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Oxygen Analyzer

Part II: Analysis Unit

Part II: 3-5

Figure 3-3: Electrical Connector/Control Panel;

For safe connections, ensure that uninsulated tips of the wires do not

extend beyond the terminal block screws to which they are attached.

Voltage Selector Switch: Set the Voltage Selector switch to the source

voltage (110 or 220 V ac) that will be used to power the Analysis Unit
internal heater. Make sure the switch is set to the correct voltage BEFORE
making or energizing the power connections.

Power Connections: 115/230 V ac, 50/ 60 Hz power is required for

the heater that keeps the enclosure at a constant temperature. Connect per
standard power wiring codes. The connections are—

N Neutral, G Ground, H Hot.

Fuse Installation: Fuses are not installed at the factory. Be sure to

install the proper fuse (5

×

20 mm, 2 A) as part of installation. (See Fuse

Replacement in chapter 5, Maintenance.)

Solenoid and Sensor Signal Connections: The Remote Probe con-

nector on the Control Unit (Part I, paragraph 3.3) connects to the Analysis
Unit's Solenoid Valves and Sensor Signal terminals. See Figure 3-4. It
provides signals to control the solenoid valves which regulate the zero, span
and sample gas flow, and accepts the sensor and thermistor signals for
processing.

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Summary of Contents for 3010PA

Page 1: ...ASES MAY BE PRESENT IN THIS MONITORING SYSTEM PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PER SIST 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 ...

Page 2: ...ions shape or weight of any parts in so far as such alterations do not adversely affect our warranty ImportantNotice 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 invo...

Page 3: ...er Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Table of Contents Specific Model Information iv Preface v Part I Control Unit Model PA Part I 1 1 Part II Analysis Unit Model P Part II 1 1 Appendix A 1 ...

Page 4: ...010PA F Built in flame arresters for Groups C and D service o 3010PA G Built in flame arresters for Groups C and D service plus gas control valves as in C option above o 3010PA H Built in flame arresters for Group B hydrogen service o 3010PA I Built in flame arresters for Group B hydrogen service plus gas control valves as in C option above o 3010PA M 4 20 mA current signal outputs for Percent of ...

Page 5: ...010PA General Purpose flush panel and or rack mount Control Unit only This Control Unit is for indoor use in a nonhazardous environment The Analysis Units or Remote Probes they control can be designed for a variety of hazardous environments Part II of this manual covers the 3010P Analysis Unit TypicalApplications A few typical applications of the Model 3010PA are Monitoringinertgasblanketing Air s...

Page 6: ...9 3010TAC CENELECtypeTraceOxygenAnalyzerwithflushmount Control Unit Consists of 3010TA Control Unit PN D 66192A and a 3010T_C Analysis Unit PN D 66193 3010PAC CENELECtypePercentOxygenAnalyzerwithflushmount Control Unit Consists of 3010PA Control Unit PN D 66192 B or C and a 3010P_C Analysis Unit PN D 66191 3010TBC CENELECtypeTraceOxygenAnalyzerwithbulkheadmount Control Unit Consists of 3010TB Cont...

Page 7: ...ation range for convenient spanning at 20 9 Auto Ranging allows analyzer 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 Self diagnostic testing at startup and on demand with continuous power supplymonitoring Two way RFI protection RS 232 ...

Page 8: ...ctive LVD The following International Symbols are used throughout the Instruc tion Manual for your visual and immediate warnings and when you have to attend CAUTION while operating the instrument CAUTION The operator needs to refer to the manual for further information Failure to do so may compromise the safe operation of the equipment STAND BY Instrument is on Stand by but circuit is active GROUN...

Page 9: ...Part I i Part I Control Unit OPERATING INSTRUCTIONS Models 3010PA Oxygen Analyzer Part I Control Unit Flush Mount Part Number D 64596B ...

Page 10: ... 3 Installation 3 1 Unpacking the Control Unit 3 1 3 2 Mounting the Control Unit 3 1 3 3 Rear Panel Connections 3 2 3 4 Installation Checklist 3 9 4 Operation 4 1 Introduction 4 1 4 2 Using the Data Entry and Function Buttons 4 2 4 3 The System Function 4 3 4 3 1 Setting the Display 4 4 4 3 2 Setting up an Auto Cal 4 5 4 3 3 Password Protection 4 5 4 3 3 1 Entering the Password 4 6 4 3 3 2 Install...

Page 11: ...e Spanning 4 12 4 5 The Alarms Function 4 13 4 6 The Range Function 4 15 4 6 1 Setting the Analog Output Ranges 4 15 4 6 2 Fixed Range Analysis 4 16 4 7 The Analyze Function 4 17 4 8 Signal Output 4 17 5 Maintenance 5 1 Routine Maintenance 5 1 5 2 Fuse Replacement 5 1 5 3 System Self Diagnostic Test 5 3 5 4 Major Internal Components 5 3 5 5 Cleaning 5 4 ...

Page 12: ...lush panel and or rack mount Control Units The Analy sis Unit is covered in Part II of this manual The Control Unit is for indoor use in a nonhazardous environment only The Analysis Units or Remote Probes it controls can be designed for a variety of hazardous environ ments 1 2 Control Unit Front Panel The standard 3010PA Control Unit is housed in a rugged metal case with all remote controls and di...

Page 13: ...escribed in detail in chapter 4 Operation Span Span calibrate the analyzer Zero Zero calibrate the analyzer Alarms Set the alarm setpoints and attributes Range Set up 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 Left Right Arrows Select between functions currently displ...

Page 14: ...e no displays or outputs CAUTION The power cable must be unplugged to fully disconnect power from the 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 front panel electronics the front panel swings open when the latch in the upper right corner of the panel is press...

Page 15: ...rms and 1 system alarm RS 232 Port Serial digital concentration signal output and control input Remote Probe Provides all electrical interconnect to the Analysis Unit or Remote Probe Remote Span Zero Digital inputs allow external control of analyzer calibration Calibration Contact To notify external equipment that instrument is being calibrated and readings are not monitoring sample Range ID Conta...

Page 16: ...etwork I O Serial digital communications for local network access For future expansion Not implemented at this printing Note If you require highly accurate Auto Cal timing use external Auto Cal control where possible The internal clock in the Model 3010PA is accurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day ...

Page 17: ...1 6 Part I 1 Introduction Model 3010PA ...

Page 18: ...strated in section 5 Maintenance Refer to Figure 2 1 Block Diagram of the 3010PA CU Electronics In the presence of oxygen the sensor in the Analysis Unit generates a current A current to voltage amplifier in the Control Unit converts this current to a voltage The second stage amplifier amplifies the voltage It also uses a signal from the thermistor which is physically located in the Analysis Unit ...

Page 19: ...2 2 Part I 2 Operational Theory Model 3010PA Figure 2 1 Block Diagram of the 3010PA CU Electronics ...

Page 20: ...ital information is also sent to a 12 bit digital to analog converter that produces the 0 1 V dc and the optional 4 20 mA dc analog concentration signal outputs and the analog range ID outputs The microprocessor monitors the power supply and activates the system failure alarm if a malfunction is detected 2 3 Temperature Control For accurate analysis this instrument is temperature controlled not to...

Page 21: ...2 4 Part I 2 Operational Theory Model 3010PA ...

Page 22: ...ck the Control Unit and inspect it for damage Immediately report any damage to the shipping agent 3 2 Mounting the Control Unit The Model 3010PA Control Unit 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 a Model 3010 standard Control Unit front panel and mount ing...

Page 23: ... Mounts All operator controls are mounted on the control panel which is hinged on the left edge and doubles as a door to provide access to the internal components of 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 Mounting Holes 4 Latch Hinge ...

Page 24: ...rear panel Connections for power communications and both digital and analog signal outputs are described in the following paragraphs Wire size and maximum length data appear in the Drawings in the back of this manual Figure 3 4 Rear Panel of the Model 3010 Control Unit For safe connections ensure that no uninsulated wire extends outside of the connectors they are attached to Stripped wire ends mus...

Page 25: ...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 Replace ment in chapter 5 maintenance Analog Outputs There are four DC output signal connectors with spring terminals on the panel There are two wires per output with the polarity noted See Figure 3 5 The outputs are 0 1 V dc of Range Voltage rises linearly with in...

Page 26: ...centrationisbelowthreshold Can be configured as failsafe or nonfailsafe Can be configured as latching or nonlatching Can be configured out defeated Threshold Alarm 2 Can be configured as high actuates when concen tration is above threshold or low actuates when concentrationisbelowthreshold Can be configured as failsafe or nonfailsafe Can be configured as latching or nonlatching Can be configured o...

Page 27: ...ction 3 3 Cal Contact This relay contact is closed while analyzer is spanning and or zeroing See Remote Calibration Protocol below Remote Calibration Protocol To properly time the Digital Remote Cal Inputs to the Model 3010 Analyzer 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 sp...

Page 28: ...signal output is a standard RS 232 serial communications port used to connect the analyzer to a computer terminal or other digital device It requires a standard 9 pin D connector The data is status information in digital form updated every two seconds Status is reported in the following order The concentration in percent The range in use HI MED LO The span of the range 0 10 etc Which alarms if any...

Page 29: ...ecture dual chassis instrument which has a Remote Probe or Analysis Unit The Remote Probe connector is used for controlling the Analysis Unit internal sample zero and span gas valves which are optional and for receiving the oxygen sensor and thermistor signals See Figure 3 7 The connections at the Analysis Unit are covered in detail in Part II section 3 4 of this manual Figure 3 7 Remote Probe Con...

Page 30: ...uired use relays power amplifiers or other matching circuitry to provide the actual driving current Note that 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 9 Figure 3 9 FET Series Resistance 3 4 Testing the System After The Control Unit and the Analysis Unit a...

Page 31: ...integrity and accuracy of all 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 by performing the following operations 1 Repeat the Self Diagnostic Test as described in chapter 4 section 4 3 5 ...

Page 32: ...n choose autoranging or select a fixed range of analysis as required Set alarm setpoints and modes latching failsafe etc Before configuration these default values are in effect PARAMETER DEFAULT LO Range 1 MED Range 5 HI Range 10 Auto Ranging ON Alarm Relays 10 Defeated HI Not failsafe Not latching Span 20 9 Auto every 0 days at 0 hours Zero Auto every 0 days at 0 hours If you choose not to use pa...

Page 33: ...analyzer monitors the oxygen content of the sample displays the concentration of oxygen and warns of any alarm conditions System The system function consists of six subfunctions that regulate the internal operations of the analyzer LCD screen contrast Auto Cal setup Passwordassignment Self Testinitiation Checking software version Logging out Zero Used to set up a zero calibration Span Used to set ...

Page 34: ...are printed in Oblique type 4 3 The System Function The subfunctions 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 See Installing or Changing a Password be...

Page 35: ...assigned to defeat the security the password must be changed back to TBEAI Logout Logging out prevents an unauthorized tampering with analyzersettings More Select and enter More to get a new screen with additional subfunctionslisted 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 an...

Page 36: ...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 move to the start time value Use 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 arrows ...

Page 37: ...g over to PSWD and press Enter to select the password function Either the default TBEAI password or AAAAA place holders for an existing password will appear on screen depending on whether or not a password has been previously installed T B E A I Enter PWD or A A A A A Enter PWD The screen prompts you to enter the current password If you are not using password protection press Enter to accept TBEAI...

Page 38: ...r the previously assigned password or press Escape to keep the existing pass word and move on If you chose Enter to change the password the password assignment screenappears T B E A I ENT To Proceed or A A A A A ENT To Proceed Enter the password using the arrow keys to move back and forth between the existing password letters and the arrow keys to change the letters to the new password The full se...

Page 39: ...rm is tripped the second line will change to show which alarm itis 0 0 Anlz A L 1 NOTE If you previously logged off the system 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 L...

Page 40: ...r at will To initiate a self diagnostic test during operation Press the System button to start the System function Contrast Auto Cal PSWD Logout More Use the arrow keys to blink More then press Enter Version Self Test Use the 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 testin...

Page 41: ...as 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 Analysis Unit SLPM flowmeter settles between 0 5 and 2 4 SLPM approximately1 5scfh If you are using password protection you wi...

Page 42: ...rmed in manual mode where the operator deter mines when the span concentration reading is acceptable and manually exits thefunction 4 4 2 1 AutoModeSpanning 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 arrow keys to toggle between AUTO and MAN span settling Stop when AUTO appears...

Page 43: ...pan gas you are using 20 90 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 and begin the span calibration Once the span has begun the microprocessor samples the output at a predeterminedrate Itcalculatesthedifferencebetweensuccessivesamplings and displays this difference as Slope on the screen It tak...

Page 44: ...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 alarm as LOW triggers the alarm when the oxygen concentration falls below 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...

Page 45: ...using the arrow keys Then press Enter to move to the next screen AL 1 10 HI Dft N Fs N Ltch N Five parameters can be changed on this screen Value of the alarm setpoint AL 1 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 nu...

Page 46: ...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 DC output will saturate at 1 V d...

Page 47: ...om autoranging to fixed range analysis enter the range function by pressing the Range button on the front panel Use the arrow keys to move the blinking over AUTO Use the arrow keys to switch from AUTO to FX LO FX MED or FX HI to set the instrument on the desired fixed range low medium or high L M H Mode FX LO or L M H Mode FX MED or L M H Mode FX HI Press Escape to re enter the Analyze mode using ...

Page 48: ... can press the Analyze button at any time to return to analyzing your sample 4 8 Signal Output The standard Model 3010PA Oxygen Analyzer are equipped with two 0 1 V dc analog output terminals accessible on the back panel one concen tration and one range ID Two isolated 4 20 mA dc current outputs one concentration and one range ID in addition to the voltage outputs are optional See Rear Panel in ch...

Page 49: ...t 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 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 mA LO 0 25 ...

Page 50: ... cells and replacing fuses in the Analysis Unit are covered in Part II Chapter 5 For recalibration see Part I section 4 4 Calibration WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL 5 1 Fuse Replacement 1 Place small screwdriver in notch and pry cover off as shown in Figure 5 1 Figure 5 1 Removing Fuse Block from Housing 2 To change between American and European fuses remove the single retai...

Page 51: ...he 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 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 Amplifier output d...

Page 52: ...ontrol Units contain the following major components Power Supply Motherboard with Microprocessor RS 232 chip and Preamplifier PCB Front Panel Display Board and Displays 5 digit LED meter 2 line 20 character alphanumeric VFD display See the drawings in the Drawings section in back of this manual for details The Front Panel Display Board is accessed by unlatching and swing ing open the front panel a...

Page 53: ...aning disconnect the instru ment 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 benzine For panel mounted instruments clean the front panel as prescribed in the above paragraph DO NOT wipe front panel while the instrument is monitoring your pro...

Page 54: ...Part II i Part II Analysis Unit OPERATING INSTRUCTIONS Model 3010P Oxygen Analyzer Part II Analysis Unit NEC Type Part Number D 65479 ...

Page 55: ...2 4 The Effect of Pressure 2 4 2 2 5 Calibration Characteristics 2 4 2 2 6 Micro Fuel Cell Class 2 5 2 3 Sample Systems 2 6 3 Installation 3 1 Unpacking the Analysis Unit 3 1 3 2 Mounting the Analysis Unit 3 1 3 3 Gas Connector Panel Connections 3 3 3 4 Electrical Connector Panel 3 4 3 5 Installing the Micro Fuel Cell 3 6 3 6 Testing the System 3 6 4 Operation 4 1 Introduction 4 1 4 2 Flowmeter 4 ...

Page 56: ...Components 5 1 5 2 Cell Replacement 5 2 5 2 1 Storing and Handling Replacement Cells 5 2 5 2 2 When to Replace a Cell 5 3 5 2 3 Removing the Micro Fuel Cell 5 4 5 2 4 Installing a New Micro Fuel Cell 5 5 5 2 5 Cell Warranty 5 5 5 3 Fuse Replacement 5 6 5 4 System Self Diagnostic Test 5 6 ...

Page 57: ...iv Part II Model 3010P Oxygen Analyzer ...

Page 58: ...ype housing with all gas connections accessible from an external connector panel Figure 1 1 is a cutaway illustration of the Analysis Unit showing the Gas Connector Panel and connectors The gas connectors are described briefly here and in detail in the Installation chapter of this manual Flowmeter Monitors the flow of gas past the sensor Readout is 0 2 to 2 4 standard liters per minute SLPM ZERO I...

Page 59: ...onents In such cases the exhaust MUST vent to a suitably contained area 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 inside the housing The connectors and controls are described briefly here They are described in detail in the Installation Operation and Maintenanc...

Page 60: ...Input termi nals Voltage Selector Power input selector switch for electric heater Adjusts input requirement for 115 or 230 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 1 is on the neutral side of the line Fuse 2 is on the hot side of the line Solenoid Valves Terminals that provide all electrical intercon nections from the Control...

Page 61: ...1 4 Part II 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction Model 3010P ...

Page 62: ...emote Control Unit covered in Part I if this manual 2 2 Micro Fuel Cell Sensor 2 2 1 Principles of Operation The oxygen sensors used in the Model 3010 series are Micro Fuel Cells designed and manufactured by Analytical Instruments They are sealed plasticdisposableelectrochemicaltransducers The active components of a Micro Fuel Cell are the cathode the anode and aqueous KOH electrolyte in which the...

Page 63: ...n 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 shows the external features of a typical cell Figure 2 1 Micro Fuel Cell Refer to Figure 2 2 Cross Section of a Micro Fuel Cell which illus trates...

Page 64: ...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 2H2 O 4e 4OH cathode Four electrons combine with one oxygen molecule in the presence of water from the electrolyte to produce four hy...

Page 65: ...n though the oxygen concen tration of the sample has not changed It is therefore important that the sample pressure at the fuel cell usually vent pressure remain relatively constantbetweencalibrations 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 p...

Page 66: ...al useandelectricalspecifications 2 2 6 1 Class A 3 Cell The class A 3 cell is for use in applications where it is exposed continu ously to carbon dioxide concentrations between 1 and 100 in the samplegas Nominal output in air is 0 20 mA and 90 response time is 45 s Expected life in flue gas is 8 months 2 2 6 2 Class A 5 Cell The class A 5 cell is for use in applications where it is exposed interm...

Page 67: ...oxide and where a longer response time is accept able in order to have a longer cell life Nominal output in air is 0 20 mA and 90 response time is 30 s Expected life in air is 18 months 2 2 6 6 Hydrogenand orHeliumService If the sample gas contains 10 or more hydrogen and or helium only clamp cells are used These Micro Fuel cells are identified by the suffix C added to the cell class number NOTE T...

Page 68: ... flowing through the system is monitored by a flowmeter downstream from the cell The sample system for the stan dard instruments incorporates 1 4 inch tube fittings for sample inlet and outlet connections on the Gas Control Panel For metric system installations 6 mm adaptersaresupplied For Vacuum Service the restrictor is located downstream of the flowmeter The restrictor is installed in the exhau...

Page 69: ...2 8 Part II 2 Operational Theory Model 3010P ...

Page 70: ...t is for use in Class 1 Division 1 Groups C and D hazardous environments group B available The standard model is designed for bulkhead mounting Overall dimen sions of the Analysis Unit will vary slightly less than an inch due to varia tions in dimensions of the main explosion proof enclosure The maximum footprint will be 19 12 and maximum height 9 4 Outline Drawing D 65479 at the back of this manu...

Page 71: ...unit will be used for pressurized service or vacuum service and low pressure applica tions 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 ow pres...

Page 72: ...nit 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 Figure 3 2 shows the Model 3010P Gas Connector panel The inlets for zero and span gas are included only with the C option Figure 3 2 Gas Connector Panel of the Model 3010P The unit is manufactured with 1 4 inch tube fi...

Page 73: ...d span gas There are electrically operated valves inside for automatic switching between sample and calibration gases These valves are completely under control of the 3010 series Control Unit They can be externally controlled only indi rectly through the Remote Cal Inputs described below EXHAUST OUT Exhaust connections must be consistent with the hazard level of the constituent gases Check local s...

Page 74: ...V ac 50 60 Hz power is required for the heater that keeps the enclosure at a constant temperature Connect per standard power wiring codes The connections are N Neutral G Ground H Hot Fuse Installation Fuses are not installed at the factory Be sure to install the proper fuse 5 20 mm 2 A as part of installation See Fuse Replacement in chapter 5 Maintenance Solenoid and Sensor Signal Connections The ...

Page 75: ...FF 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 that each individual line has a series FET with a nomina...

Page 76: ...hapter 5 Maintenance for removing and installing cells 3 6 Testing the System After The Control Unit and the Analysis Unit are both installed and interconnected and the system gas and electrical connections are complete the system is ready to test Before plugging either of the units into their respectivepowersources Check the integrity and accuracy of the gas connections Make sure there are no lea...

Page 77: ...3 Installation Model 3010P 3 8 Part II ...

Page 78: ...built in Self Test and checking the status of the Micro Fuel Cell sensor 4 2 Flowmeter Although all operation is controlled from the Control Unit at times during operation or setup it is necessary to observe the flowmeter which is located on the Analysis Unit The flowmeter monitors the flow of gas past the Micro Fuel Cell sensor The scale on the flowmeter is graduated from 0 2 to 2 4 standard lite...

Page 79: ...The Zero and Span Func tions for further instructions 4 4 System Self Diagnostic Test 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 During the test internal signals are sent through the power supply output board and sensor circuit automatically The return signal is ana lyzed and at the end of the...

Page 80: ... analyzer returns to the initial System screen 4 5 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 When the sensor in the 3010P begins to fail the analyzer will usually require more and more frequent calibration If recalibration raises the readings temporarily only su...

Page 81: ...ic Model Information in the Front Matter in this manual for the class of cell you purchased Then check Cell Replacement in chapter 5 Mainte nance and do the prescribed calculations If a weak cell is indicated replace the cell as described in chapter 5 After correcting the condition reset the Cell Fail Alarm by taking the analyzer into and then back out of STANDBY ...

Page 82: ...ection 4 4 Calibration WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL 5 2 Major Components The internal components are accessed by rotating the explosion proof housing cover counterclockwise several turns until free See Figure 5 1 below The sampling system gas piping is illustrated in Figure 2 4 WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL The 3010 Analysis Units contain the follow...

Page 83: ...el cell and 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 shortly before the end of the cell s one year warranty period Check Specific Model Information in The front matter of this manual for which class of cell you purchased CAUTION Do not stockpile cells The warran...

Page 84: ...When to Replace a Cell If the 3010P analysis readings begin to drift downward uncharacteris tically try recalibration If recalibration raises the readings for a short time only suspect the cell but first check for leaks downstream from the cell where gases may be leaking into the system You can check the output of the cell itself by going to the System function selecting More and pressing Enter Th...

Page 85: ...OUCH THE SENSING SURFACE OF THE CELL IT IS COVERED WITH A DELICATE TEFLON MEMBRANE THAT CAN LEAK CAUSTIC AND COR ROSIVE CHEMICALS WHEN PUNCTURED The Micro Fuel cell is located inside the housing in a nylon cell block Some models may have a stainless steel block See Figure 5 2 To remove an existing cell 1 Remove power to the instrument by unplugging the power cord at the power source 2 Rotate the h...

Page 86: ... it is free unscrew the Cap from the Probe Hold the Probe vertically to prevent dropping the cell out of the probe 6 Remove the Cell from the Probe and dispose of it in an environmentally safe manner Figure 5 2 Removing or Installing a Percent Micro Fuel Cell ...

Page 87: ...his will affect cell life and warranty data Also note any Addenda that may be 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 Do not attempt to stockpile spare cells If a cell was working satisfactorily but ceases to function before the...

Page 88: ...se holder cap and fuse as shown in Figure 5 3 Figure 5 3 Removing Fuse Cap and fuse from Holder 2 Replace fuse by reversing process in step 1 5 4 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 4 Observe the error code readings on the VFD Display screen and ...

Page 89: ... 5 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 Amplifier output doesn t match test input 3 Both Failed ...

Page 90: ...Appendix A 1 Oxygen Analyzers Appendix OPERATING INSTRUCTIONS Model 3010PA Oxygen Analyzers Appendix Flush Mount Control Unit PN CU64596B NEC Type Analysis Unit PN AU65479 ...

Page 91: ...PA Contents A 1 Model 3010PA Specifications A 3 A 2 Recommended 2 Year Spare Parts List A 4 A 3 Drawing List A 6 A 4 19 Inch Relay Rack Panel Mount A 6 A 5 Application notes on Restrictors Pressures Flow A 6 A 6 The Zero Functions A 10 ...

Page 92: ...or flame arrestorsoptional Sensor B 1 Micro Fuel Cell standard others avail able Cell Block Nylon 316 stainless steel available Ranges Threeuserdefinableranges0 1 to0 100 Air calibration range 0 25 Autoranging with range ID output SampleSystem Positivepressureservice Vacuumservice optional Auto Cal Auto Zero Electrically operated valves Alarms Onesystem failurealarm contacttodetect powerfailure Tw...

Page 93: ...ysis Unit 110 220 V ac 50 60 Hz OperatingTemperature 0 50 C EMF RFI Immunity and Emissions designed to meet but not yet certified to EN 50081 1 EN 50082 2 Accuracy 2 of full scale at constant temperature 5 of full scale over operating temperature range on factory default analysis ranges once thermal equilibrium has been achieved Analog outputs 0 1 V dcpercent of range 0 1 V dc range ID 4 20 mA dcp...

Page 94: ...1 C6689 B1 Micro FuelCell Forpercentmodels _____________________ Order one type only A B or C as appropriate Order one type only US or European as appropriate Check Specific Model Information for cell supplied with your unit See Cell Class in chapter 2 for descriptions of options C6689 B1 is used in the standard percent model A minimum charge is applicable to spare parts orders Note Orders for rep...

Page 95: ...utline Drawing Control Unit Percent Oxygen D 65479 Final Assembly Outline Drawing Analysis Unit Percent Oxy gen D 64950 WiringDiagram NOTE The MSDS on this material is available upon request through the Teledyne Environmental Health and Safety Coordinator Contact at 626 934 1592 ...

Page 96: ...imumvalue HigherpressureswillproducefasterO2 diffusionrates resultinginhigherO2reading andshortercelllife Tousea3000 seriesanalyzeratacellpressureotherthanatmospheric theanalyzermustbe calibratedwithaknowncalibrationgasatthenewcellpressuretoadjustforthe differentdiffusionrate Cellpressuresbelow2 3atmosphericarenotrecom mendedbecauseastheytendtocauseexcessiveinternalexpansionwhichmay resultinsealfa...

Page 97: ... inchesofmercuryshould providetheoptimumflowrate CAUTION flow restrictors have very small orifices and may be plugged by small par ticles 005 dia or larger A sample filter must be included in the sample linepriortotherestrictor a60micronfilterisrecommended 3010PAEXAMPLES Example1 withaincoming pressureof10psigthestdrestrictor blue dot willprovideaflowrateof 76SLPM Up streamoftherestrictorthe sampl...

Page 98: ...as Whenrestrictorsareused the gaspressuremustbeadjustedtoachievetheproperflowrate OPERATIONWITHOUT ARESTRICTORDEVICE Operationwithoutarestrictordeviceisnotrecommendasmentioned above A3010PA withoutanyflowrestrictordevicewastestedon11 19 97 This results in a flow rate of 2 4 SLPM 1 PSIG This is a cv of 0 023 for the standardsamplesys 6 REFERENCE FLOW_1 XLS FLOW_2 XLS forinformationon flowratesatvar...

Page 99: ...g on the display Zero Settling AUTO ENT To Begin Press Enter to begin zeroing Zero Slope ppm s The beginning zero level is shown in the upper left corner of the dis play 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...

Page 100: ...f change as Slope a value in parts per million per second ppm s 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 Slope is given in ppm s Generally you have a good zero when Slope is less than 0 05 ppm s for about 30 seconds When Slope is close enough t...

Page 101: ...A 12 Appendix Appendix Models 3010PA ...

Page 102: ...mental Health and Safety Extension 230 Date Prepared 04 26 95 Section I Product Identification Section III Physical Chemical Characteristics Section II Hazardous Ingredients Composition Material or Component C A S Quantity OSHA PEL ACGIH TLV Lead Pb 7439 92 1 3 20 gms 0 05 mg m3 0 15 mg m3 Potassium Hydroxide 1310 58 3 1 5 ml None 2 mg m3 Solution 15 KOH Specific Gravity 11 34 2 04 Material Appear...

Page 103: ...nhalation Highly unlikely Ingestion May be fatal if swallowed Skin The electrolyte potassium hydroxide is corrosive skin contact may cause irritation or chemical burns Eyes The electrolyte potassium hydroxide is corrosive eye contact may cause irritation or severe chemical burns Acute Effects The electrolyte is harmful if swallowed inhaled or adsorbed through the skin It is extremely destructive t...

Page 104: ...ove all contaminated clothing Get medical attention immedi ately If ingested give large amounts of water and DO NOT INDUCE VOMITING Obtain medical attention immedi ately If inhaled remove to fresh air and obtain medical attention immediately Medical Conditions Generally Aggravated by Exposure Signs and Symptoms of Exposure Emergency First Aid Procedures NOTE The oxygen sensors are sealed and under...

Page 105: ...rdous Waste Solid N O S Lead Class 9 NA3077 PG III Follow all Federal State and Local regulations Section X References Material Safety Data Sheets from J T Baker Chemical Aldrich Malinckrodt ASARCO U S Department of Labor form OMB No 1218 0072 Title 8 California Code of Regulations TSCA SARA Title III CFR 49 CFR 29 CFR 40 NOTE The above information is believed to be correct and is offered for your...

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