructions, protective
systems may be impaired.
DANGER is used to indicate the presence of a hazard which will cause severe
personal injury, death, or substantial property damage if the warning is ignored.
WARNING is used to indicate the presence of a hazard which can cause severe
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION is used to indicate the presence of a hazard which will or ca n cause minor
personal injury or property damage if the warning is ignored.
NOTE is used to indicate installation, operation or maintenance information which is
important but not hazard-related.
748374-E Rosemount Analytical September 2000
NGA 2000 Trace Oxygen Analyzer
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REFACE
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CAUTION
Do not operate or service before reading and understanding the Instruction
Manual and receiving appropriate training.
WARNING: PARTS INTEGRITY
Tampering with or unauthorized substitution of components may adversely
affect safety of this product. Use only factory-approved components for repair.
CAUTION: PRESSURIZED GAS
This module requires periodic use of pressurized gas. See General Precautions
for Handling and Storing High Pressure Gas Cylinders at the rear of this manual.
The electrolyte is a caustic solution. Review the Material Safety Data Sheet in
the rear of this manual.
This equipment is not designed and should not be used in the analysis of
flammable samples. Use of this equipment in this way could result in explosion
and death.
WARNING: CAUSTIC LIQUID
WARNING: POSSIBLE EXPLOSION HAZARD
P2
September 2000 Rosemount Analytical 748374-ENGA 2000 Trace Oxygen Analyzer
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LOSSARY
NALYZER MODULE
A
The module that contains all sensor/detector components for development of a
Primary Variable signal; includes all signal conditioning and temperature control
circuitry.
ACKPLANE
B
The interconnect circuit board which the Controller Board, Power Supply, Analyzer
Module power and network cables, I/O Modules and Expansion Modules plug into.
ONTROL MODULE
C
The Operator Interface plus the Controller Board.
ONTROLLER BOARD
C
The computer board that serves as the Network Manager and operates the Display
and Keypad.
REFACE
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ISTRIBUTION ASSEMBLY
D
The Backplane and the card cages that hold I/O and Expansion Modules.
XPANSION MODULE
E
A circuit board that plugs into the Backplane from the front of the Platform and
performs special features not related to I/O functions.
I/O M
A circuit board that plugs into the Backplane from the rear of the Platform. Has a
connector terminal for communication with external data acquisition devices and
provides an input/output function.
O
The Display and Keyboard.
P
Any workable collection of the following: Controller Board, Power Supply, Distribution
Assembly, Enclosure and Operator Interface.
P
ODULE
PERATOR INTERFACE
LATFORM
OWER SUPPLY
Any of a variety of components that provides conditioned power to other NGA 2000
components, from the Power Supply Board that plugs into the front of the Backplane in
a stand-alone instrument to several larger ones that can power larger collections of
modules and components.
748374-E Rosemount Analytical September 2000
NGA 2000 Trace Oxygen Analyzer
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RIMARY VARIABLE
P
The measured species concentration value from an Analyzer Module.
ECONDARY VARIABLE
S
Data placed on the network by a module regarding current status, e.g., sample flow,
source voltage and other diagnostic information.
OFTKEYS
S
The five function keys located below the front panel display; they assume the function
displayed directly above each on the display, a function dictated by software.
YSTEM
S
Any collection of Analyzer Module(s), Platform(s), I/O Module(s) and Expansion
Module(s).
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September 2000 Rosemount Analytical 748374-ENGA 2000 Trace Oxygen Analyzer
SPECIFICATIONS - GENERAL
MEASUREMENT
SPECIES
RANGES 0 to 100 ppm (output scalable down to 0-2 ppm fullscale)
A
CCURACY
S
ENSITIVITY
N
OISE
L
INEARITY
R
ESPONSE TIME
Z
ERO DRIFT
S
PAN DRIFT
E
FFECT OF
T
EMPERATURE
E
FFECT OF FLOW
O
PERATING
T
EMPERATURE
P
OWER REQUIREMENTS
Trace Oxygen
±3% of reading or ±0.02% of range (except for ranges ≤ 100
ppm: ±3% of reading or ±0.05% of range)
<10 ppb Oxygen
1% of fullscale, peak to peak
±1% of fullscale
Typically 90% in less than 20 seconds
≤±1% of fullscale/24 hours at constant temperature
≤±1% of fullscale/24 hours at constant temperature
0.32% of reading per °F from 70°F
(0.58% of reading per °C from 21°C)
≤2% of reading for a flow change of ±250 cc/min (0.5 SCFH)
32°F to 113°F (0°C to 45°C)
+24 VDC ±5%, 10 W max.
Ripple and Noise: <100 mV peak to peak
Line and Load Regulations: <±1%
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S
PECIFICATIONS
S
AMPLE
F
LOW RATE
S
UPPLY PRESSURE
T
EMPERATURE
P
ARTICULATES
S
AMPLE HUMIDITY
S
PECIFICATIONS
M
ATERIALS IN CONTACT
WITH SAMPLE
D
IMENSIONS
W
EIGHT
M
OUNTING
C
ASE CLASSIFICATION
MAX. S
FROM
EPARATION
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LATFORM
- S
AMPLE
Non-flammable (below 100% of the LEL)
0.5 to 1.5 L/min.
1027 to 1082 hPa - absolute (0.2 to 1.0 psig)
32°F to 113°F (0°C to 45°C)
filtered to <0.1 mg/L; non-condensing at ambient temperature
non-condensing at ambient temperatures
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HYSICAL
Stainless steel, Teflon, Delrin, neoprene
See Figure 2-2, Outline and Mounting Dimensions
6.8 kg (15 lbs.)
Horizontal, external to Platform or custom installed in a panel
General Purpose for installation in w eather pr otect ed ar ea
1600 m (1 mile)
748374-E Rosemount Analytical September 2000
NGA 2000 Trace Oxygen Analyzer
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SPECIFICATIONS - GAS CONNECTIONS
S
AMPLE IN
1/4 inch O.D. tube fitting
SAMPLE OUT
See the Preface Section of the Platform manual for specifications regarding Platform related components.
1/4 inch O.D. tube fitting
P6
September 2000 Rosemount Analytical 748374-ENGA 2000 Trace Oxygen Analyzer
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C
USTOMER SERVICE
For order administration, replacement Parts, application assistance, on-site or factory
repair, service or maintenance contract information, contact:
, T
ECHNICAL ASSIST ANCE AND FIELD SERVICE
Rosemount Analytical Inc.
Process Analytical Division
Customer Service Center
1-800-433-6076
RETURNING PARTS TO THE FACTORY
Before returning parts, contact the Customer Service Center and request a Returned
Materials Authorization (RMA) number. Please have the following information when
you call: Model Number, Serial Number, and Purchase Order Number or Sales Order
Number.
Prior authorization by the factory must be obtained before returned materials will be
accepted. Unauthorized returns will be returned to the sende r, f re ight collect.
When returnin g any pro duct o r compon ent t hat has be en expo sed to a toxic, corrosi ve
or other hazardous material or used in such a hazardous environment, the user must
attach an appropriate Material Safety Data Sheet (M.S.D.S.) or a written certification
that the material has been decontaminated, disinfected and/or detoxified.
Return to:
Rosemount Analytical Inc.
4125 East La Palma Avenue
Anaheim, California 92807-1802
USA
TRAINING
A comprehensive Factory Training Program of operator and service classes is
available. For a copy of the Current Operator and Service Training Schedule contact
the Technical Services Depart men t at:
Rosemount Analytical Inc.
Phone: 1-714-986-7600
FAX: 1-714-577-8006
DOCUMENTATION
The following NGA 2000 Trace Oxygen Analyzer Module instruction materials are
available. Contact Customer Service or the local representative to order.
748374 Instruction Manual (this document)
748374-E Rosemount Analytical September 2000
NGA 2000 Trace Oxygen Analyzer
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REFACE
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COMPLIANCES
This product may carry approvals from several certifying agencies for use in nonhazardous, indoor locations. If so, the product will carry approval insignia on the
product name-rating plate.
®
NRTL /C
Rosemount Analytical Inc. has satisfied all obligations from the European
Legislation to harmonize the product requirements in Europe.
This product complies with the standard level of NAMUR EMC.
Recommendation (May 1993).
This product satisfies all obligations of all relevant standards of the EMC framework in
Australia and New Zealand.
NAMUR
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September 2000 Rosemount Analytical 748374-ENGA 2000 Trace Oxygen Analyzer
I
NTRODUCTION
1
1.1 OVERVIEW
This manual describes the Trace Oxygen (TO2) Analyzer Module of Rosemount
Analytical's NGA 2000 Series of gas analysis components.
The TO2 Analyzer Module is designed to continuously determine the concentration of
trace oxygen in a flowing gaseous mixture. The concentration is expressed in partsper-million.
The TO2 Analyzer Module is configured as a shelf-mount module, designed to be
installed external from the platform on an associated shelf capable of holding two
modules side-by-side, with gas connections made from the rear. All electronics relative
to sample detection and conditioning are included in this module.
1.2 TYPICAL APPLICATIONS
The TO2 Analyzer Module has specific applications in the following areas:
Trace oxygen in product nitrogen and argon streams from air separation plants
Trace oxygen in inerting atmospheres for heat treat furnaces
Trace oxygen in glove-box applications
1.3 THEORY OF TECHNOLOGY
The TO2 Analyzer Module uses the coulometric principle of oxygen detection. This
technology is based on the fact that oxygen in the sample is reduced by an
electrochemical reaction. This reduction occurs at the cathode and results in the
generation of hydroxyl ions. These hydroxyl ions migrate to the anode where they are
oxidized to reform oxygen. The oxidation reaction generates four electrons which in
turn migrate to the anode to participate in the reduction reaction:
(Cathode Reaction)
O2 + 2 H2O + 4 e- → 4 OH
(Anode Reaction)
4 OH- → O2 + 2 H2O + 4 e
-
-
748374-E Rosemount Analytical September 2000
NGA 2000 Trace Oxygen Analyzer
1-1
NTRODUCTION
I
A polarizing voltage of approximately 1.3 VDC is applied between the anode and
cathode to drive the oxidation and reduction reactions. The resulting current flow
produced by the flow of electrons is directly proportional to the oxygen content in the
sample gas.
1.4 FEATURES
Among the features included in the TO2 Analyzer Module are:
• Quick start feature
• Electrolyte level alarm
• High oxygen protection circuit with alarm
• Sample flow indication.
BI-STRATA™ DIFF USION
BARRIER
SAMPLE IN
SAMPLE OUT
SENSING CATHOD E (-)
O
2
SECONDARY CATHODE (-)
SECONDARY ANODE (+)
-
e
S
KOH
O
2
OH
S
-
O
2
-
e
O
2
ELECTRONICS
SENSING ANODE (- )
IGURE
F
1-2
1-1. T
RACE OXYGEN DETECTOR TECHNOLOGY
September 2000 Rosemount Analytical 748374-ENGA 2000 Trace Oxygen Analyzer
Network/Power
Module
NTRODUCTION
I
Sensor Assembly
Sensor
Computer
Board
Power Board
Sample Flow
Sensor
IGURE
F
748374-E Rosemount Analytical September 2000
1-2. T
RACE OXYGEN ANALYZER MODULE
OP VIEW
- T
NGA 2000 Trace Oxygen Analyzer
1-3
NTRODUCTION
I
NOTES
1-4
September 2000 Rosemount Analytical 748374-ENGA 2000 Trace Oxygen Analyzer
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