Teledyne 3300TB Oxygen Equipment User Manual
Contents
1. After setting the value wait for the unit to time out of this mode ap proximately 5 seconds and return to displaying oxygen concentration 4 4 2 Set Alarm 2 Alarm 2 can be set either as a high or low alarm To configure this alarm to your preferences 1 Press the SET ALARM 2 function button once 2 The display will flash either HI or LO depending on what the alarm was configured in the last time If the alarm configuration must be changed use the Up or Down keys to toggle the alarm from HI to LO or viceversa if within 5 seconds no key is pressed the instrument will return to the sample mode and display oxygen concentration 3 To change the setting at which the alarm will be actuated press the SET ALARM 2 function button once more The alarm setpoint will flash on the LED display Press either the Up or Down keys to raise or lower the displayed value as required until the display reads the desired percent concentration if within 5 seconds no key is pressed the instrument will return to the sample mode and display oxygen concentration After setting the value wait for the unit to time out of this mode ap proximately 5 seconds and return to displaying oxygen concentration 4 4 3 Sensor Fail Alarm The SENSOR FAIL alarm triggers if during calibration the raw cell output for the given oxygen level is too low See Calibration Characteris tics in Chapter 2 Should this alarm trigger the ALARM indicator below the2. 3 Insertasmallflat blade screwdriver into the slotin the receptacle wall nearest the fuse and gently pry open the fuse receptacle The Teledyne Analytical Instruments 5 1 5 Maintenance Model 3300TB fuseholderwill slide out There aretwo fusesin use andare visible in the clip 4 Removethebadfuse andreplaceit witha5x20mm0 5 A 250 VAC IEC time lag T fuse P N F1128 5 Replacethe fuse holder into its receptacle pushing in firmly until it clicks 5 2 Sensor Installation or Replacement 5 2 1 When to Replace a Sensor On the trace analyzers the Micro fuel Cell will typically fail due to exces sive zero offset caused by loss of water Large zero offsets will result in inaccu rate SPAN settings To test for this condition purge the sensor and sample system with ZERO gas typically nitrogen with less than 1 ppm O It may take several hours for the sample system and cell to return to a stable low level of O ifit has been exposed to higher levels of O Ifthe instrument will notcome down to an acceptably low reading on zero gas then a depleted cell or a sample system leak should be suspected Typically offsets of 1 0 ppm or less are acceptable A Cell failure may also be indicated by an inability to SPAN or slow response to changes in O concentration at levels below 100 ppm CAUTION Read the section Cell Warranty Conditions below before replac ing the cell CAUTION After replacing the Micro Fuel Cell the analy
3. OPERATING INSTRUCTIONS FOR Model 3300T Trace Oxygen Analyzer 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 PERSIST 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 P NM70362 06 22 00 ECO 00 0228 Teledyne Analytical Instruments Copyright 1999 Teledyne Analytical Instruments All Rights Reserved No part of this manual may be reproduced transmitted tran scribed 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
4. 92 1 KOH 15 w v 10 to 0 C 100 to 115 C 1 09 20 C gt 14 Completely soluble None Colorless odorless solution Teledyne Analytical Instruments Pb pure 328 C 1744 C 11 34 N A Insoluble N A Grey metal odorless Appendix Model 3300TB Section 111 Physical Hazards Potential for fire and explosion The electrolyte in the Micro Fuel Cells is not flammable There are no fire or explosion hazards associated with Micro Fuel Cells Potential for reactivity The sensors are stable under normal conditions of use Avoid contact between the sensor electrolyte and strong acids Section IV Health Hazard Data Primary route of entry Exposure limits OSHA PEL ACGIH TLV Effects of overexposure Ingestion Eye Dermal Inhalation Signs symptoms of exposure Medical conditions aggravated by exposure Carcinogenicity Other health hazards Ingestion eye skin contact 05 mg cu m Pb 2 mg cu m KOH The electrolyte could be harmful or fatal if swallowed Oral LD50 RAT 3650 mg kg The electrolyte is corrosive eye contact could result in permanent loss of vision The electrolyte is corrosive skin contact could result in a chemical burn Liquid inhalation is unlikely Contact with skin or eyes will cause a burning sensation and or feel soapy or slippery to touch None NTP Annual Report on Carcinogens Not listed LARC Monographs Not listed O
5. SET function buttons will start blinking Replace the cell before pro ceeding 4 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 4 5 Selecting a Fixed Range or Autoranging The Model 3300TB can operate in fixed high fixed low or autoranging mode To change modes 1 Press and then release the SET HI RANGE and the SET LO RANGE buttons simultaneously 2 Within 5 seconds press either the A or V button until Auto Lo or Hi displays on the LCD as desired After about three seconds the analyzer resumes monitoring in the selected range mode NOTE Ifthe concentration exceeds 9999 ppm oxygen the analyzer will Note Note Note automatically switch to the Calibration Range EVEN THOUGH IN STRUMENT IS IN THE FIXED RANGE MODE 4 6 Calibration Preliminary If not already done Power up the Analyzer and allow the LED reading to stabilize Set the Alarm setpoints and the fullscale ranges to the desired values Procedure 1 Expose the sensor to ambient air or instrument grade air 20 9 oxygen Allow time for the sampling system to purge and the analyzerto achieve equilibrium If the analyzer output goes above the high alarm setpoint or below the low alarm setpoint the display will go blank and the front panel ALARM Indicator beneath the SET Function buttons will blink Hold down the SPAN button until the ALARM Indicator stops blinking 2 Press the SPAN button once 3 Within
6. defects become apparent within one year from the date of shipment except in cases where quotations or acknowledgements 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 autho rized 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 instrumenta tion 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 imminen
7. is being held down A Increments the displayed value upwards Increments the displayed value downwards Any of the functions can be selected at any time by holding down the appropriate button Each function will be described in the following sections Although the operator can use any function at any time the order chosen in this manual is appropriate for an initial setup 4 3 Setting the Analysis Ranges The two user definable analysis ranges are both capable of being adjusted for from 0 10ppm to 0 9999ppm oxygen concentration Whatever values are selected the analyzer automatically switches from the LO range to the HI range when the oxygen concentration reaches the LO range fullscale value and it switches back to the LO range when the oxygen concentration falls below of the LO range fullscale value Note The HI Range setpoint MUST be set at a higher concentration percent age than the LO Range setpoint 4 2 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 4 3 1 HI Range Setting the HI Range fullscale value defines the LEAST sensitive analysis range to be used To set the HI Range 1 Press the SET HI RANGE Function button once 2 Immediately within 5 seconds press either the A or V button to raise or lower the displayed value as required until the display reads the desired fullscale percent concentration 4 3 2 LO Range Setting the LO Range fullscale value defines the MOST sensi
8. sample gas diffuses through the Teflon membrane Any oxygen in the sample gas is reduced on the surface of the cathode by the following HALF REACTION O 2H 0 4e 40H cathode Four electrons combine with one oxygen molecule in the presence of water from the electrolyte to produce four hydroxylions When the oxygen is reduced at the cathode lead is simultaneously oxidized at the anode by the following HALF REACTION 2 Pb 20H 2 Pb H O 4 anode Twoelectrons are transferred for each atom of lead that is oxidized TWO ANODE REACTIONS balance one cathode reaction to transfer four elec trons The electrons released at the surface of the anode flow to the cathode surface when an external electrical path is provided The currentis proportional to the amount of oxygen reaching the cathode Itis measured and used to determine the oxygen concentration in the gas mixture The overall reaction for the fuel cellis the SUM of the half reactions above or 2Pb O gt 2PbO These reactions will hold as long as no gaseous components capable of oxidizing lead are presentin the sample The only likely components are the halogens iodine bromine chlorine and fluorine The output of the fuel cell is limited by 1 the amount of oxygen inthe cell at the time and 2 the amount of stored anode material In the absence of oxygen no currentis generated 2 2 4 The Effect of Pressure In order to state the amount of oxy
9. treshhold SS Ls This side is closed when IN ALARM N This side is closed with NO ALARM condition OR unit is NOT POWERED condition AND unit IS POWERED Figure 3 2 Contact ID for FAILSAFE Relay Operation 3 4 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 The specific descriptions for each type of alarm are as follows Alarm 1 Alarm 2 Sensor Fail CAUTION Programmable as high or low alarm actuates when concentration is above threshold Can be set anywhere between 0 and 9999ppm but must be set ABOVE the threshold set for the LO Alarm Programmable as high or low alarm actuates when concentration is below threshold Can be set anywhere from 0 to 9999ppm Actuates when the output of the Micro Fuel Cell sensor falls below the acceptable level There could be hazardous voltage at the alarms termi nals even when power is removed from the instrument 3 4 Gas Connections The standard Model 3300TB has two inlets and one outlet fixture only Calibration gasses can be connected into the Span inlet of the gas connections are 1 4 inch brass fittings A switching valve is provided to feed the analysis unit with either sample or gas A flowmwter and flow controller valve are part of the system and will assist in setting the flow of the gas Sample flow should be adjusted to 2 SCFH The sample vent connec tion should not r
10. 0TB rear panel of the control unit For detailed pinouts see the wiring interconnection drawings in the Draw ings section at the rear of this manual To gain access to the terminal blocks the analyzer door screws must be lossened and the door opened O P 0 10VDC 4 20mA O P RANGE ID RANGE Sel es leg 100 240 50 60H El 0 3 A MAX 250V 0 5A FUSE 4 HI ALARM LO ALARM SENSOR FAIL leeeleesbese REMOTE CAUTION RISK OF ELECTRIC SHOCK PROBE ene BUD CCH 1 LU Figure 3 1 Electrical Connectors for AC Control Unit Primary Input Power The power strip supplied inside the analyzer Connect ground to terminal 1 neutral to terminal 3 and hot to terminal 2 Make sure female plug end 15 inserted in the control unit power receptacle The universal power supply allows direct connection to any 100 240 VAC 50 60Hz power source The fuse block to the right of the power cord receptacle accepts two 5x20mm 0 5 A 250V IEC time lag T fuse See Fuse Replacement in chapter 5 Maintenance The Power switch is located on the right hand end of the power source inputreceptacle assembly QU oO G9 AC Power Terminal Strip 19 POWER IN 29 Teledyne Analytical Instruments 3 3 3 Installation Model 3300TB Analog Outputs There are three DC output signal conn
11. 5 seconds press either the A or V button until the display is stable and reads 20 9 The unit is now calibrated If you use a span gas other than air do not span in the 0 10 ppm range Calibration at this level is not dependable If you use a span gas other than air and the span gas oxygen concen tration is less than 10 000 ppm the analyzer could take up to 65 seconds to to settle The lag is caused by a digital filter that is active only below 10 000 ppm 1 oxygen Teledyne Analytical Instruments 4 5 4 Operation Model 3300TB 4 7 Displaying Percent amp PPM on the LED Display The analyzer displays the concentration in percent whenever the read ing is over 9999 ppm When the reading changes to percent the LED display will alternate between flashing PC and the oxygen concentration On the other hand if the instrument is displaying ppm only the concentra tion reading will be shown Supplementary Information If during the Span Procedure you pressed the SPAN button by mis take you must wait five minutes for the analyzer to resume analisis or you can press the UP button and then the DOWN button Pressing the UP and DOWN buttons causes the analyzer to time out in five seconds instead of five minutes If during the span procedure you press the RANGE or ALARM buttons either the range or alarm routine will be activated any changes to span will be rejected the 60 second alarm delay will not occ
12. 7 TDYANYL COID Fax 626 961 2538 Web www teledyne ai com or your local representative A 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix A 3 Reference Drawing D 70361 Outline Diagram D 70362 Final Assembly A 4 Miscellaneous The symbol is used on the rear panel of the model 3300TB to signify volts alternating current VAC NOTE The MSDS on this material is available upon request through the Teledyne Environmental Health and Safety Coordinator Contact at 626 934 1592 Teledyne Analytical Instruments A 3 Appendix Model 3300TB A 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix A 5 Material Safety Data Sheet Section Product Identification Product Name Micro Fuel Cells Mini Micro Fuel Cells all classes Super Cells all classes except T 5F Electrochemical Oxygen Sensors all classes Manufacturer Teledyne Electronic Technologies Analytical Instruments Address 16830 Chestnut Street City of Industry CA 91749 Phone 626 961 9221 Technical Support 626 934 1673 Environment Health and Safety 626 934 1592 Date Prepared 11 23 98 Section Il Physical and Chemical Data Chemical and Common Names Potassium Hydroxide KOH 15 w v CAS Number Melting Point Range Boiling Point Range Specific Gravity pH Solubility in Water Percent Volatiles by Volume Appearance and Odor Lead Pb pure KOH 1310 58 3 Pb 7439
13. Electrochemical Reactions 2 2 4 The 2 2 5 Calibration Characteristics 2 3 Electronics ds eee ee ER ORE NER OUR 2 9 Generali uut toes ARA EO 2 3 2 Signal Processing Installation 3 1 Unpacking the Analyzer 3 2 Location and Mounting 3 2 1 Control Unit Installation eeeeee 3 2 2 External Probe Installation 3 2 3 Installing the Micro Fuel Cell 3 3 Electrical Connections 3 4 Gas Comneclions cassino 3 5 Installation Checklist Operation 4 l troduction ss ari 4 2 Using the Function and Data Entry Buttons 4 3 Setting the Analysis Ranges 4 3 1 HI Range 492 LORANG CC 4 4 Setting the Alarm Setpoints 29 Teledyne Analytical Instruments CF GNE du b TT 4 3 AAD PAINS UU hdd 4 3 4 4 3 Sensor Fall Alarm 4 4 4 5 Selecting a Fixed Range or Autoranging 4 4 46 Cal Dra Mo 4 4 Maintenance 5 1 Replacing the Fuse wesc eina rana darai 5 1 5 2 Sensor Installation or Replacement 5 2 5 2 1 When to Replace a Sensor 5 2 5 2 2 Ordering and Handling of Spare Sensors 5 3 5 23 Removing the Micro Fuel Cell 5 3 5 2 4 Installing a Micro Fuel Cell 5 3 5 2 5 Cell W
14. HI ALARM LO ALARM SENSOR FAIL REMOTE CAUTION RISK OF ELECTRIC SHOCK DO NOT OPEN PROBE NO USER SERVICEABLE PARTS INSIDE SERVICE ONLY BY QUALIFIED PERSONNEL Figure 1 2 Rear Panel 29 Teledyne Analytical Instruments 1 3 1 Introduction Model 3300TB 1 4 Power Connection Analog Outputs Alarm Connections Sensor Connector RS 232 Port AC version 100 240 VAC at 50 60Hz The connector housing includes the fuse holder and the power switch Fuse Holder Replacing the fuse is described in Chapter 5 Maintenance I O Power Switch Turns the instrument power ON 1 or OFF 0 0 10 V de concentration output 0 10 V derange ID or optional overrange output 4 20 mA dc concentration output negative ground Alarm 1 Alarm 2 and Sensor Failure Alarm connections Internal Sampling System Sensor Connector Serial Digital Output ofconcentration and rangesignals Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 Operational Theory 2 1 Introduction The analyzeris composed of two subsystems 1 Analysis Unit with Micro Fuel Cell Sensor 2 Control Unit with Signal Processing Display and Controls The Analysis Unitis designed to accept the sample gas and direct it to the sensitive surface of the Micro Fuel Cell sensor The Micro Fuel Cellis an electrochemical galvanic device that translates the amount of oxygen pres
15. SHA Not listed Lead is listed as a chemical known to the State of California to cause birth defects or other reproductive harm 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix Section V Emergency and First Aid Procedures Eye Contact Flush eyes with water for at least 15 minutes and get im mediate medical attention Skin Contact Wash affected area with plenty of water and remove contaminated clothing If burning persists seek medical attention Ingestion Give plenty of cold water Do not induce vomiting Seek medical attention Do not administer liquids to an unconscious person Inhalation Liquid inhalation is unlikely Section VI Handling Information NOTE The oxygen sensors are sealed and under normal circumstances the contents of the sensors do not present a health hazard The following information is given as a guide in the event that a cell leaks Protective clothing Rubber gloves chemical splash goggles Clean up procedures Wipe down the area several times with a wet pa per towel Use a fresh towel each time Protective measures during cell replacement Before opening the bag containing the sensor cell check the sensor cell for leakage If the sen sor cell leaks do not open the bag If there is liquid around the cell while in the instrument put on gloves and eye protection before remov ing the cell Disposal Should be in accordance with all applicable state local a
16. ally be used If the cell package is punctured and air is permitted to enter cell life will be compromised Teledyne Analytical Instruments 3 1 3 Installation Model 3300TB 3 2 Location and Mounting 3 2 1 Control Unit Installation The 3300TB Control Unit is designed to be wall mounted in a general purpose area The unit should be installed at viewing level in a sheltered area Refer to the Outline diagram D 70361 for the physical dimensions of the analyzer 3 2 2 Installing the Micro Fuel Cell Cell Block Orientation A Micro Fuel Cell is included as a separate item It must be installed prior to instrument use Also once it is expended or if the instrument has been idle for a lengthy period the Micro Fuel Cell will need to be replaced Important Installation Note Membrane side of MFC MUST FACE DOWNWARD Contact side of MFC During the Installation and or Replacement of the MFC Membrane surface MUST ALLWAYS FACE DOWNWARD and the Contact side of the Membrane MUST be placed FIRST into Analysis Unit The reason for proper Installation Replacement is if any bubble that develops as the electrolyte dries out will be directed by the gravity away from the membrane To install or replace the Micro Fuel Cell follow the procedures in Chapter 5 Maintenance 3 2 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 3 3 Electrical Connections Figure 3 1 shows the Model 330
17. arranty Conditions 5 4 Appendix A 1 Specifications supra Dp Ie DRM imi esi dus A 1 A 2 Spare Parts LS ES cen A 2 Reference 4 444 21 3 A4MiscellaneoUs s sistuo atc 3 A 5 Material Safety Data Sheet A 3 Teledyne Analytical Instruments Model 3300TB complies with all of the requirements of the Commonwealth of Europe CE for Radio Frequency Interference Electromagnetic Interference RFI EMI and Low Voltage Directive LVD The following International Symbols are used throughout the Instruc tion Manual for your visual and immediate warnings and when you have to attend CAUTION while operating the instrument STAND BY Instrument is on Stand by but circuit is active CL GROUND Protective Earth for further information Failure to do so may CAUTION The operator needs to refer to the manual A compromise the safe operation of the equipment CAUTION Risk of Electric Shock Teledyne Analytical Instruments This is a general purpose instrument the Control Unit is de signed 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 al ways exist The customer should ensure that the principles of operating of this equipment is well understood by the user Misu
18. ectors with screw terminals on the panel There are two wires per output with the polar ity noted See Figure 3 3 The outputs are 0 10 V Range Voltage rises with increasing oxygen concentration from 0 V at 0 percent oxygen to 10 V at full scale percent oxygen Full scale 100 of programmed range 0 10 V Range ID 03 33 V Low Range 06 66 V High Range 10 V Air Cal Range 4 20 mA Range Current increases with increasing oxygen concentra tion from 4 mA at 0 percent oxygen to 20 mA at full scale percent oxygen Full scale 100 of pro grammed range Alarm Relays The three alarm circuit connectors are screw terminals for making connections to internal alarm relay contacts There is one set of contacts for each type of alarm Contacts are Form C with normally open and normally closed contact connections capable of switching up to 0 5 ampere at 125 VAC into a resistive load 2A for 30 VDC The alarm relay circuits are designed for failsafe operation meaning the relays are energized during normal operation If power fails the relays de energize alarms activated The contact connections are indicated diagrammatically on the rear panel as Normally Closed Common and Normally Open Figure 3 2 explains how these act in failsafe operation Alarm 1 and Alarm 2 can both be configured as either HI or LO A HI alarm will activate when concentration is above treshold while a LO alarm will activate concentration is below
19. emely inert plastic which can be placedconfidently in practically any environment sample stream Itis effec tively sealed though one end is permeable to oxygen in the sample gas Atthe permeable end ascreen retains a diffusion membrane through which the oxygen passes into the cell At the other end of the cell is a connector and temperature compensation network restrictors and thermistor ona printed circuit board Refer to Figure 2 1 Basic Elements of a Micro Fuel Cell which illus trates the following internal description III 4 Electrical Connector Circuit Board with temperature compensation network Figure 2 1 Basic Elements of a Micro Fuel Cell not to scale Atthe sensing end of the cell is a diffusion membrane whose thickness is very accurately controlled Near the diffusion membrane lies the oxygen sensing element the cathode The anode structure is larger than the cathode Itis made of lead and is designed to maximize the amount of metal available for chemical reaction The space between the active elements is filled by a structure saturated with electrolyte Cathode and anode are wet by this common pool They each have a 2 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 conductor connecting them through some electrical circuitry to one ofthe external contacts in the connector receptacle which is on the top of the cell 2 2 3 Electrochemical Reactions The
20. entin the sample into an electrical current The Control Unit processes the sensor output and translates it into electrical concentration range and alarm outputs anda percent oxygen meter readout It contains a microcontroller that manages all signal processing input output and display functions for the analyzer 2 2 Micro Fuel Cell Sensor 2 2 1 Principles of Operation The oxygen sensor used in the Model 3300TB is a Micro Fuel Cell de signed and manufactured by TAI Itis a sealed disposable electrochemical transducer The active components of the Micro Fuel Cell are a cathode an anode and the aqueous KOH electrolyte in which they are immersed The cell converts the energy from a chemical reaction into an electrical potential that can produce a currentin an external electrical circuit Its action is similar to that of a battery There is however an important difference in the operation of a battery as compared to the Micro Fuel Cell In the battery all reactants are stored within the cell whereas in the Micro Fuel Cell one of the reactants oxygen comes from outside the device as aconstituent of the sample gas being analyzed The s Teledyne Analytical Instruments 2 1 2 Operational Theory Model 3300TB Micro Fuel Cell is therefore a hybrid between a battery anda true fuel cell of the reactants are stored externally in a true fuel cell 2 2 2 Anatomyofa Micro Fuel Cell The Micro Fuel Cell is made of extr
21. estrict the sample flow The sensor is designed to operate at atmospheric pressure Restricting the sample vent line will result in pressur izing the sensor and altering the O reading The pressure required will depend on the sampling system When venting into a constant pressure such as the atmosphere controlling input pressure is simple If you are venting into a system of varying pressure then some form of pressure regulation is required to maintain a constant pressure across the sensor The Sample and Span pressure is not to exceed 50 psig 345 kPa A Teledyne Analytical Instruments 3 5 3 Installation Model 3300TB 3 4 1 Vacuum Service Option For vacuum service pluming reference figure 3 4 The vacuum service option is recommended for applications in which the sample source is not pressurized The customer must supply a pump and by pass system to complete the sample system The sample inlet and outlet pressure must be maintained at a constant pressure for proper performance If the sample inlet or vent pressure will not be held constant during the process a pressure regulator must be used to regulate the pressure across the cell Adjust the flow rate on a vacuum service system as follows Select Sample with the three way control valve and open the flow control valve on the analyzer to full flow located on the analyzer flow meter Open the pump by pass valve and turn on the pump Readjust the pump by pass valve to lim
22. ge current converter E I CONV produces the 4 20 mA dc analog concentration signal 2 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 Install 1 2 3 4 5 6 CAUTIONS 3 1 Installation ation of the analyzerincludes Unpacking the system Mounting the Control Unit to a wall Installing the Micro Fuel Cell Making the electrical connections Making the gas connections Testing the installation Read this chapter in its entirety before installing the units The Sample must be free of entrained solids or water How ever a high humidity sample is ideal since it will prevent water loss from the cell electrolyte The Micro Fuel Cell sensor electrolyte is caustic Do not attempt to open it Leaking or exhausted cells should be disposed of in accordance with local regulations Refer to the Material Safety Data Sheet in the Appendix Any damage or scarring of the delicate permeable membrane on the sensing end of the cell will require cell replacement Prevent contact with membrane by any solid object Unpacking the Analyzer As soon as you receive the instrument carefully unpack and inspect the Unit and any included accessories for damage Immediately report any damage to the shipping agent The analyzer is shipped with all the materials you need to install and prepare the system for operation CAUTION Do not disturb the integrity of the cell package until the cell is to actu
23. gen present in the sample as a percent age ofthe gas mixture itis necessary thatthe sample diffuse intothe cell under constant pressure If the pressure changes the rate that oxygen reaches the cathode through the diffusing membrane will also increase The electron transfer and therefore the s Teledyne Analytical Instruments 2 3 2 Operational Theory Model 3300TB external current will increase even though the proportion of oxygen has not changed Fortunately Dalton s Law confirms thatevery gas in a mixture contributes the same pressure to the mixture that it would exert ifit were alone in the same amount in that same volume This means that as long as the total pressure of the sample remains constant the mixture can change but the diffusion of the oxygen will be affected only by the concentration of the oxygen For this reason the sample system supplying sample gas to the cell should be designed to keep the pressure on the diffusion membrane constant 2 2 5 Calibration Characteristics Given that the total pressure of the sample gas at the surface of the Micro Fuel Cell inputis constant a convenient characteristic of the cell is that the current produced in an external circuit of constant impedance is directly propor tional to the rate at which oxygen molecules reach the cathode and this rate is directly proportional to the concentration of oxygen in the gaseous mixture In other words it has a linear characteristic c
24. it the maximum flow rate to full scale on the flowmeter with the flowmeter valve fully open Adjust the analyzer flow control valve flowmeter valve to a flow rate of approximately 2 SCFH Select Span and verify that the span and Sample gas are at different pres sures The calibration accuracy will be adversely affected if the Span and Sample gases are at differing pressures If the span gas is provided from pressurized source a control valve must be added between the analyzer and the span gas source This valve is used to adjust the span flow rate to match the sample flow rate Do not adjust the span flow rate with the flow control valve located on the analyzer for units with vacuum service options BYPASS VALVE SPAN FLOWMETER 3 3 SCFH 3 WAY VALVE SAMPLE O Customer Supplied Parts Figure 3 4 Piping Diagram for Vacuum Service Option 3 6 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 3 5 Installation Checklist Before connecting the instrument to the power source and turning it on make sure you have e Correctly installed the Sample and Exhaust gas lines e Checked for leaks Set the sample pressure to 5 10 psig 34 5 68 9 kPa nominal for non vacuum service units Set the flow Once the above checks have been made you can connect to the power source The instrument is now ready for operation Teledyne Analytical Instruments 3 7 3 Installation Mode
25. l 3300TB 3 8 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 Operation 4 1 Introduction Once the analyzer has been mounted the gas lines connected and the electrical connections made the Analyzer can be configured for your appli cation This involves setting the system parameters e Defining the user selectable analysis ranges e Setting alarm setpoints e Calibrating the instrument All of these functions are performed via the front panel controls shown in Figure 4 1 Analyzing for the trace oxygen level in the gas passing through the cell block is the default mode of operation As long as no front panel buttons are being pressed the Unit is analyzing Figure 4 1 Front Panel Controls and Indicators 29 Teledyne Analytical Instruments 4 1 4 Operation Model 3300TB 4 2 Using the Function and Data Entry Buttons When no buttons on the Analyzer are being pressed the instrument is in the Analyze mode It is monitoring the anount of oxygen in the sample gas that is flowing through the sampling system When one of the Function Buttons is being pressed the Analyzer is in the Setup mode or the Calibration mode The 4 Setup function buttons on the analyzer are s SET ALARM 1 SET ALARM 2 SET HI RANGE SET LO RANGE The Calibration mode button is 2 SPAN The Data Entry buttons A and V increment the values displayed on the TRACE OXYGEN meter while one of the Function buttons
26. m 2 Hi or Low and the concentration to which alarm 2 activates 1 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 e Set HI Range Setthehighanalysisrange forthe instrument up to 0 9999ppm e Set LO Range Setthelowanalysisrange for the instrument down to 0 10ppm Span Span calibrate the analyzer Data Entry Keys Two pushbutton membrane switches are used to manually change measurement parameters ofthe instrumentas they are displayed onthe LED meterreadout e UpArrow Increment values of parameters upwards as they are displayed on the LED readout DownArrow Increment values of parameters downwards as they are displayed onthe LED readout Digital LED Readout The digital display isaLED device that produces large bright 7 segment numbers that are legible in any lighting environment Ithastwo functions Meter Readout Asthe meterreadout it displays the oxygen concentration currently being measured e Measurement Parameters Readout It also displays user definable alarm setpoints ranges and span calibration point when they are being checked or changed 1 4 Rear Panel Description Therear panel contains the electrical inputand output connectors The connectors are described briefly here and in detail in the Installation chapter of this manual O P e 10VDC ES O P ES E ID 100 240 50 80Hz Du H 0 3 A MAX 250V 0 5A T FUSE
27. m Enclosure Specifications Twouser selectable ranges can be set between 0 10 ppm and 0 9999 ppm oxygen and a0 25 nominal Air Cali bration Range Voltage Current 0 10 V dc Lightemitting diode LED display Onehighalarmrelay adjustable one low alarmrelay adjustable one sensor failure relay Allare failsafe 0 50 C 2 of full scale at constant temperature 5 of full scale through operating tem perature range At 100 ppm and higher user defined ranges once temperature equilib riumisreached 1 ppmfor 10 ppmrange under above conditions 90 in less than 65 seconds at 25 C 68 F AC 100 240 VAC 50 60Hz or DC 10 36 VDC user specified Wall Mount NEMA 4 Enclosure 16 40 Hx 8 0 W x 6 0 D 416 56 mm x 203 2 mmx 152 40 mm 0 10 V dc negative ground 4 20mA negative ground Teledyne Analytical Instruments A 1 Appendix Model 3300TB A 2 Spare Parts List QTY P N DESCRIPTION 1 C 65220 A PC Board Main 1 C 64586 PC Board Power Supply 1 C 6689 B 2C Micro Fuel Cell class B 2C 2 F 1130 Fuse AC 250 VAC Type 5 x 20mm IMPORTANT Orders for replacement parts should include the part number and the model and serial number of the system for which the parts are intended Send orders to TELEDYNE ELECTRONIC TECHNOLOGIES Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Telephone 626 934 1500 TWX 910 584 188
28. nd federal regulations NOTE The above information is derived from the MSDS provided by the manufacturer The information is believed to be correct but does not purport to be all inclusive and shall be used only as a guide Teledyne Analytical Instruments shall not be held liable for any damage resulting from handling or from contact with the above product Teledyne Analytical Instruments A 7
29. put TEMPERATURE 4 COMPENSATION SENSOR A NETWORK ON AMPLIFIER ADC E L CONV 420 mA de SENSORPCB i Microamp i 4 Output 2252222 Concentration B 2C Sensor SIOE DAC RANGE ID MICRO CONTROL LER KEYBOARD DISPLAY RELAYS ALARMS RELAYS ALARMS Figure 2 3 Block Diagram of the Signal Processing Electronics 29 Teledyne Analytical Instruments 2 5 2 Operational Theory Model 3300TB In the presence of oxygen the cell generates a current The sensor has an internal thermistor compensation network The output of the sensor is converted to voltage millivolt range This output is fedto a voltage amplifier The internal thermistor network provides tempera ture compensation of the sensor output The resistance of the network changes with temperature compensating for the changes of the microfuel cell output to temperature The output from the temperature compensation amplifier is sent to an analog to digital converter ADC and the resulting digital concentration signal is sent to the microcontroller The digital concentration signal along with input from the front panel buttons KEYBOARD is processed by the microcontroller and appropriate output signals are directed to the display and alarmrelays The same digital information is also sent toa 12 bit digital to analog converter DAC that produces the 0 10 V dc analog concentration signal and the 0 10 V dc analog range ID output A volta
30. ranges from 0 10 ppm through 0 9999 ppm allow best match to users process and equipment Operator can select Autoranging which allows the analyzerto automatically select the proper preset range for a given measurement or he can lock the analyzer onto a single range Twoconcentration alarms with adjustable setpoints Panel mountflowmeter Control valve for the selection of Span gas or Sample gas Sensor failure alarm Teledyne Analytical Instruments 1 1 1 Introduction Model 3300TB e Threeanalog outputs two for measurement 0 10 V dc and negative ground 4 20 mA dc and one for range identification 0 10 V dc e Compact and rugged Control Unit wall mounted NEMA 4 rated enclosure e RS 232 Serial Digital port for output of concentration and datato a computer terminals or other digital devices e ASample flow control valve 1 3 Front Panel Description All controls except the power switch are accessible from the door and gas panel See Figure 1 1 The front panel has seven pushbutton membrane switches a digital meter and an alarm indicator LED for operating the analyzer These features are described briefly here and in greater detail in Chapter 4 Operation Figure 1 1 Front Panel Function Keys Seven pushbutton membrane switches are used to select the function performed by the analyzer Set Alarm 1 Set Alarm 1 Hi or Low and the concentration at which alarm 1 activates e Set Alarm 2 Set the Alar
31. remove aspent or damaged Micro Fuel Cell 1 Disconnect the Power Source from the Control Unit 2 Open the analyzer door 3 Unscrew the cell retainer cap from the cell block by turning it counterclockwise until itis free Screen side of MFC Contact P side of MFC Figure 5 2 Exploded View of MFC and Cell Block s Teledyne Analytical Instruments 5 3 5 Maintenance Model 3300TB 4 Slowly withdraw the cap from the block The cell should come out with the cap 5 Carefully pull the cell off of the cap DONOTTOUCH THE SCREENED END OF THE CELL OR ANY FLUID THAT MAY BE LEAKING FROM IT Dispose ofthe cellinasafe manner in accordance with all applicable ENVIRONMENTAL AND SAFETY laws 5 2 4 Installing a Micro Fuel Cell Toinstall anew Micro Fuel Cell CAUTION Do not scratch puncture or otherwise damage the sensing membrane of the Micro Fuel Cell If the membrane is damaged the cell must be replaced 1 Disconnect the Power Source from the Control Unit 2 Removethe new Micro Fuel Cell from its protective bag 3 Examine the O ring at the base of the threaded portion of the cell retainer cap and replace itifitis worn of damaged 4 Replace the cell onthe end of cell retainer cap which is designed to fit snugly into the rim on the screen side of the cell 5 Careful insert the cap and cell into the block and screw the cap clockwise into the cell block until itis held firmly in the cell 6 Reconnec
32. se of this product in any manner tampering with its components or unau thorized substitution of any component may adversely affect the safety of this instrument Since the use of this instrument is beyond the control of Teledyne no responsibility by Teledyne its affiliates and agents for damage or injury from misuse or neglect of this equipment is implied or assumed 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 Introduction 1 1 Overview The Teledyne Electronic Technologies Analytical Instruments TET AT Model 3300TB is a microprocessor based trace oxygen analyzer forreal time measurement of the parts per million of oxygen in inert gases or ina wide variety of gas mixtures It features simple operation fast response anda compact rugged construction Typical applications of the Model 3300TB are monitoring nitrogen generators and inert gas blanketing applications 1 2 Main Features of the Analyzer Themain features of the analyzer include High resolution accurate readings of oxygen content from 0 10ppm through 9999ppm Large bright LED meter readout Simple pushbutton controls Nylon cell holder Advanced Micro Fuel Cell fortrace analysis has six months warranty and anexpected lifetime ofeight months Unaffected by oxidizable gases Fast response and recovery time Microprocessor based electronics 8 bit CMOS microprocessor with on board RAM and 16 KB ROM Two user selectable
33. t 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 redun dancy 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 TAI the manufacturer of this instrument cannot accept responsibility for conditions beyond its knowledge and control No state ment 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 Contents Introduction di ONCE ge TH 1 2 Main Features of the Analyzer 1 3 Front Panel Description 1 4 Rear Panel Description Operational Theory 2 1 INTOductionia elet 2 2 Micro Fuel Cell 2 2 1 Principles of Operallon oerte 2 2 2 Anatomy of a Micro Fuel Cell 2 2 3
34. t the cell block electrical connector plug 5 2 5 Cell Warranty Conditions The B 2C Class Micro Fuel cell 15 used in the Model 3300TB These cells are warranted for 6 months with an expected life of 8 months from the date of shipment under specified operating conditions see Appendix Note any Addenda attached to the front of this manual for special information applying to yourinstrument Note that the warranty period begins on the date of shipment The cus tomer should stock only one spare cell per instrument at a time Do not attempt to stockpile spare cells Ifacell was working satisfactorily but ceases to function before the watranty period expires the customer will receive credit toward the purchase of anew cell 5 4 s Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 If you have a warranty claim you mustreturn the cell in question to the factory forevaluation If itis determined that failure is due to faulty workmanship or material the cell will be replaced at no cost to you Note Evidence of damage due to tampering or mishandling will render the cell warranty null and void Teledyne Analytical Instruments 5 5 5 Maintenance Model 3300TB 5 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix Appendix A 1 Ranges Signal Output Range ID Display Alarms System Operating Temp Accuracy Response Time System Power Requirement Syste
35. tive range to be used To set the LO Range 1 Press the SET LO RANGE Function button once 2 Immediately within 5 seconds press either the A or V button to raise or lower the displayed value as required until the display reads the desired fullscale percent concentration 4 4 Setting the Alarm Setpoints The alarm setpoints can be adjusted over the full range of the analyzer 0 9999ppm oxygen content The set point values are expressed in ppm only 4 4 1 Set Alarm 1 Alarm 1 can be set either as a high or low alarm To configure this alarm to your preferences 1 Press the SET ALARM 1 function button once 2 The display will flash either HI or LO depending on what the alarm was configured in the last time Ifthe alarm configuration must be changed use the Up or Down keys to toggle the alarm from HI to LO or viceversa if within 5 seconds no key is pressed the instrument will return to the sample mode and display oxygen concentration 3 To change the setting at which the alarm will be actuated press the SET ALARM 1 function button once more The alarm setpoint will flash on the LED display Press either the Up or Down keys to raise or lower the displayed value as required Teledyne Analytical Instruments 4 3 4 Operation Model 3300TB until the display reads the desired percent concentration if within 5 seconds no key is pressed the instrument will return to the sample mode and display oxygen concentration
36. ur i e the alarms will be responsive immediately CAUTION TET Al considers the action of pressing the ALARM or RANGE buttons to be at your the user s discretion The user should be aware that the alarms will become active within 5 five seconds if the Range or Alarm bottons are pressed during Span This may result in false alarms if the Span gas has not been fully purged from the Cell and Sample lines 4 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 Maintenance Aside from normal cleaning and checking for leaks at the gas connections the Model 3300TB should not require any maintenance beyond replacement of expended Micro Fuel Cells and perhaps a blown fuse Routine maintenance includes occasional recalibration as described in chapter 4 Operation 5 1 Replacing the Fuse Remove Power to Unit before replacing the fuse When a fuse blows check first to determine the cause then replace the fuse using the following procedure 1 Disconnect the AC power and place the power switch located on the rear panel in the O position Remove the power cord from the receptacle 2 Thefuse receptacle is located in the power cord receptacle assembly in the upper left hand corner of the rear panel See Figure 5 1 N N AI 2 J FUSE Figure 5 1 AC Fuse Replacement
37. urve as shown in Figure 2 2 Measur ing circuits do not have to compensate for nonlinearities 80 4 60 1 40 Cell Output UA 2071 10 20 30 Oxygen Concentration percent Figure 2 2 Characteristic Input Output Curve for a Micro Fuel Cell In addition since there is zero output in the absence oxygen the character istic curve has an absolute zero The cell itself does not need to be zeroed 2 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 2 3 Electronics 2 3 1 General The signal processing uses an Intel microcontroller with on board RAM and 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 most international power sources The power supply circuitry is on the Power Supply PCB which is mounted vertically just behind the rear panel of the Control Unit The signal processing electronics including the sensor amplifier microcontroller analog to digital and digital to analog converters are located on the Main PCB whichis mounted vertically just behind the front panel of the Control Unit 2 3 2 Signal Processing Figure 2 3 is a block diagram of the signal processing electronics described below i i Pot
38. zer must be recalibrated See Calibration in chapter 4 5 2 2 Ordering and Handling of Spare Sensors Tohave areplacementcell available when itis needed TAI recommends that one spare cell be purchased when the current cell s warranty period is approximately two thirds over CAUTION Do not stockpile cells The warranty period starts on the day of shipment For best results do not order a new spare cell to soon The spare cell should be carefully stored in an area that is not subject to large variations in ambient temperature 75 Fnominal andin such a way as to eliminate the possibility ofincurring damage CAUTION Do not disturb the integrity of the cell package until the cell is to actually be used If the cell package is punctured and air is permit ted to enter cell life will be compromised 5 2 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 WARNING THE SENSOR USED IN THE MODEL 3300TB CON TAINS AN ELECTROLYTE WHICH INCLUDES SUBSTANCES THAT ARE EXTREMELY HARMFUL IF TOUCHED SWALLOWED OR INHALED AVOID CONTACT WITH ANY FLUID OR POWDER IN OR AROUND THE UNIT WHAT MAY APPEAR TO BE PLAIN WATER COULD CONTAIN ONE OF THESE TOXIC SUBSTANCES IN CASE OF EYE CONTACT IMMEDIATELY FLUSH EYES WITH WATER FOR AT LEAST 15 MINUTES CALL A PHYSICIAN SEE APPENDIX Material Safety Data Sheet MSDS 5 2 3 Removing the Micro Fuel Cell Refer to Figure 5 2 for an exploded view of the cell block and cell To
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