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Teledyne 3010TA, Operating Instructions Manual, Page: 88 / 101

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5   Maintenance

Model  3010

T

5-4:  Part II

5.2.3 Removing the Micro-Fuel Cell

WARNING: DO NOT TOUCH 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 stainless steel cell

block. (See Figure 5-2.)

Figure 5-2:  Removing or Installing a Trace Micro-Fuel Cell

3 4 5 6 9

7

1

8

2

HGN

10

Cell Block

Micro-Fuel Cell

O-Ring

Cell Holder

Lift Up

Gate

Cell Adaptor

(For B-2 or A-2

series cell)

Summary of Contents for 3010TA

Page 1: ...ES 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...

Page 2: ...sions 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...

Page 3: ...r Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Table of Contents Specific Model Information iv Preface v Part I Control Unit Model TA Part I 1 1 Part II Analysis Unit Model T Part I...

Page 4: ...valves built in Valves are automatically synchronized to the analyzer s electroniccontrolsequences o 3010TA F Built in flame arresters for Groups C and D service o 3010TA G Built in flame arresters f...

Page 5: ...ers the Model 3010TA 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...

Page 6: ...5479 3010TAC CENELECtypeTraceOxygenAnalyzerwithflushmount Control Unit Consists of 3010TA Control Unit PN D 66192A and a 3010T_C Analysis Unit PN D 66193 3010PAC CENELECtypePercentOxygenAnalyzerwithfl...

Page 7: ...0 250 000 ppm for trace analysis Air calibration range for convenient spanning at 20 9 Auto Ranging allows analyzer to automatically select the proper preset range for a given measurement Manual overr...

Page 8: ...viii Model 3010 Model 3010 Model 3010 Model 3010 Model 3010T T T T TA A A A A...

Page 9: ...Part I i Part I Control Unit OPERATING INSTRUCTIONS Model 3010TA Oxygen Analyzer Part I Control Unit Flush Mount Part Numbers D 64596A...

Page 10: ...2 Mounting the Control Unit 3 1 3 3 Electrical Connections 3 3 3 4 Testing the System 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...

Page 11: ...anning 4 14 4 4 2 2 Manual Mode Spanning 4 15 4 4 3 Span Failure 4 16 4 5 The Alarms Function 4 16 4 6 The Range Function 4 18 4 6 1 Setting the Analog Output Ranges 4 19 4 6 2 Fixed Range Analysis 4...

Page 12: ...iv Part I Model 3010TA Oxygen Analyzer...

Page 13: ...ush panel and or rack mount Control Units The Analysis 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 Prob...

Page 14: ...o 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 t...

Page 15: ...instrument s circuitry is operating 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...

Page 16: ...rms and 1 system alarm RS 232 Port Serialdigitalconcentrationsignaloutput and control input Remote Probe Providesallelectricalinterconnecttothe Analysis Unit or Remote Probe Remote Span Zero Digital i...

Page 17: ...etwork I O Serialdigitalcommunicationsforlocal network access For future expansion Not implemented at this printing Note If you require highly accurate Auto Cal timing use external Auto Cal control wh...

Page 18: ...1 6 Part I 1 Introduction Model 3010TA...

Page 19: ...trated in section 5 Maintenance Refer to Figure 2 1 Block Diagram of the 3010TA CU Electronics In the presence of oxygen the sensor in the Analysis Unit generates a current A current to voltage amplif...

Page 20: ...2 2 Part I 2 Operational Theory Model 3010TA Figure 2 1 Block Diagram of the 3010TA CU Electronics...

Page 21: ...tal information is also sent to a 12 bit digital to analog converter that produces the 4 20 mA dc and the 0 1 V dc analog concentra tion signal outputs and the analog range ID outputs The microprocess...

Page 22: ...2 4 Part I 2 Operational Theory Model 3010TA...

Page 23: ...r 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 3010TA Control Unit is for indoor us...

Page 24: ...nit 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...

Page 25: ...ons Figure 3 4 shows the Control Unit rear panel Connections for power communications and both digital and analog signal outputs are described in the following paragraphs Wire size and maximum length...

Page 26: ...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...

Page 27: ...rationisbelowthreshold Can be configured as fail safe or non fail safe Can be configured as latching or nonlatching Can be configured out defeated Threshold Alarm 2 Can be configured as high actuates...

Page 28: ...tion 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 In...

Page 29: ...ionsoftheinstrument RS 232 Port The digital 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 stan...

Page 30: ...e split architecture dual chassis instruments which have a Remote Probe or Analysis Unit The Remote Probe connector is used for controlling the Analysis Unit internal sample zero and span gas valves a...

Page 31: ...ired 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 c...

Page 32: ...ntegrity 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...

Page 33: ...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 100 ppm MED Range 1000 ppm HI Rang...

Page 34: ...nditions System The system function consists of six subfunctions that regulate the internal operations of the analyzer Auto Cal setup Passwordassignment Self Testinitiation Checking software version L...

Page 35: ...haracters available Once a unique password is assigned and activated the operator MUST enter the UNIQUE password to gain access to set up functions which alter the instrument s operation such as setti...

Page 36: ...r supply output boards and amplifiers Version Displays Manufacturer Model and Software Version ofinstrument Show Negative The operator selects whether display can show negative oxygen readings or not...

Page 37: ...zen for the time displayed in the second line of the TRAK HLD menu after the analyzer returns to the Analyze mode The factory default is three minutes but the delay time is program mable To adjust to...

Page 38: ...word Protection If a password is assigned then setting the following system parameters can be done only after the password is entered span and zero settings alarm setpoints analysis range definitions...

Page 39: ...s been previously installed enter the password using the arrow keys to scroll back and forth between letters and the arrow keys to change the letters to the proper password Press Enter to enter the pa...

Page 40: ...r pass word 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...

Page 41: ...TRAK HLD Auto Cal PSWD Logout More Use the arrow keys to position the blinking over the Logout func tion and press Enter to Log out The screen will display the message ProtectedUntil Password Reenter...

Page 42: ...ea of the instrument Refer to chapter 5 Maintenance for number code information The results screen alternates for a timewith Press Any Key ToContinue Then the analyzer returns to the initial System sc...

Page 43: ...ation lim its The analyzer is calibrated using zero and span gases Any suitable oxygen free gas can be used for zero gas as long as it is known that it will not react adversely with the sample system...

Page 44: ...1 1 AutoModeZeroing Press Zero to enter the zero function mode The screen allows you to select whether the zero calibration is to be performed automatically or manu ally Use the arrow keys to toggle b...

Page 45: ...ait 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...

Page 46: ...ettling AUTO ENT For Next Press Enter to move to the next screen Calib Holdingtime Cal hold 5 min This menue allows the operator to set the time the analyzer should be held in the span mode after the...

Page 47: ...t affect anything in Manual Mode Just press Enter to continue Span Val 000008 00 ENT Span UP Mod Press UP topermitmodification Mod ofspanvalue Use the arrow keys to enter the oxygen concentration of t...

Page 48: ...et if the next span cycle is correct A trace cell is unlikely to fail span As explained before when the sensor reaches the end of its useful life the zero offset begins to rise until the analyzer find...

Page 49: ...n alarms to operate in failsafe or nonfailsafe mode 3 Are either of the alarms to be latching In latching mode once the alarm or alarms trigger they will remain in the alarm mode even if process condi...

Page 50: ...member setpointunitsare parts per million To set the other parameters use the arrow keys to move the blinking over to the desired parameter Then use the arrow keys to change the parameter Once the par...

Page 51: ...nue to read accurately with full precision See Front Panel description in chapter 1 The automatic air calibration range is always 0 25 and is not pro grammable 4 6 1 Setting the Analog Output Ranges T...

Page 52: ...ticular range the output saturates at 1 V dc or 20 mA However the digital readout and the RS 232 output continue to read the true value of the oxygen concentration regardless of the analog output rang...

Page 53: ...tput 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 The analog output signal has a voltage which depe...

Page 54: ...quickly saturate the cell with oxygen which can then require a quite a long purge down time for the sensor when then exposed to low oxygen concen trations In the event that flow is to be interrupted i...

Page 55: ...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 Repl...

Page 56: ...e 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...

Page 57: ...ontrol Units contain the following major components Power Supply Motherboard with Microprocessor RS 232 chip and PreamplifierPCB Front Panel Display Board and Displays 5 digit LED meter 2 line 20 char...

Page 58: ...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 hars...

Page 59: ...art II Analysis Unit Part II Analysis Unit Part II Analysis Unit Part II Analysis Unit Part II Analysis Unit OPERATING INSTRUCTIONS Model 3010TA Oxygen Analyzer Part II Analysis Unit NEC Type Part Num...

Page 60: ...rs 2 1 2 2 1 Principles of Operation 2 1 2 2 2 Anatomy of a Micro Fuel Cell 2 2 2 2 3 Electrochemical Reactions 2 3 2 2 4 The Effect of Pressure 2 4 2 2 5 Calibration Characteristics 2 4 2 2 6 Micro F...

Page 61: ...ance 5 1 Routine Maintenance 5 1 5 2 Major 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...

Page 62: ...el 3010T Model 3010T Model 3010T Model 3010T Model 3010T Thermal Conductivity Anal Thermal Conductivity Anal Thermal Conductivity Anal Thermal Conductivity Anal Thermal Conductivity Analyz yz yz yz yz...

Page 63: ...C type 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 con...

Page 64: ...nents 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 p...

Page 65: ...nput termi nals Voltage Selector Power input selector switch for electric heater Adjusts input requirement for 110 or 220 V ac depending on available source voltage Use 50 60 Hz Fuses 1 6 A 250 V T ty...

Page 66: ...1 4 Part II 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction Model 3010T...

Page 67: ...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...

Page 68: ...ally 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 of two concentric...

Page 69: ...eneath the anode is filled with electrolyte Cathode and anode are submerged in this common pool They each have a conductor connecting them to one of the external contact rings on the contact plate whi...

Page 70: ...on transfer and therefore the external current will increase even though the oxygen concen tration of the sample has not changed It is therefore important that the sample pressure at the fuel cell usu...

Page 71: ...plication This designation is its class 2 2 6 1 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...

Page 72: ...as pockets that can interfere with trace analysis The metal restrictor upstream from the cell helps manage the flow through the system 1SLPM at 20 psig for nitrogen It is corrosion resistant The sampl...

Page 73: ...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 slightl...

Page 74: ...nit 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 diam...

Page 75: ...ll circular orifice should face toward the back of the unit against the direction of gas flow Remove the blue sticker from the restrictor before using WARNING Operating the unit without restrictors ca...

Page 76: ...Panel ZERO IN and SPAN IN These are inlets for zero gas and span gas There are electrically operated valves inside for automatic switching between sample and calibration gases These valves are complet...

Page 77: ...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...

Page 78: ...noid outputs is nominally 0 V for the OFF and 15 V dc for the ON conditions The maximum combined current that can be pulled from these output lines is 100 mA If two lines are ON at the same time each...

Page 79: ...pter 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 connect...

Page 80: ...3 Installation Model 3010T 3 8 Part II...

Page 81: ...uilt 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 o...

Page 82: ...4 4 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 c...

Page 83: ...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 Cell failure in the 3010T is usually associated with inability t...

Page 84: ...4 Operation Model 3010T 4 4 Part II...

Page 85: ...art I section 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 counterclock...

Page 86: ...to local regulations This section describes storage and handling of the fuel cell and when and how to replace it 5 2 1 Storing and Handling Replacement Cells To have a replacement cell available when...

Page 87: ...f the cell package until the cell is to actually be used If the cell package is punctured and air is permitted to enter the cell will require an excessively long time to reach zero after installation...

Page 88: ...EFLON MEMBRANE THAT CAN LEAK CAUSTIC AND COR ROSIVE CHEMICALS WHEN PUNCTURED The Micro Fuel cell is located inside the housing in a stainless steel cell block See Figure 5 2 Figure 5 2 Removing or Ins...

Page 89: ...ate Teflon membrane that can leak when punctured The sensor must be replaced if the membrane is damaged Before installing a new cell check the O ring in the base of the cell holder Replace if worn or...

Page 90: ...he date of ship ment The customer should purchase only one spare cell Do not attempt to stockpilesparecells Note The L 2C cell is not designed for applications where CO2 is a major component in the sa...

Page 91: ...ess 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 pres...

Page 92: ...5 Maintenance Model 3010T 5 8 Part II...

Page 93: ...A 1 Oxygen Analyzer Appendix OPERATING INSTRUCTIONS Models 3010TA Oxygen Analyzers Appendix Flush Mount Control Unit PN CU64596A NEC Type Analysis Unit PN AU65478...

Page 94: ...odel 3010TA Contents A 1 Model 3010TA Specifications A 3 A 2 Recommended 2 Year Spare Parts List A 5 A 3 Drawing List A 6 A 4 Application Notes on Restrictors Pressures Flow A 7 A 5 Material Safety Da...

Page 95: ...e External gas connector panel with flow indicator flame arrestorsoptional Sensor L 2 trace Micro Fuel Cell Cell Block 316stainlesssteel Ranges Threeuserdefinableranges 0 10 ppmto0 250 000 ppm Air cal...

Page 96: ...supply 85 250 V ac 47 63 Hz Explosion Proof Analysis 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...

Page 97: ...be 1 T976 Molex Crimp Terminals for RemoteProbeConnector 1 O165 O ring 1 C6689 L2C Micro FuelCell _____________________ Order one type only US or European as appropriate A minimum charge is applicable...

Page 98: ...ine Drawing Control Unit Trace Oxygen D 65478 Final Assembly Outline Drawing Analysis Unit Trace Oxygen D 64950 WiringDiagram NOTE The MSDS on this material is available upon request through the Teled...

Page 99: ...lue HigherpressureswillproducefasterO2 diffusionrates resultinginhigherO2reading andshortercelllife Tousea3000 seriesanalyzeratacellpressureotherthanatmospheric theanalyzermustbe calibratedwithaknownc...

Page 100: ...sofmercuryshould 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 lin...

Page 101: ...enrestrictorsareused thegaspressuremust beadjustedtoachievetheproperflowrate OPERATIONWITHOUT ARESTRICTORDEVICE Operationwithoutarestrictordeviceisnotrecommendasmentioned above A3010TA withoutanyflowr...

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