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Trace Oxygen Analyzer

Teledyne Analytical Instruments

OPERATING INSTRUCTIONS

Model

3010

Trace Oxygen Analyzer

Bulkhead Mount Control Unit, PN D-66190A*

NEC Type Analysis Unit, PN D-65478*

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 PERSIST
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 M62927

11/24/04

ECO: #03-0126

Summary of Contents for 3010TB

Page 1: ...RESENT IN THIS MONITORING SYSTEM PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FOR A TIME EVEN AF...

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: ...race Oxygen Analyzer Teledyne Analytical Instruments Table of Contents Specific Model Information iv Preface v Part I Control Unit Model TB Part I 1 1 Part II Analysis Unit Model T Part II 1 1 Appendi...

Page 4: ...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 electroniccontrolsequences o 3010...

Page 5: ...mote probe that can operate in a hazardous area Part I of this manual covers the Model 3010TB General Purpose NEMA 4 Bulkhead mount Control Unit only This Control Unit is for outdoor indoor use in a n...

Page 6: ...D 64596B or C and 3010P Explosion Proof Analysis Unit PN D 65479 3010TB NEC type Trace Oxygen Analyzer with bulkhead mount Control Unit PN D 66190A and a 3010T Explosion Proof Analysis Unit PN D 6547...

Page 7: ...or based electronics 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 10 ppm through 0 250 000 ppm for trace...

Page 8: ...viii Model 3010TB Teledyne Analytical Instruments...

Page 9: ...Part I i Part I Control Unit Teledyne Analytical Instruments OPERATING INSTRUCTIONS Model 3010TB Oxygen Analyzer Part I Control Unit NEMA 4 Bulkhead Mount Part Numbers D 66190A...

Page 10: ...Mounting the Control Unit 3 1 3 3 Electrical Connections 3 3 3 4 Testing the System 3 12 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...

Page 11: ...2 2 Manual Mode Spanning 4 16 4 4 3 Span Failure 4 16 4 5 The Alarms Function 4 15 4 6 The Range Function 4 18 4 6 1 Setting the Analog Output Ranges 4 19 4 6 2 Fixed Range Analysis 4 20 4 7 The Analy...

Page 12: ...iv Part I Model 3010TB Oxygen Analyzer Teledyne Analytical Instruments...

Page 13: ...locations are illustratedinsection5 Maintenance Refer to Figure 2 1 Block Diagram of the 3010TB CU Electronics In the presence of oxygen the sensor in the Analysis Unit generates a current A current t...

Page 14: ...2 2 Part I 2 Operational Theory Model 3010TB Teledyne Analytical Instruments Figure 2 1 Block Diagram of the 3010TB CU Electronics...

Page 15: ...directed to the display alarms and communications port as well as to the gas control valves in the Analysis Unit The same digital information is also sent to a 12 bit digital to analog converter that...

Page 16: ...2 4 Part I 2 Operational Theory Model 3010TB Teledyne Analytical Instruments...

Page 17: ...yzer is shipped with all the materials you need to install and prepare the system for operation Carefully unpack the Control Unit and inspect it for damage Immediately report any damage to the shippin...

Page 18: ...al components of the instrument The door will swing open when the button of the latch is pressed all the way in with a narrow gauge tool less than 0 18 inch wide such as a small hex wrench or screwdri...

Page 19: ...and both digital and analog signal outputs are described in the following paragraphs Wire size and maximum length data appear in the Drawings at the back of this manual Figure 3 3 Interface Panel of t...

Page 20: ...lders accept 5 x 20 mm 1 0 A T type slow blow fuses Fuses are not installed at the factory Be sure to install the proper fuse as part of installation See Fuse Replacement in chapter 5 maintenance Anal...

Page 21: ...tions Examples The analog output signal has a voltage which depends on the oxygen concentration AND the currently activated analysis range To relate the signal output to the actual concentration it is...

Page 22: ...16 8 9 0 9 18 4 10 1 0 20 0 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 r...

Page 23: ...entration is above threshold or low actuates when concentration is below thresh old Can be configured as fail safe or non fail safe Can be configured as latching or nonlatching Can be configured out d...

Page 24: ...d close the external span valve appropriately See Remote Probe Connector at end of section 3 3 With the C option the internal valves automati callyoperatesynchronously Cal Contact This relay contact i...

Page 25: ...edium range is assigned to RANGE 2 ID and High range is assigned to RANGE 3 ID RANGE 4 ID is reserved for the Air Cal Range 25 Network I O A serial digital input output for local network protocol At t...

Page 26: ...ter Immediatelystartsanautospan az enter Immediatelystartsanautozero st enter Toggling input Stops Starts any status message output from the RS 232 Until st enter is sent again The RS 232 protocol all...

Page 27: ...s 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 obtainab...

Page 28: ...her of the units into their respectivepowersources Check the integrity and accuracy of the gas connections Make sure there are no leaks Check the integrity and accuracy of all electrical connections M...

Page 29: ...hoose 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...

Page 30: ...are Analyze This is the normal 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...

Page 31: ...scriptions 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 32: ...nter 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 Versio...

Page 33: ...is selected the concentration alarms will remain frozen 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 minut...

Page 34: ...these fields ON because there is a nonzero span interval defined 4 3 3 Password Protection If a password is assigned then setting the following system parameters can be done only after the password i...

Page 35: ...er to accept TETAI as the default password If a password has been previously installed enter the password using the arrow keys to scroll back and forth between letters and the arrow keys to change the...

Page 36: ...ers available for 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...

Page 37: ...System function 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 Protected Until...

Page 38: ...n a specific area of the instrument Refer to chapter 5 Maintenance for number code information The results screen alternates for a timewith Press Any Key To Continue Then the analyzer returns to the i...

Page 39: ...ublished specification 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 t...

Page 40: ...ion 4 4 1 3 4 4 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...

Page 41: ...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...

Page 42: ...ction 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 arro...

Page 43: ...move to the next screen Press Enter to move to the next screen Calib Holding time Cal hold 5 min This menue allows the operator to set the time the analyzer should be held in the auto span mode It doe...

Page 44: ...erator 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 not reset if the next span cycle i...

Page 45: ...ailsafe operation the relay is energized in an alarm condition You can set either or both of the concentration alarms to operate in failsafe or nonfailsafe mode 3 Are either of the alarms to be latchi...

Page 46: ...rementing or decrementing Remember setpoint units are 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 cha...

Page 47: ...readout and the RS 232 output of the concentra tion are unaffected by the fixed range They continue to read accurately with full precision See Front Panel description in chapter 1 The automatic air c...

Page 48: ...tion rises above the upper limit or default value as established by the operator for that particular range the output saturates at 1 V dc or 20 mA However the digital readout and the RS 232 output con...

Page 49: ...nt 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 The analog output signal has a...

Page 50: ...nd in most cases quickly saturate the cell with oxygen which can then require a quite long purge down time for the sensor when then exposed to low oxygen concen trations In the event that flow is to b...

Page 51: ...t 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 The 3010TB requires two 5 x 20 mm 1 0 A T type Slow Blow...

Page 52: ...2 System Self Diagnostic Test 1 Press the System button to enter the system mode 2 Use the arrow keys to move to More and press Enter 3 Use the arrow keys to move to Self Test and press Enter The foll...

Page 53: ...3 Both Failed 5 3 Major Internal Components The major components in the Control Unit are shown in Figure 5 3 Figure 5 3 Control Unit Major Internal Components Teledyne Analytical Instruments Outer Do...

Page 54: ...TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED The 3010TB Control Units contain the following major components Power Supply Motherboard with Microprocessor RS 232 chip and PreamplifierPCB F...

Page 55: ...Part II i Part II Analysis Unit Teledyne Analytical Instruments OPERATING INSTRUCTIONS Model 3010TB Oxygen Analyzer Part II Analysis Unit NEC Type Part Number D 65478...

Page 56: ...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 Fuel Cell Class 2 5 2 3 Sample Systems 2 6 3 Installation 3 1 Unpacking the Anal...

Page 57: ...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 5 4 5 2 4 Installing a New M...

Page 58: ...iv Part II Model 3010TB Oxygen Analyzer Teledyne Analytical Instruments...

Page 59: ...s housed in a NEC 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 connec...

Page 60: ...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 i...

Page 61: ...to the Power 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...

Page 62: ...1 4 Part II 1 Introduction Model 3010T Teledyne Analytical Instruments...

Page 63: ...ed 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 3010 series are Micro Fuel Cells designed a...

Page 64: ...ently 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 o...

Page 65: ...rear membrane beneath 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 c...

Page 66: ...rease The electron 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 t...

Page 67: ...tent with its application 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 cell...

Page 68: ...ni mizes residual gas pockets that can interfere with trace analysis The metal restrictor upstream from the cell helps manage the flow through the system 1 SLPM at 20 psig for nitrogen It is corrosion...

Page 69: ...l 3010T Analysis Unit 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...

Page 70: ...ermined if the 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 un...

Page 71: ...rt 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 rest...

Page 72: ...nnector Control 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 va...

Page 73: ...tions 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 Fus...

Page 74: ...See drawing D 64949 for wire recommendations Figure 3 5 Remote Probe Connector Pinouts Thermistor Block Sensor Block Thermistor 1 Thermistor 2 Sensor Return Sensor Hot Sensor Signal 8 Sensor Signal 2...

Page 75: ...on the load impedance applied See Figure 3 6 Figure 3 6 FET Series Resistance 3 5 Installing the Micro Fuel Cell The Micro Fuel Cell is not installed in the cell block when the instrumentisshipped Itm...

Page 76: ...e are no leaks Check the integrity and accuracy of the electrical connections Make sure there are no exposed conductors Check that sample pressure is between 3 and 40 psig according to the requirement...

Page 77: ...ro 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 Analysi...

Page 78: ...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 in...

Page 79: ...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...

Page 80: ...ruments c Check whether more time is needed for PPM readings to drop to an acceptable level This is true when coming down from high level If there are no leaks and the span gas is OK replace the cell...

Page 81: ...alibration see Part 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 co...

Page 82: ...ndling 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 it is needed it is recom mended that one spare cell be pur...

Page 83: ...tted to enter the cell will require an excessively long time to reach zero after installation as much as a week or more for the L 2C trace oxygen cell 5 2 2 When to Replace a Cell The characteristics...

Page 84: ...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...

Page 85: ...ls CAUTION Do not touch the sensing surface of the cell It is covered with a delicate Teflon membrane that can leak when punctured The sensor must be replaced if the membrane is damaged Before install...

Page 86: ...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 da...

Page 87: ...h in and rotate 1 4 turn The cap will pop out a few millimeters Pull out the fuse holder cap and fuse as shown in Figure 5 3 Figure 5 3 Removing Fuse Cap and Fuse from Holder 2 Replace fuse by reversi...

Page 88: ...el 3010TB 5 8 Part II Teledyne Analytical Instruments 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 inp...

Page 89: ...1 Oxygen Analyzer Appendix Teledyne Analytical Instruments OPERATING INSTRUCTIONS Models 3010TB Oxygen Analyzers Appendix NEMA 4 Bulkhead Mount Control Unit PN D66190A NEC Type Analysis Unit PN AU6547...

Page 90: ...dyne Analytical Instruments Contents A 1 Model 3010TB 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 Ma...

Page 91: ...orsoptional Sensor L 2C trace Micro Fuel Cell Cell Block 316stainlesssteel Ranges Threeuserdefinableranges 0 10 ppm to 0 250 000 ppm Air calibration range 0 25 Autoranging with range ID output SampleS...

Page 92: ...is Unit 115 230 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 temperatur...

Page 93: ...Molex Connector for Remote Probe 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...

Page 94: ...90A Final Assembly Control Unit D 65478 Final Assembly Outline Drawing Analysis Unit Trace Oxygen D64949 InterconnectionDiagram D64808 Outline Diagram Control Unit NOTE The MSDS on this material is av...

Page 95: ...entthanoptimumvalue HigherpressureswillproducefasterO2 diffusionrates resultinginhigherO2reading andshortercelllife Tousea3000 seriesanalyzeratacellpressureotherthanatmospheric theanalyzermustbe calib...

Page 96: ...velof 5 10 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 i...

Page 97: ...sthesamplegas Whenrestrictorsareused the gaspressuremustbeadjustedtoachievetheproperflowrate OPERATIONWITHOUT ARESTRICTORDEVICE Operationwithoutarestrictordeviceisnotrecommendasmentioned above A3010TB...

Page 98: ...A 10 Appendix Model 3010TB Teledyne Analytical Instruments...

Page 99: ...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 100: ...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 electrolyte p...

Page 101: ...es 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 remove to...

Page 102: ...on 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 Malinckrodt...

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