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Teledyne 3010PAC, Operating Instructions Manual

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     Oxygen Analyzer

 Teledyne Analytical Instruments

OPERATING INSTRUCTIONS

Model 3010PAC

Percent Oxygen Analyzer

Flush Mount Control Unit, PN D-66192B

CENELEC Type Remote Probe, PN B-39923C

Intrinsic Safe Barriers Assy., PN C-66426

HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS
MONITORING SYSTEM.

PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.

HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY 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
SUPERVISOR/MANAGER.

DANGER

P/N M66395

08/06/99

ECO # 99-0323

Summary of Contents for 3010PAC

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

Page 2: ...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...

Page 3: ...n Analyzer TeledyneAnalyticalInstruments Table of Contents Specific Model Information iv Preface v Part I Control Unit Model PAC Part I 1 1 Part II Intrinsic Safe Barriers Part II 1 1 Remote Probe App...

Page 4: ...for which this manual was supplied are indicated by a check mark in the box InstrumentSerialNumber __________________________ 19 Rack Mount The 19 Relay Rack Mount units are available with either one...

Page 5: ...te in a hazardous area Part I of this manual covers the Model 3010PAC General Purpose flush panel and or rack mount Control Unit only This Control Unit is for indoor use in a nonhazardous environment...

Page 6: ...with bulkhead mount Control Unit Consists of 3010TB PB Control Unit PN D 66190A and a 3010T Analysis Unit PN D 65478 3010PB NECtypePercentOxygenAnalyzerwithbulkheadmount Control Unit Consists of 3010...

Page 7: ...onics 8 bit CMOS microprocessor with 32 kB RAM and 128 kB ROM Three user definable output ranges allow best match to users process and equipment 0 1 through 0 100 Air calibration range for convenient...

Page 8: ...ments of the Commonwealth of Europe CE for Radio Frequency Interference Electromagnetic Interference RFI EMI and Low Voltage Directive LVD The Analysis Unit is Intrinsically safe and CENELEC approved...

Page 9: ...Part I i Part I Control Unit TeledyneAnalyticalInstruments OPERATING INSTRUCTIONS Models 3010PAC Oxygen Analyzer Part I Control Unit Flush Mount Part Number D 66192B...

Page 10: ...1 Unpacking the Control Unit 3 1 3 2 Mounting the Control Unit 3 1 3 3 Electrical Connections 3 3 3 3 1 Primary Input Power 3 4 3 3 2 50 Pin Interface Connector 3 4 3 3 3 RS 232 Port 3 9 3 3 4 Remote...

Page 11: ...4 2 Span Cal 4 11 4 4 2 1 Auto Mode Spanning 4 11 4 4 2 2 Manual Mode 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 Ra...

Page 12: ...iv Part I Model 3010PAC Oxygen Analyzer TeledyneAnalyticalInstruments...

Page 13: ...General Purpose flush 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 U...

Page 14: ...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 Set up the 3 user definab...

Page 15: ...ating but there are 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 i...

Page 16: ...oncentration alarms 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 R...

Page 17: ...sample system Network 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...

Page 18: ...1 6 Part I 1 Introduction Model 3010PAC Teledyne Analytical Instruments...

Page 19: ...cations are illustrated in section 5 Maintenance Refer to Figure 2 1 Block Diagram of the 3010PAC CU Electronics In the presence of oxygen the sensor in the Analysis Unit generates a current A current...

Page 20: ...2 2 Part I 2 Operational Theory Model 3010PAC Teledyne Analytical Instruments Figure 2 1 Block Diagram of the 3010PAC CU Electronics...

Page 21: ...to the display alarms and communications port as well as to the optional gas control valves in the Analysis Unit The same digital information is also sent to a 12 bit digital to analog converter that...

Page 22: ...2 4 Part I 2 Operational Theory Model 3010PAC Teledyne Analytical Instruments...

Page 23: ...the system for operation Carefully unpack the Control Unit and inspect it for damage Immediately report any damage to the shipping agent 3 2 Mounting the Control Unit The Model 3010PAC Control Unit is...

Page 24: ...t Figure 3 2 Single and Dual 19 Rack 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 o...

Page 25: ...3 Required Front Door Clearance 3 3 Electrical Connections Figure 3 4 shows the Control Unit rear panel Connections for power communications and both digital and analog signal outputs are described i...

Page 26: ...trument s circuitry as long as the instrument is connected to the power source The switch on the front panel is for switching power on or off to the displays and outputs only Fuse Installation The fus...

Page 27: ...oating 6 Range 4 20 mA floating 8 Range ID 0 1 V dc 23 Range ID 0 1 V dc negative ground 24 Range 0 1 V dc 7 Range 0 1 V dc negative ground Alarm Relays The three alarm circuit connectors are spring t...

Page 28: ...44 Threshold Alarm 2 moving contact 43 Threshold Alarm 2 normally open contact 36 System Alarm normally closed contact 20 System Alarm moving contact 37 System Alarm normally open contact Digital Remo...

Page 29: ...d and a zero or span command can be sent When the contact is CLOSED the analyzer is already calibrating It will ignore your request to calibrate and it will not remember that request Once a zero or sp...

Page 30: ...n connections Table 3 4 Range ID Relay Connections Pin Function 21 Range 1 ID Contact 38 Range 1 ID Contact 22 Range 2 ID Contact 39 Range 2 ID Contact 19 Range 3 ID Contact 18 Range 3 ID Contact 34 R...

Page 31: ...e obtainable voltage depending on the load impedance applied See Figure 3 6 Figure 3 6 FET Series Resistance 3 3 3 RS 232 Port The digital signal output is a standard full duplex RS 232 serial communi...

Page 32: ...010PAC implementation Table 3 6 Required RS 232 Options Parameter Setting Baud 2400 Byte 8 bits Parity none Stop Bits 1 Message Interval 2 seconds 3 3 4 Remote Probe Connection The Models 3010PAC are...

Page 33: ...oth 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 respective power sources Check th...

Page 34: ...3 Installation Model 3010PAC 3 12 Part I Teledyne Analytical Instruments...

Page 35: ...ysis ranges Then 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 PARAMETE...

Page 36: ...operating mode The 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 tha...

Page 37: ...shbutton names 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 t...

Page 38: ...ique password is 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 ge...

Page 39: ...o 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 move to the start time...

Page 40: ...roll the blinking 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 whet...

Page 41: ...default TBEAI or 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 E...

Page 42: ...0 100 If an alarm 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...

Page 43: ...n by the operator 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 t...

Page 44: ...ll scale oxygen analysis immediately following calibrationinair Connect the calibration gases to the analyzer according to the instruc tions given in Section 3 4 1 Gas Connections observing all the pr...

Page 45: ...n also be performed 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...

Page 46: ...tration of the span 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...

Page 47: ...ints 1 Which if any of the alarms are to be high alarms and which if any are to be low alarms Setting an alarm as HIGH triggers the alarm when the oxygen concentration rises above the setpoint Setting...

Page 48: ...ng over to AL 1 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...

Page 49: ...low 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 autorangin...

Page 50: ...nge To switch from 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...

Page 51: ...lternatively you can press the Analyze button at any time to return to analyzing your sample 4 8 Signal Output The standard Model 3010PAC Oxygen Analyzer are equipped with two 0 1 V dc analog output t...

Page 52: ...sary to know what range the instrument is currently on especially when the analyzer is in the autoranging mode To provide an indication of the range a second pair of analog output terminals are used T...

Page 53: ...cing Micro Fuel 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 MANU...

Page 54: ...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 appl...

Page 55: ...ED The 3010PAC Control 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 met...

Page 56: ...me of cleaning 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...

Page 57: ...PartII i Part II Analysis Unit TeledyneAnalyticalInstruments OPERATING INSTRUCTIONS Model 3010PAC Oxygen Analyzer Part II Intrinsic Safe Barriers and Remote Probe CENELEC Type Part Number C 66426...

Page 58: ...Pressure 2 4 2 2 5 Calibration Characteristics 2 4 2 2 6 Micro Fuel Cell Class 2 5 2 2 6 1 Class A 3 Cell 2 5 2 2 6 2 Class A 5 Cell 2 5 2 2 6 3 Class B 1 Cell 2 6 2 2 6 4 Class B 3 Cell 2 6 2 2 6 5...

Page 59: ...ically and are intended for applica tions where remote control of the sample analysis is desirable Safety barrier box isolate the BASEEFA approved probes from the control unit The intrinsically safe s...

Page 60: ...barriers P N B366 and P N B367 and barrier box P N E324 as shown in drawing C66191 1 4 Cell Housing Probe The cell housing probe provides an enclosure for the B1 sensor and temperature compensation th...

Page 61: ...sed in the remote Control Unit covered in Part I of this manual 2 2 Micro Fuel Cell Sensor 2 2 1 Principles of Operation The oxygen sensors used in the Model 3010PAC series are Micro Fuel Cells design...

Page 62: ...idently in practically any environment or sample stream The cell is effectively sealed although one end is permeable to oxygen in the sample gas The other end of the cell is a contact plate consisting...

Page 63: ...rear membrane beneath the anode is filled with electro lyte Cathode and anode are submerged in this common pool They each have a conductor connecting them to one of the external contact rings on the c...

Page 64: ...rease The electron transfer and therefore the external current will increase even though the oxygen concentration of the sample has not changed It is therefore important that the sample pressure at th...

Page 65: ...pical use and electri cal specifications 2 2 6 1 Class A 3 Cell The class A 3 cell is for use in applications where it is exposed con tinuously to carbon dioxide concentrations between 1 and 100 in th...

Page 66: ...ptable in order to have a longer cell life Nominal output in air is 0 30 mA and 90 response time is 13 s Expected life in air is 12 months 2 2 6 5 Class C 3 Cell The class B 1 cell is for use in appli...

Page 67: ...that is sheltered from the elements In areas where the ambient temperature is expected to drop below 0 C auxiliary heating must be provided Install the probe with a suitable sample system in an area...

Page 68: ...the instrument has been idle for too long When the micro Fuel Cell needs to be installed or replaced follow the procedures in chapter 5 Maintenance for removing and installing cells 3 4 Testing the Sy...

Page 69: ...ic safety barrier strips one each P N B366 single channel B367 dual channel are installed between the cell and the control unit The barrier strips are housed in an approved bulkhead mountable barrier...

Page 70: ...0 1 V 13 Network 15 Zero Solenoid Return 16 Span Solenoid Return 17 Span Solenoid Hot 18 Range 3 Contact 19 Range 3 Contact 20 Alarm 3 C Contact 21 Range 1 Contact 22 Range 2 Contact 23 Range ID 0 1...

Page 71: ...O Contact 48 Exhaust Solenoid Return 49 Zero Solenoid 50 Sample Solenoid Return 3 5 Remote Probe Connection The Models 3010PAC are split architecture dual chassis instru ments which have a Remote Prob...

Page 72: ...3 Installation Model 3010PAC 3 6 Part II Teledyne Analytical Instruments...

Page 73: ...ON THE TITLE PAGE OF THIS MANUAL 4 2 When to Replace a Cell If the 3010P analysis readings begin to drift downward uncharacteristi cally try recalibration If recalibration raises the readings for a sh...

Page 74: ...concentration of your span gas If the quotient is less than the Index value for the cell class you are using replace the cell Table 5 1 Cell Indices Cell Class Index A 3 1 818 A 5 1 818 B 1 4 545 B 3...

Page 75: ...ou Note Evidence of damage due to tampering or mishandling will render the cell warranty null and void 4 4 System Self Diagnostic Test 1 Press the System button to enter the system mode 2 Use the arro...

Page 76: ...4 Maintenance Model 3010PAC 4 4 Part II Teledyne Analytical Instruments...

Page 77: ...endix A 1 Oxygen Analyzers Appendix TeledyneAnalyticalInstruments OPERATING INSTRUCTIONS Model 3010PAC Oxygen Analyzers Appendix Flush Mount Control Unit PN D66192B CENELEC Type Analyssis Unit PN B399...

Page 78: ...2 Appendix Appendix Models 3010PAC TeledyneAnalyticalInstruments Contents A 1 Model 3010PAC Specifications A 3 A 2 Recommended 2 Year Spare Parts List A 5 A 3 Drawing List A 6 A 5 The Zero Functions A...

Page 79: ...Threeuserdefinableranges0 1 to0 100 Air calibration range 0 25 Autoranging with range ID output SampleSystem Positivepressureservice Vacuumservice optional Auto Cal Auto Zero Electrically operated va...

Page 80: ...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 therma...

Page 81: ...66 Safety Barrier 1 Channel 1 B367 Safety Barrier 2 Channel _____________________ Order one type only A B or C as appropriate Order one type only US or European as appropriate Check Specific Model Inf...

Page 82: ...ntrol Unit 3010PAC D 66192C Final Assembly Outline Drawing Control Unit 3010PAC MA D66191 Sensor Block Interconnection Diagram C66426 Safety Barrier Housing Assembly B39923C Final Assembly Top 4 Probe...

Page 83: ...appears blinking 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 rea...

Page 84: ...ys the rate of 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 Sl...

Page 85: ...2 Environmental Health and Safety Extension 230 Date Prepared 04 26 95 Section I Product Identification Section III Physical Chemical Characteristics Section II Hazardous Ingredients Composition Mater...

Page 86: ...utes of Entry Inhalation Highly unlikely Ingestion May be fatal if swallowed Skin The electrolyte potassium hydroxide is corrosive skin contact may cause irritation or chemical burns Eyes The electrol...

Page 87: ...inutes and remove 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 remov...

Page 88: ...mation RQ Hazardous 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 Malinck...

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