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Trace Oxygen Analyzer

Operational Theory

Teledyne Analytical Instruments

15

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 3000TB 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
the cell.

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Summary of Contents for 3000TB

Page 1: ...ONS FOR MODEL 3000TB Trace Oxygen Analyzer P N M66673 10 06 17 Use and Disclosure of Data Information contained herein is classified as EAR99 under the U S Export Administration Regulations Export reexport or diversion contrary to U S law is prohibited ...

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Page 5: ... 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 ...

Page 6: ...t for which this manual is supplied are indicated by a check mark in the box Instrument Serial Number _______________________ Options Included in the Instrument with the Above Serial Number Auto Calibration Valves Three gas inputs for sample zero and span gases with three solenoid actuated gas flow control valves built in Valves are automatically synchronized to the analyzer s electronic control s...

Page 7: ... 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 page 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 information Failure to do ...

Page 8: ...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 ...

Page 9: ...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 M...

Page 10: ...tomer 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...

Page 11: ...r Button 7 1 5 5 Access Door 7 1 6 Recognizing Difference Between LCD VFD 7 1 7 Equipment Interface 7 1 7 1 Electrical Connector Panel 7 1 7 2 Gas Connector Panel 9 Operational Theory 11 2 1 Introduction 11 2 2 Micro Fuel Cell Sensor 11 2 2 1 Principles of Operation 11 2 2 2 Anatomy of a Micro Fuel Cell 12 2 2 3 Electrochemical Reactions 13 2 2 4 The Effect of Pressure 14 2 2 5 Calibration Charact...

Page 12: ...ting the System 33 Operation 35 4 1 Introduction 35 4 2 Using the Data Entry and Function Buttons 35 4 3 The System Function 37 4 3 1 Tracking Oxygen Readings During Calibration and Alarm Delay 38 4 3 2 Setting up an Auto Cal 40 4 3 3 Password Protection 41 4 3 3 1 Entering the Password 41 4 3 3 2 Installing or Changing the Password 42 4 3 4 Logout 44 4 3 5 System Self Diagnostic Test 45 4 3 6 Ver...

Page 13: ...rial 63 4 10 2 Stream 63 4 10 3 SerMode 64 Maintenance 67 5 1 Routine Maintenance 67 5 2 Major Internal Components 67 5 3 Cell Replacement 68 5 3 1 Storing and Handling Replacement Cells 69 5 3 2 When to Replace a Cell 69 5 3 3 Removing the Micro Fuel Cell 70 5 3 4 Installing a New Micro Fuel Cell 72 5 3 5 Cell Lifetime 73 5 4 Fuse Replacement 73 5 5 System Self Diagnostic Test 74 5 6 Troubleshoot...

Page 14: ...agram 16 Figure 2 5 Block Diagram of the Model 3000TB Electronics 17 Figure 3 1 Front View of the Model 3000TB Simplified 20 Figure 3 2 Required Front Door Clearance 21 Figure 3 3 Electrical Connector Panel 21 Figure 3 4 Primary Input Power Connections 22 Figure 3 5 Analog Output Connections 23 Figure 3 6 Types of Relay Contacts 25 Figure 3 7 Remote Sensor Connector Pinouts 29 Figure 3 8 Remote So...

Page 15: ...i List of Tables Table 3 1 Analog Concentration Output Example 24 Table 3 2 Analog Range ID Output Example 24 Table 3 3 RS 232 Signals 28 Table 3 4 Commands via RS 232 Input 28 Table 3 5 Required RS 232 Input 29 Table 5 1 Self Test Failure Codes 74 ...

Page 16: ... Model 3000TB 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 3000B Trace Oxygen Analyzer is sophisticated yet simple to use The main features of the analyzer include A 2 line alphanumeric display screen ...

Page 17: ...n 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 RS 232 serial digital port for use with a computer or other digital communication device Analog outputs for concentration and range identification 0 1...

Page 18: ... front door of the main housing and a sample flowmeter on the gas control panel attached to the main housing They give the operator constant feedback from the instrument The operator controls are pushbutton membrane switches located behind the front door of the main housing All of them are reached by swinging open the outer door of the enclosure They are described briefly here and in greater detai...

Page 19: ...Introduction Model 3000TB Teledyne Analytical Instruments 4 Figure 1 1 Model 3000TB Outer Door Open Showing Control Panel ...

Page 20: ...Trace Oxygen Analyzer Introduction Teledyne Analytical Instruments 5 Figure 1 2 Model 3000TB Inner Door Open Showing Internal Components ...

Page 21: ...per minute SLPM 1 5 2 Function Keys Six touch sensitive membrane switches are used to change the specific function performed by the analyzer Analyze Perform analysis for oxygen content of a sample gas System Perform system related tasks described in detail in chapter 4 Operation Span Span calibrate the analyzer Zero Zero calibrate the analyzer Alarms Set the alarm setpoints and attributes Range Se...

Page 22: ...or To access the electrical connector panel or the cell block the control panel doubles as an inner door that can be unlatched and swung open after unlatching and swinging open the outer access door See Figure 1 2 unfastening rear panel screws and sliding the unit out of the case 1 6 Recognizing Difference Between LCD VFD LCD has GREEN background with BLACK characters VFD has DARK background with ...

Page 23: ...Teledyne Analytical Instruments 8 Figure 1 3 Electrical Connector Panel Electrical Connections The electrical connections on the electrical connector panel are described briefly here and in more detail in chapter 3 Installation ...

Page 24: ...t that instrument is being calibrated and readings are not monitoring sample Range ID Contacts Four separate dedicated range relay contacts Low Medium High Cal Network I O Serial digital communications for local network access For future expansion Not implemented at this printing 1 7 2 Gas Connector Panel The gas connector panel shown in Figure 1 4 contains the gas connections for external inlets ...

Page 25: ...igure 1 4 Model 3000TB Gas Connector Panel Note If you require highly accurate Auto Cal timing use external Auto Cal control where possible The internal clock in the Model 3000TB is accurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day ...

Page 26: ...e 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 plastic 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 t...

Page 27: ...oncentric 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 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...

Page 28: ...uctor connecting them to one of the 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 O2 2H2O 4e 4OH cathode Four electrons combine with one oxygen molecule in the presence of water from...

Page 29: ... 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...

Page 30: ...nd 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 inst...

Page 31: ...Figure 2 4 Flow Diagram 2 4 Electronics and Signal Processing The signal processing and display electronics PCBs are mounted on the back of the inner door See Major Internal Components in chapter 5 for illustration The power supply module is mounted underneath the bottom end of the Electrical Connector Panel The Model 3000TB Trace Oxygen Analyzer uses an 8031 microcontroller with 32 kB of RAM and ...

Page 32: ...Trace Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 17 Figure 2 5 Block Diagram of the Model 3000TB Electronics ...

Page 33: ...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 The digital concentration signal along with input from the control panel is processed by the microprocessor and appropriate control signal...

Page 34: ...on hazardous environments There are four mounting lugs one in each corner of the enclosure The outline drawing at the back of this manual gives the mounting hole size and spacing The drawing also contains the overall dimensions Do not forget to allow an extra 1 3 8 for the hinges Be sure to allow enough space in front of the enclosure to swing the door open a 11 3 4 radius as shown in Figure 3 2 A...

Page 35: ...Installation Model 3000TB Teledyne Analytical Instruments 20 Figure 3 1 Front View of the Model 3000TB Simplified ...

Page 36: ...ure 3 2 Required Front Door Clearance 3 3 Electrical Connections Figure 3 3 shows the Model 3000TB Electrical Connector Panel There are terminal blocks for connecting power communications and both digital and analog concentration outputs Figure 3 3 Electrical Connector Panel ...

Page 37: ...r source The actual input voltage used must show in the window of the VOLTAGE SELECTOR switch before the power source is connected See Figure 3 4 for detailed connections DANGER Power is applied to the instrument s circuitry as long as the instrument is connected to the power source The Standby Function switches power on or off to the displays and outputs only Figure 3 4 Primary Input Power Connec...

Page 38: ...e outputs are 0 1 V dc 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 V dc 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 ...

Page 39: ...a range that was defined as 0 100 ppm O2 then the output would be as shown in Table 3 1 Table 3 1 Analog Concentration Output Example Voltage Signal Current Signal ppm O2 Output V dc Output mA dc 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 To provide an indication of the range a second pair of analog output termina...

Page 40: ...le of switching up to 3 amperes at 250 V ac into a resistive load See Figure 3 6 Figure 3 6 Types of Relay Contacts Threshold Alarm 1 Can be configured as high actuates when concentration is above threshold or low actuates when concentration is below threshold Can be configured as failsafe or non failsafe Can be configured as latching or non latching Can be configured out defeated Threshold Alarm ...

Page 41: ...ed 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 section 3 3 9 Remote Sensor and Solenoid Valves With the C option internal valves operate synchronously Span Floating input 5 to 24 V input across the and pins puts the analyzer into the Span mode Either side may ...

Page 42: ...an 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 Note The remote probe 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...

Page 43: ...tal 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 Three input functions using RS 232 have been implemented to date They are described in Table 3 4 Table 3 4 Commands via RS 232 Input Comm...

Page 44: ...in the C option its own gas control solenoid valves However The REMOTE SENSOR and SOLENOID RETURN connectors are provided for use with a remote sensor and or gas flow control valves if desired See Figures 3 7 and 3 8 Figure 3 7 Remote Sensor Connector Pinouts Figure 3 8 Remote Solenoid Return Connector The voltage from these outputs is nominally 0 V for the OFF and 15 V dc for the ON conditions Th...

Page 45: ...o Fuel Cell The Micro Fuel Cell is not installed in the cell block when the instrument is 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 repl...

Page 46: ...strictor without the blue dot in the Sample in line in the same manner 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 restrictor...

Page 47: ...once established will keep the front panel flowmeter reading in an acceptable range 0 1 to 2 4 SLPM 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 Note If the unit is for vacuum service the above numbers apply instead to the vacuum at the EXHAUST OUT connector described below wi...

Page 48: ...uired Note If the unit is for vacuum service see Sample In above for gas pressure flow considerations 3 6 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 devi...

Page 49: ...Installation Model 3000TB Teledyne Analytical Instruments 34 BLANK PAGE ...

Page 50: ...onfigure your 3000TB 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 ...

Page 51: ...ssword assignment Self Test initiation Checking software version Logging out Zero Used to set up a zero calibration Span Used to set up a span calibration 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 Range Used to set up three analysis ranges that can be switched automatically with auto ranging or used a...

Page 52: ...he System Function The subfuctions of the System function are described below Specific procedures for their use follow the descriptions Auto Cal Used to define an automatic calibration sequence and or start an Auto Cal PSWD Security can be established by choosing a 5 digit password PSWD from the standard ASCII character set ...

Page 53: ...ord must be changed back to TETAI Logout Logging out prevents an unauthorized tampering with analyzer settings More Select and enter More to get a new screen with additional subfunctions listed Self Test The instrument performs a self diagnostic test to check the integrity of the power supply output boards and amplifiers Version Displays Manufacturer Model and Software Version of the instrument Sh...

Page 54: ...es 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 ...

Page 55: ...o Cal PSWD Logout More Use 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 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 0 d Start 0 h from now Use arrows to set an interval value then use arrows to m...

Page 56: ...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 En...

Page 57: ...ssword 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 ENT Yes ESC 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 passwo...

Page 58: ...ers 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 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 When you have finished typing the new password press Enter A verification screen appears The screen will prompt you to re...

Page 59: ...nd line will change to show which alarm it is 0 0 ppm Anlz 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 ...

Page 60: ... 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 during operation Press the System button to start the S...

Page 61: ...l System screen 4 3 6 Version Screen Move the 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 ...

Page 62: ...rated 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 oxygen concentration in air is 20 9 209 0...

Page 63: ... gas is connected to the instrument 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 arrow keys to toggle between AUTO and MAN zero settling Stop when AUTO appears blinking on the display Zero Settling AUTO E...

Page 64: ...ss 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 ...

Page 65: ...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 ...

Page 66: ...t screen Span Val 000008 00 ENT Span UP Mod Use the arrow keys to enter the oxygen concentration mode Use the arrow keys to blink the digit you are going to modify Use the 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 ...

Page 67: ...de It does not affect anything in Manual Mode Just press Enter to continue Span Val 000008 00 ENT Span UP Mod Press UP 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 arrows choose the digit and the arrows choose the value of the digit Press Enter to enter the span value into the system a...

Page 68: ...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 reac...

Page 69: ...ow the setpoint Decide whether you want the alarms to be set as Both high high and high high alarms or One high and one low alarm or 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 t...

Page 70: ...AL 1 1000 ppm HI Dft N Fs N Ltch N Five parameters can be changed on this screen Value of the alarm setpoint AL 1 ppm oxygen Out of range direction HI or LO Defeated Dft Y N Yes No Failsafe Fs Y N Yes No Latching Ltch Y N Yes No To define the setpoint use the arrow keys to move the blinking over to AL 1 Then use the arrow keys to change the number Holding down the key speeds up the incrementing or...

Page 71: ...tion 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 stays on a fixed range regardless of the oxygen concentration detected If the concentration exceeds the upper limit of the range the D...

Page 72: ...er the entire 0 250 000 ppm range even though all concentration data outputs change from ppm units to percent when the concentration is above 10 000 ppm 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...

Page 73: ... also switches the analyzer back to the Analyze function Alternatively you can press the Analyze button at any time to return to analyzing your sample 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 qu...

Page 74: ... in months M and days D on the top line of the display The maximum setting is M 30 and D 30 The default is M 6 and D 0 The user has the option of turning the function On or Off or to have it trigger the system alarm Alarm To change the notification period use the RIGHT arrow key to move the blinking to the appropriate field M onth or D ay and then use the keys to increment or decrement the value P...

Page 75: ...he normal Anlz replaced by MAINT Note The system alarm can be reset only after the timer has been reset 0 00 ppm MAINT Range 0 100 4 9 Sensor Detection The sensor detection feature detects whether a sensor is installed in the analyzer or not The software checks if the output of the amplifier is within a user defined threshold around the electronic zero output of the amplifier without sensor In the...

Page 76: ...ro level is set on the second line It defaults to 300 but it can be adjusted This numbers is the ADC counts on the A to D converter and it is equivalent to 0 114 of the full scale of the A to D converter Adjust the threshold for the alarm by moving the blinking over to the value adjacent to Thres Use the keys to increase or decrease the threshold value When the desired value is displayed press Ent...

Page 77: ...tem alarm is triggered and the message FSEN and ERRS appear in the upper right corner of the display instead of Anlz 0 01 ppm FSEN Range 0 100 0 01 ppm ERRS Range 0 100 To reset the message and the system alarm contacts the operator must go back to the Sensor function in the system menu and select Reset then press the Enter key The display will be followed by a prompt to confirm the reset Reset Se...

Page 78: ...and selecting More until the following display appears Maintenance Serial Stream SerMode More Use the keys again to move to Serial and press Enter The Enter Serial Number screen will appear Enter Serial 100000 Use the keys to enter the serial number and then press Enter to save 4 10 2 Stream The Stream function is useful when the analyzer is connected with a TAI Valve Box It allows the user to swi...

Page 79: ...ode is used primarily in conjunction with a TAI Valve Box It is used to communicate specific commands for controlling or receiving input from the Valve Box This feature requires either special software or a Profibus Adapter Board TAPA available from TAI which converts the RS232 to Profibus and adds additional commands To view or change the current communication mode use the and Enter keys to navig...

Page 80: ...cal Instruments 65 Note that valve box or TAPA board support requires the baud rate to be set to 9600 Dip switches in motherboard must be set as shown below to change baud rate to 9600 Position 1 set to ON Position 2 to OFF Position 3 to 8 set to OFF ...

Page 81: ...Operation 3000TB Teledyne Analytical Instruments 66 BLANK PAGE ...

Page 82: ...tching and swinging open the front cover as described earlier The major internal component locations are shown in Figure 5 1 the cell block is illustrated in Figure 5 2 and the fuse receptacle is shown in Figure 5 3 The 3000TB contains the following major internal components Micro Fuel Cell Insta Trace P N B71875 std Stainless steel cell block Customer Interface PCB Power Supply on bottom surface ...

Page 83: ...lean 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 when and how to replace it The Insta Trace P N B71875 Micro Fuel Cell is used in the standard Model 3000TB If any other cell is supplied with your instrument check the front of this manual for any addenda applyi...

Page 84: ...d or Inhaled Avoid contact with any fluid or powder in or around the unit What may appear to be plain water could contain one of these toxic substances In case of eye contact immediately flush eyes with water for at least 15 minutes Call physician See appendix Material Safety Data Sheet CAUTION DO NOT DISTURB THE INTEGRITY OF THE CELL PACKAGE UNTIL THE CELL IS TO ACTUALLY BE USED IF THE CELL PACKA...

Page 85: ... 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 inner door by unlatching it and swinging it open on its hinges 3 Leave the cell block installed Place one hand underneath the cell block ready to catch the ...

Page 86: ...Trace Oxygen Analyzer Maintenance Teledyne Analytical Instruments 71 Figure 5 2 Exploded View of Cell Block and Micro Fuel Cell ...

Page 87: ...k The hole in the cell block holder must align with the guide pin on the cell block 1 Remove power from instrument 2 Remove the old sensor if installed from the analyzer 3 Purge the analyzer at approximately 1 SCFH flow rate with N2 or zero gas with the sensor holder removed 4 Remove sensor from double bag storage 5 Remove sensor shorting button 6 Place sensor on sensor holder so that the gold con...

Page 88: ...to stockpile spare cells If a cell was working satisfactorily but ceases to function prematurely within the warranty period contact the factory With any 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 mis...

Page 89: ...ere 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 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 Table 5 1 for number code information The results screen alternates for a time with Press Any Key To Continue The following ...

Page 90: ...ck 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 ve...

Page 91: ... 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 ...

Page 92: ...ge ID output Sample System Flow indicator visible from front of unit Positive pressure service Vacuum service optional Auto Cal Auto Zero Available with optional electrically operated valves except XL option Alarms One system failure alarm contact to detect power failure Two adjustable concentration threshold alarms with fully programmable setpoints Diagnostics Start up or on demand comprehensive ...

Page 93: ...sis ranges once thermal equilibrium has been achieved XL Option Accuracy 1 ppm on 0 10 ppm once thermal equilibrium is reached 0 1 ppm range is 0 2 ppm once thermal equilibrium has been achieved Analog outputs 0 1 VDC percent of range 0 1 VDC range ID 4 20 mA DC percent of range isolated 4 20 mA DC range ID isolated Password Access Can be user configured for password protection ...

Page 94: ...for Cell Block Option 1 A68729 Restrictor Kit See page iii for sensor used in this instrument 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 Analytical Instruments 16830 Chestnut Street City of Industry CA 91748 Phone 626 934 1500 Fax 626 961 2538 Web ...

Page 95: ...uld 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 pressure At pressures other than atmospheric the diffusion rate of O2 will be different than optimum value Higher pressures will produce faster O2 diffusion rates resulting in higher O2 reading and shorter cell life To use a 3000 series ana...

Page 96: ...arts 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 psi...

Page 97: ...low 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 analy...

Page 98: ...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 ...

Page 99: ...stry CA 91749 Phone 626 961 9221 Technical Support 626 934 1673 Environment Health and Safety 626 934 1592 Date Prepared 11 23 98 Section II Physical and Chemical Data Chemical and Common Names Potassium Hydroxide KOH 15 w v Lead Pb pure CAS Number KOH 1310 58 3 Pb 7439 92 1 KOH 15 w v Pb pure Melting Point Range 10 to 0 C 328 C Boiling Point Range 100 to 115 C 1744 C Specific Gravity 1 09 20 C 11...

Page 100: ...cu m KOH Effects of overexposure Ingestion The electrolyte could be harmful or fatal if swallowed Oral LD50 RAT 3650 mg kg Eye The electrolyte is corrosive eye contact could result in permanent loss of vision Dermal The electrolyte is corrosive skin contact could result in a chemical burn Inhalation Liquid inhalation is unlikely Signs symptoms of exposure Contact with skin or eyes will cause a bur...

Page 101: ...in the event that a cell leaks Protective clothing Rubber gloves chemical splash goggles Clean up procedures Wipe down the area several times with a wet paper towel Use a fresh towel each time Protective measures during cell replacement Before opening the bag containing the sensor cell check the sensor cell for leakage If the sensor cell leaks do not open the bag If there is liquid around the cell...

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