Teledyne 3000MA User Manual

Percent Oxygen Analyzer

OPERATING INSTRUCTIONS FOR

Model 3000MA

P er cent Oxygen Anal yzer

DANGER

HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING SYSTEM.

PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM. HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PER-

SIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED. ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING.

BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/MANAGER.

Teledyne Analytical Instruments

P/N M71700

04/27/00

ECO:# 00-0000

Model 3000MA

All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any other language or computer language in whole or in part, in any form or by any means, whether it be electronic, mechanical, magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-1580.

Warranty

This equipment is sold subject to the mutual agreement that it is warranted by us free from defects of material and of construction, and that our liability shall be limited to replacing or repairing at our factory (without charge, except for transportation), or at customer plant at our option, any material or construction in which defects become apparent within one year from the date of shipment, except in cases where quotations or acknowledgments provide for a shorter period. Components manufactured by others bear the warranty of their manufacturer. This warranty does not cover defects caused by wear, accident, misuse, neglect or repairs other than those performed by Teledyne or an authorized service center. We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage which may result from its use or misuse.

We reserve the right to employ any suitable material in the manufacture of our apparatus, and to make any alterations in the dimensions, shape or weight of any parts, in so far as such alterations do not adversely affect our warranty.

Important Notice

This instrument provides measurement readings to its user, and serves as a tool by which valuable data can be gathered. The information provided by the instrument may assist the user in eliminating potential hazards caused by his process; however, it is essential that all personnel involved in the use of the instrument or its interface, with the process being measured, be properly trained in the process itself, as well as all instrumentation related to it.

The safety of personnel is ultimately the responsibility of those who control process conditions. While this instrument may be able to provide early warning of imminent danger, it has no control over process conditions, and it can be misused. In particular, any alarm or control systems installed must be tested and understood, both as to how they operate and as to how they can be defeated. Any safeguards required such as locks, labels, or redundancy, must be provided by the user or specifically requested of Teledyne at the time the order is placed.

Therefore, the purchaser must be aware of the hazardous process conditions. The purchaser is responsible for the training of personnel, for providing hazard warning methods and instrumentation per the appropriate standards, and for ensuring that hazard warning devices and instrumentation are maintained and operated properly.

Teledyne Analytical Instruments, the manufacturer of this instrument, cannot accept responsibility for conditions beyond its knowledge and control. No statement expressed or implied by this document or any information disseminated by the manufacturer or its agents, is to be construed as a warranty of adequate safety control under the

user’s process conditions.

Teledyne Analytical Instruments

Percent Oxygen Analyzer

Specific Model Information

The instrument for which this manual was supplied may incorporate one or more options not included with the standard instrument. Commonly available options are listed below, with check boxes. Any that are incorporated in the instrument for which this manual is supplied are indicated by a check mark in the box.

Instrument Serial Number _______________________

includes the following options:

❑❑

❑ 3000MA-C: In addition to all standard features, this model also has

❑❑

separate ports for zero and span gases, and built-in control valves. The internal valves are entirely under the control of the 3000MA electronics, to automatically switch between gases in synchronization with the analyzer’s operations

❑❑

❑ 3000MA-M: In models with this option, the 4-20 mA Analog Current

❑❑

output is active. (In the standard units, it is not active.)

❑❑

❑ 19" Rack Mnt: The 19" Relay Rack Mount units are available with

❑❑

either one or two 3000 series analyzers installed on a 19" panel, and ready to mount in a standard rack.

Teledyne Analytical Instruments

iii

Model 3000MA

1 Introduction

1.1 Overview........................................................................ 1-1

1.2 Typical Applications ....................................................... 1-1

1.3 Main Features of the Analyzer ....................................... 1-1

1.4 Model Designations ....................................................... 1-2

1.5 Front P anel (Operator Interface)..................................... 1-3

1.6 Recognizing Difference Between LCD & VFD............... 1-5

1.7 Rear Panel (Equipment Interf ace).................................. 1-5

2 Operational Theory

2.1 Introduction .................................................................... 2-1

2.2 Precise Paramagnetic Sensor........................................ 2-1

2.2.1 Principles of Operation ............................................ 2-1

2.3 Cross Interface............................................................... 2-3

2.4 Sample System.............................................................. 2-5

2.5 Electronics and Signal Processing ................................ 2-6

Table of Contents

3 Installation

3.1 Unpacking the Analyzer................................................. 3-1

3.2 Mounting the Analyzer ................................................... 3-1

3.3 Rear Panel Connections................................................ 3-2

3.3.1 Gas Connections ................................................... 3-3

3.3.2 Electrical Connections........................................... 3-4

3.3.3 Remote Probe Connector ...................................... 3-9

3.4 Testing the System.........................................................3-10

4 Operation

4.1 Introduction .................................................................... 4-1

4.2 Using the Data Entry and Function Buttons ................... 4-2

4.3 The

4.3.1 Setting the Display................................................. 4-4

4.3.2 Setting up an Auto-Cal........................................... 4-5

4.3.3 Passw ord Protection.............................................. 4-5

4.3.4 Logout.................................................................... 4-8

4.3.5 System Self-Diagnostic Test .................................. 4-9

4.3.6 Version Screen ...................................................... 4-9

4.4 The

System

4.3.3.1 Entering the Password................................... 4-6

4.3.3.2 Installing or Changing the Password ............. 4-7

Span

Function ..................................................... 4-3

Functions...................................................... 4-10

Teledyne Analytical Instruments

Percent Oxygen Analyzer

4.4.1 Span Cal................................................................ 4-11

4.4.1.1 Auto Mode Spanning ..................................... 4-10

4.4.1.2 Manual Mode Spanning................................. 4-11

4.5 The

4.6 The

4.6.1 Setting the Analog Output Ranges......................... 4-15

4.6.2 Autoranging Analysis............................................. 4-15

4.6.3 Fixed Range Analysis ............................................ 4-15

4.7 The

4.8 Signal Output ................................................................. 4-16

Maintenance

5.1 Routine Maintenance..................................................... 5-1

5.2 Fuse Replacement ......................................................... 5-1

5.3 System Self Diagnostic Test........................................... 5-2

5.4 Major Internal Components............................................ 5-3

5.5 Cleaning ........................................................................ 5-4

5.6 Troubleshooting ............................................................. 5-4

Alarms Range

Function ...................................................... 4-14

Analyze

Function...................................................... 4-12

Function.................................................... 4-16

Appendix

A-1 Model 3000MA Specifications ....................................... A-1

A-2 Recommended 2-Year Spare Parts List ......................... A-3

A-3 Drawing List................................................................... A-4

A-4 19-Inch Relay Rack Panel Mount................................... A-4

A-5 Zero Functions............................................................... A-5

Teledyne Analytical Instruments

Model 3000MA

D ANGER

COMBUSTIBLE GAS USAGE WARNING

This is a general purpose instrument designed for usage in a nonhazardous area. It is the customer's responsibility to ensure safety especially when combustible gases are being analyzed since the potential of gas leaks always exist.

The customer should ensure that the principles of operating of this equipment is well understood by the user . Misuse of this product in any manner , tampering with its components, or unauthorized substitution of any component may adversely affect the safety of this instrument.

Since the use of this instrument is beyond the control of T eledyne, no responsibility b y T eledyne, its affiliates, and agents for damage or injury from misuse or neglect of this equipment is implied or assumed.

Teledyne Analytical Instruments

Percent Oxygen Analyzer Introduction 1

Introduction

1.1 Overview

The Teledyne Analytical Instruments Model 3000MA Percent Oxygen Analyzer is a versatile microprocessor-based instrument for detecting the percentage of oxygen in a variety of background gases. This manual covers the Model 3000MA General Purpose flush-panel and/or rack-mount units only. These units are for indoor use in a nonhazardous environment.

1.2 Typical Applications

A few typical applications of the Model 3000MA are:

• Monitoring inert gas blanketing

• Air separation and liquefaction

• Chemical reaction monitoring

• Semiconductor manufacturing

• Petrochemical process control

• Quality assurance

• Gas analysis certification.

1.3 Main Features of the Analyzer

The Model 3000MA Percent Oxygen Analyzer is sophisticated yet simple to use. The main features of the analyzer include:

• A 2-line alphanumeric display screen, driven by microprocessor electronics, that continuously prompts and informs the operator.

• High resolution, accurate readings of oxygen content from low percent levels through 100 %. Large, bright, meter readout.

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1 Introduction Model 3000MA

• Advanced Paramagnetic sensor, designed for percent oxygen analysis. Several options are available.

• Versatile analysis over a wide range of applications.

• Microprocessor based electronics: 8-bit CMOS microprocessor with 32 kB RAM and 128 kB ROM.

• Three user definable output ranges (from 0-1% through 0-100 %) allow best match to users process and equipment.

• Air-calibration range for convenient spanning at 20.9 %.

• Auto Ranging allows analyzer to automatically select the proper preset range for a given measurement. Manual override allows the user to lock onto a specific range of interest.

• Two adjustable concentration alarms and a system failure alarm.

• Extensive self-diagnostic testing, at startup and on demand, with continuous power-supply monitoring.

• Two way RFI protection.

• RS-232 serial digital port for use with a computer or other digital communication device.

• Analog outputs for percent-of-range and for range identification. 0–1 V dc. (Isolated 4–20 mA dc optional)

• Convenient and versatile, steel, flush-panel or rack-mountable case with slide-out electronics drawer.

1.4 Model Designations

3000MA: Standard model. 3000MA-C: In addition to all standard features, this model also has

3000MA-M: This model has current output signals (4-20 mA) for percent-

of-range and range ID, in addition to voltage outputs.

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Percent Oxygen Analyzer Introduction 1

Digital Meter

Door Latch

Alphanumeric Display

Data Entry Buttons

Figure 1-1: Model 3000MA Front Panel

Sample System Flow Indicator

Standby Sw itch

Function Buttons

1.5 Front Panel (Operator Interface)

The standard 3000MA is housed in a rugged metal case with all controls and displays accessible from the front panel. See Figure 1-1. The front panel has thirteen buttons for operating the analyzer, a digital meter, an alphanumeric display, and a window for viewing the sample flowmeter.

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1 Introduction Model 3000MA

Function Keys: Six touch-sensitive membrane switches are used to

change the specific function performed by the analyzer:

• Analyze Perform analysis for oxygen content of a sample gas.

• System Perform system-related tasks (described in detail in

chapter 4, Operation.).

• Span Span calibrate the analyzer.

• Zero Zero calibrate the analyzer.

• Alarms Set the alarm setpoints and attributes.

• Range Set up the 3 user definable ranges for the instrument.

Data Entry Keys: Six touch-sensitive membrane switches are used to

input data to the instrument via the alphanumeric VFD display:

• Left & Right Arrows Select between functions currently

displayed on theVFD screen.

• Up & Down Arrows Increment or decrement values of

functions currently displayed.

• Enter Moves VFD display on to the next screen in a series. If

none remains, returns to the

• Escape Moves VFD display back to the previous screen in a

series. If none remains, returns to the

Digital Meter Display: The meter display is a LED device that

produces large, bright, 7-segment numbers that are legible in any lighting environment. It produces a continuous readout from 0-100 %. It is accurate across all ranges without the discontinuity of analog range switching.

Alphanumeric Interface Screen: The VFD screen is an easy-to-use

interface from operator to analyzer. It displays values, options, and messages that give the operator immediate feedback.

Flowmeter: Monitors the flow of gas past the sensor. Readout is 0 to

1000 standard cubic centimeters per minute (SCCM).

 Standby Button: The Standby turns off the display and outputs,

but circuitry is still operating.

Analyze

screen.

Analyze

screen.

CAUTION: The power cable must be unplugged to fully

disconnect power from the instrument. When chassis is exposed or when access door is open and power cable is connected, use extra care to avoid contact with live electrical circuits.

1-4

Teledyne Analytical Instruments

Percent Oxygen Analyzer Introduction 1

Access Door: To provide access to the sensor, the front panel swings open when the latch in the upper right corner of the panel is pressed all the way in with a narrow gauge tool. Accessing the main circuit board requires unfastening the rear panel screws and sliding the unit out of the case.

1.6 Recognizing Difference Between LCD & VFD

LCD has GREEN background with BLACK characters. VFD has DARK background with GREEN characters. In the case of VFD - NO CONTRAST ADJUSTMENT IS NEEDED.

1.7 Rear Panel (Equipment Interface)

The rear panel, shown in Figure 1-2, contains the gas and electrical connectors for external inlets and outlets. The Zero and Span gas connectors, and the Current signal outputs are optional and may not appear on your instrument. The connectors are described briefly here and in detail in the Installation chapter of this manual.

Figure 1-2: Model 3000MA Rear Panel

• Power Connection Universal AC power source.

• Gas Inlet and Outlet One inlet (must be externally valved)

and one exhaust out.

• Analog Outputs 0-1 V dc concentration output, plus

0-1 V dc range ID.

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1-5

1 Introduction Model 3000MA

• Alarm Connections 2 concentration alarms and 1 system

alarm.

• RS-232 Port Serial digital concentration signal output

and control input.

• Remote Probe Used in the 3000MA for controlling

external solenoid valves only.

• Remote Span/Zero Digital inputs allow external control of

analyzer calibration. (See Note, below.)

• Calibration Contact To notify external equipment that

instrument is being calibrated and readings are not monitoring sample.

• Range ID Contacts Four separate, dedicated, range relay

contacts. Low, Medium, High, Cal.

• Network For future expansion. Not implemented

at this printing.

Optional:

• Calibration Gas Ports Separate fittings for zero, span and

sample gas input, and internal valves for automatically switching the gases.

• Current Signal Output Additional isolated 4-20 mA dc plus

4-20 mA dc range ID.

Note: If you require highly accurate Auto-Cal timing, use external

Auto-Cal control where possible. The internal clock in the Model 3000MA is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day.

1-6

Teledyne Analytical Instruments

Percent Oxygen Analyzer Operational Theory 2

Operational Theory

2.1 Introduction

The analyzer is composed of three subsystems:

1. Paramagnetic Sensor

2. Sample System

3. Electronic Signal Processing, Display and Control

The sample system is designed to accept the sample gas and transport it through the analyzer without contaminating or altering the sample prior to analysis. The Paramagnetic Sensor is an electromechanical device that translates the amount of oxygen present in the sample into an electrical signal. The electronic signal processing, display and control subsystem simplifies operation of the analyzer and accurately processes the sampled data. The microprocessor controls all signal processing, input/output and display functions for the analyzer.

2.2 Precise Paramagnetic Sensor

2.2.1 Principles of Operation

The heart of the 3000MA is a paramagnetic type oxygen sensor that is maintanance free and has a long lifetime. Oxygen has a very high magnetic sucseptibility compared to other gases and thus displays a particularly paramagnetic behavior. A small glass dumbbell filled with nitrogen and rotating on a taut platinum wire is suspended in an inhomogneous magnetic field. This glass dumbbell is diamagnetic and tends to rotate out of the magnetic field. The strength of the resulting torque determined by an susceptibility of the sample gas. This torque is compensated for by a counter torque induced by an electrically charged platinum coil on the dumbbell. The zero position of the dumbbell is controlled by means of an optical system consisting of a light source, a mirror at the dumbbell axis and a pair of detectors. The difference between the compensating currents required to bring the dumb-

Teledyne Analytical Instruments

2-1

2 Operational Theory Model 3000MA

bell to the zero position in the presence of zero gas (i.e. no O2 present) or of sample gas is proportional to the partial pressure of oxygen in the sample gas.

The sensor enclosure is temperature controlled to 55 degrees centigrade to insure that the magnetic susceptibility of oxygen in the sample is not affected by the ambient temperature. The measuring cell has a measuring volume of approximately 3 cm

Sensor

(side view shown)

The Paramagnetic sensor enclosure holds not only the sensing elements, but the temperature controller electronics, heating elements, sensor electronics, and preamplifier. The Electronics and heating elements require a separate power source, from the rest of the 3000MA capable of delivering 1.5 amps approximately at 24 volts dc. The output of the sensor is roughly calibrated to be 0 to 1 volt DC for the the range of 0 to 100 % 02. The true calibration of the sensor is carried out by the microprocessor as described later in chapter 4. The electrical interconnections to the sensor are done through a 15 pin D connector. Some signals from the sensor are not connected. They are only useful for troubleshooting, by trained personnel, as test points.

2-2

Teledyne Analytical Instruments

Percent Oxygen Analyzer Operational Theory 2

Sensor

(rear view shown)

Pin out:

1 -15Vdc test pin (Not connected) 2 +15Vdc test pin (Not connected) 3 Measuring ground 4 Not used 5 Preamplifier output ~0- 1 Vdc 6 Not used 7 24 Vdc return, power ground 8 Collector of transistor switching heating element (Not con-

nected) 9 Fault signal: <0 Vdc= OK, >4.6 Vdc = Fault (Not connected) 10 Not used 11 Negative reference voltage (Not connected) 12 Positive reference voltage (Not connected) 13 Nominal temperature voltage signal (Not connected) 14 Actual temperature voltage signal (Not connected) 15 +24 Vdc power.

2. 3 Cross Interference

As mentioned previously, the selectivity of the measuring system is

based on the extraordinarily high magnetic susceptibility of Oxygen compared to other gases. In most cases the presence of other gases can be ignored but significant errors can occur when the sensor is calibrated with a mixture of oxygen and nitrogen and the sample gas consists mainly of other gases with considerable magnetic susceptibility. In this case, the reading shows a measured value even if the sample gas contains no Oxygen. It is actually displaying the cross sensitivity to another gas.

The following table shows the cross sensitivity of some gases when

changing from pure nitrogen to 100% of one of the gases listed.

Teledyne Analytical Instruments

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2 Operational Theory Model 3000MA

Gas Cross Gas Cross

Sensitivity Sensitivity in vol. % in vol. %

Acetylene C Allene C3H

Ammonia NH

2H2

-0.24 Hydrogen chloride HCI -0.30

-0.44 Hydrogen fluoride HF +0.10

-0.26 Hydrogen iodide HI -1.10 Argon Ar -0.22 Hydrogen sulphide H2S -0.39 Bromine Br

1.2 Butadiene C4H

1.3 Butadiene C4H n-Butane C4H

6 6

-1.30 Iodine I -2.40

-0.49 Isobutane C4H

-0.49 Isopantane C5H

-1.11

-1.11 Krypton Kr -0.51 I-Butane C4H8 -085 Laughing gas N2O -0.20 cis 2-Butane C4H trans 2-Butane C Carbon dioxide CO

4H8

Carbon monoxide CO +0.06 Nitric acid HNO Chlorine Cl Cyclo hexane C6H Ethane C2H Ethylene C2H

Helium He +0.30 Propane C3H n-Heptane C7H n-Hexane C6H Hydrogen H

-0.89 Methane CH

-0.20

-0.92 Neon Ne +0.13

-0.27 Neopentane C5H

-0.77 Nitrogen dioxide NO

-1.49 +0.43 +28.00

-1.56 Nitrous oxide NO +40.00

-0.43 n-Octane C8H

-0.26 n-Pentane C5H

-2.10 Propylene C3H

-2.50

-1.45

-0.86

-0.55

-1.70 Vinyl chloride -0.63

+0.24 Water H2O -0.02

Hydrogen bromide HBr -.0.61 Xenon Xe -0.95

-1.49

With gas mixtures the components are weighted according to their

proporational volumes.

The cross interference with a gas mixture can be determined in advance if the

concentration of the individual background gases is known.

Example:

Cross sensitivity calculation for a gas mixture:

The gas to be measured consists of 10 % CO2, 40 % of N2, and 50%

of Ar.

C02: -0.27 x 10% = -0.027 Ar: -0.22x5O%= -0.11

TOTAL CROSS INTERFERENCE -0.137

Calculation of the zero value:

2-4

Teledyne Analytical Instruments

Percent Oxygen Analyzer Operational Theory 2

(0% 02) - (Cross Interference Value) = Zero Point Value

0%-(-0.137) = +0.137%0

2.4 Sample System

The sample system delivers gases to the sensor from the analyzer gas panel inlets. Depending on the mode of operation either sample or calibration gas is delivered.

The Model 3000MA sample system is designed and fabricated to ensure that the oxygen concentration of the gas is not altered as it travels through the sample system. The sample encounters almost no dead space. This minimizes residual gas pockets that can interfere with low percent range analysis.

The sample system for the standard instrument incorporates ¼ inch tube fittings for sample inlet and outlet connections at the rear panel. For metric system installations, 6 mm adapters are available with each instrument to be used if needed. The sample or calibration gas flowing through the system is monitored by a flowmeter downstream from the sensor.

The gases delivered to the instrument should be at constant pressures and flow rates and must exit freely into the ambient atmosphere. The Span, Zero and Sample gases should be delivered at constant pressures of about 10 psig (Range 5-20). The flow rate must be maintained at about 700 cc/minute (Range 500-900) and must exit freely into atmospheric pressure.

Span In

Zero In

Sample In

In vacuum service the restrictor should be placed here.

Exhaust Out

Figure 2-4 is the flow diagram for the sampling system. In the standard instrument, calibration gases (zero and span) can be connected directly to the Sample In port by teeing to the port with appropriate valves. The shaded portions of the diagram show the components added when the –C options are ordered. The solenoid valves, when supplied, are installed inside the 3000MA enclosure and are regulated by the instruments internal electronics.

Components in the shaded area are in the -C option (internal control valves) only and are not shown in the piping diagram above.

Cell

Solenoid Valves

Flowmeter

Restrictor

In normal service the restrictor should be placed here.

Figure 2-4: Flow Diagram

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2 Operational Theory Model 3000MA

2.5 Electronics and Signal Processing

The Model 3000MAPercent Oxygen Analyzer uses an 8031 microcontroller with 32 kB of RAM and 128 kB of ROM to control all signal processing, input/output, and display functions for the analyzer. System power is supplied from a universal power supply module designed to be compatible with any international power source. Figure 2-6 shows the location of the power supply and the main electronic PC boards.

Figure 2-5: Location of Electronic Components

The signal processing electronics including the microprocessor, analog to digital, and digital to analog converters are located on the motherboard at the bottom of the case. The preamplifier board is mounted on top of the motherboard as shown in the figure. These boards are accessible after removing the back panel. Figure 2-7 is a block diagram of the Analyzer electronics.

2-6

Teledyne Analytical Instruments

Percent Oxygen Analyzer Operational Theory 2

Sensor Amplifier

Sensor

24V Power

Supply

Auto

Range

Self Test Signal

Power

Supply

System

Failure

Alarm

Displays

A to D

Converter

Micro-

Processor

0-1 V

Concentration

D to A

Converter

Range

0-1 V

Figure 2-6: Block Diagram of the Model 3000MA Electronics

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