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Teledyne 3000TA Oxygen Equipment User Manual

1. 18 Required Front Door Clearance 18 Rear Panel of the Model 3000TA 19 Equipment Interface Connector Pin Arrangement 22 Remote Probe Connections 27 FET Series Resistance 27 Removing the Micro Fuel 59 Removing Fuse Block from Housing 61 installing FUSES sers terne trs tte een 62 Rear Panel Screws nenn 64 Single and Dual 19 Rack Mounts 70 j Teledyne Analytical Instruments xi 3000TA EU List of Tables Table 3 1 Analog Output Connections Pin Function 23 Table 3 2 Alarm Relay Contact PINs ccceeceeeeeeeeeeeeeeeeeees 24 Table 3 3 Remote Calibration Connections 25 Table 3 4 Range ID Relay Connections 26 Table 3 5 Commands via RS 232 Input 28 Table 5 1 Self Test Failure Codes 62 Teledyne Analytical Instruments xii Trace Oxygen Analyzer Introduction Introduction 1 1 Overview The Teledyne Analytical Instruments Model 3000TA Trace Oxygen Analyzer is a versatile microprocessor based instrument for detecting oxygen at the parts per million ppm lev
2. Top View Bottom View Concentric Sensing FoilContact Surface Rings Figure 2 1 Micro Fuel Cell Refer to Figure 2 2 Cross Section of a Micro Fuel Cell which illustrates the following internal description Figure 2 2 Cross Section of a Micro Fuel Cell not to scale At the top end of the cell is a diffusion membrane of Teflon whose thickness is very accurately controlled Beneath the diffusion membrane lies the oxygen sensing element the cathode with a surface area almost 4 cm The cathode has many perforations to ensure Teledyne Analytical Instruments 8 Trace Oxygen Analyzer Operational Theory sufficient wetting of the upper surface with electrolyte and it is plated with an inert metal The anode structure is below the cathode It is made of lead and has a proprietary design which is meant to maximize the amount of metal available for chemical reaction At the rear of the cell just below the anode structure is a flexible membrane designed to accommodate the internal volume changes that occur throughout the life of the cell This flexibility assures that the sensing membrane remains in its proper position keeping the electrical output constant The entire space between the diffusion membrane above the cathode and the flexible rear membrane beneath the anode is filled with electrolyte Cathode and anode are submerged in this common pool They each have a conductor connecting them to one of the
3. Cell Block amp Micro fuel Cell Cell Holder Figure 5 1 Removing the Micro Fuel 5 2 4 Installing a New Micro Fuel Cell It is important to minimize the amount of time that a Teledyne Trace Oxygen Sensor is exposed to air during the installation process The quicker the sensor can be installed into the unit the faster your TAI O2 sensor will recover to low O2 measurement levels NN Teledyne Analytical Instruments 59 Maintenance 3000TA EU CAUTION DO NOT TOUCH THE SENSING SURFACE OF THE CELL IT IS COVERED WITH A DELICATE TEFLON MEMBRANE THAT CAN LEAK WHEN PUNCTURED THE SENSOR MUST BE REPLACED IF THE MEMBRANE IS DAMAGED Before installing a new cell check the O ring in the base of the cell holder Replace if worn or damaged Place the cell on the holder with the screen side facing down Note There is a small location hole drilled in the holder This hole mates with a guide pin on the bottom rear of the cell block The hole in the cell block holder must align with the guide pin on the cell block Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Remove power from instrument Remove the old sensor if installed from the analyzer Purge the analyzer at approximately 1 SCFH flow rate with N or applicable sample gas with the sensor holder re moved Remove sensor from double bag storage Remove sensor shorting button Place sensor on
4. Installation 3000TA EU eee eee SSS eee The small circular orifice should face away from the back of the unit against the direction of gas flow For positive pressures less than 5 psig use the low pressure restrictor without the blue dot in the Sample in line For vacuum service 5 10 in Hg use the restrictor without the blue dot sticker and union but attach it to the Exhaust Out port The small circular orifice should face toward the back of the unit against the direction of gas flow Remove the blue sticker from the restrictor before using Warning Operating the unit without restrictors can cause damage to the micro fuel cell The unit is manufactured with 1 4 inch tube fittings and 6 mm adapters are supplied for metric system installations For a safe connection 1 Insert the tube into the tube fitting and finger tighten the nut until the tubing cannot be rotated freely by hand in the fitting This may require an additional 1 8 turn beyond finger tight 2 Hold the fitting body steady with a backup wrench and with another wrench rotate the nut another 1 1 4 turns SAMPLE IN In the standard model gas connections are made at the SAMPLE IN and EXHAUST OUT connections Calibration gases must be tee d into the Sample inlet with appropriate valves The gas pressure in should be reasonably regulated Pressures between 2 and 50 psig are acceptable as long as the pressure once established will keep the front p
5. Instrument Serial Number Options Included in the Instrument with the Above Serial Number CI 3000TA C In addition to all standard features this model also has separate ports for zero and span gases and built in control valves The internal valves are entirely under the control of the 3000TA electronics to automatically switch between gases in synchronization with the analyzer s operations L 19 Rack Mnt The 19 Relay Rack Mount units are available with either one or two 3000 series analyzers installed in a standard 19 panel and ready to mount in a standard instrument rack Sensor Options Available for the Instrument with the Above Serial Number Insta Trace B2C Default A2C L2C L2CL Insta Trace A2C OOoOeoDO NN Teledyne Analytical Instruments iii 3000TA EU Important Notice Model 3000TA EU 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 Instruction Manual These symbols are visual indicators of important and immediate warnings and when you must exercise CAUTION while operating the instrument See also the Safety Information on the next se ga oO STAND BY Instrument is on Stand by but circuit is active GROUND Protective Earth CAUTION The operator needs to refer to the manual for further in
6. Operation 3000TA EU 4 3 2 Setting up an Auto Cal When proper automatic valving is connected see Chapter 3 Installation the analyzer can cycle itself through a sequence of steps that automatically zero and span the instrument Note If you require highly accurate Auto Cal timing use external Auto Cal control where possible The internal clock in the Model 3000TA is accurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day To setup an Auto Cal cycle Choose System from the Function buttons The LCD will display five subfunctions TRAK HLD Auto Cal PSWD Logout More Use lt P arrows to blink Auto Cal and press Enter A new screen for Span Zero set appears Span OFF Nxt 0d 0h Zero OFF Nxt 0d 0h Press lt b arrows to blink Span or Zero then press Enter again You won t be able to set OFF to ON if a zero interval is entered A Span Every or Zero Every screen appears Span Every 0d Start 0 h from now Use A V arrows to set an interval value then use lt arrows to move to the start time value Use A V arrows to set a start time value To turn ON the Span and or Zero cycles to activate Auto Cal Press System again choose Auto Cal and press Enter again When the Span Zero values screen appears use the lt arrows to blink the Span or Zero OFF ON field Use A V arrows to set the OFF ON field to ON You can now turn these fields ON because there is a nonzero spa
7. Power up the system and test it by repeating the Self Diagnostic Test as described in Chapter 4 Section 4 3 5 NN Teledyne Analytical Instruments 29 Trace Oxygen Analyzer Operation Operation 4 1 Introduction Once the analyzer has been installed it can be configured for your application To do this you will e Set system parameters e Establish a security password if desired requiring Operator to log in e Establish and start an automatic calibration cycle if desired e Calibrate the instrument e Define the three user selectable analysis ranges Then choose autoranging or select a fixed range of analysis as required e Set alarm setpoints and modes of alarm operation latching failsafe etc Before you configure your 3000TA these default values are in effect Ranges LO 100 ppm MED 1000 ppm HI 10 000 ppm Auto Ranging ON Alarm Relays Defeated 1000 ppm HI Not failsafe Not latching Zero Auto every 0 days at 0 hours Span Auto at 000008 00 ppm every 0 days at 0 hours If you choose not to use password protection the default password is automatically displayed on the password screen when you start up and you simply press Enter for access to all functions of the analyzer 4 2 Using the Data Entry and Function Buttons Data Entry Buttons The lt gt arrow buttons select options from the menu currently being displayed on the VFD screen The selected option blinks j Teledyne A
8. 3 3 2 1 Primary Input Power 3 3 2 2 50 Pin Equipment Interface Connector 3 3 2 3 RS 232 Port Teledyne Analytical Instruments NOR ON NNN 10 11 13 EET 17 17 17 19 19 21 21 22 27 viii Trace Oxygen Analyzer 3 4 Installing the Micro Fuel Cell 3 5 Testing the System LO 0 lt 1 LiLo eee ee ee ee 4 1 Introduction 4 2 Using the Data Entry and Function Buttons 4 3 The System Function 4 3 1 Tracking Oxygen Readings During Calibration and Alarm Delay 4 3 2 Setting up an Auto Cal 4 3 3 Password Protection 4 3 3 1 Entering the Password 4 3 3 2 Installing or Changing the Password 4 3 4 Logout 4 3 5 System Self Diagnostic Test 4 3 6 Version Screen 4 3 7 Showing Negative Oxygen Readings 4 4 The Zero and Span Functions 4 4 1 Zero Cal 4 4 1 1 Auto Mode Zeroing 4 4 1 2 Manual Mode Zeroing 4 4 1 3 Cell Failure 4 4 2 Span Cal 4 4 2 1 Auto Mode Spanning 4 4 2 2 Manual Mode Spanning 4 4 3 Span Failure 4 5 The Alarms Function 4 6 The Range Function 4 6 1 Setting the Analog Output Ranges 4 6 2 Fixed Range Analysis 4 7 The Analyze Function 4 8 Signal Output Maint NancCe 2 ccscceeceecceeceeccneceeccescneceeccuseneceaseneceeseusensecaseneees 5 1 Routine Maintenance 5 2 1 Storing and Handling Replacement Cells NN Teledyne Analytical Instruments 29 29 31 31 31 33 34 36 37 37 38 40 41 42 42 43 44 44 45 45 46 46 47 49 49 51 52 53 54 54 DT 57
9. 4 6 2 Fixed Range Analysis The autoranging mode of the instrument can be overridden forcing the analyzer DC outputs to stay in a single predetermined range To switch from autoranging to fixed range analysis enter the range function by pressing the Range button on the front panel Use the lt 4 gt arrow keys to move the blinking over AUTO Use the A V arrow keys to switch from AUTO to FX LO FX M ED or FX H to set the instrument on the desired fixed range low medium or high L 100 M 1000 H 1 0000 Mode FX LO or L 100 M 1000 H 1 0000 Mode FX MED or L 100 M 1000 H 1 0000 Mode FX HI Press Escape to re enter the Analyze mode using the fixed range Note When performing analysis on a fixed range if the oxygen concentration rises above the upper limit or default value as established by the operator for that particular range the output saturates at 1 VDC or 20 mA However the digital readout and the RS 232 output continue to read the true value of the oxygen concentration regardless of the analog output range j Teledyne Analytical Instruments 53 Operation 3000TA EU 4 7 The Analyze Function Normally all of the functions automatically switch back to the Analyze function when they have completed their assigned operations Pressing the Escape button in many cases also switches the analyzer back to the Analyze function Alternatively you can press the Analyze button at any ti
10. In practical application zeroing may still used to compensate for the combined zero offsets of the cell and the electronics The Teledyne Analytical Instruments 10 Trace Oxygen Analyzer Operational Theory electronics is zeroed automatically when the instrument power is turned on 375 4 Cell Output LA 125 50 100 k 150 k 200k Oxygen Concentration ppm Figure 2 3 Characteristic Input Output Curve for a Micro Fuel Cell 2 3 Sample System The sample system delivers gases to the Micro Fuel Cell sensor from the analyzer rear panel inlet Depending on the mode of operation either sample or calibration gas is delivered The Model 3000TA sample system is designed and fabricated to ensure that the oxygen concentration of the gas is not altered as it travels through the sample system The sample encounters almost no dead space This minimizes residual gas pockets that can interfere with trace analysis The sample system for the standard instrument incorporates 1 4 inch tube fittings for sample inlet and outlet connections at the rear panel For metric system installations 6 mm adapters are supplied with each instrument to be used if needed The sample or calibration gas flows through the system is monitored by a flowmeter downstream from NN Teledyne Analytical Instruments 11 Operational Theory 3000TA EU the cell Figure 2 4 shows the piping layout and flow diagram for the standard model
11. message output from the RS 232 until st lt enter gt is sent again The RS 232 protocol allows some flexibility in its implementation Table 3 6 lists certain RS 232 values that are required by the 3000TA implementation Table 3 6 Required RS 232 Options Parameter Setting Baud 2400 Byte 8 bits Parity none Stop Bits 1 Message Interval 2 seconds When CRC opens again zero and span are done Teledyne Analytical Instruments 28 Trace Oxygen Analyzer Installation 3 4 Installing the Micro Fuel Cell The Micro Fuel Cell is not installed in the cell block when the instrument 1s shipped Install it before the analyzer is placed in service Once it is expended or if the cell is exposed to air for too long the Micro Fuel Cell will need to be replaced The cell could also require replacement if the instrument has been idle for too long When the micro Fuel Cell needs to be installed or replaced follow the procedures in Chapter 5 Maintenance for removing and installing cells 3 5 Testing the System Before plugging the instrument into the power source Check the integrity and accuracy of the gas connections Make sure there are no leaks Check the integrity and accuracy of the electrical connections Make sure there are no exposed conductors Verify that the restriction device has been properly installed see section 3 3 1 Check that inlet sample pressure is within the accepted range se section 3 3 1
12. 250 VAC at 47 63 Hz 0 9 A MAX Operating Temperature 0 50 C 32 122 F Humidity 99 Altitude 1 609 m Accuracy 2 of full scale at constant temperature 5 of full scale over operating NN Teledyne Analytical Instruments 67 Appendix 3000TA EU temperature range except 0 10 ppm analysis range once thermal equilibrium is reached 1 ppm on 0 10 ppm analysis range once thermal equilibrium is reached Analog Outputs 0 1 VDC percent of range 0 1 VDC range ID 4 20 mA DC isolated percent of range 4 20 mA DC isolated trange ID Dimensions 19 cm high 24 9 cm wide 31 cm deep 6 96 in high 8 7 in wide 12 2 in deep A 2 Recommended 2 Year Spare Parts List Qty Part Number Description 1 C65507A Back Panel Board 1 C62371 Front Panel Board 1 C62368 A Trace Preamplifier Board 1 C73870 A Main Computer Board 2 F 1296 Fuse 2A 250 V 5x20 mm Slow Blow 1 O165 O ring 1 Micro Fuel Cell A68729 Restrictor Kit See page iii for sensor used in this instrument A minimum charge is applicable to spare parts orders Note Orders for replacement parts should include the part number if available and the model and serial number of the instrument for which the parts are intended Teledyne Analytical Instruments 68 Trace Oxygen Analyzer Appendix Orders should be sent to TELEDYNE Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Phone 626 934 1500 Fax 62
13. 57 Appendix 5 2 2 When to Replace a Cell 5 2 3 Removing the Micro Fuel Cell 5 2 4 Installing a New Micro Fuel Cell 5 2 5 Cell Warranty 5 3 Fuse Replacement 5 4 System Self Diagnostic Test 5 5 Major Internal Components 5 6 Cleaning 5 7 Troubleshooting A 1 Model 3000TA Specifications A 2 Recommended 2 Year Spare Parts List A 3 Drawing List A 4 19 inch Relay Rack Panel Mount A 5 Application notes A 5 Material Safety Data Sheet Teledyne Analytical Instruments 3000TA EU 58 58 59 61 61 62 63 64 64 sabcvaweteatiassdersds 67 67 68 70 70 71 75 Trace Oxygen Analyzer List of Figures Figure 1 1 Figure 1 2 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure A 1 Model 3000TA Front Panel 3 Model 3000 TA Rear Panel 5 Micro Fuel Celles an 8 Cross Section of a Micro Fuel Cell not to scale 8 Characteristic Input Output Curve for a Micro Fuel Cela Beet en A cr cn rs 11 Piping Layout and Flow Diagram for Standard Model 12 Flow Diagramme srssrrimr a trs tn rss 13 3000TA Internal Electronic Component Location 14 Block Diagram of the Model 3000TA EU Electronics 15 Front Panel of the Model 3000TA
14. Cells Super Cell all classes except T 5F Electrochemical Oxygen Sensors all classes Teledyne Electronic Technologies Analytical Instruments 16380 Chestnut Street City of Industry CA 91749 626 961 9221 626 934 1673 626 934 1592 11 23 98 Section Il Physical and Chemical Data Potassium Hydroxide KOH 15 w v Chemical and Common Names CAS Number Melting Point Range Boiling Point Range Specific Gravity pH Solubility in Water Percent Volatiles by Vol Appearance and Odor Lead Pb pure KOH 1310 58 3 Pb 7439 92 1 KOH 15 w v Pb pure 10 to 0 C 328 C 100 to 115 C 1744 C 1 09 20 C 11 34 gt 14 N A Completely soluble Insoluble None N A Colorless odorless Grey metal solution odorless j Teledyne Analytical Instruments 75 Appendix 3000TA EU Section Ill 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 haz
15. Display Sample System Flow Indicator Standby Switch Data Entry Buttons Function Buttons Figure 1 1 Model 3000TA Front Panel Function Keys Six touch sensitive membrane switches are used to change the specific function performed by the analyzer e Analyze Perform analysis for oxygen content of a sample gas e System Perform system related tasks described in detail in chapter 4 Operation e Span Span calibrate the analyzer e Zero Zero calibrate the analyzer e Alarms Set the alarm setpoints and attributes e Range Setup the 3 user definable ranges for the instrument Data Entry Keys Six touch sensitive membrane switches are used to input data to the instrument via the alphanumeric VFD display NW Teledyne Analytical Instruments 3 Introduction 3000TA EU e Left amp Right Arrows Select between functions currently displayed on the VFD screen e Up amp Down Arrows Increment or decrement values of functions currently displayed e Enter Moves VFD display on to the next screen in a series If none remains returns to the Analyze screen e Escape Moves VFD display back to the previous screen in a series If none remains returns to the Analyze screen Digital Meter Display The meter display is a LED device that produces large bright 7 segment numbers that are legible in any lighting It produces a continuous readout from 0 10 000 ppm and then switches to a continuous percent readout from 1 25 It is a
16. Figure 5 4 Rear Panel Screws To detach the rear panel remove only the 14 screws marked with an X 5 6 Cleaning If instrument is unmounted at time of cleaning disconnect the instrument from the power source Close and latch the front panel access door Clean outside surfaces with a soft cloth dampened slightly with plain clean water DO NOT use any harsh solvents such as paint thinner or benzene For panel mounted instruments clean the front panel as prescribed in the above paragraph DO NOT wipe front panel while the instrument is controlling your process 5 7 Troubleshooting Problem Erratic readings of the Oxygen concentration as reported by the analyzer Possible Cause The analyzer may have been calibrated in an inaccurate fashion Solution Teledyne Analytical Instruments 64 Trace Oxygen Analyzer Maintenance Turn the analyzer off then back on again Press the System key when prompted by the analyzer Press System for default Values This will return the analyzer to its default settings in calibration and zero values If erratic behavior continues replace the sensor Possible Cause Atmospheric Oxygen may be diffusing in through the vent and affecting the oxygen level which the sensor sees Solution Increase flow rate and or length or vent tubing in order to dilute or mini mize the diffusion of oxygen from the vent back to the sensor Problem Inaccurate zero operation i e the user has z
17. RIGHT SIDE Flowmeter Figure 2 4 Piping Layout and Flow Diagram for Standard Model Figure 2 5 is the flow diagram for the sampling system In the stan dard instrument calibration gases zero and span can be connected di rectly to the Sample In port by teeing to the port with appropriate valves The shaded portion of the diagram shows the components added when the C option is ordered The valving is installed inside the 3000TA C enclosure and is regulated by the instruments internal electronics Teledyne Analytical Instruments 12 Trace Oxygen Analyzer Operational Theory Span In gt al lt T Components in the shaded area are in di the C option Internal 1 only and are not shown in the piping diagram above Zero In Sample In gt lt 4 ca Solenoid Valves In vacuum service the restrictor should be In normal service the Flowmeter placed here a juld N 4 Exhaust Out Restrictor 1 Figure 2 5 Flow Diagram 2 4 Electronics and Signal Processing The Model 3000TA Trace Oxygen Analyzer uses an 8031 microcontroller with 32 kB of RAM and 128 kB of ROM to control all signal processing input output and display functions for the analyzer System power is supplied from a universal power supply module designed to be compatible with any international power source Figure 2 6 shows the location of the power supply and the main electronic PC boards The signal processing
18. electronics including the microprocessor analog to digital and digital to analog converters are located on the motherboard at the bottom of the case The preamplifier board is mounted on top of the motherboard as shown in the figure These boards are accessible after removing the back panel Figure 2 7 is a block diagram of the Analyzer electronics 7 Teledyne Analytical Instruments 13 Operational Theor 3000TA EU Universal Power Supply Front Panel Display Board Slide out Electronics Drawer Motherboard Preamplifier PCB Figure 2 6 3000TA Internal Electronic Component Location In the presence of oxygen the cell generates a current A current to voltage amplifier converts this current to a voltage which is amplified in the second stage amplifier The second stage amplifier also supplies temperature compensation for the oxygen sensor output This amplifier circuit incorporates a ther mistor which is physically located in the cell block The thermistor is a temperature dependent resistance that changes the gain of the amplifier in proportion to the temperature changes in the block This change is in versely proportional to the change in the cell output due to the same temperature changes The result is a signal that is temperature independent The output from the second stage amplifier is sent to an 18 bit analog to digital converter controlled by the microprocessor Teledyne Analytical Instru
19. external contact rings on the contact plate which is on the bottom of the cell 2 2 3 Electrochemical Reactions The 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 2H20 4e 40H cathode Four electrons combine with one oxygen molecule in the presence of water from the electrolyte to produce four hydroxy ions When the oxygen is reduced at the cathode lead is simultaneously oxidized at the anode by the following HALF REACTION Pb 20H Pb H2O 2e anode Two electrons are transferred for each atom of lead that is oxidized Therefore it takes two of the above anode reactions to balance one cathode reaction and transfer four electrons The electrons released at the surface of the anode flow to the cathode surface when an external electrical path is provided The current is proportional to the amount of oxygen reaching the cathode It is NN Teledyne Analytical Instruments 9 Operational Theory 3000TA EU measured and used to determine the oxygen concentration in the gas mixture The overall reaction for the fuel cell is 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 such as iodine bromine chlorine and fluorine are present in the sample The output of the fuel cell is limited by 1 the a
20. low alarms by the operator The alarm modes can be set as latching or non latching and either failsafe or non failsafe or they can be defeated altogether The setpoints for the alarms are also established using this function Decide how your alarms should be configured The choice will depend upon your process Consider the following four points 1 Which if any of the alarms are to be high alarms and which if any are to be low alarms Setting an alarm as HIGH triggers the alarm when the oxygen concentration rises above the setpoint Setting an NN Teledyne Analytical Instruments 49 Operation 3000TA EU alarm as LOW triggers the alarm when the oxygen concentration falls below the setpoint Decide whether you want the alarms to be set as e Both high high and high high alarms or e One high and one low alarm or e Both low low and low low alarms 2 Are either or both of the alarms to be configured as failsafe In failsafe mode the alarm relay de energizes in an alarm condition For non failsafe operation the relay is energized in an alarm condition You can set either or both of the concentration alarms to operate in failsafe or non failsafe mode 3 Are either of the alarms to be latching In latching mode once the alarm or alarms trigger they will remain in the alarm mode even if process conditions revert back to non alarm conditions This mode requires an alarm to be recognized before it can be reset In the non lat
21. sure it is within specifications e Check for leaks downstream from the cell where oxygen may be leaking into the system If there are no leaks and the span gas is OK replace the cell as de scribed in Chapter 5 Maintenance 4 4 2 Span Cal The Span button on the front panel is used to span calibrate the analyzer Span calibration can be performed using the automatic mode where an internal algorithm compares consecutive readings from the sensor to determine when the output matches the span gas concentration Span calibration can also be performed in manual mode where the operator determines when the span concentration reading is acceptable and manually exits the function 4 4 2 1 AUTO MODE SPANNING Press Span to enter the span function The screen that appears allows you to select whether the span calibration is to be performed automatically or manually Use the A V arrow keys to toggle between AUTO and MAN span settling Stop when AUTO appears blinking on the display Span Settling AUTO lt ENT gt For Next Press Enter to move to the next screen Calib Holding time Cal hold 5 min Teledyne Analytical Instruments 46 Trace Oxygen Analyzer Operation This menu allows the operator to set the time the analyzer should be held in the span mode after the readings of the analyzer settle Five minutes is the default but it could be adjusted anywhere from 1 to 60 minutes by using the UP or DOWN keys Press Ente
22. time progresses the sensor may drift below the zero calibration setpoint To show negative oxygen readings on the display Press the System key TRAK HLD Auto Cal PSWD Logout More Use the Right or Left arrow keys and select More Press Enter Version Self Test Show_Negative NO Use the Right or Left Arrow keys and select Show_Negative NO Use the Up or Down key to toggle from NO to YES Press the Escape key twice to return to the analyze mode Teledyne Analytical Instruments 42 Trace Oxygen Analyzer Operation This preference is stored in non volatile memory so this configuration is remembered after a power shutdown If the instrument is cold started it will go back to default not showing negative oxygen readings 4 4 The Zero and Span Functions Note Zeroing is not required in order to achieve the published accuracy specification of this unit Zeroing will eliminate offset error contributed by sensor electronics and internal and external sampling system and improve performance beyond published specification limits The analyzer is calibrated using zero and span gases Any suitable oxygen free gas can be used for zero gas as long as it is known to be oxygen free and does not react adversely with the sample system Although the instrument can be spanned using air a span gas with a known oxygen concentration in the range of 70 90 of full scale of the range of interest is recommended Since the o
23. when and how to replace it 5 2 1 Storing and Handling Replacement Cells To have a replacement cell available when it is needed it is recom mended that one spare cell be purchased 9 10 months after commissioning the 3000TA or shortly before the end of the cell s one year warranty period CAUTION DO NOT STOCKPILE CELLS THE WARRANTY i PERIOD STARTS ON THE DAY OF SHIPMENT The spare cell should be carefully stored in an area that is not subject to large variations in ambient temperature 75 F nominal 24 C or to rough handling WARNING The sensor used in the model 3000TA Trace Oxygen Analyzer uses electrolytes which contain toxic A substances mainly Lead and potassium hydroxide that can be harmful if touched swallowed or Inhaled Avoid contact with any fluid or powder in or j Teledyne Analytical Instruments 57 Maintenance 3000TA EU 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 physician See appendix Material Safety Data Sheet CAUTION DO NOT DISTURB THE INTEGRITY OF THE CELL PACKAGE UNTIL THE CELL IS TO ACTUALLY BE A USED IF THE CELL PACKAGE IS PUNCTURED AND AIR IS PERMITTED TO ENTER THE CELL WILL REQUIRE AN EXCESSIVELY LONG TIME TO REACH ZERO AFTER INSTALLATION 1 2 WEEKS 5 2 2 When to Replace a Cell The characteristics of the Micro Fuel Cell show an almost cons
24. 6 961 2538 Web www teledyne ai com or your local representative NN Teledyne Analytical Instruments 69 Bppene x 3000TA EU A 3 Drawing List D66316 Final Assembly Outline Drawing D77800 Final Assembly Trace Oxygen Analyzer 3000TA EU Series A 4 19 inch Relay Rack Panel Mount 5 75 8 72 Figure A 1 Single and Dual 19 Rack Mounts dimensions in mm Teledyne Analytical Instruments 70 Trace Oxygen Analyzer Appendix A 5 Application notes 3000 SERIES ANALYZERS APPLICATION NOTES ON PRESSURES AND FLOW RECOMMENDATIONS The 3000 series analyzers require reasonably regulated sample pressures While the 3000 analyzers are not sensitive to variations of incoming pressure provided they are properly vented to atmospheric pressure The pressure must be maintained as to provide a useable flow rate trough the analyzer Any line attached to sample vent should be 1 4 or larger in diameter FLOW RATE RECOMMENDATIONS A usable flow rate for a 3000 series analyzer is one which can be measured on the flowmeter This is basically 2 2 4 SLPM The optimum flow rate is 1 SLPM mid scale Note Response time is dependent on flow rate a low flow rate will result in slow response to Oz changes in the sample stream The span flow rate should be the approximately same as the sample flow rate CELL PRESSURE CONCERNS The sensors used in 3000 series analyzers are optimized to function at atmospheric press
25. ON FILTER IS RECOMMENDED 3000TA EXAMPLES Teledyne Analytical Instruments 72 Trace Oxygen Analyzer Appendix Example 1 With an incoming pressure of 10 psig the standard restrictor blue dot will provide a flow rate of 76 SLPM Up stream of the restrictor the sample line pressure will be 10 psig while down stream including the cell the pressure will be at atmospheric pressure analyzer vented to atmospheric pressure Note all other pressure drops in the sample path are insignificant at these flowrates This insures that the cell operates at atmospheric pressure At very high flow rates off scale of flow meter pressure drops other than the restriction device could become significant and result in pressurizing the cell Example 2 A 3000TA is configured for vacuum service as follows The un marked restrictor is placed in the sample vent port The downstream end of the restrictor is then connected to a vacuum pump and bypass valve The bypass valve is adjusted to provide a flow rate of 1 SLPM The sample pressure between the pump and the restrictor will be approximately 7 inches of mercury while the pressure in the balance of the sample system including the cell will be approximately at atmospheric pressure Provided the sample flow into the analyzer is not blocked BYPASS To improve the system response a bypass can be added to increase the sample flow rate to the analyzer by a factor of ten A bypass provides a sa
26. OPERATING INSTRUCTIONS FOR MODEL 3000TA Trace Oxygen Analyzer P N M66316 3 09 11 DANGER Toxic gases and or flammable liquids may be present in this monitoring system Personal protective equipment may be required when servicing this instrument 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 Teledyne Analytical Instruments 3000TA EU Copyright 2011 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 without charge except for transportation or at customer plant at our option any material or construction in which defects b
27. Oz the span will not be accepted The analyzer will return to the previous calibration values trigger the System Alarm and display in the VFD Span Failed This message will be shown for five seconds and the instrument will return to the Analyze mode In the upper right hand corner of the VFD display FCAL will be shown This message flag will help the operator troubleshoot in case calibration was initiated remotely To reset the alarm and the flag message the unit must be turned off by cycling the standby key It will reset if the next span cycle is correct A trace cell is unlikely to fail span As explained before when the sensor reaches the end of its useful life the zero offset begins to rise until the analyzer finds the zero unsatisfactory Nevertheless feeding the wrong span gas or electronics failure could set this feature off at the end of the span Consider this before replacing the cell 4 5 The Alarms Function The Model 3000TA is equipped with 2 fully adjustable concen tration alarms and a system failure alarm Each alarm has a relay with a set of form C contacts rated for 3 amperes resistive load at 250 V ac See Figure in Chapter 3 Installation and or the Interconnection Diagram included at the back of this manual for relay connections The system failure alarm has a fixed configuration described in Chapter 3 Installation The concentration alarms can be configured from the front panel as either high or
28. TENED TO THE ANALYZER WITH ITS FASTENING SCREWS ULTIMATELY IT IS THE INSTALLER WHO ENSURES THAT THE CONNECTIONS PROVIDE ADEQUATE EMI RFI SHIELDING 3 3 2 1 PRIMARY INPUT POWER The power cord receptacle and fuse block are located in the same assembly Insert the power cord into the power cord receptacle CAUTION POWER IS APPLIED TO THE INSTRUMENT S CIRCUITRY AS LONG AS THE INSTRUMENT IS CONNECTED TO THE POWER SOURCE THE RED SWITCH ON THE FRONT PANEL IS FOR SWITCHING POWER ON OR OFF TO THE DISPLAYS AND OUT PUTS ONLY The universal power supply requires a 85 250 V ac 47 63 Hz power source NN Teledyne Analytical Instruments 21 Installation 3000TA EU Fuse Installation The fuse block at the right of the power cord receptacle accepts US or European size fuses A jumper replaces the fuse in whichever fuse receptacle is not used Fuses are not installed at the factory Be sure to install the proper fuse as part of installation See Fuse Replacement in chapter 5 maintenance 3 3 2 2 50 PIN EQUIPMENT INTERFACE CONNECTOR Figure 3 4 shows the pin layout of the Equipment Interface connector The arrangement is shown as seen when the viewer faces the rear panel of the analyzer The pin numbers for each input output function are given where each function is described in the paragraphs below o o e Por IPS Te es aoe aa 33 o o o o eo o e o o o o e 18 50 34 Figure 3 4 Equipment Interface Conne
29. act Digital Remote Cal Inputs Accept 0 V off or 24 VDC on inputs for remote control of calibration See Remote Calibration Protocol below See Table 3 3 for pin connections Zero Span Floating input 5 to 24 V input across the and pins puts the analyzer into the Zero mode Either side may be grounded at the source of the signal 0 to 1 volt across the terminals allows Zero mode to terminate when done A synchronous signal must open and close the external zero valve appropriately See Remote Probe Connector The C option internal valves operate automatically Floating input 5 to 24 V input across the and pins puts the analyzer into the Span mode Either side may be grounded at the source of the signal 0 to 1 volt across the terminals allows Span mode to terminate when done A synchronous signal must open and close external span valve appropriately See Figure 3 5 Teledyne Analytical Instruments 24 Trace Oxygen Analyzer Installation Remote Probe Connector The C option internal valves operate automatically Cal Contact This relay contact is closed while analyzer is spanning and or zeroing See Remote Calibration Protocol below Table 3 3 Remote Calibration Connections Pin Function 9 Remote Zero 11 Remote Zero 10 Remote Span 12 Remote Span 40 Cal Contact 41 Cal Contact Remote Calibration Protocol To properly time the Digital Remote Cal Inputs to the Model 3000TA An
30. alyzer the customer s controller must monitor the Cal Relay Contact When the contact is OPEN the analyzer is analyzing the Remote Cal Inputs are being polled and a zero or span command can be sent When the contact is CLOSED the analyzer is already calibrating It will ignore your request to calibrate and it will not remember that request Once a zero or span command is sent and acknowledged contact closes release it If the command is continued until after the zero or span is complete the calibration will repeat and the Cal Relay Contact CRC will close again For example 1 Test the CRC When the CRC is open Send a zero command until the CRC closes The CRC will quickly close 2 When the CRC closes remove the zero command 3 When CRC opens again send a span command until the CRC closes The CRC will quickly close 4 When the CRC closes remove the span command When CRC opens again zero and span are done and the sample is being analyzed Teledyne Analytical Instruments 25 Installation 3000TA EU Note The Remote Valve connections described below provides signals to ensure that the zero and span gas valves will be controlled synchronously If you have the C Internal valve option which includes additional zero and span gas inouts the 3000T automatically regulates the zero span and sample gas flow Range ID Relays Four dedicated Range ID relay contacts The first three ranges ar
31. anel flowmeter reading in an acceptable range 0 1 to 2 4 SLPM For non pressurized sample or very low pressure 2 psig or less vacuum service plumbing is recommended Exact figures will depend on your process If greater flow is required for improved response time install a bypass in the sampling system upstream of the analyzer input Teledyne Analytical Instruments 20 Trace Oxygen Analyzer Installation EXHAUST OUT Exhaust connections must be consistent with the hazard level of the constituent gases Check Local State and Federal laws and ensure that the exhaust stream vents to an appropriately controlled area if required ZERO IN and SPAN IN Optional These are additional ports for inputting span gas and zero gas There are electrically operated valves inside for automatic switching between sample and calibration gases These valves are completely under control of the 3000T Electronics They can be externally controlled only indirectly through the Remote Cal Inputs described below Pressure flow and safety considerations are the same as prescribed for the SAMPLE IN inlet above 3 3 2 Electrical Connections For safe connections no uninsulated wiring should be able to come in contact with fingers tools or clothing during normal operation CAUTION USE SHIELDED CABLES ALSO USE PLUGS THAT PROVIDE EXCELLENT EMI RFI PROTECTION THE PLUG CASE MUST BE CONNECTED TO THE CABLE SHIELD AND IT MUST BE TIGHTLY FAS
32. ards Ingestion eye skin contact 0 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 OSHA Not listed Lead is listed as a chemical known to the State of California to cause birth defects or other reproductive harm Teledyne Analytical Instruments 76 Trace Oxygen Analyzer 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 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 leak
33. as no control over process conditions and it can be misused In particular any alarm or control systems installed must be tested and understood both as to how they operate and as to how they can be defeated Any safeguards required such as locks labels or redundancy must be provided by the user or specifically requested of Teledyne at the time the order is placed Therefore the purchaser must be aware of the hazardous process conditions The purchaser is responsible for the training of personnel for providing hazard warning methods and instrumentation per the appropriate standards and for ensuring that hazard warning devices and instrumentation are maintained and operated properly Teledyne Analytical Instruments the manufacturer of this instrument cannot accept responsibility for conditions beyond its knowledge and control No statement expressed or implied by this document or any information disseminated by the manufacturer or its agents is to be construed as a warranty of adequate safety control under the user s process conditions Teledyne Analytical Instruments ii Trace Oxygen Analyzer Specific Model Information The instrument for which this manual was supplied may incorporate one or more options not supplied in the standard instrument Commonly available options are listed below with check boxes Any that are incorporated in the instrument for which this manual is supplied are indicated by a check mark in the box
34. assigned the system assigns TETAI by default This allows access to anyone After a unique password is assigned to defeat the security the password must be changed back to TETAI e Logout Logging out prevents an unauthorized tampering with analyzer settings e More Select and enter More to get a new screen with additional subfunctions listed e Self Test The instrument performs a self diagnostic test to check the integrity of the power supply output boards and amplifiers e Version Displays Manufacturer Model and Software Version of the instrument e Show Negative The operator selects whether display can show negative oxygen readings or not e TRAK HLD The operator sets whether the instrument analog outputs track the concentration change during calibration and sets a time delay for the concentration alarms after calibration 4 3 1 Tracking Oxygen Readings During Calibration and Alarm Delay The user has the option of setting the preference as to whether the analog outputs track the display readings during calibration or not To set the preference press the System key once and the first System menu will appear in the VFD display Teledyne Analytical Instruments 34 Trace Oxygen Analyzer Operation TRAK HLD Auto Cal PSWD Logout More TRAK HLD should be blinking To enter this system menu press the Enter key once Output Sttng TRACK Alarm Dly 10 min or Output Sttng HOLD Alarm Dly 10 min In the f
35. ccurate across all analysis ranges without the discontinuity inherent in analog range switching Alphanumeric Interface Screen The VFD screen is an easy to use interface from operator to analyzer It displays values options and messages that give the operator immediate feedback Flowmeter Monitors the flow of gas past the sensor Readout is 0 2 to 2 4 standard liters per minute SLPM Standby Button The Standby button turns off the display and outputs but circuitry is still operating CAUTION THE POWER CABLE MUST BE UNPLUGGED TO FULLY DISCONNECT POWER FROM THE A INSTRUMENT WHEN CHASSIS IS EXPOSED OR WHEN ACCESS DOOR IS OPEN AND POWER CABLE IS CONNECTED USE EXTRA CARE TO AVOID CONTACT WITH LIVE ELECTRICAL CIRCUITS Access Door For access to the Micro Fuel Cell the front panel swings open when the latch in the upper right corner of the panel is pressed all the way in with a narrow gauge tool Accessing the main circuit board requires unfastening rear panel screws and sliding the unit out of the case 1 6 Recognizing Difference Between LCD amp VFD LCD has GREEN background with BLACK characters VFD has DARK background with GREEN characters In the case of VFD NO CONTRAST ADJUSTMENT IS NEEDED Teledyne Analytical Instruments 4 Trace Oxygen Analyzer Introduction 1 7 Rear Panel Equipment Interface The rear panel shown in Figure 1 2 contains the gas and electrical connectors for external inlets and ou
36. ching mode the alarm status will terminate when process conditions revert to non alarm conditions 4 Are either of the alarms to be defeated The defeat alarm mode is incorporated into the alarm circuit so that maintenance can be performed under conditions which would normally activate the alarms The defeat function can also be used to reset a latched alarm See procedures below If you are using password protection you will need to enter your password to access the alarm functions Follow the instructions in section 4 3 3 to enter your password Once you have clearance to proceed enter the Alarm function Press the Alarm button on the front panel to enter the Alarm function Make sure that AL 1 is blinking AL 1 AL 2 Choose Alarm Teledyne Analytical Instruments 50 Trace Oxygen Analyzer Operation Set up alarm 1 by moving the blinking over to AL 1 using the lt gt arrow keys Then press Enter to move to the next screen AL 1 1000 ppm HI Dft N Fs N Ltch N Five parameters can be changed on this screen e Value of the alarm setpoint AL 1 ppm oxygen e Out of range direction HI or LO e Defeated Dft Y N Yes No e Failsafe Fs Y N Yes No e Latching Ltch Y N Yes No To define the setpoint use the lt P arrow keys to move the blinking over to AL 1 Then use the A V arrow keys to change the number Holding down the key speeds up the incrementing or decrementing Remember the se
37. ctor Pin Arrangement Analog Outputs There are four DC output signal pins two pins per output For polarity see Table 3 1 The outputs are 0 1 VDC of Range Voltage rises linearly with increasing oxygen from 0 V at 0 ppm to 1 V at full scale ppm Full scale 100 of programmable range 0 1 VDC Range ID 0 25 V Low Range 0 5 V Medium Range 0 75 V High Range 1 V Air Cal Range 4 20 mA DC Range Current increases linearly with increasing oxygen from 4 mA at 0 ppm to 20 mA at full scale ppm Full scale 100 of programmable range 4 20 mA DC Range ID 8 mA Low Range 12 mA Medium Range 16 mA High Range 20 mA Air Cal Range Teledyne Analytical Instruments 22 Trace Oxygen Analyzer Installation Table 3 1 Analog Output Connections Pin Function Pin Function 3 Range ID 4 20 mA floating 4 Range ID 4 20 mA floating 5 Range 4 20 mA floating 6 Range 4 20 mA floating 8 Range ID 0 1 VDC 23 Range ID 0 1 VDC negative ground 24 Range 0 1 VDC 7 Range 0 1 VDC negative ground Alarm Relays The nine alarm circuit connector pins connect to the internal alarm relay contacts Each set of three pins provides one set of Form C relay contacts Each relay has both normally open and normally closed contact connections The contact connections are shown in Table 3 2 They are capable of switching up to 3 amperes at 250 V ac into a resistive load The connector
38. e assigned to relays in ascending order Low range is assigned to Range 1 ID Medium range is assigned to Range 2 ID and High range is assigned to Range 3 ID The fourth range is reserved for the Air Cal Range 25 Table 3 4 lists the pin connections Table 3 4 Range ID Relay Connections Pin Function 21 Range 1 ID Contact 38 Range 1 ID Contact 22 Range 2 ID Contact 39 Range 2 ID Contact 19 Range 3 ID Contact 18 Range 3 ID Contact 34 Range 4 ID Contact Air Cal 35 Range 4 ID Contact Air Cal Network I O A serial digital input output for local network protocol At this printing this port is not yet functional It is to be used for future options to the instrument Pins 13 and 29 Remote Valve Connections The 3000TA is a single chassis instrument which has no Remote Valve Unit Instead the Remote Valve connections are used as a method for directly controlling external sample zero span gas valves See Figure 3 5 Teledyne Analytical Instruments 26 Trace Oxygen Analyzer Installation ee Se ee m Solenoid 2 hot m Solenoid 3 hot Matching Solenoid 1 hot Circuitry Solenoid 4 hot If Solenoid 2 return Necessary mue Figure 3 5 Remote Probe Connections The voltage from these outputs is nominally 0 V for the OFF and 15 VDC for the ON conditions The maximum combined current that can be pulled from these output lines is 100 mA If two lines are ON at the sa
39. e flow rate over that range The second function that the restriction device provides is a pressure drop This device is selected to provide the only significant pressure drop in the sample path RESTRICTOR KIT The current revision of the 3000 series analyzers are supplied with a kit containing two restrictors and a union which are user installed These parts supplied to give the end user more flexibility when installing the analyzer The restrictor kit is suitable for high and low positive pressure applications as well as vacuum service atmospheric pressure sample applications see manual for installation instructions The standard restrictor BLUE DOT is recommended for pressures between 5 psig and 50 psig For positive low pressure application 5 psig or less the un marked restrictor is better suited For non pressurized sample applications the marked restrictor should be used and configured for vacuum service For extremely low positive pressure applications less than 2 psig the vacuum service configuration should provide higher performance higher flow rates For vacuum service the end user must supply a vacuum pump and a bypass valve for the pump A vacuum level of 5 10 inches of mercury should provide the optimum flow rate CAUTION FLOW RESTRICTORS HAVE VERY SMALL ORIFICES AND MAY BE PLUGGED BY SMALL PARTICLES A 005 DIA OR LARGER A SAMPLE FILTER MUST BE INCLUDED IN THE SAMPLE LINE PRIOR TO THE RESTRICTOR A 60 MICR
40. ecome 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 authorized service center We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage which may result from its use or misuse We reserve the right to employ any suitable material in the manufacture of our apparatus and to make any alterations in the dimensions shape or weight of any parts in so far as such alterations do not adversely affect our warranty Important Notice This instrument provides measurement readings to its user and serves as a tool by which valuable data can be gathered The information provided by the instrument may assist the user in eliminating potential hazards caused by his process however it is essential that all personnel involved in the use of the instrument or its interface with the process being measured be properly trained in the process itself as well as all instrumentation related to it The safety of personnel is ultimately the responsibility of those who control process conditions While this instrument may be able to provide early warning of imminent danger it h
41. el in a variety of gases This manual covers the Model 3000TA General Purpose flush panel and or rack mount units only These units are for indoor use in a nonhazardous environment 1 2 Typical Applications A few typical applications of the Model 3000TA are Monitoring inert gas blanketing Air separation and liquefaction Chemical reaction monitoring Semiconductor manufacturing Petrochemical process control Quality assurance Gas analysis certification 1 3 Main Features of the Analyzer The Model 3000TA Trace Oxygen Analyzer is sophisticated yet simple to use The main features of the analyzer include A 2 line alphanumeric display screen driven by microprocessor electronics that continuously prompts and informs the operator High resolution accurate readings of oxygen content from low ppm levels through 25 Large bright meter readout Nylon cell block Stainless steel optional NN Teledyne Analytical Instruments 1 Introduction 3000TA EU Advanced Micro Fuel Cell designed for trace analysis has a one year warranty and an expected lifetime of two years Versatile analysis over a wide range of applications Microprocessor based electronics 8 bit CMOS microprocessor with 32 kB RAM and 128 kB ROM Three user definable output ranges from 0 10 ppm through 0 250 000 ppm allow best match to users process and equipment Air calibration range for convenient spanning at 20 9 Auto Ranging allows analy
42. ent If you get a CELL FAILURE message skip to Section 4 4 1 3 4 4 1 1 AUTO MODE ZEROING Press Zero to enter the zero function mode The screen allows you to select whether the zero calibration is to be performed automatically or manually Use the A V arrow keys to toggle between AUTO and MAN zero settling Stop when AUTO appears blinking on the display Zero Settling AUTO lt ENT gt To Begin Press Enter to begin zeroing PPM Zero Slope ppm s The beginning zero level is shown in the upper left corner of the display As the zero reading settles the screen displays and updates information on Slope unless the Slope starts within the acceptable zero range and does not need to settle further Then and whenever Slope is less than 0 08 for at least 3 minutes instead of Slope you will see a countdown 5 Left 4 Left and so forth These are five steps in the zeroing process that the system must complete AFTER settling before it can go back to Analyze PPM Zero 4 Left ppm s Teledyne Analytical Instruments 44 Trace Oxygen Analyzer Operation The zeroing process will automatically conclude when the output is within the acceptable range for a good zero Then the analyzer automatically returns to the Analyze mode 4 4 1 2 MANUAL MODE ZEROING Press Zero to enter the Zero function The screen that appears allows you to select between automatic or manual zero calibration Use the A V keys to toggle b
43. epending on whether or not a password has been previously installed TETAI Enter PWD or NN Teledyne Analytical Instruments 37 Operation 3000TA EU AAAAA Enter PWD The screen prompts you to enter the current password If you are not using password protection press Enter to accept TETAI as the default password If a password has been previously installed enter the password using the lt q gt arrow keys to scroll back and forth between letters and the A V arrow keys to change the letters to the proper password Press Enter to enter the password If the password is accepted the screen will indicate that the password restrictions have been removed and you have clearance to proceed PSWD Restrictions Removed In a few seconds you will be given the opportunity to change this password or keep it and go on Change Password lt ENT gt Yes lt ESC gt No Press Escape to move on or proceed as in Changing the Password below 4 3 3 2 INSTALLING OR CHANGING THE PASSWORD If you want to install a password or change an existing password proceed as above in Entering the Password When you are given the opportunity to change the password Change Password lt ENT gt Yes lt ESC gt No Press Enter to change the password either the default TETAI or the previously assigned password or press Escape to keep the existing password and move on If you chose Enter to change the password the password assignment screen a
44. eroed the analyzer accidentally on gas much higher than one would normally use for a zero gas Solution Turn the analyzer off then back on again Press the System key when prompted by the analyzer Press System for default Values This will return the analyzer to its default settings in calibration and zero values Now proceed to carefully calibrate and zero the analyzer NN Teledyne Analytical Instruments 65 Maintenance 3000TA EU RE U a l r Teledyne Analytical Instruments 66 Trace Oxygen Analyzer Appendix Appendix A 1 Model 3000TA Specifications Packaging General Purpose e Flush panel mount Standard e Relay rack mount Contains either one or two instruments in one 19 relay rack mountable plate Optional Sensor Teledyne L 2 trace analysis Micro Fuel Cell Cell Block 316 stainless steel Sample System All wetted parts of 316 stailess steel 90 Response Time 65 seconds at 25 C 77 F Ranges Three user definable ranges from 0 10 ppm to 0 250 000 ppm plus air calibration range 0 250 000 ppm 25 Autoranging with range ID output Alarms One system failure alarm contact to detect power failure or sensor zero failure Two adjustable concentration threshold alarm contacts with fully programmable setpoints Displays Two line by 20 character VFD screen and one 5 digit LED display Digital Interface Full duplex RS 232 communications port Power Universal power supply 85
45. es are being analyzed since the potential of gas leaks always exist The customer should ensure that the principles of operation of this equipment are well understood by the user Misuse of this product in any manner tampering with its components or unauthorized substitution of any component may adversely affect the safety of this instrument Since the use of this instrument is beyond the control of Teledyne no responsibility by Teledyne its affiliates and agents for damage or injury from misuse or neglect of this equipment is implied or assumed NN Teledyne Analytical Instruments vii 3000TA EU Table of Contents Safety Messages ccscsssunensonnnmenancnnenmenats IMTFOdUCHOME EEE Rene a 1 1 Overview 1 2 Typical Applications 1 3 Main Features of the Analyzer 1 4 Model Designations 1 5 Front Panel Operator Interface 1 6 Recognizing Difference Between LCD amp VFD 1 7 Rear Panel Equipment Interface Operational Theory initier tiisnennee 2 1 Introduction 2 2 Micro Fuel Cell Sensor 2 2 1 Principles of Operation 2 2 2 Anatomy of a Micro Fuel Cell 2 2 3 Electrochemical Reactions 2 2 4 The Effect of Pressure 2 2 5 Calibration Characteristics 2 3 Sample System 2 4 Electronics and Signal Processing Install tioni 5 52 3 tement cine rues t lt bean ti coto tel runtede eine te 3 1 Unpacking the Analyzer 3 2 Mounting the Analyzer 3 3 Rear Panel Connections 3 3 1 Gas Connections 3 3 2 Electrical Connections
46. es not affect anything in Manual Mode Just press Enter to continue Span Val 000008 00 lt ENT gt Span lt UP gt Mod Press A lt UP gt to permit modification Mod of span value Use the arrow keys to enter the oxygen concentration of the span gas you are using 209000 00 if you are using air The lt gt arrows choose the digit and the A V arrows choose the value of the digit Press Enter to enter the span value into the system and begin the span calibration Once the span has begun the microprocessor samples the output at a predetermined rate It calculates the difference between successive samplings and displays this difference as Slope on the screen It takes several seconds for the first Slope value to display Slope indicates rate of change of the Span reading It is a sensitive indicator of stability Span Slope ppm s When the Span value displayed on the screen is sufficiently stable press Enter Generally when the Span reading changes by 1 or less of the full scale of the range being calibrated for a period of ten minutes it is sufficiently stable Once Enter is pressed the Span reading changes to the correct value The instrument then automatically enters the Analyze function Teledyne Analytical Instruments 48 Trace Oxygen Analyzer Operation 4 4 3 Span Failure The analyzer checks the output of the cell at the end of the span If the raw output of the cell is less than 0 5 uA ppm
47. etween AUTO and MAN zero settling Stop when MAN appears blinking on the display Zero Settling Man lt ENT gt To Begin Press Enter to begin the zero calibration After a few seconds the first of five zeroing screens appears The number in the upper left hand corner is the first stage zero offset The microprocessor samples the output at a predetermined rate It calculates the differences between successive samplings and displays the rate of change as Slope a value in parts per million per second ppm s ppm Zero Slope ppm s Note It takes several seconds for the true Slope value to display Wait about 10 seconds Then wait until Slope is sufficiently close to zero before pressing Enter to finish zeroing Generally you have a good zero when Slope is less than 0 05 ppm s for about 30 seconds When Slope is close enough to zero press Enter In a few seconds the screen will update Once span settling completes the information is stored in the microprocessor and the instrument automatically returns to the Analyze mode 4 4 1 3 CELL FAILURE Cell failure in the 3000TA is usually associated with inability to zero the instrument down to a satisfactorily low ppm reading When this occurs the 3000TA system alarm trips and the LCD displays a failure message NN Teledyne Analytical Instruments 45 Operation 3000TA EU ppm Aniz CELL FAIL ZERO HIGH Before replacing the cell e Check your span gas to make
48. formation Failure to do so may compromise the safe operation of the equipment CAUTION Risk of Electrical Shock gt gt Teledyne Analytical Instruments iv Trace Oxygen Analyzer Safety Messages Your safety and the safety of others is very important We have provided many important safety messages in this manual Please read these messages carefully A safety message alerts you to potential hazards that could hurt you or others Each safety message is associated with a safety alert symbol These symbols are found in the manual and inside the instrument The definition of these symbols is described below gt BPE Symbol GENERAL WARNING CAUTION Refer to the instructions for details on the specific danger These cautions warn of specific procedures which if not followed could cause bodily Injury and or damage the instrument CAUTION HoT SURFACE WARNING This warning is specific to heated components within the instrument Failure to heed the warning could result in serious burns to skin and underlying tissue WARNING ELECTRICAL SHOCK HAZARD Dangerous voltages appear within this instrument This warning is specific to an electrical hazard existing at or nearby the component or procedure under discussion Failure to heed this warning could result in injury and or death from electrocution Technician Symbol All operations marked with this symbol are to be performed by qualified maintenance personnel o
49. ic disposable electrochemical transducer The active components of the Micro Fuel Cell are a cathode an anode and the 15 aqueous KOH electrolyte in which they are immersed The cell converts the energy from a chemical reaction into an electrical current in 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 a constituent of the sample gas being analyzed The Micro Fuel Cell is therefore a hybrid between a battery and a true fuel cell All of the reactants are stored externally in a true fuel cell Teledyne Analytical Instruments 7 Operational Theory 3000TA EU 2 2 2 Anatomy of a Micro Fuel Cell The Micro Fuel Cell is a cylinder only 11 4 inches in diameter and 11 4 inches thick It is made of an extremely inert plastic which can be placed confidently in practically any environment or sample stream It is effectively sealed although one end is permeable to oxygen in the sample gas The other end of the cell is a contact plate consisting of two concentric foil rings The rings mate with spring loaded contacts in the sensor block assembly and provide the electrical connection to the rest of the analyzer Figure 2 1 illustrates the external features
50. irst line TRACK or HOLD should be blinking The operator can toggle between TRACK and HOLD with the Up or Down keys When TRACK is selected the analog outputs 0 1 VDC and 4 20 mA and the range ID contacts will track the instrument readings during calibration either zero or span TRACK is the factory default When HOLD is selected the analog outputs 0 1 VDC and 4 20 mA and the range ID contacts will freeze on their last state before entering one of the calibration modes When the instrument returns to the Analyze mode either by a successful or an aborted calibration there will be a three minute delay before the analog outputs and the range ID contacts start tracking again The concentration alarms freeze on their last state before entering calibration regardless of selecting HOLD or TRACK But when HOLD is selected the concentration alarms will remain frozen for the time displayed in the second line of the TRAK HLD menu after the analyzer returns to the Analyze mode The factory default is three minutes but the delay time is program mable To adjust to delay time use the Left or Right arrow keys When the time displayed on the second line blinks it can be adjusted by Pressing the Up or Down keys to increase or decrease its value The minimum delay is 1 minute the maximum is 30 This preference is stored in non volatile memory so that it is recovered if power is removed from the instrument NN Teledyne Analytical Instruments 35
51. itial setup Each of these functions is described in greater detail in the following procedures The VFD screen text that accompanies each operation is reproduced at the appropriate point in the procedure in a Monospaced type style Pushbutton names are printed in Oblique type Teledyne Analytical Instruments 32 Trace Oxygen Analyzer Operation Figure 4 1 Hierarchy of Functions and Sub functions 4 3 The System Function The subfuctions of the System function are described below Specific procedures for their use follow the descriptions e Auto Cal Used to define an automatic calibration sequence and or start an Auto Cal e PSWD Security can be established by choosing a 5 digit password PSWD from the standard ASCII character set NN Teledyne Analytical Instruments 33 Operation 3000TA EU See Installing or Changing a Password below for a table of ASCII characters available Once a unique password is assigned and activated the operator MUST enter the UNIQUE password to gain access to set up functions which alter the instrument s operation such as setting the instrument span or zero setting adjusting the alarm setpoints or defining analysis ranges After a password is assigned the operator must log out to activate it Until then anyone can continue to operate the instrument without entering the new password Only one password can be defined Before a unique password is
52. lure Codes Power 0 OK 1 5 V Failure 2 15 V Failure 3 Both Failed Analog 0 OK l DAC A 0 1 V Concentration 2 DAC B 0 1 V Range ID 3 Both Failed Teledyne Analytical Instruments 62 Trace Oxygen Analyzer Maintenance Preamp 0 OK 1 Zero too high 2 Amplifier output doesn t match test input 3 Both Failed 5 5 Major Internal Components The Micro Fuel cell is accessed by unlatching and swinging open the front panel as described earlier Other internal components are accessed by removing the rear panel and sliding out the entire chassis See Figure 5 4 below The gas piping is illustrated in Figure 2 4 and the major electronic components locations are shown in Figure 2 5 in chapter 2 WARNING See warnings on the title page of this manual A The 3000TA contains the following major components e Analysis Section e Micro Fuel Cell L 2 or other e Stainless steel cell block e Sample system e Power Supply e Microprocessor e Displays e 5 digit LED meter e 2 line 20 character alphanumeric VFD display e RS 232 Communications Port See the drawings in the Drawings section in back of this manual for details j Teledyne Analytical Instruments 63 Maintenance 3000TA EU Le Teledyne Analytical Instruments AE AN 85 250Vac 47 63Hz E OSAMA ree O A A xO O x ZERO IN SAMPLE IN SPAN IN SEE MANUAL FOR INTERCONNECTION DETAIL LEE Jo arr X Le OD
53. lz AL 1 Note If you log off the system using the logout function in the system menu you will now be required to re enter the password to gain access to Span Zero Alarm and Range functions 4 3 4 Logout The Logout function provides a convenient means of leaving the analyzer in a password protected mode without having to shut the instrument off By entering Logout you effectively log off the instrument leaving the system protected against use until the password is reentered To log out press the System button to enter the System function TRAK HLD Auto Cal PSWD Logout More Use the lt gt arrow keys to position the blinking over the Logo ut function and press Enter to Log out The screen will display the message Teledyne Analytical Instruments 40 Trace Oxygen Analyzer Operation Protected Until Password Reentered 4 3 5 System Self Diagnostic Test The Model 3000TA has a built in self diagnostic testing routine Pre programmed signals are sent through the power supply output board and sensor circuit The return signal is analyzed and at the end of the test the status of each function is displayed on the screen either as OK or as a number between 1 and 3 See System Self Diagnostic Test in Chapter 5 for number code The self diagnostics are run automatically by the analyzer whenever the instrument is turned on but the test can also be run by the operator at will To initiate a self diagnostic test duri
54. mA LO 0 25 8 MED 0 50 12 HI 0 75 16 CAL 0 25 1 00 20 IMPORTANT In the event of loss of flow through the analyzer if the vent is vented to a location of high oxygen content oxygen will back diffuse through the vent line and in most cases quickly saturate the cell with oxygen which can then require a quite long purge down time for the sensor when then exposed to low oxygen concentrations In the event that flow is to be interrupted into the analyzer it is suggested that the user do one ofthe following 1 Bag the sensor in nitrogen during this time 2 install a shut off valve on the vent port of the analyzer or somewhere within the users sample system NN Teledyne Analytical Instruments 55 Operation 3000TA EU Teledyne Analytical Instruments 56 Trace Oxygen Analyzer Maintenance Maintenance 5 1 Routine Maintenance Aside from normal cleaning and checking for leaks at the gas connections routine maintenance is limited to replacing Micro Fuel cells and fuses and recalibration For recalibration see Section 4 4 Calibration Warning See warnings on the title page of this manual 5 2 Cell Replacement The L 2 Micro Fuel Cell is a sealed electrochemical transducer with no electrolyte to change or electrodes to clean When the cell reaches the end of its useful life it is replaced The spent fuel cell should be discarded according to local regulations This section describes fuel cell care as well as
55. me time each must be limited to 50 mA etc If more current and or a different voltage is required use a relay power amplifier or other matching circuitry to provide the actual driving current In addition each individual line has a series FET with a nominal ON resistance of 5 ohms 9 ohms worst case This can limit the obtainable voltage depending on the load impedance applied See Figure 3 6 Figure 3 6 FET Series Resistance 3 3 2 3 RS 232 PORT The digital signal output is a standard full duplex RS 232 serial communications port used to connect the analyzer to a computer NN Teledyne Analytical Instruments 27 Installation 3000TA EU terminal or other digital device It requires a standard 9 pin D connector The output data is status information in digital form updated every two seconds Status is reported in the following order The concentration in ppm or percent The range in use HI MED LO The span of the range 0 100 ppm etc Which alarms if any are disabled AL x DISABLED Which alarms if any are tripped AL x ON Each status output is followed by a carriage return and line feed Three input functions using RS 232 have been implemented to date They are described in Table 3 5 Table 3 5 Commands via RS 232 Input Command Description as lt enter gt Immediately starts an autospan az lt enter gt Immediately starts an autozero st lt enter gt Toggling input Stops Starts any status
56. me to return to analyzing your sample 4 8 Signal Output The standard Model 3000TA Trace Oxygen Analyzer is equipped with two 0 1 VDC analog output terminals accessible on the back panel one concentration and one range ID and two isolated 4 20 mA DC current outputs one concentration and one range ID See Rear Panel in Chapter 3 Installation for illustration The signal output for concentration is linear over the currently selected analysis range For example if the analyzer is set on range that was defined as 0 100 ppm Oz then the output would be Voltage Signal Current Signal Output VDC Output mA dc ppm O2 0 0 0 4 0 10 0 1 5 6 20 0 2 7 2 30 0 3 8 8 40 0 4 10 4 50 0 5 12 0 60 0 6 13 6 70 0 7 15 2 80 0 8 16 8 90 0 9 18 4 100 1 0 20 0 The analog output signal has a voltage which depends on the oxygen concentration AND the currently activated analysis range To relate the signal output to the actual concentration it is necessary to know what range the instrument is currently on especially when the analyzer is in the autoranging mode To provide an indication of the range a second pair of analog output terminals are used They generate a steady preset voltage or Teledyne Analytical Instruments 54 Trace Oxygen Analyzer Operation current when using the current outputs to represent a particular range The following table gives the range ID output for each analysis range Range Voltage V Current
57. ments 14 Trace Oxygen Analyzer Operational Theor Current Second to Voltage Rene Amplifier Amplifier Gonz Ato D Converter Temi Micro Processor Processing a DtoA 1 A Converter 0 1 V 4 20 mA Figure 2 7 Block Diagram of the Model 3000TA EU Electronics Teledyne Analytical Instruments 15 Operational Theory 3000TA EU The digital concentration signal along with input from the control panel is processed by the microprocessor and appropriate control signals are directed to the display alarms and communications port The same digital information is also sent to a 12 bit digital to analog converter that produces the 4 20 mA DC and the 0 1 VDC analog concentration signal outputs and the analog range ID outputs Signals from the power supply are also monitored and through the microprocessor the system failure alarm is activated if a malfunction is detected Teledyne Analytical Instruments 16 Trace Oxygen Analyzer Installation Installation Installation of the Model 3000TA Analyzer includes 1 Unpacking Mounting Gas connections Electrical connections Installing the Micro Fuel Cell Testing the system Nn BW ND 3 1 Unpacking the Analyzer Although the analyzer is shipped complete certain parts such as fuses and sensors are wrapped separately to be installed on site as part of the installation Carefully unpack the analyzer and inspect it for damage Immedia
58. mount of oxygen in the cell at the time and 2 the amount of stored anode material In the absence of oxygen no current is generated 2 2 4 The Effect of Pressure In order to state the amount of oxygen present in the sample in parts per million or a percentage of the gas mixture it is necessary that the sample diffuse into the cell under constant pressure If the total pressure increases the rate that oxygen reaches the cathode through the diffusing membrane will also increase The electron transfer and therefore the external current will increase even though the oxygen concentration of the sample has not changed It is therefore important that the sample pressure at the fuel cell usually vent pressure remain relatively constant between calibrations 2 2 5 Calibration Characteristics Given that the total pressure of the sample gas on the surface of the Micro Fuel Cell input is constant a convenient characteristic of the cell is that the current produced in an external circuit is directly proportional to the rate at which oxygen molecules reach the cathode and this rate is directly proportional to the concentration of oxygen in the gaseous mix ture In other words it has a linear characteristic curve as shown in Figure 2 3 Measuring circuits do not have to compensate for nonlinearities In addition since there is zero output in the absence oxygen the characteristic curve has close to an absolute zero within 1 ppm oxygen
59. mple flow path around the analyzer of 2 18 scfh typically CALIBRATION GAS For 3000 series analyzers r with the Auto Cal option the customer must supply control valves or restrictors for any SPAN or ZERO gas source which is attached to the Auto Cal ports The valve should be adjusted to the same flow rate as the sample gas When restrictors are used the gas pressure must be adjusted to achieve the proper flow rate OPERATION WITHOUT A RESTRICTORDEVICE Operation without a restrictor device is not recommend as mentioned above A 3000TA without any flow restrictor device was tested on 11 19 97 This results in a flow rate of 2 4 slpm at 1 psig This is a cv of 0 023 for the standard sample system NN Teledyne Analytical Instruments 73 Appendix 3000TA EU REFERENCE FLOW_1 XLS amp FLOW _2 XLS for information on flow rates at various pressures TAI PART NUMBERS Restrictor Kit A68729 Union ss U11 LP Restrictor R2323 low pressure vac service Std Restrictor R2324 Blue Dot Nut N73 Ferrule F73 Ferrule F74 Both ferrules are required CONVERSIONS 1 PSI 2 04 INCHES OF MERCURY in Hg 1 SCFH 0 476 SLPM A Teledyne Analytical Instruments 74 Trace Oxygen Analyzer Appendix A 5 Material Safety Data Sheet Section Product Identification Product Name Manufacturer Address Phone Technical Support Environment Health and Safety Date Prepared Micro fuel Cells Mini Micro fuel
60. n interval defined Teledyne Analytical Instruments 36 Trace Oxygen Analyzer Operation 4 3 3 Password Protection If a password is assigned then setting the following system parameters can be done only after the password is entered span and zero settings alarm setpoints analysis range definitions switching between autoranging and manual override setting up an auto cal and assigning a new password However the instrument can still be used for analysis or for initiating a self test without entering the password If you have decided not to employ password security use the default password TETAI This password will be displayed automatically by the microprocessor The operator just presses the Enter key to be allowed total access to the instrument s features Note If you use password security it is advisable to keep a copy of the password in a separate safe location 4 3 3 1 ENTERING THE PASSWORD To install a new password or change a previously installed password you must key in and ENTER the old password first If the default password is in effect pressing the ENTER button will enter the default TETAI password for you Press System to enter the System mode TRAK HLD Auto Cal PSWD Logout More Use the lt gt arrow keys to scroll the blinking over to PSWD and press Enter to select the password function Either the default TETAI password or AAAAA place holders for an existing password will appear on screen d
61. nalytical Instruments 31 Operation 3000TA EU When the selected option includes a modifiable item the A V arrow buttons can be used to increment or decrement that modifiable item The Enter button is used to accept any new entries on the VFD screen The Escape button is used to abort any new entries on the VFD screen that are not yet accepted by use of the Enter button Figure 4 1 shows the hierarchy of functions available to the operator via the function buttons The six function buttons on the analyzer are e Analyze This is the normal operating mode The analyzer monitors the oxygen content of the sample displays the percent of oxygen and warns of any alarm conditions e System The system function consists of six subfunctions that regulate the internal operations of the analyzer e Auto Cal setup e Password assignment e Self Test initiation e Checking software version e Logging out e Zero Used to set up a zero calibration e Span Used to set up a span calibration e Alarms Used to set the alarm setpoints and determine whether each alarm will be active or defeated HI or LO acting latching and or failsafe e Range Used to set up three analysis ranges that can be switched automatically with auto ranging or used as individual fixed ranges Any function can be selected at any time by pressing the appropriate button unless password restrictions apply The order as presented in this manual is appropriate for an in
62. ng operation Press the System button to start the System function TRAK HLD Auto Cal PSWD Logout More Use the lt P arrow keys to blink More then press Enter Version Self Test Use the lt P arrow keys again to move the blinking to the Self Test function The screen will follow the running of the diagnostic RUNNING DIAGNOSTIC Testing Preamp 83 During preamp testing there is a countdown in the lower right corner of the screen When the testing is complete the results are displayed Power OK Analog OK Preamp 3 j Teledyne Analytical Instruments 41 Operation 3000TA EU The module is functioning properly if it is followed by OK A number indicates a problem in a specific area of the instrument Refer to Chapter 5 Maintenance and Troubleshooting for number code information The results screen alternates for a time with Press Any Key To Continue Then the analyzer returns to the initial System screen 4 3 6 Version Screen Move the lt gt arrow key to More and press Enter With Version blinking press Enter The screen displays the manufacturer model and software version information 4 3 7 Showing Negative Oxygen Readings For software version 1 4 4 or later the instrument only displays oxygen readings that are positive or zero The instrument can be reconfigured to show negative readings if sensor output drifts below zero This situation may arise after the instrument has been zeroed as
63. nly NOTE Additional information and comments regarding a specific component or procedure are highlighted in the form of a note Teledyne Analytical Instruments V 3000TA EU CAUTION THE ANALYZER SHOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL IF YOU USE THE ANALYZER IN A MANNER OTHER THAN THAT FOR WHICH IT WAS INTENDED UNPREDICTABLE BEHAVIOR COULD RESULT POSSIBLY ACCOMPANIED WITH HAZARDOUS CONSEQUENCES This manual provides information designed to guide you through the installation calibration and operation of your new analyzer Please read this manual and keep it available Occasionally some instruments are customized for a particular application or features and or options added per customer requests Please check the front of this manual for any additional information in the form of an Addendum which discusses specific information procedures cautions and warnings that may be peculiar to your instrument Manuals do get lost Additional manuals can be obtained from Teledyne at the address given in the Appendix Some of our manuals are available in electronic form via the internet Please visit our website at www teledyne ai com Teledyne Analytical Instruments vi Trace Oxygen Analyzer ee a WARNING This is a general purpose instrument designed for use in a nonhazardous area It is the customer s responsibility to ensure safety especially when combustible gas
64. on Not implemented at this printing e Optional e Calibration Gas Ports Auto Cal Option Separate fittings for zero span and sample gas input and internal valves for automatically switching the gases Note If you require highly accurate Auto Cal timing use external Auto Cal control where possible The internal clock in the Model 3000TA is accurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day Teledyne Analytical Instruments 6 Trace Oxygen Analyzer Operational Theory Operational Theory 2 1 Introduction The analyzer is composed of three subsystems 1 Micro Fuel Cell Sensor 2 Sample System 3 Electronic Signal Processing Display and Control The sample system is designed to accept the sample gas and transport it through the analyzer without contaminating or altering the sample prior to analysis The Micro Fuel Cell is an electrochemical galvanic device that translates the amount of oxygen present in the sample into an electrical current The electronic signal processing display and control subsystem simplifies operation of the analyzer and accurately processes the sampled data The microprocessor controls all signal processing input output and display functions for the analyzer 2 2 Micro Fuel Cell Sensor 2 2 1 Principles of Operation The oxygen sensor used in the Model 3000T series is a Micro Fuel Cell designed and manufactured by Analytical Instruments It is a sealed plast
65. ot adversely affect the cell performance Consult the factory for available options for either intermittent or continuous CO exposure If a cell was working satisfactorily but ceases to function before the warranty period expires the customer will receive credit toward the purchase of a new cell If you have a warranty claim you must return the cell in question to the factory for evaluation If it is 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 5 3 Fuse Replacement 1 Place small screwdriver in notch and pry cover off as shown in Figure 5 2 Fuse Block Cover Housing Notch Figure 5 2 Removing Fuse Block from Housing NN Teledyne Analytical Instruments 61 Maintenance 3000TA EU 2 To change between American and European fuses remove the single retaining screw flip Fuse Block over 180 degrees and replace screw 3 Replace fuse as shown in Figure 5 3 4 Reassemble Housing as shown in Figure 5 2 American Fuses European Fuses Figure 5 3 Installing Fuses 5 4 System Self Diagnostic Test 1 Press the System button to enter the system mode 2 Use the lt P arrow keys to move to More and press Enter 3 Use the lt P arrow keys to move to Self Test and press Enter The following failure codes apply Table 5 1 Self Test Fai
66. ppears Teledyne Analytical Instruments 38 Trace Oxygen Analyzer Operation TETAI lt ENT gt To Proceed or AAAAA lt ENT gt To Proceed Enter the password using the lt 4 gt arrow keys to move back and forth between the existing password letters and the A V arrow keys to change the letters to the new password The full set of 94 characters available for password use are shown in the table below Characters Available for Password Definition A B C D E F G H K L M N O P Q R S U V W X Y Z a b c d e f g i j k l m n o p q S t u Vv Ww X y Z D OO amp 0 1 2 3 4 5 6 7 8 9 ge RS gt When you have finished typing the new password press Enter A verification screen appears The screen will prompt you to retype your password for verification AAAAA Retype PWD To Verify Wait a moment for the entry screen You will be given clearance to proceed AAAAA lt ENT gt TO Proceed NW Teledyne Analytical Instruments 39 a Sy Se Operation 3000TA EU Use the arrow keys to retype your password and press Enter when finished Your password will be stored in the microprocessor and the system will immediately switch to the Analyze screen and you now have access to all instrument functions If all alarms are defeated the Analyze screen appears as 0 0 ppm Anlz Range 0 100 If an alarm is tripped the second line will change to show which alarm it is 0 0 ppm An
67. r to move to the next screen Span Val 000008 00 lt ENT gt Span lt UP gt Mod Use the A V arrow keys to enter the oxygen concentration mode Use the lt gt arrow keys to blink the digit you are going to modify Use the A V arrow keys again to change the value of the selected digit When you have finished typing in the concentration of the span gas you are using 209000 00 if you are using air press Enter to begin the Span calibration ppm Span Slope ppm s The beginning span value is shown in the upper left corner of the display As the span reading settles the screen displays and updates information on Slope Spanning automatically ends when the span output corresponds within tolerance to the value of the span gas concentration Then the instrument automatically returns to the analyze mode 4 4 2 2 MANUAL MODE SPANNING Press Span to start the Span function The screen that appears allows you to select whether the span calibration is to be performed automatically or manually Span Settling MAN lt ENT gt For Next NN Teledyne Analytical Instruments 47 Operation 3000TA EU Use the A V keys to toggle between AUTO and MAN span settling Stop when MAN appears blinking on the display Press Enter to move to the next screen Press Enter to move to the next screen Calib Holding time Cal hold 5 min This menu allows the operator to set the time the analyzer should be held in the auto span mode It do
68. s 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 Before opening the bag containing the sensor during cell replacement 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 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 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 j Teledyne Analytical Instruments 77
69. s are e Threshold Alarm 1 e Can be configured as high actuates when concentration is above threshold or low actuates when concentration is below threshold e Can be configured as failsafe or non failsafe e Can be configured as latching or non latching e Can be configured out defeated e Threshold Alarm 2 e Can be configured as high actuates when concentration is above threshold or low actuates when concentration is below threshold e Can be configured as failsafe or non failsafe e Can be configured as latching or non latching e Can be configured out defeated e System Alarm e Actuates when DC power supplied to circuits is unacceptable in one or more parameters Permanently NN Teledyne Analytical Instruments 23 Installation 3000TA EU configured as failsafe and latching Cannot be defeated Actuates if self test fails e Reset by pressing button to remove power Then press again and any other button EXCEPT System to resume Further detail can be found in Chapter 4 Section 4 5 Table 3 2 Alarm Relay Contact Pins Pin Contact 45 Threshold Alarm 1 normally closed contact 28 Threshold Alarm 1 moving contact 46 Threshold Alarm 1 normally open contact 42 Threshold Alarm 2 normally closed contact 44 Threshold Alarm 2 moving contact 43 Threshold Alarm 2 normally open contact 36 System Alarm normally closed contact 20 System Alarm moving contact 37 System Alarm normally open cont
70. sensor holder so that the gold contact plate of the sensor is facing up towards the sky Install sensor and sensor holder into cell block With O ring in place align the guide pin with the hole on the cell holder Then with the holder lift cell into the cell block Push the gate on the cell block down so that the slots on the side of the gate engage the locating screws on the side of the block This forces the holder into position and forms a gas tight seal Purge system with sample or zero gas Power up Note If steps 4 through 10 are accomplished quickly elapsed time less than 15 seconds recovery to less than 1ppm level should occur in less than 8 hours Teledyne Analytical Instruments 60 Trace Oxygen Analyzer Maintenance 5 2 5 Cell Warranty The Class L 2 Micro Fuel cell is typically used in the Model 3000TA Other cell options are available See page iii for the cell shipped with your analyzer The L 2 cell is a long life cell and is warranted for 1 year from the date of shipment Note any Addenda attached to the front of this manual for special information applying to your instrument With regard to spare cells warranty period begins on the date of shipment The customer should purchase only one spare cell per section 5 2 1 Do not attempt to stockpile spare cells The L 2 cell is not designed applications where CO is a major component in the sample however concentrations of 1 000 ppm or less will n
71. stays on a fixed range regardless of the oxygen concentration detected If the concentration exceeds the upper limit of the range the DC output will saturate at 1 VDC 20 mA at the current output However the digital readout and the RS 232 output of the concentration are unaffected by the fixed range They continue to read accurately with full precision See Front Panel description in Chapter 1 The automatic air calibration range is always 0 25 and is not pro grammable 4 6 1 Setting the Analog Output Ranges To set the ranges enter the range function mode by pressing the Range button on the front panel L 100 M 1000 H 1 0000 Mode AUTO Use the lt gt arrow keys to blink the range to be set low L medium M or high H Use the A V arrow keys to enter the upper value of the range all ranges begin at 0 ppm Repeat for each range you want to set Press Enter to accept the values and return to Analyze mode See note below Note The ranges must be increasing from low to high for example if range 1 is set as 0 100 ppm and range 2 is set as 0 1 000 ppm range 3 cannot be set as 0 500 ppm since it is lower than range 2 Ranges alarms and spans are always set in ppm units over the entire 0 250 000 ppm range even though all concentration data outputs Teledyne Analytical Instruments 52 Trace Oxygen Analyzer Operation change from ppm units to percent when the concentration is above 10 000 ppm
72. struments 18 Trace Oxygen Analyzer Installation 3 3 Rear Panel Connections Figure 3 3 shows the Model 3000TA rear panel There are ports for gas power and equipment interface The Zero In and Span In ports are not included on the standard model but are available as options ye Teledyne Analytical Instruments RS 2392 ojo N CAUTION BRKOF BEC EH ee ee DO NOT OP N LAER BERVICEAGLE PARTS NEDE SEPMIDE DALY RE PORTER 85 250Vac 47 68Hz f E 0 9 A MAX USE 250V 1 04 T FUSE i 9 90 ZERC IN SAMPLE IN SPAN IN SEE MANUAL FOR INTERGONNECTION DETAIL a EXHAUST OUT Figure 3 3 Rear Panel of the Model 3000TA 3 3 1 Gas Connections Before using this instrument it should be determined if the unit will be used for pressurized service or vacuum service and low pressure applications Inspect the restrictor kit that came with the unit The kit consist of two restrictors and a union for 1 4 diameter tubing Notice that the two 1 3 4 long 1 4 diameter tubing are restrictors It has an open end and a closed end with a small circular orifice The restrictor without the blue sticker is for low pressure and vacuum service For high pressure applications 5 50psig use the restrictor that has a blue sticker on the body For pressurized service gt 5psig use the restrictor with the blue dot and union from the restrictor kit and attach it to the Sample In port NN Teledyne Analytical Instruments 19
73. tant output throughout its useful life and then fall off sharply towards zero at the end Cell failure in the 3000TA is usually characterized inability to zero the instrument down to a satisfactorily low ppm reading When this occurs the 3000TA system alarm trips and the LCD displays a failure message 4 ppm Aniz CELL FAIL ZERO HIGH Before replacing the cell a Check your span gas to make sure it is within specifications b Check for leaks downstream from the cell where oxygen may be leaking into the system If there are no leaks and the span gas is OK replace the cell 5 2 3 Removing the Micro Fuel Cell The Micro Fuel cell is located inside the stainless steel cell block behind the front panel see Figure 5 1 To remove an existing cell 1 Remove power to the instrument by unplugging the power cord at the power source 2 Open the front panel door by pressing the release button on the top right corner of the door all the way in with a narrow gauge tool such as a small screwdriver and releasing it Teledyne Analytical Instruments 58 Trace Oxygen Analyzer Maintenance 3 With one hand placed underneath the cell block ready to catch the Micro Fuel cell lift up on the stainless steel gate in front of the cell block This releases the cell and cell holder from the block The cell and holder will fall out in your hand WARNING Risk of electric shock high voltage exposed at the end of enclosure
74. tely report any damage or shortages to the shipping agent 3 2 Mounting the Analyzer The Model 3000TA is for indoor use in a general purpose area It is NOT for hazardous environments of any type The standard model is designed for flush panel mounting Figure 3 1 is an illustration of the 3000TA standard front panel and mounting bezel There are four mounting holes one in each corner of the rigid frame The Drawings section in the rear of this manual contains outline dimensions and mounting hole spacing diagrams On special order a 19 rack mounting panel can be provided For rack mounting one or two 3000 series analyzers are flush panel mounted on the rack panel See Appendix for dimensions of the mounting panel j Teledyne Analytical Instruments 17 Installation 3000TA EU ee 10 gt Figure 3 1 Front Panel of the Model 3000TA All operator controls are mounted on the control panel which is hinged on the left edge and doubles as the door that provides access to the sensor and cell block inside the instrument The door is spring loaded and will swing open when the button in the center of the latch upper right corner is pressed all the way in with a narrow gauge tool less than 0 18 inch wide such as a small hex wrench or screwdriver Allow clearance for the door to open in a 90 degree arc of radius 7 125 inches See Figure 3 2 Figure 3 2 Required Front Door Clearance Teledyne Analytical In
75. tlets Those that are optional are shown shaded in the figure The connectors are described briefly here and in detail in the nstallation chapter of this manual 4 Teledyne Analytical Instruments RS 232 of Jo NUE IN Some N 85 Fr El 83Hz 0 9 USE 2S0V 1 CAT FUSE eee wet ERC SAMPLE IN SPAN IN SEE MANUAL FOR INTERCONNECTION DETAIL i 3 OL Jo EXHAUST OUT Le oer Figure 1 2 Model 3000 TA Rear Panel e Power Connection Universal AC power source e Gas Inlet and Outlet One inlet must be externally valved and one exhaust out Three inlet when C option ordered e RS 232 Port Serial digital concentration signal output and control input e Remote Valves Used in the 3000TA for controlling external solenoid valves only e 50 Pin Equipment Interface Port e Analog Outputs 0 1 VDC concentration plus 0 1 VDC range ID and isolated 4 20 mA DC plus 4 20 mA DC range ID e Alarm Connections 2 concentration alarms and 1 system alarm Teledyne Analytical Instruments 5 Introduction 3000TA EU e Remote Span Zero Digital inputs allow external control of analyzer calibration e Calibration Contact To notify external equipment that instrument is being calibrated and readings are not monitoring sample e Range ID Contacts Four separate dedicated range relay contacts Low Medium High Cal e Network I O Serial digital communications for local network access For future expansi
76. tpoint units are ppm O2 To set the other parameters use the B arrow keys to move the blinking over to the desired parameter Then use the A V arrow keys to change the parameter Once the parameters for alarm 1 have been set press Alarms again and repeat this procedure for alarm 2 AL 2 To reset a latched alarm go to Dft and then press either two times or two times Toggle it to Y and then back to N OR Go to Lich and then press either A two times or Y two times Toggle it to N and back to Y 4 6 The Range Function The Range function allows the operator to program up to three concentration ranges to correlate with the DC analog outputs If no ranges are defined by the user the instrument defaults to Low 0 100 ppm Med 0 1 000 ppm High 0 1 0 000 ppm NN Teledyne Analytical Instruments 51 Operation 3000TA EU The Model 3000TA is set at the factory to default to autoranging In this mode the microprocessor automatically responds to concen tration changes by switching ranges for optimum readout sensitivity If the current range limits are exceeded the instrument will automatically shift to the next higher range If the concentration falls to below 85 of full scale of the next lower range the instrument will switch to that range A corresponding shift in the DC percent of range output and in the range ID outputs will be noticed The autoranging feature can be overridden so that analog output
77. ure At pressures other than atmospheric the diffusion rate of O2 will be different than optimum value Higher pressures will produce faster O diffusion rates resulting in higher O2 reading and shorter cell life To use a 3000 series analyzer at a cell pressure other than atmospheric the analyzer must be calibrated with a known calibration gas at the new cell pressure to adjust for the different diffusion rate Cell pressures below 2 3 atmospheric are not recommended because they tend to cause excessive internal expansion which may result in seal failure For operation at cell pressures other than atmospheric care must be taken not to change the sample pressure rapidly or cell damage may occur For cell pressures above atmospheric caution must be exercised to avoid over pressuring the cell holder Percent analyzers will require some type of cell retainer to prevent the cell from being pushed out by NN Teledyne Analytical Instruments 71 Appendix 3000TA EU the pressure For operation at pressures below atmospheric pressure a suffix C clamped cell is required RESTRICTION DEVICES For proper operation all 3000 series analyzers require a flow restriction device This device is typically a restrictor or a valve This restriction device serves two functions in the sample path The first function is to limit the flow rate of the sample through the analyzer A restrictor is chosen to operate over a range of pressures and provide a useabl
78. xygen concentration in air is 20 9 209 000 ppm the cell can take a long time to recover if the instrument is used for trace oxygen analysis immediately following calibration in air Connect the calibration gases according to the instructions given in Section 3 4 1 Gas Connections observing all the prescribed precautions Shut off the gas pressure before connecting it to the analyzer and be sure to limit the pressure to 40 psig or less when turning it back on Readjust the gas pressure into the analyzer until the flowrate as read on the analyzer s SLPM flowmeter settles between 0 15 and 2 4 SLPM approximately 0 2 5 SCFH If you are using password protection you will need to enter your password to gain access to either of these functions Follow the instructions in Sections 4 3 3 to enter your password Once you have gained clearance to proceed you can enter the Zero or Span function NN Teledyne Analytical Instruments 43 Operation 3000TA EU 4 4 1 Zero Cal The Zero button on the front panel is used to enter the zero calibration function Zero calibration can be performed in either the automatic or manual mode In the automatic mode an internal algorithm compares consecutive readings from the sensor to determine when the output is within the acceptable range for zero In the manual mode the operator determines when the reading is within the acceptable range for zero Make sure the zero gas is connected to the instrum
79. zer to automatically select the proper preset range for a given measurement Manual override allows the user to lock onto a specific range of interest Two adjustable concentration alarms and a system failure alarm Extensive self diagnostic testing at startup and on demand with continuous power supply monitoring CE Compliance RS 232 serial digital port for use with a computer or other digital communication device Four analog outputs two for measurement 0 1 VDC and Isolated 4 20 mA DC and two for range identification Convenient and versatile steel flush panel or rack mountable case with slide out electronics drawer 1 4 Model Designations 3000TA Standard model 3000TA C In addition to all standard features this model also has separate ports for zero and span gases and built in control valves The internal valves are entirely under the control of the 3000TA electronics to automatically switch between gases in synchronization with the analyzer s operations Teledyne Analytical Instruments 2 Trace Oxygen Analyzer Introduction 1 5 Front Panel Operator Interface The standard 3000TA is housed in a rugged metal case with all controls and displays accessible from the front panel See Figure 1 1 The front panel has thirteen buttons for operating the analyzer a digital meter an alphanumeric display and a window for viewing the sample flowmeter Door Latch Digital Meter Alphanumeric

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