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Teledyne 3160 Computer Drive User Manual

1. ZERO SPAN SETUP RANGE ALRMR 1 2 3 4 5 VALVE MODE ANALYZE SENSOR A ON LINE SELECT AUTO RANGE OR FIXED RANGE FOR 02 AUTO FIXED ESC 1 2 3 4 5 VALVE MODE ANALYZE SENSOR A ON LINE SET FIXED O2 RANGE 1000 PPM UP DOWN ESC 1 2 3 4 5 VALVE MODE ANALYZE SENSOR A ON LINE 25 00 a MAN RANGE 1000 PPM ZERO SPAN SETUP RANGE ALRMR 1 2 3 4 5 O Range Set Up 1 Enter Range Set Up mode from the Analyze mode by pressing RANGE Press AUTO for AutoRanging or FIXED to manually fix the O measurement range In AutoRange mode the range will be automatically determined so that the O measurements are within a range which maximizes the accuracy of the reading If AUTO is chosen in step 2 the main Analyze mode menu will appear and will indicate the automatically de termined range see screen for step 1 If FIXED is chosen in step 2 use the UP and DOWN keys to choose the desired manual range and press ACCPT If FIXED was chosen in step 2 and the range was speci fied in step 3 the main Analyze mode screen will ap pear and will indicate the new manually set range TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 VALVE MO
2. VALVE MODE SPAN OXYGEN 5 0 PPM SENSOR A ON LINE AUTORANGE 10 PPM SPANNING IN PROGRESS ES PLEASE WAIT 0 1 2 3 4 5 7 10 11 12 If AUTO was chosen in step 6 wait for the O level to settle before the system spans This may take from fif teen 15 to thirty 30 minutes or longer depending on the sample gas oxygen level Go to step 11 if MAN was chosen in step 6 If any key was pressed in step 7 the screen indicates that the span has been aborted Press ACK to retry spanning or ESC to abort the span After the system has automatically detected sensor sta bility the system will automatically span If the system spans correctly the next screen will be the Analyze mode main menu see step 14 If the O cell current is too strong or too weak to be spanned an error message will appear Insure that the span gas concentration has been entered correctly Press ACK to retry or ESC to abort the span If MAN was pressed in step 6 watch the logger or the O value on the screen to determine when the output is constant and then press ACK After step 11 the system will automatically span to the user entered span value TELEDYNE ANALYTICAL INSTRUMENTS 4 9 4 Operations VALVE MODE SPAN WARNING CELL TOO STRONG PRESS ACK TO RE TRY SPAN
3. Installation of analyzer includes 1 Unpacking the system Recognizing the necessary precautions when installing the system Hooking up the sample span gas and air supply to appropriate connections Installing the Micro Fuel Cell sensor s Hooking up electrical connections Qv e Testing the system 3 1 Unpacking the Analyzer The analyzer is shipped with all the materials and special items you need to install and prepare the system for operation Carefully unpack the analyzer and inspect it for damage Immediately report any damage to the shipping agent Remove the packing slip and verify that you have received all the components listed in Table 3 1 Table 3 1 Accessory Kit for Model 3160 Qty Part No Description 3 G285 Weld glands VCR type 3 G284 Gaskets VCR type 3 N284 Nuts female Hoke 4NM316 2 W64 Wrench Open End 3 4 5 8 1 M52973 Instruction Manual 3 2 Front Panel The Model 3160 front and rear panels are illustrated in Figure 3 1 on the follow ing page The front panel contains the following displays and controls 1 Main power switch 2 Light Emitting Diode LED display the O concentration is displayed in bold lettering se TELEDYNE ANALYTICAL INSTRUMENTS 3 1 3 Installation 3 Parts Per Million PPM and Percent Oxygen indicators the PPM light will light while the instrument is measuring O in units of PPM The percent light will light while
4. VALVE MODE OFF SENSOR A ON LINE SELECT SENSOR OR ESC ESC 1 2 3 4 5 VALVE MODE OFF CONNECT A SAMPLE GAS TO THE SAMPLE PORT PRESS ACK WHEN READY ESC 1 2 3 4 5 VALVE MODE OFF SENSOR A ON LINE SET FLOW RATE TO 2 SCFH PRESS ACK WHEN READY ESC 1 2 3 4 5 VALVE MODE ANALYZE SENSOR A ON LINE 5 00 PPM O2 AUTORANGE 10 PPM 0 ZERO SPAN SETUP RANGE ALRMR 1 2 3 4 5 Cold Start Up A cold start will automatically occur the first time you start the analyzer In any other situation you can cold start by turning the analyzer off and holding down the red key below the LCD screen while you turn the power back on Continue to hold the red key until the screen comes on There will be a two minute wait for system initialization before the second screen A warm start will take you directly to step 5 Set the time using the SELEC UP and DOWN keys and press ACCPT Select sensor A or B as the active sensor This menu is omitted if only one cell block is installed If you have not done so connect the sample gas to the sample port
5. VALVE MODE ANALYZE 4 SELECT FUNCTION TO SETUP LOG JALRMS SENSR MORE ESC 1 2 3 4 5 VALVE MODE ANALYZE SENSOR A ON LINE 5 SELECT SENSOR OR ESC Esc 1 2 3 4 5 VALVE MODE ANALYZE 6 SENSOR B ON LINE 5 00 PPM O2 AUTORANGE 10 PPM o ZERO SPAN SETUP RANGE ALRMR 1 2 3 4 5 Enter set up from the Analyze mode main menu by pressing SETUP If only one cell block is installed the TEST and INSTL options on the next screen are omitted Press SET to change the active sensor Enter your authorization code by using the SELEC UP and DOWN keys and press ACCPT Press SENSR This option will not appear if only one sensor block is installed Select sensor A or B The main Analyze mode menu will appear and will indi cate the chosen sensor TELEDYNE ANALYTICAL INSTRUMENTS 4 11 4 Operations Install Sensor and Test Alternate Sensor Two Cells Only VALVE MODE ANALYZE 1 SENSOR A 5 00 PPM O2 AUTORANGE 10 PPM ol ZERO SPAN SETUP RANGE ALRMR 1 2 3 4 5 VALVE MODE ANALYZE STAT VIEW SYSTEM STATUS TEST CHECK ALTERNATE SENSOR INS
6. 1 2 3 4 5 VALVE MODE ANALYZE SPANNING BEFORE ZEROING WILL CAUSE INCORRECT O2 READINGS SCHEDULED SPAN IS OFF NO SPAN SINCE START PRESS ACK WHEN READY 4 8 ACK ESC 1 2 3 4 5 VALVE MODE ANALYZE SENSOR A ON LINE CONNECT THE SPAN GAS TANK TO THE SPAN PORT PRESS ACK WHEN READY Esc 1 2 3 4 5 VALVE MODE ANALYZE OXYGEN 5 0 PPM AUTORANGE 10 PPM SENSOR A ON LINE ENTER SPAN GAS CONCENTRATION 5 1 PPM ESC UP DOWN 1 2 3 4 5 VALVE MODE SPAN OXYGEN 5 00 PPM AUTORANGE 10 PPM SENSOR A ON LINE SET FLOW RATE TO 2 SCFH PRESS ACK WHEN READY AcK Esc 1 2 3 4 5 VALVE MODE SPAN OXYGEN 5 0 PPM AUTORANGE 10 PPM SENSOR A ON LINE CHOOSE MANUAL OR AUTO SETTLING ESC AUTO MAN 1 2 3 4 5 1 Enter the Calibration mode from the Analyze mode by pressing SPAN Press ACK if zeroing has already been done Make sure to zero before calibrating to ensure correct O readings If the span gas tank is not connected to the span port connect it
7. C 1744 11 34 na na Insoluble Solid silver Lead na 328 gray odorless 1320 2 04 na na Complete White or Potassium na 360 slightly Hydroxide yellow no odor 4 TELEDYNE ANALYTICAL INSTRUMENTS Appendix Section IV Fire and Explosion Hazard Data Flash Point na Flammable Limits na LEL na UEL na Extinguishing Media Use extinguishing media appropriate to surrounding fire conditions No specific agents recommended Special Fire Fighting Wear NIOSH OSHA approved self contained breathing Equipment apparatus and protective clothing to prevent contact with skin and eyes Unusual Fire and Explosion Emits toxic fumes under fire conditions Hazards Section V Reactivity Data Stability Stable Incompatibilities Aluminum organic materials acid chlorides acid anhydrides magnesium copper Avoid contact with acids Hazardous Decomposition of and hydrogen peroxide gt 52 Byproducts Toxic fumes Hazardous Polymerization Will not occur Section VI Health Hazard Data Routes of Entry Inhalation Highly unlikely Ingestion May be fatal if swallowed Skin The electrolyte potassium hydroxide is corrosive skin contact may cause irritation or chemical burns Eyes The electrolyte potassium hydroxide is corrosive eye contact may cause irritation or severe chemical burns Acute Effects The electrolyte is harmful if swallowed inhaled or adsorbed through the skin It is extremely destru
8. Completely soluble Insoluble Percent Volatiles by Volume None N A Appearance and Odor Colorless odorless solution Grey metal odor less A 8 TELEDYNE ANALYTICAL INSTRUMENTS Appendix Section Physical Hazards Potential for fire and explosion The electrolyte in the Micro Fuel Cells is not flam mable 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 Exposurelimits OSHA PEL ACGIH TLV Effects of overexposure Ingestion Eye Dermal Inhalation Signs symptoms of exposure Medical conditions aggravated by exposure Carcinogenity Other health hazards TELEDYNE ANALYTICAL INSTRUMENTS Ingestion eye skin contact 05 mg cu m Pb 2 mg cu m KOH The electrolyte could be harmful or fatal if swal lowed 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 sensa tion and or feel soapy or slippery to touch None NTP Annual Report on Carcinogens Not listed LARC Monographs Not listed OSHA Not listed Lead is listed as a chemical known
9. Maximum The maximum of all values measured in the time period between samples Minimum The minimum of all values measured in the time period between samples Sample The last sample measured in the time period between samples Press EDIT in step 6 and then use the UP and DOWN keys to select the above choices for the logger chart mode 4 18 TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 VALVE MODE ANALYZE SENSOR A ON LINE 5 00 PPM O2 AUTORANGE 10 PPM ol ZERO SPAN SETUP RANGE 1 2 3 4 5 VALVE MODE ANALYZE STAT VIEW SYSTEM STATUS TEST CHECK ALTERNATE SENSOR INSTL INSTALL A SENSOR SET SET ALARMS CLOCK LOG PASSWORDS OR SENSOR STAT TEST INSTL SET ESC 1 2 3 4 5 VALVE MODE ANALYZE SELECT AUTHORIZATION CODE SELECT YOUR CODE SELEC UP DOWN ESC 1 2 3 4 5 VALVE MODE ANALYZE SELECT FUNCTION TO SETUP LOG JALRMS SENSR MORE ESC 1 2 3 4 5 VALVE MODE ANALYZE SELECT FUNCTION TO SETUP cLocK 51 2 Esc 1 2 3 4 5 VALVE MODE ANALYZE TIME 6
10. ZERO SPAN RANGE ALRMR 1 2 3 4 5 LATCHING actuates the alarm above a certain setpoint even if the level falls back below the setpoint RELAY indicates the relay on the rear panel actuated by the alarm which is changeable FAILSAFE YES enables the relay which actu ates the alarm during system failure DEFEAT NO actuates the alarms for normal use 7 If MORE was pressed in step 5 choose alarms 3 4 or 5 by pressing AL3 ALA or AL5 Choose ALS to set up a system alarm 10 If ALS was pressed in step 7 choose alarm 5 to be an O or system alarm by pressing O or SYSTEM Configured as a system alarm alarm 5 will ring when a scheduled calibrator zeroing or a scheduled span calibra tion fails when there is an internal system failure or when the RAM back up battery fails If SYSTM was pressed in step 8 configure the system alarm using the SELEC UP and DOWN keys LATCHING YES actuates alarm 5 above a cer tain setpoint even if the level falls back below the setpoint FAILSAFE YES enables the relay which actu ates the alarm during system failure DEFEAT YES actuates the alarm for normal use Press ACCPT to accept the new system alarm configu ration The next screen will ask you if there are more alarms to set If not pressing ESC three times will take you back to the Analyze mode main menu If O was pressed in step 8 the screen wil
11. IS STABLE a I ESC VALVE MODE ZERO OXYGEN 0 15 PPM SENSOR A ON LINE AUTORANGE 1 PPM ZEROING IN PROCESS PLEASE WAIT a 4 6 1 2 3 4 5 Calibration Zeroing 1 At the main Analyze mode screen press ZERO Press ACK to acknowledge that a low O gas has al ready been connected to the sample port The sample gas O level should be close to zero to preserve the life of the scrubber if one is installed Set the flow rate to 2 SCFH using the knob on the sys tem front panel and press ACK Press AUTO to let the system determine the settling time before spanning or press MAN for manual If MAN was chosen in step 4 watch the logger or the O value on the screen to assess when the output is con stant and then press ACK After step 5 the system will automatically span to the user entered span value If the zeroing is successful the main Analyze mode menu will appear as in step 10 ee TELEDYNE ANALYTICAL INSTRUMENTS VALVE MODE ZERO WARNING SENSOR CURRENT TOO BIG TO ZERO PRESS ACK TO RE TRY ZERO PRESS ESC TO ABORT ZERO OR ESC 1 2 3 4 5 VALVE MODE ZERO OXYGEN 0 15 PPM SENSOR A ON LINE AUTORANGE 1 PPM W
12. If this is a COLD START the code you enter will be the code set for every subsequent start up until the next COLD START If this isa WARM START enter the code used during the last COLD START Press ALRMS Press e ALI for alarm 1 e AL2 for alarm 2 e MORE for alarms 3 5 e ESC twice to return to the main menu Note that alarm 5 may be programmed as a system alarm If ALI or AL2 was chosen in step 5 use the SELEC UP and DOWN keys to configure alarm 1 or 2 and press ACCPT which will take you back to step 5 LEVEL is the O concentration for the alarm threshold e HIGH LOW determines whether the alarm con dition is above or below the alarm threshold TELEDYNE ANALYTICAL INSTRUMENTS 4 15 4 Operations VALVE MODE ANALYZE MORE ALARMS TO SETUP SELECT ALARM TO SETUP VALVE MODE ANALYZE ALARM 5 MAY BE SET TO MONITOR O2 LEVELS OR SYSTEM ERRORS CURRENTLY MONITORING O2 SELECT TYPE OF ALARM 02 SYSTM Esc 1 2 3 4 5 VALVE MODE ANALYZE ALARM 5 SETUP SYSTEM MODE RELAY TB5 FAILSAFE YES LATCHING YES DEFEAT YES SELEC UP Down Esc 1 2 3 4 5 VALVE MODE ANALYZE SENSOR A ON LINE ALARM T 5 00 PPM O2 AUTORANGE 10 PPM
13. Micro Fuel Cell sensor C6689B2 C6689B2C C6689A2 C6689A2C O ring 0165 Suction purifier P670 Solenoid valve V462 Pneumatic valve upper body B435 Hose fittingtee T978 Fuse 3A T Type F68 Fuse 1 6A T Type European F768 Scrubber C58750 A 3 Drawing List D 56534 Outline Drawing C 64819 Interconnection Drawing 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 A 4 Material Safety Data Sheet I Section Product Identification Product Name Micro Fuel Cells and Super Cells all classes except A 2C A 3 and A 5 Electrochemical Oxygen Sensors all classes except R 19 Mini Micro Fuel Cells all classes Manufacturer Teledyne Analytical Instruments Address 16830 Chestnut Street City of Industry CA 91749 Phone 818 961 9221 Customer Service Extension 222 Environmental Health and Safety Extension 230 Date Prepared 2 12 96 Section II Hazardous Ingredients Composition Material or Component C A S Quantity OSHA PEL ACGIH TLV Lead Pb 7439 92 1 3 20 gms 0 05 mg m 0 15 mg m Potassium Hydroxide1310 58 3 1 5 ml None 2 mg m Solution 1596 KOH Section Physical Chemical Characteristics Material Appearance Boiling Specific Vapor Melting Density Evap Solubility Odor Compo Point C Gravity Pres Point Rate in Water nent sure
14. OPERATING INSTRUCTIONS FOR Model 3160 Trace Oxygen Analyzer TRACE OXYGEN ANALYZER Model 3160 A Teledyne Analytical Instruments OXYGEN SENSOR COMPARTMENT CONTROL MODULE HIGHLY TOXIC AND ORFLAMMABLE 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 FORA TIME EVEN AFTER THE POWERIS 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 N M52972 ECO 99 0323 08 06 99 TELEDYNE ANALYTICAL INSTRUMENTS Copyright O 1999 Teledyne Analytical Instruments 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 wit
15. passi 552 Esc 1 2 3 4 5 VALVE MODE ANALYZE CHANGE PASSWORD FOR REMOTE MONITORING READ ONLY ACCESS CURRENT PASSWORD MONITR SELEC UP DOWN Esc 1 2 3 4 5 l Enter set up from the Analyze mode by pressing SETUP Press SET to set the password s Enter your authorization code by using the SELEC UP and DOWN keys and press ACCPT You must enter the same authorization code set during the last COLD START Press MORE Press ESC to return to the Analyze mode main menu Press PASSI to change the remote monitoring pass word or PASS2 to change the remote control pass word If you pressed PASSI in step 5 the next screen will al low you to change the remote monitoring password Use SELEC UP and DOWN to choose the new pass word and then press ACCPT which will take you to step 4 W TELEDYNE ANALYTICAL INSTRUMENTS 4 21 4 Operations VALVE MODE ANALYZE CURRENT PASSWORD CONTRL CHANGE PASSWORD FOR REMOTE CONTROL READ ONLY ACCESS SELEC uP DOWN AccPT Esc 1 2 3 4 5 4 22 7 If you pressed PASS2 in step 5 the next screen will al low you to change the remote control password Use SELEC UP and DOWN to choose the new password and press ACCPT which will take yo
16. SELEC Accept Esc 1 2 3 4 5 Logger Set Up Enter set up from the Analyze mode by pressing SETUP Press SET to set up the logger Enter the authorization code by using the SELEC UP and DOWN keys Then press ACCPT Press LOG for the logger functions Press ESC to return to the Analyze mode main menu Press CLEAR if you want to clear the current logger data Press SETUP to continue setting up the logger If you chose SETUP in step 5 use SELEC to choose logger ON OFF the time period between samples or the mode of measurement Then choose EDIT to change the values After you are finished press ACCPT which will take you to step 4 The choices for the logger chart sampling mode MODE are on the next page TELEDYNE ANALYTICAL INSTRUMENTS 4 17 4 Operations Note The above screens use T to indicate two values seconds and minutes The first value is the time perlod between samples on the logger and is programmable The second time value is the width of the logger chart page and is not programmable There are 64 samples per logger chart page and over 20 pages of past data which may be viewed Mode determines how to calculate the sample values shown on the logger chart Average The average of all measurements in the time period between samples Median The average of the minimum and the maximum values measured in the time period between samples
17. 00 00 PM 01 01 91 SELECT CLOCK FUNCTION SET SKED SKED VIEW TIME ZERO SPAN TIME SET ZERO span anus ESC 1 2 3 4 5 Set Up Clock Functions 1 Enter set up from the Analyze mode by pressing SETUP Press SET to set the clock functions If only one cell block is installed TEST and INSTL will be omitted Enter the authorization code by using the SELEC UP and DOWN keys and press ACCPT Press MORE Press CLOCK to select clock functions Enter the function that you would like to change SET Sets the time ZERO Sets the time for the next zero and the inter val times for automatic zeroing SPAN Sets the time for the next span and interval times for automatic spanning ALRMS Displays alarm times and dates TELEDYNE ANALYTICAL INSTRUMENTS 4 19 4 20 4 Operations VALVE MODE ANALYZE TIME 6 00 00PM 12 01 90 NEW TIME 6 00 00PM 12 01 90 SET NEW TIME AND DATE SELEC Down ESC 1 2 3 4 5 VALVE MODE ANALYZE TIME 6 00 00PM 12 01 90 gt SCHEDULED ZERO OFF INTRVAL DAY HR MIN 007 00 00 NEXT ZERO 01 00 AM 01 01 91 SELEC EDIT ACCPT ESC 1 2 3 4 5 VALVE MODE ANALYZE TIME 6 00 00PM 12 01 90 SCHEDULED ZERO ON gt I
18. 0PPM LO Y Y TB4 5 OFF 5 0PPM HI Y Y TB5 ESC PREV NEXT 1 2 3 4 5 W TELEDYNE ANALYTICAL INSTRUMENTS System Statistics l Enter set up from the Analyze mode by pressing SETUP ESC in any status page will take you to the last set up screen and eventually the main analyze mode PREV steps you back one status page NEXT moves forward one status page Press STAT for system status If only one cell block is installed TEST and INSTL will be omitted Status page one displays the active sensor A or B the system time date and the system hardware configura tion The number and date of the installed software ver sion are also shown Press PREV for the previous screen or NEXT for the next screen Status page two shows the O level set for spanning the cell strength factor the type and time of the last span the time interval for scheduled spanning AutoSpan and whether or not scheduled spanning is active The cell strength factor is an indication of the amount of cell life left in the cell with 1 00 being the most and 0 00 be ing the least Status page three shows the time of the last zero the time interval for scheduled zeroing AutoZero and whether or not scheduled zeroing is active Status page four shows the settings for the five pro grammable alarms 4 23 4 Operations ALARM NUM MIN MON DAY YR 00 00
19. Press EDIT to change the configuration Mode ON OFF Interval 3 32000 seconds NOTE The printer report will always be in the same for 14 15 16 17 mat O Level Range Active Sensor Time amp Date After pressing EDIT a cursor will appear and you will be able to edit the settings Status page nine shows whether or not the last and next start ups were WARM or COLD The next start up may be changed by pressing the COLD or WARM keys Status page ten displays logger data Press VIEW to see the logger data history Press NEXT to return to status page one Press ESC twice to return to the Analyze mode main menu If VIEW was pressed in step 13 logger data may be viewed by using the REV and FWD keys level range and time are shown for each data point NEXT takes you to status page two REV and FWD change the date by one page or 64 points while and go through the data one point at a time within a single page Press ESC to return to status page ten 4 25 4 Operations 4 26 TELEDYNE ANALYTICAL INSTRUMENTS Maintenance amp Troubleshooting 5 Maintenance amp Troubleshooting 5 1 Routine Maintenance 1 Calibrate the analyzer at least once each week during the first four weeks and then once every two weeks during the next eight weeks Afterwards the analyzer should be calibrated once a month 2 Check the pressure of the air supply to the analyzer Air pressure
20. Solid N O S Lead 9 UN3077 PG III Follow all Federal State and Local regulations Section X References Material Safety Data Sheets from J T Baker Chemical Aldrich Mallinckrodt ASARCO U S Department of Labor form OMB No 1218 0072 Title 8 California Code of Regulations TSCA SARA Title III CFR 49 CFR 29 CFR 40 NOTE The above information is believed to be correct and is offered for your information consideration and investigation It should be used 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 Appendix A 5 Material Safety Data Sheet Il Section Product Identification Product Name Micro Fuel Cells Mini Micro Fuel Cells all classes Super Cells all classes except T 5F Oxygen Sensors all classes Manufacturer Teledyne Analytical Instruments Address 16830 Chestnut Street City of Industry CA 91749 Phone 818 961 9221 Date Prepared or Last Revised 08 08 91 Emergency Phone Number 818 961 9221 Section Il Physical and Chemical Data Chemical and Common Names Potassium Hydoxide KOH 1596 w v Lead Pb pure CAS Number 1310 58 3 Pb 7439 92 1 KOH 15 w v Pb pure Melting Point Range 10 to 0 C 328 C Boiling Point Range 100 to 115 1744 C Specific Gravity 1 09 20 C 11 34 pH gt 14 N A Solubility in Water
21. and press ACK Using the valve and meter on the sample gas supply set the flow rate to 2 SCFH and press ACK If you have warm started this is the second screen you will see The main Analyze mode menu will appear and the measured O level of the sample gas will display The system should first be zeroed then spanned to obtain the most accurate O measurements TELEDYNE ANALYTICAL INSTRUMENTS 4 5 4 Operations UVALVE MODE ANALYZE SENSOR A ON LINE 0 1 5 PPM 02 AUTORANGE 1 PPM D ZERO SPAN sETUP RANGE ALRMR 1 2 3 4 5 VALVE MODE ANALYZE SENSOR A ON LINE SCHEDULED ZERO IS OFF NO ZEROING SINCE START CONNECT LOW O2 GAS TO SAMPLE PORT PRESS ACK WHEN READY ACK ESC 1 2 3 4 5 VALVE MODE ZERO OXYGEN z 0 15 PPM AUTORANGE 1 PPM SENSOR A ON LINE SET FLOW RATE TO 2 SCFH PRESS ACK WHEN READY ack Esc 1 2 3 4 5 VALVE MODE ZERO OXYGEN 0 15 PPM AUTORANGE 1 PPM SENSOR A ON LINE CHOOSE MANUAL OR TRS AUTO SETTLING LL m o AUTO MAN 1 2 3 4 5 VALVE MODE ZERO OXYGEN 0 15 PPM AUTORANGE 1 PPM SENSOR A ON LINE PRESS ACK WHEN 02 Shek
22. at 8096 of full scale of the current range The analyzer is programmed to prevent oscillation between ranges during rapidly changing oxygen levels TELEDYNE ANALYTICAL INSTRUMENTS 4 3 4 Operations Set Up Alarms Each of five alarms provided may be programmed to actuate at any O trace level above or below a threshold The fifth alarm may also be programmed as a system alarm to monitor several system level condi tions The system alarm can be triggered by the following system operations Scheduled zero AutoZero failure Scheduled span AutoSpan failure Battery failure nternal errors Any condition triggering the system alarm can be determined from status page 4 see this chapter System Statistics When the alarms are disabled scheduled zeroing or spanning will not take place Logger Set Up A system data logger keeps a record of past oxygen measurements The logger is presented in the form of a graphed chart on the system LCD gaps in time will not display and all points shown on a single chart have the same range and sensor number The logger will not record in the Test Alternate Sensor mode Set Up Clock Functions internal clock provides the time and date for events scheduled by the user The internal clock is also used by the logger to record events scheduled at timed intervals Scheduled zeroing and spanning AutoZeroing and AutoSpanning are set in this mode The mode uses an electronic timer to s
23. be delayed until the alarms have been enabled Calibration Using Span Gas After zeroing the instrument can now be calibrated using a span gas with a known oxygen concentration The analyz er may be calibrated on any range other than 0 1 PPM but it is best to cali brate one range up from the range where the sample is expected to be The span gas concentration should be within 70 to 99 of full scale of the range selected NOTE 3 Prior to calibration allow the analyzer reading to come to a stable value with zero or sample gas flowing through the analyzer Select Active Sensor Two cell blocks only One or two sensor blocks can be installed in the system In dual sensor systems either sensor can be isolated with pneumatic valves and the other sensor chosen as the active sensor for O measurements The system software is aware of how many sensor blocks are present but will not automatically switch sensors should one fail This menu will not appear if only one cell block is installed Install Sensor and Test Alternate Sensor Two cell blocks only Pro cedures are provided for installing a new sensor and for testing the alternate O sensor This menu will not appear if only one cell block is installed O Range Set Up The measurement range may be manually chosen or the system may be set to automatically choose the range AutoRanging In the AutoRanging mode the range will step up at greater than 10096 and step down
24. now and press ACK Enter the span gas concentration using the UP and DOWN keys and press ACCPT Set the flow rate to 2 SCFH and press ACK Select manual or automatic sensor settling detection by pressing MAN or AUTO Automatic sensor settling de tection lets the system determine when the sensor has stabilized ee TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 VALVE MODE SPAN OXYGEN 5 0 PPM AUTORANGE 10 PPM SENSOR A ON LINE WAIT FOR O2 SETTLING _ OR ANY KEY TO ABORT gt 1 2 3 4 5 VALVE MODE SPAN WARNING USER ABORTED AUTO SETTLING MODE PRESS ACK TO RE TRY SPAN OR PRESS ESC TO ABORT SPAN ACK ESC 1 2 3 4 5 IU VALVE MODE SPAN SENSOR A ON LINE OXYGEN 5 0 PPM AUTORANGE 10 PPM SPANNING IN PROGRESS PLEASE WAIT 0 1 2 3 4 5 VALVE MODE SPAN WARNING CELL TOO STRONG PRESS ACK TO RE TRY SPAN OR PRESS ESC TO ABORT SPAN ESC 1 2 3 4 5 VALVE MODE SPAN OXYGEN 5 0 PPM AUTORANGE 10 PPM SENSOR A ON LINE PRESS ACK WHEN O2 Em IS STABLE a ESC
25. should be maintained between 70 and 80 psig Note The instrument air pressure must be greater than 70 psig in order to open and close the pneumatic solenoid valves 3 Check the sample pressure Pressure should be maintained between 5 and 10 psig Sample and span gas pressures should be within 2 psig of each other 5 1 1 Sensor Maintenance Sensor maintenance in the 3160 is limited to replacing the sensor s when replace ment is indicated Consult the troubleshooting section for symptoms that indicate that the sensor needs replacing A guide to the relative life left in the cell can be found on status page 2 See Cell Strength Factor at the beginning of Chapter 3 0 In units with 2 cell blocks if sensor A fails sensor B will not automatically switch online This must be done manually through the Install Sensor and Test Alternate Sensor menu 5 1 2 Scrubber Maintenance The oxygen scrubber is a replaceable component With normal use the scrubber usually lasts for several years NOTE Do not zero in ranges other than 0 1 ppm as zeroing in higher ranges will exhaust the scrubber se TELEDYNE ANALYTICAL INSTRUMENTS 5 1 5 Maintenance amp Troubleshooting Analyzers equipped with a scrubber should only be used with inert gases and saturat ed hydrocarbons 5 2 Troubleshooting To troubleshoot the analyzer identify the problem in the following list and then follow the procedures to correct the problem If you can
26. software automatically adjusts when a second cell block is present TELEDYNE ANALYTICAL INSTRUMENTS 1 1 1 Introduction The 3160 features six full scale linear ranges of analysis e 0 1 PPM 0 10 PPM 0 100 PPM e 0 1000 PPM 0 1 025 An AutoRanging feature automatically selects the range that is appropriate for a given reading For example if the O level exceeds 100 of the current range the analyzer switches to the next higher range When desired a manual override feature allows a particular range of interest to be locked in With the AutoSpan feature the analyzer automatically calibrates at scheduled intervals and automatically performs electronic zeroing and sensor settling detection during calibration Five user programmable absolute reading PPM alarm setpoints with assignable Form 1C SPDT relays are provided along with a RS 232C bidirectional serial data port and four signal outputs for chart recorders etc The RS 232 serial port can be used with or without a modem to connect with a personal computer loaded with the Teledyne Remote Analytical Control Software TRACS any terminal or terminal emulation software a custom computer program Several analyzer functions including troubleshooting can be run from your PC through the phone line to the analyzer The analyzer has separate sample and span gas ports which allow the installation of an external source of span gas for calibration
27. the instrument is measuring O concentration in percent 4 Flow Indicator and Flow Set a flowmeter and flow set knob are provided for adjusting gas flow in standard cubic feet per hour SCFH 5 Liquid Crystal Display LCD with keypad the LCD shows system menus and data during instrument operation The keypad is the primary user input device used to enter information in the system 3 3 Rear Panel Figure 3 1 also shows the rear panel of the 3160 Located on the rear panel are the following electrical power and gas input ports alarm relay outputs and analog and digital outputs 1 Gas Input Vent three input fittings are provided for span gas sample gas and compressed air for pneumatic valve operation A single vent is used for the sample and span gas outlet Consult the Appendix for scrubber selec tion 2 AC Power Input 110 120 220 or 240 V at 50 60 Hz 1 5 A MAX Use 250 V 1 6 A T Fuse for 110 120 V Use 250 V 0 8 A T Fuse for 220 240 V 3 Alarm Circuit Connections there are five contact closures openings provided for external alarms The alarm functions are defined by the user via keypad input within the LCD menu system 4 Analog Outputs four analog output connectors are provided for use with a chart recorder Two provide range and data in voltages the other two provide range and data for current driven recorders 5 RS 232 Serial Port a 9 pin digital input output connector is provided for connecting eithe
28. without interfering with the sample gas line An optional scrubber installed into the sample system allows sample gas to be used as a zero gas after treatment with the scrubber If the scrubber is installed pneu matic valves on either side of the scrubber open automatically during zeroing Note Units equipped with a scrubber should only be used with inert gases and saturated hydrocarbons The analyzer output is not affected by minor changes in the flow rate Analyzer performance is stable under minor mechanical vibration 1 5 TELEDYNE ANALYTICAL INSTRUMENTS Introduction 1 1 2 Components The analyzer is designed to mount in a standard 19 inch rack All of the opera tional controls are easily accessed through the front panel The analyzer contains each of the following Analysis Section e Single or Dual Electrochemical Micro Fuel Cell Sample System e Power Supply e Microcontroller Module LED Display The front panel consists of LED Display LCD Display with Touch Panel e Micro Fuel Cell Access Panel e Flowmeter and flow set knob The back panel ports are Gas Inlet Outlet Ports e Electrical Connections 1 3 Options and Model Numbers The 3160 is available with the following standard options which are designated by a descriptive suffix on the model number Most of the options can be combined 3160SA Single fuel cell 3160SB Single fuel cell and oxygen scrubber e 3160DA Dual fuel c
29. 00 00 00 00 00 00 00 00 00 00 00 00 00 ALARM1 00 00 AM ALARM2 00 00 AM ALARM3 00 00 AM ALARM4 00 00 AM ALARM5 00 00 AM PREv Next Esc 1 2 3 4 5 4 24 STATUS PAGE 6 SERIAL PORT BAUD 2400 DATA BITS 8 PARITY NONE STOP BITS 1 MODE MONITOR INTERVAL 3 SECS TERMINATORS TX CR LF PREv Next esc 1 2 3 4 5 EDIT SERIAL SETUP BAUD 2400 DATA BITS 8 PARITY NONE STOP BITS 1 MODE MONITOR INTERVAL 3 SECS TERMINATORS TX CR LF SeLec UP Esc 1 2 3 4 5 STATUS PAGE 7 MODEM REMOTE MODEM MODE AUTO MODEM STATUS NO MODEM CTS 0 LOGIN ACCESS NONE PHONE JACK SINGLE LINE RJ11 COMM STD FOR 1200B BELL USA EDIT INIT PREV NEXT ESC 1 2 3 4 5 EDIT MODEM SETUP MODEM MODE AUTO MODEM STATUS NO MODEM CTS 0 LOGIN ACCESS NONE PHONE JACK SINGLE LINE RJ11 COMM STD FOR 1200B BELL USA SELEC UP DOWN Esc 1 2 3 4 5 7 Status page five shows the time and date of the last time 10 1 the alarm was triggered for each of the five program mable alarms
30. AIT FOR O2 SETTLING UD OR ANY KEY TO ABORT 1 2 3 4 VALVE MODE ZERO OXYGEN 0 15 PPM SENSOR A ON LINE al AUTORANGE 1 PPM ZEROING IN PROCESS Fo PLEASE WAIT a 1 2 3 4 VALVE MODE ANALYZE 1 SENSOR A ON LINE 0 00 PPM 02 AUTORANGE 1 PPM o ZERO SPAN SETUP RANGE 1 2 3 4 TELEDYNE ANALYTICAL INSTRUMENTS 7 10 Operations 4 If the O cell current is too large to be zeroed an error message will appear Press ACK to retry or ESC to abort the zeroing process If AUTO was chosen in step 4 wait for the O level to settle before the system zeros This may take from thirty 30 seconds to fifteen 15 minutes depending on the sample gas oxygen level After a stable low oxygen level is detected by the sys tem the system will automatically zero If the O cell current is too large to be zeroed an error message will appear see step 7 You will then have to press ESC to abort or ACK to retry If the zero is successful the system will return to the main Analyzer mode menu 4 7 4 Operations Calibration Using Span Gas VALVE MODE ANALYZE 1 SENSOR A ON LINE 5 00 2 AUTORANGE 10 PPM ol ZERO SPAN SETUP RANGE
31. DE ANALYZE SENSOR A ON LINE 5 00 PPM O2 AUTORANGE 10 PPM ZERO SPAN SETUP RANGE 1 2 3 4 5 VALVE MODE ANALYZE STAT VIEW SYSTEM STATUS TEST CHECK ALTERNATE SENSOR INSTL INSTALL A SENSOR SET SET ALARMS CLOCK LOG PASSWORDS OR SENSOR STAT TEST INSTL SET ESC 1 2 3 4 5 VALVE MODE ANALYZE SELECT AUTHORIZATION CODE SELECT YOUR CODE SELEC UP DOWN ESC 1 2 3 4 5 VALVE MODE ANALYZE SELECT FUNCTION TO SETUP LOG JALRMS SENSR MORE ESC 1 2 3 4 5 VALVE MODE ANALYZE ALARMS SETUP SELECT ALARM TO SETUP Esc AL 1 AL2 MORE 1 2 3 4 5 VALVE MODE ANALYZE ALARM1 SETUP LEVEL 1 00 PPM RELAY TB1 HIGH LOW HI FAILSAFE YES LATCHING NO DEFEAT NO SELEC Down ESC 1 2 3 4 5 l Set Up Alarms Enter set up from the Analyze mode by pressing SETUP Press SET to set the alarms Enter the authorization code by using the SELEC UP and DOWN keys and press ACCPT
32. GNAL RANGE SIGNAL _ RANGE 0 1 VDC OUT 4 20 MA OUT POWER IN REFER TO MANUAL FOR VOLTAGE SELECTION REMOVABLE 110 120 220 or 240 V COVER 50 60 Hz 15 A MAX USE 250 V 3 0 A T FUSE FOR 110 120 V USE 250 V 16 A T FUSE FOR 220 240 V CAUTION eer e ALARM CIRCUITS TB1 TB2 TB3 TB4 TBS i NO WC NOONE N6 C NC NO EC w M p EL di m lt Q COMPRESSED AIR IN 80 PSIG SAMPLE SAMPLE SPAN AC POWER IN 5 ALARM CIRCUIT 1 4 TUBE FITTING SWAGELOK IN VENT CONNECTIONS Figure 3 3 3160 Rear Panel 3 6 1 Voltage Selection WARNING Power cord must be disconnected before performing any voltage selection The voltage setting and fuses of the analyzer can be changed to international standards To change the voltage setting or fuses 1 Open the cover using a small blade screwdriver 2 Remove the cover and the fuse block assembly 3 Pull the voltage selector card straight out of the housing by pulling on the indicator pin see Figure 3 4 se TELEDYNE ANALYTICAL INSTRUMENTS 3 7 3 Installation Cover Fuse Block Indicator Pin Voltage Selector Card Housing Figure 3 4 Removing the Voltage Card 4 Turn the card so that the desired voltage can be read at the bottom 5 Slide the indicator pin around the card so that it is pointing up when the voltage is read at the bottom see Figure 3 5 90 I20V 90 90 Fig
33. NTRVAL DAY HR MIN 007 00 00 NEXT ZERO 01 00 AM 01 01 91 SELEC UP Down ESC 1 2 3 4 5 VALVE MODE ANALYZE TIME 6 00 00PM 12 01 90 gt SCHEDULED SPAN OFF SKED SPAN O2 5 0 PPM INTRVAL DAY HR MIN 007 00 00 NEXT SPAN 01 00 AM 01 01 91 SELEC EDIT Esc 1 2 3 4 5 VALVE MODE ANALYZE TIME 6 00 00 12 01 90 SCHEDULED SPAN ON gt SKED SPAN 02 5 0 PPM INTRVAL DAY HR MIN 007 00 00 NEXT SPAN 01 00 AM 01 01 91 SELEC UP DOWN ACCPT ESC 1 2 3 4 5 VALVE MODE ANALYZE ALARM 1 00 00PM 00 00 00 ALARM 2 00 00PM 00 00 00 ALARMS 00 00PM 00 00 00 ALARM 4 00 00PM 00 00 00 ALARM 5 00 00PM 00 00 00 Esc 1 2 3 4 5 7 10 11 12 If SET was pressed in step 1 the menu for setting the time and date will appear Use the SELEC UP and DOWN keys to set the time and date and then press ACCPT If ZERO was pressed in step 1 the menu for setting AutoZeroing ON OFF time date of the next zeroing and time interval for automatic zeroing will appear Use the SELEC UP and DOWN keys to make selec tions and press ACCPT If SPAN
34. OB S E of UM E j _ OXYGEN ANALYZER c POWER daret 3160 SWITCH m M TELEDYNE ANALYTICAL INSTRUMENTS C LCD DISPLAY _ SENSOR COMPARTMENT C SS 1 4 SLOTS FOR 19 RELAY RACK MOUNTING CONTROL MODULE BENE ACCESS Figure 4 1 Analyzer front panel Below the LED screen are two red LED lights Each will light to indicate whether the oxygen is being displayed in parts per million PPM or percent 96 To the right of the LED screen is a flowmeter in standard cubic feet per hour SCFH The flow set knob adjusts the flow rate of the gas during calibration and zeroing In the panel below the LED screen is the LCD display The five colored buttons below it are used to interface with the computer module in selecting modes with the LCD W gt TELEDYNE ANALYTICAL INSTRUMENTS 4 1 4 Operations displaying the function of each button directly above it The LCD screen displays the current mode and any warning messages instructions and button functions 4 1 1 Spinning Wheel A spinning wheel appears in the upper left hand corner of the LCD display to indicate that the alarms are enabled any that are not defeated or that scheduled zeroing AutoZeroing or scheduled spanning AutoSpanning may take place If the spinning wheel does not appear the alarms are disabled and a scheduled zero or span is defeated Note that there is a delay of several minutes before the spinning wheel appear
35. OR PRESS ESC TO ABORT SPAN ack Esc 1 2 3 4 5 VALVE MODE ANALYZE 1 SENSOR A ON LINE 5 1 0 PPM O2 AUTORANGE 10 PPM o ZERO SPAN SETUP RANGE LRMR 1 2 3 4 5 4 10 13 If the O cell current is too strong or too weak to span an error message will appear This will not occur if the user entered span gas concentration is correct Press ACK to retry or ESC to abort the span 14 If the span is successful the system will return the main Analyze mode menu Check to see that the span value is correct ee TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Select Active Sensor Two Cells Only VALVE MODE ANALYZE 7 1 SENSOR ON LINE 5 00 PPM 02 AUTORANGE 10 PPM al ZERO SPAN SETUP RANGE ALRMR 1 2 3 4 5 VALVE MODE ANALYZE 2 STAT VIEW SYSTEM STATUS TEST CHECK SENSOR B INSTL INSTALL A SENSOR SET SET ALARMS CLOCK LOG PASSWORDS OR SENSOR STAT TEST INSTL SET ESC 1 2 3 4 5 VALVE MODE ANALYZE 3 SELECT AUTHORIZATION CODE SELECT YOUR CODE SELEC Down ESC 1 2 3 4 5
36. Status page six shows the set up for the serial port and allows you to reconfigure the serial port Press EDIT to bring up the following screen Press NEXT to go to status page 7 Use the SELEC UP and DOWN keys to select the de sired serial port configuration and press ACCPT Baud rate 300 2400 Parity Odd Even or None Mode Monitor Remote or Off ASCII Data Bits 7 or 8 Stop Bits 1 or 2 Modem On Off or Auto Output Interval for Monitoring 1 32000 sec Transmit Receive Line Terminators CR or CRLF Status page seven allows for configuration of the mo dem remote Press EDIT to change the configuration Modem Mode AUTO OFF ON Modem Status NO set by system Login Access LOCAL set by system Phone Jack SINGLE MULTI RJ12 Comm Std for 1200B BELL USA CCITT After pressing EDIT a cursor will appear and you will be able to edit the settings Press ACCPT when done Pressing INIT in status page seven step 10 takes you to the screen at the top of the next page and gives you the option of either checking for a modem or setting up the modem Set up sets up the modem for auto answer and other communication protocols TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 STATUS PAGE 7 MODEM REMOTE PRESS CHECK TO TEST MODEM OR SETUP TO START AUTO ANSWER SETUP CHECK ESC 1 21 3 4 5 STATUS PAGE 8 PRINTER POR
37. T MODE ON INTERVAL 3 SECS PRESS EDIT TO CHANGE SETUP EDIT PREV NEXT ESC 1 2 3 4 5 STATUS PAGE 8 PRINTER PORT MODE ON INTERVAL 3SECS EDIT PRINTER SETUP SELEC uP DOWN Esc 1 2 3 4 5 STATUS PAGE 9 STARTUP STATUS STARTUP WAS COLD START NEXT STARTUP WARM START PRESS COLD OR WARM TO CHANGE NEXT SETUP COLD WARM PREV NEXT ESC 1 2 3 4 5 STATUS PAGE 10 LOGGER DATA LOGGER IS ON T 2 SEC 2 MINS MODE MAXIMUM VIEW PREV NEXT ESC 1 2 3 4 5 LOG POS 11 PAGE 0 O2 0 00 PPM SENSOR A RANGE 1 PPM T 2SECS 2 MINS MODE MAXIMUM TD 00 01 06 00 00 00 REV FWD ESC 1 2 3 4 5 TELEDYNE ANALYTICAL INSTRUMENTS 12 After checking for the modem pressing ESC returns 13 you to status page seven in step 10 If INIT was pressed in status page 7 and then SETUP pressed in step 11 pressing ACK will return you to this screen Press ESC to return to status page seven in step 10 If you have purchased the parallel printer option status page eight allows for configuration of the port
38. TL INSTALL A SENSOR SET SET ALARMS CLOCK LOG PASSWORDS OR SENSOR STAT TEST INSTL SET ESC 1 2 3 4 5 VALVE MODE ANALYZE SENSOR A ON LINE PRESS ACK TO TEST SPARE SENSOR ACK ESC 4 12 1 2 3 4 5 VALVE MODE ANALYZE OXYGEN 5 00 PPM O2 AUTORANGE 1 PPM SENSOR B ON LINE FLUSHING ALARMS DISABLED TIME REMAINING 00 10 00 SKIP RESET ESC 1 2 3 4 5 VALVE MODE ANALYZE SENSOR A ON LINE PRESS A OR B FOR THE SENSOR TO BE INSTALLED ESC A 1 2 3 4 5 VALVE MODE ZERO SENSOR B ON LINE INSTALL THE NEW SENSOR QUICKLY DO NOT LEAVE OPEN FOR MORE THAN 2 MINUTES PRESS ACK WHEN READY ESC 1 2 3 4 5 I Enter set up from the Analyze mode by pressing SETUP If only one cell is installed the TEST and INSTL op tions on the next screen are omitted Press TEST to test the alternate sensor or INSTL to in stall a new sensor If TEST was chosen in step 2 the active sensor is dis played and you are directed to press ACK to test the al ternate sensor If INSTL was chosen in step 2 go to step 5 After pressin
39. The 3160 computer uses an Intel 80188 microprocessor combined with 32 kilobytes of random access memory RAM and 128 kilobytes of read only memory ROM The total computer program resides in the ROM and is not affected by shut down periods loss of power or battery failure However calibration parameters and stored measurement readings are retained in battery backed up RAM which require continuous battery voltage in order to be retained This information will be lost if battery power is interrupted as in battery replacement Two displays help you monitor trace oxygen levels a red 4 digit light emitting diode LED display with one inch numerals is easily read at a distance or even in bright daylight and a liquid crystal display LCD helps you keep track of alarm setpoints ranges mode and system statistics 1 1 2 Variable Features Various models are available The following features describe the basic model but the exact configuration depends on the standard options incorporated Paragraph 1 3 contains a list of standard variations on the basic model The Class B 2 Micro Fuel Cell measures trace O in a mixture of gases Because the Micro Fuel Cell sensor is a sealed electrochemical device it is replaced as a unit There are no electrolytes to change or electrodes to clean making the sensor mainte nance free The analyzer can be configured with one or two sensor blocks Each block can be isolated by pneumatically switched valves The
40. acing the cells remember to inspect the replacement sensor for leaks or damage See Figure 3 2 TRACE OXYGEN ANALYZER Figure 3 2 Sensor Installation W TELEDYNE ANALYTICAL INSTRUMENTS 3 5 3 Installation l The sensor compartment is located in the lower right hand corner of the analyzer front panel To remove the sensor compartment panel loosen the thumbscrews located left and right center of the panel Make sure that sample gas is flowing through the analyzer then shut off the flow completely This insures that air does not diffuse into the analyzer Inside the compartment should be two one stainless steel cylindrical sensor block s each with a clamp lever across the front The bottom half of the clamp face is bent outward To release the clamp pull the clamp lever up and toward you slowly Releasing the clamp releases the stainless steel block cap on the bottom of the sensor block Pull the cap downward to remove it There is a guide pin to the rear of the sensor block that aligns the cap to the block Note It is important to minimize the amount of time that the new cell is ex posed to air in order to reduce the time required for the reading to drop to zero 5 Remove the Micro Fuel Cell from the plastic bag The cell has a mesh screen with a raised plastic dress ring on one side and flat gold contact rings on the other Place the screen side of the cell face down on the block cap so that the dress
41. al Port The RS 232 port is configured as data terminal equipment DTE and uses a 9 pin D connector wired as follows 1 No connection 2 Transmit Data 3 Receive Data 4 5 Ground 6 NC 7 8 CTS 9 NC Connecting the analyzer to a modem requires a PC to modem cable When con necting the analyzer directly to a PC terminal or other data terminal equipment a null modem cable is required The following serial interface default parameters are used Defaults Programmable Options 1200 Baud 1200 Baud 8 Bits 5 6 7 or 8 Bits No Parity Even Odd or None 1 Stop Bit 1 or 2 Stop Bits 3 7 Installation Checklist Have you Checked for leaks from any of the rear panel connections Checked the sample and span gas pressures 5 10 psi Checked the instrument air pressure 70 80 psi 3 10 TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4 14 Front Panel Controls The front panel of the analyzer shown in Figure 4 1 contains indicators and displays through which the computer module can be accessed The upper left hand side of the panel has an LED screen that displays the oxygen content of the sample in one inch high numerals This display can be brightened or dimmed by a potentiometer located directly behind the panel inside of the analyzer case To access it remove the top cover of the analyzer FLOW TON ET LED DISPLAY NDIGATOR KN
42. alve flow set knob on front panel is sufficiently open Clear and check connection to back panel vent Will not switch modes See a above See a above Sensor output does not drop to a stable low value during zeroing or spanning a Sensor has been exposed to high concentrations of O for an extended time period b Bad sensor C Leak in system a Replace sensor and or wait for stable reading b Replace sensor c Check sensor block clamp Make sure the sensor block is tightly closed Check the gas supply tank line and connections for leaks Unit will not turn on although it is plugged in and the Power Switch Is ON at I position Fuse is blown Check fuse s in back panel fuse block assembly located above the power cord recep tacle se TELEDYNE ANALYTICAL INSTRUMENTS 5 3 5 Maintenance amp Troubleshooting 5 4 TELEDYNE ANALYTICAL INSTRUMENTS Appendix Appendix A 1 Specifications Subject to change without notice Ranges Six ranges with AutoRanging on all ranges 0 1 part per million ppm O 0 10 ppm O 0 100 ppm O 0 1000 ppm O 0 1 46 O 0 25 96 O Suc doo e Accuracy 2 of full scale when calibrated and operated at the same constant temperature and pressure 5 of full scale over the operating temperature range once tempera ture equilibrium is reached Additional 0 04 ppm on 0 1 ppm range generated by internal scrub ber
43. analyzer is equipped with a scrubber it is important to zero the analyzer with a near zero gas connected to the sample port The zeroing process automatically opens pneumatic valves on either side of the scrubber and a gas with a high concentration of oxygen will react with the scrubber and necessitate replacement sooner 4 2 TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 When waiting for manual sensor settling during calibration zeroing wait until the oxygen concentration has reached its lowest value and has remained so for 10 15 minutes It is important to make sure that the sensor is reading the lowest possible value since zeroing will reset the point at which the sensor reads zero Do not zero prior to reaching the lowest possible oxygen concentra tion When initially installing the sensor s do a zero calibration then a span calibration If desired the instrument may be programmed for automatic periodic zeroing AutoZeroing if the optional scrubber is installed AutoZero ing uses the scrubber to generate a zero gas from a low O sample gas NOTE 1 Zeroing in the 0 1 PPM range preserves the life of the scrubber In scheduled zeroing and spanning AutoZeroing and AutoSpanning a time interval must be chosen This interval determines how often the instru ment zeros or spans itself To change the scheduled time edit it after setting the interval in the Set Up Clock Functions mode NOTE 2 AutoZeroing and AutoSpanning may
44. ation is belleved 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 A 10 TELEDYNE ANALYTICAL INSTRUMENTS
45. c du e exe au Pia ue Ee ee etae dta 4 6 Calibration Using Span Gas sees 4 8 Select Active Sensor Two Cells Only 4 11 Install Sensor and Test Alternate Sensor Two Cells Only 4 12 O R nge Set bo D STER NP Sa 4 14 Set p Alaris esto pott vis bti esta ost devo een su bs 4 15 uie ost im vetu ats 4 17 Set Up COCK EUDQUOHS 4 19 Changing Passwords For Remote Monitoring and Control 4 21 System Statistics cue ou best pup t a ne 4 23 5Maintenance amp Troubleshooting Appendix 5 1 Routine Maintenance oue costi e none 5 1 5 1 1 Sensor Maintenance nant 5 1 5 1 2 Scrubber Maintenance 5 1 a Ras 5 2 A 1 Specifications SEC hide 1 2 Recommended Spare Parts List esses A 2 A 3 Drawing bist aede nite tr iie at aen espoir A 3 A 4 Safety Data Sheet seen A 4 A 5 Material Safety Data Sheet receives reae eee A 5 se TELEDYNE ANALYTICAL INSTRUMENTS vi TELEDYNE ANALYTICAL INSTRUMENTS Introduction 1 Introduction 1 1 Features 1 1 1 Fixed Features The Model 3160 is a microprocessor based trace oxygen monitoring system that provides on line monitoring of trace oxygen at parts per million PPM levels and can directly measure the level of purity in high grade gases
46. ctive to tissue of the mucous membranes stomach mouth upper respiratory tract eyes and skin Chronic Effects Prolonged exposure with the electrolyte has a destructive effect on tissue Chronic exposure to lead may cause disease of the blood and blood forming organs kidneys and liver damage to the reproductive systems and decrease in fertility in men and women and damage to the fetus of a pregnant woman Chronic exposure from the lead contained in this product is extremely unlikely TELEDYNE ANALYTICAL INSTRUMENTS A 5 Appendix Signs and Symptoms of Exposure Carcinogenicity OSHA NTP Medical Conditions Generally Aggravated by Exposure Emergency First Aid Procedures Contact of electrolyte with skin or eyes will cause a burning sensation and or feel soapy or slippery to touch Other symptoms of exposure to lead include loss of sleep loss of appetite metallic taste and fatigue Lead is classified by the IARC as a class 2B carcinogen possibly carcinogenic to humans Where airborne lead exposures exceed the OSHA action level refer to OSHA Lead Standard 1910 1025 na Lead exposure may aggravate disease of the blood and blood forming organs hypertension kidneys nervous and possibly reproductive systems Those with preexist ing skin disorders or eye problems may be more suscepti ble to the effects of the electrolyte In case of contact with the skin or eyes immediately flush with plenty
47. current is back calculated and an analog to digital converter on the analog board is driven by the software to produce a voltage that is used to force a current into the current to voltage converter located on the pre amp board The current injected is equal and opposite in polarity to the portion of the sensor current that needs offsetting Digitization is provided by a 12 bit analog to digital converter which digitizes the oxygen and temperature signals 2 6 TELEDYNE ANALYTICAL INSTRUMENTS Operational Theory 2 The analog output printed circuit board PCB generates the two 0 1 volt and the two 4 20 mA analog signal outputs available on the rear panel of the analyzer These signals generated in digital format by the microcomputer are converted into analog signals by the circuitry on this PCB The output signals represent the following 0 1V Signal Oxygen Measurement This output goes from 0 to 1 represent ing 0 to 100 of the scale that has been set i e 0 6 volt is equal to 60 of the full scale or 6 PPM when on the 10 PPM scale It is possible that the signal may go past zero into the negative range up to 0 25 especially if the analyzer has been zeroed with a gas that contains a significant concentration of oxygen See Figure 2 3 0 1V Range Identifier This 0 to 1 volt output represents each range with a particular voltage as shown in Table 2 1 e Isolated 4 20 mA Signal Oxygen Measurement This is a 4 to 20 mA o
48. ell e 3160DB Dual fuel cell and oxygen scrubber 3160SAS Single cell and stainless steel cell block 3160SBS Single cell stainless steel cell block and oxygen scrubber 3160DAS Dual cell and stainless steel cell block e 3160DBS Dual cell stainless steel cell block and oxygen scrubber TELEDYNE ANALYTICAL INSTRUMENTS 1 3 1 Introduction 1 4 Applications The analyzer is an invaluable tool in the following applications and industries Inert and gaseous hydrocarbon stream monitoring Measuring the purity of various gases in air separation plants Prevention of oxidation by measuring the purity of blanketing gases in fiber and glass industries Monitoring and controlling gas atmospheres in the heat treatment of metals in steel and other metal industries Gas analysis and research in laboratories and research and development areas Semiconductor manufacturing Process monitoring of gaseous monomers vinyl chloride propylene butadiene or ethylene Gas purity certification Glove box leak detection Natural gas treatment and transmission Inert gas welding of exotic metals TELEDYNE ANALYTICAL INSTRUMENTS Operational Theory 2 Operational Theory 2 4 Principles of Operation The sub systems that make up the analyzer are 1 Micro Fuel Cell Sensor 2 Sample System 3 Electronic Signal Processing The Micro Fuel Cell sensor is an electrochemical galvanic device that translates the amou
49. et off the zeroing or spanning sequence at pre selected intervals During an AutoZero or AutoSpan the alarms are defeated and the screen displays PLEASE WAIT SCHED ULED SPAN IN PROGRESS Since AutoZeroing and AutoSpanning uses automatic settling detection of the sensor which can take up to fifteen minutes oxygen monitoring will be interrupted for the length of time it takes to zero or span after which monitor ing will resume The LCD will display the current background level during zeroing or spanning Changing Passwords For Remote Monitoring and Control Programmable security passwords are provided to prevent unauthorized access to remote monitoring and control Monitor is the lowest authorization level and only permits monitoring of analyzer functions while Control allows remote control of any function System Statistics Menu screens are available to view various system parameters and for setting serial link operation parameters including modem operation TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Model 3160 OXYGEN ANALYZER COPYRIGHT 1990 1 VER 1 0 TELEDYNE ANALYTICAL INSTRUMENTS COLD START PLEASE WAIT 1 2 3 4 5 VALVE MODE OFF TIME 6 00 00 12 01 90 NEW TIME 6 00 00PM 12 01 90 SET NEW TIME AND DATE SELEC UP DOWN ESC 1 2 3 4 5
50. g ACK in step 3 the alternate sensor is flushed for 10 minutes while the measured O level is displayed The 10 minute flush may be restarted by pressing RESET or aborted by pressing SKIP Go to step 8 If INSTL was chosen in step 3 the screen will display the active sensor Press A or B for the sensor you are installing Install the sensor either A or B from step 5 into the sensor block within two minutes and press ACK se TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 VALVE MODE ZERO SENSOR B ON LINE OXYGEN 5 00 PPM ALARMS DISABLED FLUSH IN PROGRESS TIME REMAINING 00 10 00 SKIP RESET 1 2 3 4 5 VALVE MODE ANALYZE SENSOR A ON LINE 5 00 PPM 02 AUTORANGE 10 PPM ZERO SPAN SETUP RANGE ALRMR 1 2 3 4 5 7 After pressing ACK in step 6 the new sensor is flushed for 10 minutes while the measured O level is displayed The 10 minute flush may be restarted by pressing RE SET or aborted by pressing SKIP 8 When sensor installation or alternate sensor test are complete the system will return to the main Analyze mode menu TELEDYNE ANALYTICAL INSTRUMENTS 4 13 4 Operations VALVE MODE ANALY ZE 7 SENSOR A ON LINE 25 00 PPM O2 AUTORANGE 100 PPM
51. hout 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 acknowledgements provide for a shorter period The Micro Fuel Cell warranty period begins on the date of shipment from Teledyne 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 is intended to be used as a tool to gather valuable data The information provided by the instrument may assist the user in eliminating potential hazards caused by the process that the instrument is intended to monitor 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 instrumentatio
52. ieo detente ns Se cet 1 3 Options and Model Numbers eene 1 e Uer c epe ERAN 2 Operational Theory 2 1 Principles OF Op ration s doeet tette 2 1 1 Micro Fuel Cell Sensor sss 2 1 2 SAMPlE SY SLEM estat ao RU 2 1 3 Electronics and Signal Processing Range Identifier Table iiit eese 3Installation 3 1 Unpacking the Analy Zens scade tote te ados eta ae fn 3 2 Front PANG trt a fas NR 3 3 Rear AMC 3 4Gas Line Connections DAM Span ss nr ed 3 42 Instrument AIT 3 4 3 Sampl G s IR idi iter a SAA IVETE 3 5 Micro Fuel Cell Installation or Replacement 3 6 Blectrical Connections e pte hee Eon 3 6 1 Voltage Selection een PO aires 3 0 2 PUSS Cha gihg ation 3 6 3 Parallel and Serial Ports 3 7 Installation Checklist est eu e ta ote RG ie 4 Operations 4 1 Front Panel Controls PONI s 4 1 1 Spinning Wheel nets presi 4 1 2 Cell Output Factor amiens teen ern 4 2 Modes of Operation eset tune ot etre Cold Start UD continued iv TELEDYNE ANALYTICAL INSTRUMENTS Table of Contents continued Calibration Zeroing ss to
53. ing and digitization of the signal from the Micro Fuel Cell takes place on two circuit boards the six decade programmable printed circuit board PCB and the analog input board The first step in the chain takes place on the six decade programmable PCB which is mounted directly on top of the cell block The output of the sensor is a current that is linearly proportional to the oxygen concentration At low concentra tions the current from the sensor is low which makes the close physical proximity of the pre amp circuitry to the Micro Fuel Cell necessary The sensor current is routed into a low offset low bias current operational amplifier configured as a current to voltage converter The signal is sent through two amplifiers to the analog input board The pre amp board provides sensor zeroing and a connection to the thermistor in the sensor cell block The analog input PCB which plugs into a DIN connector on the digital PCB performs three functions Temperature compensation in the sensor signal Sensor offset correction Digitization A thermistor inside the sensor block registers resistance and thus the temperature of the sensor Accordingly an analog to digital converter configured as a digitally programmed attenuator DPA is used to reduce or increase the gain of the sensor signal so that the signal coming out of the DPA is independent of temperature If the software determines that the sensor needs offsetting the sensor
54. l tanks Overall Design The design of the sample system minimizes the volume of dead space which can retain residual gas from another route or previous mode of analysis Sample in Vent Flowmeter Optional metering valve PV Sensor Housing 1 pneumatic valve Figure 2 2 Model 3160 flow schematic 2 1 3 Electronics and Signal Processing The Model 3160 analyzer has an embedded microcomputer which controls all signal processing input output and display functions for the analyzer System power is supplied from a power supply module designed to be compatible with any interna tional power source The microcomputer a liquid crystal display LCD and all analog signal pro cessing electronics are located inside a replaceable control module A light emitting diode LED display is located outside the control module TELEDYNE ANALYTICAL INSTRUMENTS 2 5 2 Operational Theory Electronics in the analyzer are grouped according to function 1 Analog in 2 Analog out 3 Digital circuit 4 Power supply Analog signal processing is accomplished in two plug in circuit cards operating under control of the microcomputer All analog signals are converted to digital early in the processing cycle to minimize analog processing and assure maximum system accuracy since digital processing is much more accurate than analog and immune to many parameters such as drift and aging The initial process
55. l resemble the one in step 6 Use the SELEC UP and DOWN keys to configure alarm 5 When finished press ACCPT The next screen will ask you if there are more alarms to set If not pressing ESC three times will take you back to the Analyze mode main menu se TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 VALVE MODE ANALYZE SENSOR A ON LINE 5 00 PPM 02 AUTORANGE 10 PPM al ZERO SPAN SETUP RANGE ALRMR 1 2 3 4 5 VALVE MODE ANALYZE STAT VIEW SYSTEM STATUS TEST CHECK SENSOR B INSTL INSTALL A SENSOR SET SET ALARMS CLOCK LOG PASSWORDS OR SENSOR STAT TEST INSTL SET ESC 1 2 3 4 5 VALVE MODE ANALYZE SELECT AUTHORIZATION CODE SELECT YOUR CODE SELEC Down ESC 1 2 3 4 5 VALVE MODE ANALYZE SELECT FUNCTION TO SETUP LOG ALRMS sENSR MORE ESC 1 2 3 4 5 VALVE MODE ANALYZE PRESS CLEAR TO ERASE THE LOG PRESS SETUP TO SETUP THE LOG CLEAR setup Esc 1 2 3 4 5 VALVE MODE ANALYZE SETUP LOGGER LOGGER IS ON T 2 SECS 2 MINS MODE MAXIMUM
56. n 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 can be misused In particular any alarm or control system 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 when the order is placed The purchaser must be aware of the hazardous conditions inherent in the process es he uses He is responsible for training his 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 his agents is to be construed as a warranty of adequate safety control under the user s process conditions TELEDYNE ANALYTICAL INSTRUMENTS TELEDYNE ANALYTICAL INSTRUMENTS Table of Contents 1Introduction MET Ics Rixed 1 142 Variable Peat tes rte Eee ee 2C ompoletils a
57. nd provide the electrical connection to the rest of the analyzer The sensing cathode located beneath the diffusion membrane has a surface area of 2 48 cm The sample gas enters the sensor block through an inlet tube between the cathode and the sensor block cap diffuses through the Teflon membrane and any oxygen in the sample gas is reduced on the surface of the cathode by the following mechanism 2H 0 4 gt 4OH cathode When the oxygen is reduced at the cathode lead is simultaneously oxidized at the anode by the following mechanism 2Pb 2Pb 4 anode The electrons released at the surface of the anode flow to the cathode surface via an external circuit This current is proportional to the amount of oxygen It is mea sured and used to determine the oxygen concentration in the gas mixture The overall reaction for the fuel cell is 2Pb O 2PbO The output of the fuel cell is limited by the amount of oxygen in the cell at any one time and the amount of stored anode material In the absence of oxygen there is no current generated 2 1 2 Sample System The sample system delivers gases to the Micro Fuel Cell sensor from the ana lyzer rear panel inlet Depending on the mode of operation either a sample or zero gas is delivered The Model 3160 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 followi
58. ng list of sample system and analyzer features are among those available but the exact configuration depends on the standard options incorporated Paragraph 1 3 contains a list of the standard variations on the basic model TELEDYNE ANALYTICAL INSTRUMENTS 2 3 2 Operational Theory Electropolished 316L type stainless steel components To eliminate oxygen absorption and desorption from the internal wetted surfaces of the sample system components the sample system is fabricated from electropolished 316L type stainless steel Welding Metal Gasket Type Fittings All of the joints upstream of the Micro Fuel Cell oxygen sensor are orbitally welded Orbital welding is used in the sample system wherever feasible Orbital welding fuses the electropolished 316L stainless steel components together forming a smooth clean internal wetted weld junction and eliminating small spaces around the weld junction where gases can get trapped or absorbed AII of the weld junctions in the entire assembly are purged using an inert gas during welding to ensure that there is no oxygen contamination Orbital welding is used where practical otherwise conventional precision welding is used For example conventional precision welding is used to fuse the tubes to the mounting blocks Valves The analyzer sampling system utilizes three different types of valves Each valve is selected to prevent oxygen contamination of the sample depending on its p
59. not identify the problem or if you cannot resolve the problem after following the corrective procedure call a service repre sentative Symptom LCD or LED display will not light Display too bright Cause Faulty LCD or LED Correction Return the unit to factory Remove analyzer cover Adjust potentiometer located behind LCD display No analog output Faulty electrical connection Remove analyzer cover Check PC board connections and make sure that they are firmly seated Zero gas signal gt 2 PPM Slow response recovery time Displays value Bad sensor High O level Bad sensor Replace sensor Check zero gas inlet connec tion Replace sensor Re zero sensor Can t calibrate with sensor Installed Display reads cell too strong or cell too weak a The wrong span gas concentration has been entered a Re enter span gas concen tration b Replace or reinstall sensor No sample gas flow a The pneumatic air supply pressure is too low making the valves stick b The sample supply pressure is too low a Raise air supply pressure to at least 70 psig b Check back panel connec tions Raise sample supply to at least 5 psig but within 2 psig of the span gas pressure 5 2 TELEDYNE ANALYTICAL INSTRUMENTS Maintenance amp Troubleshooting 5 Symptom Cause Back panel vent is blocked Correction c Make sure metering v
60. nt of oxygen present in the sample into an electrical current The sample system delivers the sample gas in a form that is as unaltered as possible for testing and for leak free transport of gases through the analyzer The electronic signal processing unit control module is designed to simplify the operation of the analyzer and accurately process the signal from various components The control module incorporates a microprocessor which allows the operation of the analyzer with a minimum of operator interaction Figure 2 1 illustrates major components TELEDYNE ANALYTICAL INSTRUMENTS 2 1 2 Operational Theory Removable Top Cover LED Display Rack Mount Slots Computer Module Sensor Access Panel Power Supply LED Display Display LIT Sampie system Computer p Sensor Blocks Figure 2 1 Major Components 2 2 TELEDYNE ANALYTICAL INSTRUMENTS Operational Theory 2 2 1 1 Micro Fuel Cell Sensor The Micro Fuel Cell is a sealed plastic disposable oxygen transducer that mea sures 114 inches in diameter and is 34 inch thick Inside of the cell are a cathode and anode immersed in 15 aqueous KOH electrolyte At one end of the sensor is a Teflon diffusion membrane the other end is sealed with a polyethylene membrane At the rear of the cell is a contact plate consisting of two concentric foils The foils mate with spring loaded contacts in the sensor block assembly a
61. of water for at least 15 minutes and remove all contaminated clothing Get medical attention immediately If ingested give large amounts of water and DO NOT INDUCE VOMITING Obtain medical attention immedi ately If inhaled remove to fresh air and obtain medical attention immediately Section VII Precautions for Safe Handling and Use NOTE The oxygen sensors are sealed and under normal circum stances 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 measures during cell replacement Cleanup Procedures Before opening the bag containing the sensor cell check the sensor cell for leakage If the sensor cell leaks do not open the bag If there is liquid around the cell while in the instrument wear eye and hand protection Wipe down the area several times with a wet paper towel Use a fresh towel each time Contaminated paper towels are considered hazardous waste A 6 TELEDYNE ANALYTICAL INSTRUMENTS Appendix Section VIII Control Measures Eye Protection Chemical splash goggles Hand Protection Rubber gloves Other Protective Clothing Apron face shield Ventilation na Section IX Disposal Both lead and potassium hydroxide are considered poisonous substances and are regulated under TSCA and SARA Title III EPA Waste Number D008 California Waste Number 181 DOT Information RQ Hazardous Waste
62. osition and purpose in the circuit Air Actuated Bellows Valves These valves are normally closed in the sample system They are used to control the delivery through the sample system of the sample or zero gas The valve bodies are orbitally welded in the system and the valve bonnets make a metal to metal seal to the body This valve system eliminates inboard and outboard gas leakage The valves are activated open closed by computer controlled solenoid valves Metering Valve The metering valve is used to manually control the gas flow rate to the sensor The body of the metering valve is orbitally welded and the bonnet is sealed to the body with metal O rings This type of valve eliminates inboard and outboard gas leakage Solenoid Valves The solenoid valves control the air flow to the air activated bellows valves The solenoid valves are controlled by the microprocessor module When de energized the valve outlet is open to ambient air allowing the air activated bellows valve to close Scrubber optional See Appendix for details In systems with a scrubber oxygen trapping media is used to remove any trace oxygen from the sample gas This occurs automatically in the zero menu where the pneumatic valves leading to the scrubber are triggered by a certain menu sequence This process enables sample gas TELEDYNE ANALYTICAL INSTRUMENTS Operational Theory 2 to be used to zero the analyzer eliminating the need to switch externa
63. r a serial printer or a serial link to an external computer Optional serial link software such as TRACS can be used with the instru ment for remote external computer monitoring and control of the instrument via modem or hardware link 3 2 TELEDYNE ANALYTICAL INSTRUMENTS Installation 3 In DIMENSIONS mr REMOVABLE TOP COVER LED oo 17 06 POWER DISPLAY 442 SWITCH INDICATOR ees E L 3 _8 000 ro S T Es D Oxygen PERCENT o Le A n INDICATOR _ TELEDYNE LIQUID fe pu TU e A SENSOR c LCD ZE CORN Em COMPUTER MODULE KEYPAD SE FLOWMETER 88 FLOW SET SENSOR ACCESS PANEL ANALOG RS 232 OUTPUT SERIAL PORT CONNECTIONS i n 27 8 688 221 Bw SSA INSTRUMENT AIR SAMPLE IN pee VOLTAGE SELECT SAMPLE SPAN CONNECTIONS Figure 3 1 Analyzer front and rear panels TELEDYNE ANALYTICAL INSTRUMENTS 3 3 3 Installation 3 4 Gas Line Connections All of the gas lines to the system hook up at the back of the unit see Figure 3 1 All of the fittings on the removable back panel 14 male VCR type fittings with the exception of the compressed air inlet fitting Use the wrenches provided to connect the gas lines Insert the gasket between the fitting and tighten the female and male nuts until finger tight then by holding the male nut with the wrench tighten the female nut wi
64. re listed in Table 2 2 Table 2 2 Default and Programmable Parameters Defaults Programmable Options 1200 Baud 1200 Baud 8 Bits 5 6 7 or 8 Bits No Parity Even Odd or No Parity Stop Bit 1 or 2 Stop Bits 4 Controls the LCD and the LED displays LCD This screen is a dot matrix display located on the control module of the analyzer It is the user interface for system operations It displays the menus and command options available for each function LED This screen is a 7 segment display located on the front panel of the analyzer above the control module It displays only the oxygen concentration It is large and bright to allow the operator to read it at a greater distance A dimmer switch for this display is located on the display PCB behind the front panel The analyzer power supply module is a replaceable assembly containing four power supplies and five alarm relays Electronic circuitry used to drive and interface the alarm relays to the output of the microcomputer is also located inside this module Note This power supply contains an International Power Entry Module This feature allows operation on any of four international voltage ranges 100V 120V 220V or 240V 50Hz or 60Hz It also facilitates both North American and European fusing arrangements Programming this mod ule is described in the installation section of this manual 2 8 se TELEDYNE ANALYTICAL INSTRUMENTS Installation 3 Installation RE
65. ring locks onto the cap ridges and will not move side to side The gold contact rings will be facing up Carefully guide the sensor and cap into the block putting the guide pin through the hole in the back edge of the cap While holding the cap in place squeeze the clamp down firmly until the notches on the clamp lock onto the block side pins Immediately start the sample flow and set to about 2 SCFH The analyzer now needs to be zeroed and calibrated 3 6 Electrical Connections All of the electrical connections are located on the analyzer back panel The analyzer is shipped with all of the electrical connections intact with no assembly or installation required The power cord receptacle is located in the lower center of the panel The voltage selection terminal and the fuse block are in the same fitting directly above the power cord receptacle There are four output signal connectors with screw terminals in the upper right hand panel There are two wires per output with the polari ty noted below each The five alarm circuit connectors located in the lower center right hand panel are screw terminals for alarm relay contacts These five provide a set of Form C contacts for the user The contacts are capable of switching up to 3 am peres at 115 V ac into a resistive load TELEDYNE ANALYTICAL INSTRUMENTS Installation 3 RS232 SERIAL 4 SIGNAL CONNECTIONS PORT 9 PIN D SUB 0 1VDC amp 4 20MADC gt j RS232 SI
66. s whenever the Analyze mode is re entered 4 1 2 Cell Output Factor Span Factor The expected life of the Micro Fuel Cell sensor is about eight months A guide to the relative life left in the cell can be found on status page 2 see System Statistics near the end of this chapter or retrieved from the serial port through the serial command SF The span factor ranges from 0 00 to 1 00 with 1 00 representing full life expectancy A span factor below 0 1 indicates that the Micro Fuel Cell needs replacing 4 2 Modes of Operation To use the system and select displayed options press the button directly underneath the option you wish to select There are eleven different menus Cold Start Up During the first startup and when subsequent cold start ups are chosen by the user initial values set at the factory for alarms I O calibration zeroing and other data are used Upon cold start zeroing and calibration should be performed before accurate oxygen measurements are obtained A system warm start is automati cally performed on each subsequent power up For a warm start previous user input configuration data is preserved in RAM by battery preserved memory in the system control module Calibration Zeroing For the highest possible accuracy the analyzer must be zeroed using an oxygen free gas By eliminating normal background noise from the sensor reading zeroing resets the level referred to as the Zero oxygen concentration If the
67. th the second wrench by turn CAUTION Do not put any torque on the tubes welded on the sampling system Check that each of the lines is hooked up to the correct connection The lines should be connected in the following order from left to right 3 4 1 Span Gas In Provide at least one sample gas of a known oxygen concentration Using 70 99 of the range just one range above the range of interest is recommended Any range EXCEPT 0 1 ppm may be used to calibrate 3 4 2 Instrument Air Compressed Air Fitting The gas pressure 70 80 psi needed to operate the pneumatic valves in the analyzer can be supplied through this fitting CAUTION Pressure higher than 80 psig can damage the solenoid valves 3 4 3 Sample Gas In Hook up the sample gas to the sample gas inlet When the sample gas flows through the optional oxygen scrubber the sample gas becomes the zero gas and can be used for calibration Note Sample and span gas pressure should be between 5 and 10 psig and within 2 psi of each other A substantial difference in the span and sample gas pressures will cause a sudden change in gas flow rate 3 4 4 Vent The vent transports the sample or span gas out of the system after exposure to the Micro Fuel Cell sensor 3 4 TELEDYNE ANALYTICAL INSTRUMENTS Installation 3 3 5 Micro Fuel Cell Sensor Installation or Replacement The 3160 comes with the Micro Fuel Cell s already installed When installing or repl
68. to the State of California to cause birth defects or other reproductive harm Appendix Section V Emergency and First Aid Procedures Eye Contact Flush eyes with water for at least 15 minutes and get immediate 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 at tention Do not administer liquids to an unconscious person Inhalation Liquid inhalation is unlikely Section VI Handling Information NOTE Theoxygen 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 paper 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 sensor cell leaks do not open the bag If there is liquid around the cell while in the instru ment put on gloves and eye protection before removing the cell Disposal Should be in accordance with all applicable state local and federal regulations NOTE The above information is derived from the MSDS provided by the manufacturer The inform
69. u to step 4 TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 VALVE MODE ANALYZE 1 SENSOR A ON LINE 5 00 PPM O2 AUTORANGE 10 PPM ol ZERO SPAN SETUP RANGE 1 2 3 4 5 VALVE MODE ANALYZE STAT VIEW SYSTEM STATUS TEST CHECK ALTERNATE SENSOR INSTL INSTALL A SENSOR SET SET ALARMS CLOCK LOG PASSWORDS OR SENSOR STAT TEST INSTL SET ESC 1 2 3 4 5 STATUS PAGE 1 MAIN CONFIG TIME 00 00 AM 00 00 00 SENSOR A ON LINE TEMP 17 2 HW CFG SCRUBBER 2 SENSORS VERSION 1 0 VERSION DATE Tue Feb 12 11 00 00 1991 PREV NEXT ESC 1 2 3 4 5 STATUS PAGE 2 SPAN SPAN 02 5 0 PPM CELL STRENGTH NO SPAN NO SPAN SINCE START INTRVAL DAT HR MIN 008 00 00 SCHEDULED SPAN IS OFF PREV NEXT ESC 1 2 3 4 5 STATUS PAGE 3 ZERO ZERO BACKGROUND NO ZERO NO ZEROING SINCE START INTERVL DAT HR MIN 007 00 00 SCHEDULED ZERO IS OFF PREV NEXT ESC 1 2 3 4 5 ALRM ON TRIG THRESH HL L RLY 1 N OFF 5 0PPM HI N Y TB1 2 OFF 5 0PPM LO Y TB2 3 N OFF 5 0PPM HI Y Y TB3 4 N OFF 5
70. ure 3 5 Voltage Selection 6 Place the voltage selector card back into the housing The edge where the desired voltage is printed should go in first and the printed side of the card should be facing the IEC connector 7 Replace the fuse block and the cover Verify that the indicator pin is pointing to the correct voltage 3 6 2 Fuse Changing NOTE Spare fuses are located in a clip attached to the power supply enclosure inside of the analyzer 3 8 TELEDYNE ANALYTICAL INSTRUMENTS Installation 3 WARNING Power cord must be disconnected before performing any voltage selection To change from North American to European fuses perform the following Use a small blade screwdriver to open the cover 2 Loosen the Phillips screw two turns and remove the fuse block by sliding it away from the screw and up from the pedestal 3 Remove the North American fuse and turn the fuse block over Replace the fuse with European fuses Two European fuses are required but the lower one may be replaced with a dummy fuse or jumper bar see Figure 3 6 European 1 6 Amp T Fuses 5x 20mm Jumper Bar North American 3 A T Fuses Figure 3 6 Fuse Replacement 5 Slide the fuse block back on the Phillips screw and pedestal 6 Tighten the Phillips screw and replace the cover NOTE The fuses that go into the housing first are the active set se TELEDYNE ANALYTICAL INSTRUMENTS 3 9 3 Installation 3 6 3 RS 232 Serial Digit
71. utput representing 0 to 100 of the scale with 4 mA equal to 0 and 20 mA equal to 100 of that range This output may also range lower than 4 mA especially if the analyzer has been zeroed with a gas that contains a significant concentration of oxy gen See Figure 2 3 solated 4 20 mA Range Identifier This 4 to 20 mA output represents individual ranges with discrete current output as shown in Table 2 1 Table 2 1 Range Identifier Identifier Identifier Range Scale Voltage V Current mA 1 1 PPM 0 0 4 0 2 10 PPM 0 2 7 2 3 100 0 4 10 4 4 1000 0 6 13 6 5 1 0 8 16 8 6 25 1 0 20 0 Voltage V Current 1 1V 20 mA 4 5 1 4 full value Full 2 1 4 ful 0 Full 2 Scale scale Scale 0 25 value Figure 2 3 Analog signal output offset TELEDYNE ANALYTICAL INSTRUMENTS 2 7 2 Operational Theory The digital printed circuit board PCB is a general purpose microcomputer used to control all functions of the analyzer The analog input PCB and the analog output PCB plug directly into connectors located on the digital PCB In addition to control ling these analog PCBs the digital board performs the following functions 1 Processes input from the control panel pushbuttons 2 Provides signals for the selectable alarms 3 Processes serial I O functions RS 232 data The serial interface default and programmable parameters a
72. was pressed in step 1 the menu for setting AutoSpanning ON OFF time date for the next calibra tion and interval for automatic calibration will appear Use the SELEC UP and DOWN keys to make selec tions and press ACCPT If ALRMS was pressed in step 1 a menu displaying the most recent triggering time and date of each of the alarms will appear From here press ESC three times to return to the main menu screen TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Changing Passwords for Remote Monitoring and Control VALVE MODE ANALYZE 1 SENSOR A ON LINE 5 00 PPM O2 AUTORANGE 10 PPM ol ZERO SPAN SETUP RANGE 1 2 3 4 5 VALVE MODE ANALYZE STAT VIEW SYSTEM STATUS TEST CHECK ALTERNATE SENSOR INSTL INSTALL A SENSOR SET SET ALARMS CLOCK LOG PASSWORDS OR SENSOR STAT TEST INSTL SET ESC 1 2 3 4 5 VALVE MODE ANALYZE SELECT AUTHORIZATION CODE SELECT YOUR CODE SELEC UP DOWN ACCPT ESC 1 2 3 4 5 VALVE MODE ANALYZE SELECT FUNCTION TO SETUP LOG ALRMS sENSR MORE ESC 1 2 3 4 5 VALVE MODE ANALYZE SELECT FUNCTION TO SETUP cLocK
73. which is necessary to maintain these specifications Response Time 90 of final reading in less than 61 seconds at 25 C Operating Temperature 0 50 C 32 122 F Analog Signal Outputs For percent of full scale indication one 0 1 V dc non isolated signal one 4 20 mA dc isolated signal Forrange identification one 0 1 V dc non isolated signal one 4 20 mA dc isolated signal Digital Data Lines RS 232C serial interface for 2 way communications with separate host computer for remote monitoring and control of all functions Alarms Fiveuser programmable absolute reading alarm setpoints with Form C SPDT relays 3A resistive TELEDYNE ANALYTICAL INSTRUMENTS A 1 Appendix Mounting and Enclosure Sensor Altitude Relative Humidy Power Requirements 19 relay rack 20 3 cm 12 25 inches high for general purpose nonhazardous areas Class I Division II hazardous area models available on special order Class B 2 B2C A2 or A2C Micro Fuel Cells 1 609 m Up to 9996 100 120 220 or 240 50 60 Hz 1 5 AMAX Use 250 V 3 0 A T Fuse for 110 120 V Use 250 V 1 6 A T Fuse for 220 240 V TELEDYNE Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Phone 626 934 1500 Fax 626 961 2538 TWX 910 584 1887 TDYANYL COID Web www teledyne ai com A 2 TELEDYNE ANALYTICAL INSTRUMENTS Appendix A 2 Recommended Spare Parts List Description P N

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