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ii:  Part II             

 

Teledyne Analytical Instruments

Model 2010A Thermal Conductivity Analyzer

Table of Contents

1

Introduction

1.1 Overview ........................................................................ 1-1
1.2 Connections ................................................................... 1-1
1.3 Electrical Connector Panel ............................................ 1-2

2

Installation

2.1 Unpacking the Analysis Unit .......................................... 2-1
2.2 Mounting the Analysis Unit ............................................ 2-1
2.3 Sample System Design ................................................. 2-2
2.4 Pressure and Flowrate Regulation ................................ 2-3
2.5 VENT Exhaust ............................................................... 2-3
2.6 SAMPLE Gas ................................................................. 2-4
2.7 REFERENCE Gas......................................................... 2-4
2.8 ZERO Gas ..................................................................... 2-5
2.9 SPAN Gas ...................................................................... 2-5
2.10 Electrical Connector Panel ............................................ 2-5
2.11 Signal Wiring Recommendations ................................... 2-7
2.12 Testing the System ......................................................... 2-7

3

Operation

3.1 System Self Diagnostic Test ........................................... 3-1
3.2 Cell Failure Checks ....................................................... 3-2

4

Maintenance

4.1 Routine Maintenance ..................................................... 4-1
4.2 Major Components......................................................... 4-1
4.3 Fuse Replacement......................................................... 4-2
4.4 System Self Diagnostic Test ........................................... 4-3
4.5 Cell, Heater, and/or Thermistor Replacement ................ 4-4

4.5.1   Removing the Cell Compartment ........................ 4-4
4.5.2   Removing and Replacing the Cell Block ............. 4-5
4.5.3   Removing the Heater and/or Thermocouple ........ 4-6
4.5.4   Replacing the Heater and/or Thermister .............. 4-7

Summary of Contents for 2010A

Page 1: ...G SYSTEM PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM HAZARDOUS VOLTAGES EXISTON CERTAIN COMPONENTS INTERNALLYWHICH MAYPERSISTFOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED ONLYAUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCEAND OR SERVICING BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR MANAGER DANGER P N M70194 07 19 0...

Page 2: ...ght 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 as sist the user in eliminating potential hazards caused by his process however it is essential that all personnel involved in the use...

Page 3: ...edyne Analytical Instruments Thermal Conductivity Analyzer Table of Contents Specific Model Information iv Part I Control Unit Model 2010A Part I 1 1 Part II Analysis Unit Model 2010A Part II 1 1 Appendix A 1 ...

Page 4: ...ents and Stainless Steel fittings and tubing q H Stainless steel cell block with gold filaments for corrosive gas streams and Stainless Steel fittings and tubing q K 19 Rack Mount option with one or two analyzer Control Units installed and ready to mount in a standard rack q K2 19 Rack Mount option with two Control Units mounted q K3 19 Rack Mount option with one Control Unit mounted and a blank c...

Page 5: ... 3 Effects of Flowrate and Gas Density 2 3 2 2 4 Measurement Results 2 3 2 3 Electronics and Signal Processing 2 3 2 4 Temperature Control 2 5 3 Installation 3 1 Unpacking the Analyzer 3 1 3 2 Mounting the Control Unit 3 1 3 3 Electrical Connections Rear Panel 3 3 3 3 1 Primary Input Power 3 4 3 3 2 Fuse Installation 3 4 3 3 3 Analog Outputs 3 4 3 3 4 Alarm Relays 3 6 3 3 5 Digital Remote Cal Inpu...

Page 6: ...ing 4 15 4 5 The Alarms Function 4 16 4 6 The Range Select Function 4 18 4 6 1 Manual Select Define Range Screen 4 19 4 6 2 Auto Single Application Screen 4 19 4 6 3 Precautions 4 21 4 7 The Analyze Function 4 21 4 8 Programming 4 22 4 8 1 The Set Range Screen 4 23 4 8 2 The Curve Algorithm Screen 4 25 4 8 2 1 Checking the Linearization 4 25 4 8 2 2 Manual Mode Linearization 4 26 4 8 2 3 Auto Mode...

Page 7: ...ledyne Analytical Instruments Thermal Conductivity Analyzer 5 7 Phone Numbers 5 5 Appendix A 1 Specifications A 1 A 2 Recommended 2 Year Spare Parts List A 3 A 3 Drawing List A 4 A 4 TG Option Calibration A 5 ...

Page 8: ... by the user Misuse of this product in any manner tampering with its components or un authorized substitution of any component may adversely affect the safety of this instrument Since the use of this instrument is beyond the control of Tele dyne no responsibility by Teledyne its affiliates and agents for damage or injury from misuse or neglect of this equipment is implied or assumed ...

Page 9: ...of a reference gas of known composition The 2010A can measure the concentration of one gas in a mixture of two gases measure the concentration of a gas in a specific mixture of back ground gases measure the purity of a sample stream containing a single impu rity or a mixture of impurities The standard 2010A is pre programmed with automatic linearization algorithms for a large number of gases and g...

Page 10: ...applications Recalibrat ing one recalibrates all Automatic independent linearization for each range Auto Ranging allows analyzer to automatically select the proper preset range for a given single application Manual override al lows the user to lock onto a specific range of interest RS 232 serial digital port for use with a computer or other digi tal communications device Six adjustable concentrati...

Page 11: ...al for those that apply to your Model 2010A analyzer Some standard models that are not covered in this manual are listed here Models 2000A Both analysis section and control unit are in a single general purpose enclosure Models 2020 Both the analysis section and control unit are in a single explosion proof enclosure 1 5 Operator Interface Front Panel The standard 2010A is housed in a rugged metal c...

Page 12: ...nctions currently displayed on the VFD screen Up Down Arrows Increment or decrement values of functions currently displayed Enter Moves VFD on to the next screen in a series If none remains returns to the Analyze screen Escape Moves VFD back to the previous screen in a series If none remains returns to the Analyze screen Digital Meter Display The meter display is a VFD device that produces large b...

Page 13: ...e electrical circuits Access Door For access to the thermal conductivity sensor or the front panel electronics 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 electronics circuit board requires unfasten ing rear panel screws and sliding the electronics drawer out of the case See chapter 5 1 6 Re...

Page 14: ... control input Remote Probe Used in the 2010A to interface the ex ternal Analysis Unit Remote Span Zero Digital inputs allow external control of analyzer calibration Calibration Contact To notify external equipment that in strument is being calibrated and read ings are not monitoring sample Range ID Contacts Four separate dedicated range identifi cation relay contacts 01 02 03 CAL Network I O Seri...

Page 15: ...ytical Instruments Thermal Conductivity Analyzer Part I Control Unit Auto Cal control where possible The internal clock in the Model 2010A is accurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day ...

Page 16: ...Teledyne Analytical Instruments 1 Part 1 Introduction Model 2010A ...

Page 17: ...trolsallsignalprocessing input output anddisplay functions for the analyzer 2 2 Sensor Theory For greater clarity Figure 2 1 presents two different illustrations a and b of the operating principle of the thermal conductivity cell 2 2 1 Sensor Configuration The thermal conductivity sensor contains two chambers one for the reference gas of known conductivity and one for the sample gas Each chamber c...

Page 18: ...com pensate for diurnal effects in the output over the operating ranges of the analyzer See Specifications in the Appendix for details 2 2 2 Calibration Because analysis by thermal conductivity is not an absolute measure ment calibration gases of known composition are required to fix the upper and lower parameters zero and span of the range or ranges of analy sis These gases must be used periodica...

Page 19: ... the analyzer to detect a specific component in a sample stream the sample must be composed of the component of interest and one other gas or spe cific and constant mixture of gases in order for the measured heat transfer differences to be nonambiguous If on the other hand the user is primarily interested in the purity of a process stream and does not require specific identification of the impurit...

Page 20: ...tment Coarse Adjustment Auto Range M U X AtoD Converter Digitial to Analog Converter DAC 0 1Vdc Concentration andRange 4 20mAdc Concentration andRange Differential Amplifier V ariable Gain Amplifier Central Processing Unit CPU Alarm1 Alarm2 System Failure Alarm RS 232 Range Contacts 4 External V alve Control Rem oteSpan Control Rem ote Zero Control Cal Contact Keyboard Displays Processing Selt T e...

Page 21: ...ovides appropriate control signals to the Displays Alarms and External Valve Controls and accepts digital inputs for external Remote Zero and Remote Span commands It monitors the power supply through an analog to digital converter as part of the data for the system failurealarm The RS 232 port provides two way serial digital communications to and from the CPU These and all of the above electrical ...

Page 22: ...2 6 Part I 2 Operational Theory Model 2010A Teledyne Analytical Instruments ...

Page 23: ...s for indoor use in a general purpose area It is NOT for hazardous environments of any type It must be protected from Direct sunlight Drafts of air Shock and vibration Temperatures below 30 F 1 C or above 110 F 43 C Locate the 2010A as close as possible subject to the above conditions to the Analysis Unit The standard model is designed for flush panel mounting Figure 3 1 is an illustration of the ...

Page 24: ...rator controls are mounted on the front panel which is hinged on the left edge and doubles as the door that provides access to the sensor 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 clearanc...

Page 25: ...tion output and analog range indicators Figure 3 3 Rear Panel of the Model 2010A For safe connections ensure that no uninsulated wire extends outside of the connectors they are attached to Stripped wire ends must insert com pletely into terminal blocks No uninsulated wiring should be able to come in contact with fingers tools or clothing during normal operation Use shielded cable nominally 20 to 2...

Page 26: ...ight of the power cord receptacle accepts US or European size fuses A jumper replaces the fuse in the neutral line when the US size fuses are used If the European size fuses are selected both sides at the line will be fused Be sure to install the proper fuse as part of installation See Fuse Replacement in chapter 5 maintenance 3 3 3 Analog Outputs There are four DC output signal connectors with sp...

Page 27: ...ecially when the analyzer is in the autoranging mode The signal output for concentration is linear over the currently se lected analysis range For example if the analyzer is set on a range that was defined as 0 10 hydrogen then the output would be as shown in Table 3 1 Table 3 1 Analog Concentration Output Example Percent Voltage Signal Current Signal Hydrogen Output Vdc Output mAdc 0 0 0 4 0 1 0 ...

Page 28: ... rear panel They are capable of switching up to 3 amperes at 250Vac into a resistive load See Figure 3 5 The connectors are Threshold Alarm 1 Can be configured as high actuates when concen tration is above threshold or low actuates when concentration is below threshold Can be configured as fail safe or non fail safe Can be configured as latching or nonlatching Can be configured out defeated Thresh...

Page 29: ... appro priately See 3 3 9 Remote Probe Connector With the C option the internal valves operate automatically Span Floating input 5 to 24V input across the and terminals puts the analyzer into the Span mode Either side may be grounded at the source of the signal A synchronous signal must open and close the external gas control valves appro priately See 3 3 9 Remote Probe Connector With the C option...

Page 30: ...ns again send a span command until the CRC closes The CRC will close quickly 4 When the CRC closes remove the span command When CRC opens again zero and span are done and the sample is being analyzed Note The Remote Probe connector paragraph 3 3 9 provides sig nals to operate the zero and span gas valves synchronously However if you have the C P or Q Internal valve option which includes zero and s...

Page 31: ...y are tripped AL x ON Each status output is followed by a carriage return and line feed Input The input functions using RS 232 that have been implemented to date are described in Table 3 3 Table 3 3 Commands via RS 232 Input Command Description as enter Immediately starts an autospan az enter Immediately starts an autozero rp enter Allows reprogramming of the APPLICATION gas use and ALGORITHM line...

Page 32: ...uts The voltage from these outputs is nominally 0V for the OFF and 15Vdc for the ON conditions The maximum combined current that can be pulled from these output lines is 100mA If two lines are ON at the same time each must be limited to 50mA 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 ad...

Page 33: ...erations 1 Repeat the Self Diagnostic Test as described in chapter 4 sec tion 4 3 5 3 5 Warm Up at Power Up Every time the unit is turned on the instrument stays with the intro duction screen for thirty minutes This is to allow the cell to come up to temperature 60o C The only way to bypass this warm up period is by pressing any key once such as the Enter key The instrument warms up for half an ho...

Page 34: ...Teledyne Analytical Instruments 3 Installation Model 2010A 3 12 Part I ...

Page 35: ...f desired RoutineOperation Calibratetheinstrument Choose autoranging or select a fixed range of analysis Set alarm setpoints and modes of alarm operation latching fail safe etc Program Reprogramtheanalyzer Define new applications Linearize your ranges Ifyouchoosenottousepasswordprotection thedefaultpasswordis automaticallydisplayedonthepasswordscreenwhenyoustartup andyou simplypressEnterforaccesst...

Page 36: ...and software version Displaymoresubfunctions Two of these are for programming reprogramming the analyzer Define gas applications and ranges Refer to programming section or contact factory Use the Curve Algorithm to linearize output Refer to programmingsection orcontactfactory Zero Used to set up a zero calibration Span Used to set up a span calibration Alarms Used to set the alarm setpoints and de...

Page 37: ...o Manual LinearityCal Input Output Values SelectLinrty SpanValues Enter Enter Auto Ver Set Zero Span Alarms GasUse Range ppm Select Select Range Setpoints Attributes Range Auto Manual RangeAdj Gas Application Auto Define Range Select Range Analyze Analyze Sample Set LCD Contrast Show Model and Version ALGORITHM SELF TEST MORE LOGOUT PASSWORD CONTRAST SecureSys AnalyzeOnly APPLICATION MODEL Enter P...

Page 38: ... alter the instrument s operation LOGOUT Logging out prevents an unauthorized tampering withanalyzersettings MORE Select and enter MORE to get a new screen with additionalsubfunctionslisted MODEL Displays Manufacturer Model and Software Version ofinstrument APPLICATION Arestrictedfunction notgenerallyaccessedby theenduser Usedtodefineuptothreeanalysisrangesanda calibrationrange includingimpurity b...

Page 39: ...re you understand the Zero and Span functions as described in section 4 4 and follow the precautions given there Note If you require highly accurate AUTO CAL timing use external AUTO CAL control where possible The internal clock in the Model 2010A is accurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day Note If all your ranges are for the same gas application then AUTO...

Page 40: ...nter to go to the next screen Use to select OFF ON field Use Δ Δ Δ Δ Δ arrows to set the OFF ON field to ON You can now turn thesefieldsONbecausethereisanonzerospanintervaldefined 4 3 3 Password Protection Beforeauniquepasswordisassigned thesystemassignsTAIbydefault Thispasswordwillbedisplayedautomatically Theoperatorjustpressesthe Enterkeytobeallowedtotalaccesstotheinstrument sfeatures Ifapasswor...

Page 41: ...thecurrentpassword Ifyouarenotusing password protection press Enter to accept TAI as the default password If a passwordhasbeenpreviouslyinstalled enterthepasswordusingthe arrow keystoscrollbackandforthbetweenletters andthe Δ Δ Δ Δ Δ arrowkeystochange the letters to the proper password Press Enter to enter the password Inafewseconds youwillbegiventheopportunitytochangethispass word or keep it and g...

Page 42: ...H I J K L M N O P Q R S T U V W X Y Z _ a b c d e f g h i j k l m n o p q r s t u v w x y z 0 1 2 3 4 5 6 7 8 9 Whenyouhavefinishedtypingthenewpassword pressEnter Averifica tionscreenappears Thescreenwillpromptyoutoretypeyourpasswordfor verification Enter PWD To Verify A A A Use the arrow keys to retype your password and press Enter when finished Yourpasswordwillbestoredinthemicroprocessorandthesy...

Page 43: ...gnostictestingroutine Pre programmedsignalsaresentthroughthepowersupply outputboard preamp boardandsensorcircuit Thereturnsignalisanalyzed andattheendofthetest thestatusofeachfunctionisdisplayedonthescreen eitherasOKorasa number between 1 and 1024 See System Self Diagnostic Test in chapter 5 fornumbercode Ifanyofthefunctionsfails theSystemAlarmistripped Note The sensor will always show failed unle...

Page 44: ...ss Any Key To Continue ThentheanalyzerreturnstotheinitialSystemscreen 4 3 6 The Model Screen Move the arrow key to MORE and press Enter With MODEL blinking pressEnter Thescreendisplaysthemanufacturer model andsoft wareversioninformation 4 3 7 Checking Linearity with ALGORITHM FromtheSystemFunctionscreen selectALGORITHM andpress Enter sel rng to set algo Ø1 Ø2 Ø3 Use the keys to select the range 01...

Page 45: ...rection pointintothemicroprocessorviathefrontpanelbuttons Again thenumberof pointsrequiredisdeterminedbytheuser 4 4 The Zero and Span Functions 1 TheModel2010Acanhaveasmanyasthreeanalysisrangesplusa specialcalibrationrange CalRange andtheanalysisranges ifmorethanone maybeprogrammedforseparateoridenticalgasapplications 2 Ifallrangesareforthesameapplication thenyouwillnotneedtheCal Range Calibrating...

Page 46: ...possible 4 4 1 Zero Cal TheZerobuttononthefrontpanelisusedtoenterthezerocalibration function Zerocalibrationcanbeperformedineithertheautomaticormanual mode CAUTION If you are zeroing the Cal Range by itself multiple application analyzers only use manual mode zeroing If you want to calibrate ALL of the ranges at once multiple application analyzers only use auto mode zeroing in the Cal Range Makesur...

Page 47: ...lyconcludewhentheoutputiswithin theacceptablerangeforagoodzero Thentheanalyzerautomaticallyreturnsto the Analyze mode 4 4 1 2 ManualModeZeroing PressZerotoentertheZerofunction Thescreenthatappearsallowsyou toselectbetweenautomaticormanualzerocalibration UsetheΔ keysto togglebetweenAUTOandMANzerosettling StopwhenMANUALappears blinking onthedisplay Select zero mode MANUAL PressEntertobeginthezerocal...

Page 48: ...ro gas to make sure it is within specifications b Check for leaks downstream from the sensor where contamina tion may be leaking into the system c Check flowmeter to ensure that the flow is no more than 200SCCM d Checktemperaturecontrollerboard e Check gas temperature Ifnoneoftheaboveasindicated thesensormayneedtobereplaced Checkwarranty andcontactAnalyticalInstrumentsCustomerService 4 4 2 Span Ca...

Page 49: ...ettheconcentrationofthespangasyouare using pressEntertobegintheSpancalibration H2 N2 Slope Span Thebeginningspanvalueisshownintheupperleftcornerofthedisplay Asthespanreadingsettles thescreendisplaysandupdatesinformationon Slope Spanningautomaticallyendswhenthespanoutputcorresponds within tolerance tothevalueofthespangasconcentration Thentheinstrumentauto maticallyreturnstotheanalyzemode 4 4 2 2 Ma...

Page 50: ...0Aisequippedwith6fullyadjustablesetpointsconcentra tionwithtwoalarmsandasystemfailurealarmrelay Eachalarmrelayhasaset ofform C contactsratedfor3amperesresistiveloadat250V ac SeeFigure inChapter3 Installationand ortheInterconnectionDiagramincludedatthe backofthismanualforrelayterminalconnections Thesystemfailurealarmhasafixedconfigurationdescribedinchapter3 Installation Theconcentrationalarmscanbec...

Page 51: ...s will terminate when process conditions revert to non alarmconditions 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 Ifyouareusingpasswordprotection youwillneedtoent...

Page 52: ...e the parameters for alarm 1 have been set press Alarms again and repeat this procedure for alarm 2 AL2 To reset a latched alarm go to Dft and then press either Δ two times or two times Toggle it to Y and then back to N OR Go to Ltch and then press either Δ two times or two times Toggle it to N and back to Y 4 6 The Range Select Function TheRangefunctionallowsyoutomanuallyselecttheconcentration ra...

Page 53: ...reen Ifabovescreendisplays usetheΔ arrowkeystoSelectMANUAL and pressEnter Select range to run Ø1 Ø2 Ø3 CAL Use the keys to select the range 01 02 03 or CAL Then press Enter Gas use H2 N2 Range Ø 10 Usethe keystotogglebetweentheRange low endfieldandthe Range high endfield UsetheΔ Δ Δ Δ Δ keystochangethevaluesofthefields PressEscapetoreturntothepreviousscreentoselectordefineanother range PressEntert...

Page 54: ...settinguntilamplifiersaturationisreached Belowamplifiersaturation the overrangereadingsareaccurateUNLESStheapplicationuseslinearizationover theselectedrange TheconcentrationrangescanberedefinedusingtheRangefunction Manualscreen andtheapplicationgasescanberedefinedusingtheSystem function iftheyarenotalreadydefinedasnecessary CAUTION Redefining applications or ranges might require relinearization an...

Page 55: ...of magnitude Ranges whose upper limits coincide with the lower limits of the next higher range Ranges where there is a gap between the upper limit of the range and the lower limit of the next higher range Rangeschemesthataretobeavoidedinclude Ranges that overlap Ranges whose limits are entirely within the span of an adjoining range Figure4 2illustratestheseschemesgraphically Figure 4 2 Examples of...

Page 56: ...ing functions of the Set Range and Curve Algorithm screens are configured at the facto ry to the users application specification These func tions should only be reprogrammed by trained qualified personnel Toprogram youmust 1 Enter the password if you are using the analyzer s password protectioncapability 2 Connect a computer or computer terminal capable of sending an RS 232 signal to the analyzer ...

Page 57: ...tion unlessitisorderedasasingle applicationmultiple rangeunit inwhich caseitdefaultstoautoranging Ineithercase autorangingormanualrange selectioncanbeprogrammedbytheuser Intheautorangingmode themicroprocessorautomaticallyrespondsto concentrationchangesbyswitchingrangesforoptimumreadoutsensitivity Ifthe upperlimitoftheoperatingrangeisreached theinstrumentautomaticallyshifts tothenexthigherrange Ift...

Page 58: ...o high for example if Range 1 is set to 0 10 and Range 2 is set to 0 100 then Range 3 cannot be set to 0 50 since that makes Range 3 lower than Range 2 Ranges alarms andspansarealwayssetineitherpercentorppmunits as selectedbytheoperator eventhoughallconcentration dataoutputschange fromppmtopercentwhentheconcentrationisabove9999 ppm Note When performing analysis on a fixed range if the concentra ti...

Page 59: ...ebeginningofsection4 8Programming Youwillthenbeinthesecond Systemmenuscreen MODEL APPLICATION SELF_TEST ALGORITHM 4 8 2 1 Checkingthelinearization FromtheSystemFunctionscreen selectALGORITHM andpress Enter Sel rng set algo Ø1 Ø2 Ø3 Use the keys to select the range 01 02 or 03 Then press Enter Gas use H2 N2 Range Ø 10 PressEnteragain Algorithm setup VERIFY SETUP SelectandEnterVERIFYtocheckwhetherth...

Page 60: ...e setup All correction points must be between Zero and Span concentrations Do not enter Zero and Span points as part of the correction 4 8 2 2 Manual Mode Linearization Tolinearizemanually youmusthavepreviousknowledgeofthenonlinear thermal conductivitycharacteristicsofyourgases Youenterthevalueofthe differentialbetweentheactualconcentrationandtheapparentconcentration analyzeroutput AnalyticalInstr...

Page 61: ...roughthefrontpanel turntheinstrumentoffandbackon Press the Enter key twice to return to the Analyze mode 4 8 2 3 Auto Mode Linearization TolinearizeintheAutoMode youmusthaveonhandaseparatecalibra tiongasforeachofthedatapointsyouaregoinguseinyourlinearization First theanalyzeriszeroedandspannedasusual Then eachspecialcalibrationgas foreachoftheintermediatecalibrationpoints isflowed inturn throughth...

Page 62: ...wandhighend oftheconcentrationrange Forexample ifanapplicationinvolvestheanalysis of85 oxygeninabackgroundofargonbymeasuringthethermalconductivity ofthebinarygas theanalyzerwouldnormallybesetupsothatthe100 oxygen 0 argon concentrationwouldcorrespondtothezerolevel 4mA0V oftheoutputsignal Then 85 oxygen 15 argon wouldcorrespondto 20mA 1V inthesignaloutput Itmaybeconvenientfortheusertohavetheoutputsr...

Page 63: ... which range s willrequired polarity coding Iftheanalyzerindicatesanegativeconcentrationwithproperspangasor formula1indicatesanegativevalue settheS1accordinglytothetablebelow Close S1 5 range 1 Close S1 6 range 2 Close S1 7 range 3 CloseS1 8calrange PressI Otorestartthesystem 4 9 4 Special Nonlinear Application Gain Preset NOTE This section apply during GAS TEST routine for the unit that has more ...

Page 64: ... 4 30 Part I Teledyne Analytical Instruments 6 Press and hold the RIGHT key for approximate 5 to 7 seconds 7 SelectAUTOandsetthereadingtospangaslevel Press ENTERkey Repeat steps 1 to 7 if more than two ranges need to be setup ...

Page 65: ...recalibration see Section 4 4Calibration WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL 5 2 System Self Diagnostic Test 1 Press the System button to enter the system mode 2 Use the arrow keys to move to More and press Enter 3 Use the arrow keys to move to Self Test and press Enter The following failure codes apply Table 5 1 Self Test Failure Codes Power 0 OK 1 5 V Failure 2 15 V Failure 3 B...

Page 66: ... to ground no power 2 Unbalance deteriorationoffilaments blocked tube 5 3 VFDD Display NOTE When a vacuum Fluorescent Display is used It will not require contrast adjustment If you cannot read anything on the VFD especially after first powering up check that VFD cable is not loose 5 4 Fuse Replacement 1 Place small screwdriver in notch and pry cover off as shown in Figure 5 1 Figure 5 1 Removing F...

Page 67: ...ront Panel PCBs are accessed by unlatch ing and swinging open the front panel as described earlier The balance of the PCBs are accessed by removing the rear panel retaining screws and sliding out the entire subassembly See Figure 5 3 below The major elec tronic components locations are shown in Figure 5 4 with Cell Compart ment removed for clarity WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MAN...

Page 68: ...tach the rear panel remove only those screws marked with an X Figure 5 4 Locations of Printed Circuit Board Assemblies See the drawings in the Drawings section in back of this manual fordetails X X X X M otherboard Pream plifier PCB Front P anel DisplayBoard Universal P ower Supply Slide out Electronics Assem bly ...

Page 69: ...aces with a soft cloth dampened slightly with plain clean water Do not use any harsh solvents such as paint thinner or benzene For mounted instruments DO NOT wipe the front panel while the instrument is controlling your process Clean the front panel as prescribed in the above paragraph 5 7 Phone Numbers CustomerService 626 934 1673 Environmental Health and Safety 626 961 9221 Extension 1592 Fax 62...

Page 70: ...5 Maintenance Model 2010A 5 6 Part I Teledyne Analytical Instruments ...

Page 71: ...nstanttemperature 5 of full scale over operating temperature range once temperature equilibrium has been reached Response Time 90 in less than 50 seconds SystemOperating Temperature 32 F to 122 F 0 50 C Sensor Type StandardTCcell 4 filamentdetector SignalOutput Two 0 1 VDC concentration and range ID Two 4 20 mADC isolated concentration and range ID Alarm Two fully programmable concentration alarm ...

Page 72: ...ss block with nickel alloy filaments and stainless steel and plates O PInterface Full duplex RS 232 implement a subset of Tracs Command Mounting Standard General purpose flush panel mounting Options General purpose relay rack mounted to con tain either one or two in a 19 relay rack mountableplate Other configurations including a totally explosion proof areavailable ...

Page 73: ...250 V 5 20 mm T SlowBlow European 1 R1460 Molex Connector for Remote Probe 1 T976 Molex Crimp Terminals for RemoteProbeConnector _____________________ Order one type only US or European as appropriate 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 Orders should be sent to TELEDYNE Anal...

Page 74: ...nts A 3 Drawing List D 67061 Outline Drawing standard unit with optional sealed ref D 67056 Outline Drawing with optional gas selector panel and or sealed ref B 67057 PipingDiagram D 66922 Wiring Diagram Interconnect Drawing D 70231 InterconnectionDiagram ...

Page 75: ...have the option to select AUTO or MANual AUTO lets the analyzer adjust itself and may take longer while in MANual mode the operator has to adjust the zero reading on the display manually using the Up and Down arrows 4 Press ZERO select manual press the arrow hold until OK is displayed in the upper right corner of the VFD display 5 If you choose manual you first will do the Coarse zero adjustment u...

Page 76: ...e for the time needed to get readings that are leveled Feed CO2 to the analyzer 3 Press ZERO You have the option to select AUTO or MANual AUTO lets the analyzer adjust itself and may take longer while in MANual mode the operator has to adjust the zero reading on the display manually using the Up and Down button 4 Press ZERO select manual press the arrow hold until OK is displayed in the upper righ...

Page 77: ...ow calibrated CALIBRATERANGE3 1 Select the RANGE function on the main menu and place the analyzer in Range 3 DOTHIS EVENIFANALYZERISINRANGE3 2 Feed zero gas to analyzer and purge for the time needed to get readings that are leveled Feed H2 to the analyzer 3 Press ZERO You have the option to select AUTO or MANual AUTO lets the analyzer adjust itself and may take longer while in MANual mode the oper...

Page 78: ...he analyzer should end the span by itself if AUTO was selected or when you press the Enter switch if MANual was selected 10 This range is now calibrated CALIBRATECALRANGE 1 Select the RANGE function on the main menu and place the analyzer in the Cal Range 2 Feed zero gas to analyzer and purge for the time needed to get readings that are leveled Feed H2 to the analyzer 3 Now select the ZERO functio...

Page 79: ...ndplacetheanalyzerinRange1 DO THIS EVEN IF ANALYZER IS IN RANGE 1 2 Feed zero gas to analyzer and purge for the time needed to get readings that are leveled Feed CO2 to the analyzer 3 Press ZERO You have the option to select AUTO or MANual AUTO lets the analyzer adjust itself and may take longer while in MANual mode the operator has to adjust the zero reading on the display manually using the Up a...

Page 80: ...he time needed to get readings that are leveled Feed 10 Air in H2 90 H2 in air to the analyzer 6 Now select the SPAN function from the main menu and press Enter If you want to calibrate only the Cal Range select MANual If you want to calibrate all ranges select AUTO Set the span value to 20 0 7 The analyzer should end the span by itself if AUTO was selected or when you press the Enter if MANual wa...

Page 81: ...Teledyne Analytical Instruments Part II i Part II Analysis Unit OPERATING INSTRUCTIONS Model 2010A Thermal Conductivity Analyzer Part II Analysis Unit NEC Type Part Number D 70089 ...

Page 82: ...FERENCE Gas 2 4 2 8 ZERO Gas 2 5 2 9 SPAN Gas 2 5 2 10 Electrical Connector Panel 2 5 2 11 Signal Wiring Recommendations 2 7 2 12 Testing the System 2 7 3 Operation 3 1 System Self Diagnostic Test 3 1 3 2 Cell Failure Checks 3 2 4 Maintenance 4 1 Routine Maintenance 4 1 4 2 Major Components 4 1 4 3 Fuse Replacement 4 2 4 4 System Self Diagnostic Test 4 3 4 5 Cell Heater and or Thermistor Replaceme...

Page 83: ...Gas Connections The gas connectors are de scribed briefly here and in detail in the Installation chapter of this manual NOTE The version of the 2010 Analysis Unit depicted has no options The gas connections found on the 2010A Analysis Unit depend on the options selected Refer to the outline diagram in the rear of this manual for the actual configuration These options may include gas panels with fl...

Page 84: ...reference gas vents must be re turned to areas of equal pressure The actual tubing size and connection type will depend on actual options selected See outline diagram in the rear of the manual for piping requirements 1 3 Electrical Connector Panel Figure 1 2 shows the internal Electrical Connector Panel Cables enter the housing through access ports visible in Figure 1 1 and connect to terminals in...

Page 85: ...FORE applying power to the Power Input termi nals VoltageSelector Power input selector switch for electric heater Adjusts input requirement for 110 or 220 V ac depending on available source voltage Use 50 60 Hz Fuses 1 6 A 250 V T type European size 5 20 mm fuses Fuse 2 is on the neutral side of the line Fuse 1 is on the hot side of the line Solenoid Valves Terminalsthatprovideallelectricalinterco...

Page 86: ...1 4 Part II Teledyne Analytical Instruments 1 Introduction Model 2010A ...

Page 87: ...ting the Analysis Unit The Model 2010A Analysis Unit is for use in Class 1 Division 1 Groups C and D hazardous environments group B available The actual class is limited by the flame arrestor option The standard model is designed for bulkhead mounting Overall dimen sions of the Analysis Unit will vary depending on options The maximum footprint will be 19 12 and maximum height 9 4 An Outline Drawin...

Page 88: ...corporate their own sample system electronic input output ports are provided on the rear panel for the operation of solenoid valves under the complete control of the Model 2010A electron ics See section 3 3 The recommended system piping schematic is included among the drawings at the rear of the manual For best results use the recommended piping system Select a flowmeter that can resolve 0 08 scfh...

Page 89: ...te Note Gases lighter than air have a flowrate higher than indicated on the flowmeter while gases heavier than air have a flowrate lower than indicated Values can range from one half to twice the indicated flowrate For example For hydrogen or helium set the flowrate to 0 1 scfh 50 cc min For carbon dioxide or argon set the flowrate to 0 4 scfh 200 cc min When installing pressure regulators on supp...

Page 90: ...eded as a reference to which the sample gas will be compared The reference gas is normally selected to represent the main background gas of the analysis For most applications a constant supply of reference gas flowing at the same rate as the sample is required for best results However in many cases the flow of reference gas can be slowed to about 0 08 scfh 40 cc min with goodresults For some appli...

Page 91: ...ground gas containing 70 100 of the component of interest is required as a minimum Note If your analyzer range is set for inverting output your zero gas will be at 100 of the range interest and span will be 70 to 100 of the low end range If linearization is required intermediate concentrations of the target gas in the background gas may be necessary From one to nine separate span gases may be used...

Page 92: ...age from the solenoid outputs is nominally 0 V for the OFF and 15 V dc 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 same 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 Note ...

Page 93: ... The first is associated with the local installation environment The number proximity and power associated with local sources of EMI radiation can not be accounted for by TAI These issues can only be controlled by the end user The other factor is the amplitude of the signals generated by the thermal conductivity cell This signal level is a function of the gas composition of the gases involved This...

Page 94: ...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 Check that sample pressure is between 3 and 40 psig according to the requirements of your process Power up the system and test it as follows 1 Repeat the Self Diagnostic Test as described in Part I chapter 4 section 4 3 5 ...

Page 95: ... the screen either as OK or as a number between 1 and 3 See Table 4 1 for number code Note Remote Probe connector must be connected to the Analysis Unit or sensor circuit will not be properly checked Instructions for running self diagnostics are repeated here for your convenience 1 Press the System button to enter the system mode 2 Use the arrow keys to move to More and press Enter 3 Use the arrow...

Page 96: ...K 1 Zero too high 2 Amplifier output doesn t match test input 3 Both Failed The results screen alternates for a time with Press Any Key To Continue Then the analyzer returns to the initial System screen 3 2 Cell Failure Checks Cell failure is covered in detail in Part I Control Units section 4 4 1 3 Cell Failure Cell replacement is covered Part II Analysis Units chapter 5 Maintenance ...

Page 97: ... For recalibration see Part I section 4 4 Calibration WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL 4 2 Major Components The internal components are accessed by rotating the explosion proof housing cover counterclockwise several turns until free See Figure 4 1 below WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL The 2010A Analysis Unit contains the following major components TC Cell...

Page 98: ...are located inside the explosion proof housing on the Electrical Connector Panel as shown in Figure 4 2 To replace a fuse 1 Disconnect the Unit from its power source 2 Place a small screwdriver in the notch in the fuse holder cap push in and rotate 1 4 turn The cap will pop out a few millimeters Pull out the fuse holder cap and fuse as shown in Figure 4 2 Figure 4 2 Removing Fuse Cap and Fuse from...

Page 99: ...o move to More and press Enter 3 Use the arrow keys to move to Self Test and press Enter 4 Observe the error code readings on the VFD Display screen and check Table 4 1 below to interpret the codes Table 4 1 Self Test Failure Codes Power 0 OK 1 5 V Failure 2 15 V Failure 3 Both Failed Analog 0 OK 1 DAC A 0 1 V Concentration 2 DAC B 0 1 V Range ID 3 Both Failed Preamp 0 OK 1 Zero too high 2 Amplifi...

Page 100: ...that the power has been removed from the analysis unit prior to removing cover b Verify that the analysis unit is free from any toxic gas prior disconnectinganyplumbing c Remove the screw on lid and the six 6 screws securing the interfacecoverpanel d Remove the cover panel and the four 3 4 6 stands off securing the 1st interface PCB e Remove the 1st PCB and the four 7 16 6 stand off securing the 2...

Page 101: ...ytical Instruments Part II 4 5 4 5 2 Removing and Replacing the Cell Block a Refer to Figure 4 3 which illustrates removal of the Cell Block from the Cell Compartment Exploded view is as seen from the top of the Cell Block Figure 4 3 Removal of Cell from Cell Housing ...

Page 102: ...hed between the plates You should now be able to slide the Cell free e Leave the electrical connections connected at the Cell Unlace the cabling and unplug the grey Cell cable at the Interface PCB connector J3 The Preamplifier PCB can be more easily accessed by removing the analyzer s rear panel f Replace the cell by reversing the above procedure steps a through e g On analyzers with the sealed ai...

Page 103: ...t 2 To remove the Thermistor grasp BOTH Thermistor wires firmly and pull the Thermistor slowly out of the Heater Block breaking the silicone seal Do not allow any foreign matter to enter the empty duct e Undo the cable lacing and separate the Heater Thermistor wires Then disconnect the wires from the interface PCB 4 5 4 Replacing the Heater and or Thermister a To replace the Heater and or Thermist...

Page 104: ...4 Maintenance Model 2010A 4 8 Part II Teledyne Analytical Instruments ...

Page 105: ...ruments A 1 Thermal Conductivity Analyzer Appendix OPERATING INSTRUCTIONS Models 2010A Thermal Conductivity Analyzer Appendix Flush Mount Control Unit PN D70898 NEC Type Analysis Unit PN D70089 NEC Type Analysis Unit PN D70147 ...

Page 106: ...A 2 Teledyne Analytical Instruments Appendix Model 2010A Contents A 1 Model 2010A Specifications A 3 A 2 Recommended 2 Year Spare Parts List A 5 A 3 Drawing List A 6 ...

Page 107: ...nstanttemperature 5 of full scale over operating temperature range once temperature equilibrium has been reached Response Time 90 in less than 50 seconds SystemOperating Temperature 32 F to 122 F 0 50 C Sensor Type StandardTCcell 4 filamentdetector SignalOutput Two 0 1 VDC concentration and range ID Two 4 20 mADC isolated concentration and range ID Alarm Two fully programmable concentration alarm ...

Page 108: ...ns General purpose relay rack mounted to con tain either one or two in a 19 relay rack mountableplate Other configurations including a totally explosion proof areavailable Dimensions Control Unit 6 96 H x 10 8 W x 10 5 D Analysis Unit 13 6 W x 18 1 H x 8 25 D Control Unit General Purpose Flush Panel Mounting Analysis Unit Explosion Proof Enclosure is UL and CSA Listed for Class 1 Division 1 Groups...

Page 109: ...erminals for RemoteProbeConnector 1 D70082 Customer Interface PCB Assy 1 D67651 Std T C Cell Assy Brass SS 2 F768 Fuse 1 6A Analysis Unit 1 D64849B 2010 Front Door w overlay _____________________ Order one type only US or European as appropriate Note Orders for replacement parts should include the part number if available and the model and serial number of the instru ment for which the parts are i...

Page 110: ... 3 Drawing List C70381 Outline Drawing Standard Auto Cal option C D70117 PipingDiagram C70146 Outline Diagram AU Auto Cal Valve and Gas Panel C L C70335 Outline Diagram gas panel option L D70081 Schematic Diagram Interface Board D 70231 InterconnectionDiagram ...

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