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Teledyne Analytical Instruments

Trace Oxyg

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Model 356WA

Trace Oxygen Analyzer

Instruction Manual

P/N M356WA

09/14/99

ECO # 99-0373

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

Summary of Contents for 356WA

Page 1: ...99 ECO 99 0373 HIGHLYTOXICANDORFLAMMABLELIQUIDSORGASESMAYBEPRESENTINTHISMONITORINGSYSTEM PERSONALPROTECTIVEEQUIPMENTMAYBEREQUIREDWHENSERVICINGTHISSYSTEM HAZARDOUSVOLTAGESEXISTONCERTAINCOMPONENTSINTERNALLYWHICHMAYPERSISTFORA TIMEEVENAFTERTHEPOWERISTURNEDOFFANDDISCONNECTED ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND OR SERVICING BEFORE CONDUCTINGANYMAINTENANCEORSERVICINGCONSULTWITHAUTHO...

Page 2: ...cess that all personnel involved in the use of the instrument or its interface with the process that all personnel involved in the use of the instrument or its interface with the process being measured be properly trained in the process itself as well as all instrumentation being measured be properly trained in the process itself as well as all instrumentation being measured be properly trained in...

Page 3: ...tem 2 2 3 Installation 3 1 Location 3 1 3 2 Electrical Connections 3 1 3 3 Sample Connections 3 2 4 Operations 4 1 Filling the Reservoir 4 1 4 2 Detector Cell 4 1 4 2 1 Cell Packaging 4 1 4 2 2 Electrolyte 4 1 4 2 3 Cell Installation 4 3 4 3 Throttle Valve 4 5 4 4 Humidity Control 4 5 4 5 Power 4 7 4 6 Warm Up and Stabilization 4 7 4 7 Calibration 4 7 5 Maintenance Troubleshooting 5 1 Flowmeter an...

Page 4: ... Model 356W Model 356WA A A A A 5 7 Reservoir and Humidifier Column 5 4 5 8 Leak Detection 5 6 5 8 1 Leak Detection Procedure 5 6 5 8 2 Cell Leak 5 7 Appendix Specifications A 1 Spare Parts List A 2 Drawing List A 3 Calibration Data A 4 Material Safety Data Sheets A 9 ...

Page 5: ... identical with the exception of housing or options such as special meters For purposes of clarity this manual will discuss the unit in general The differ ences between the configurations are minor and will be obvious to the user 1 1 1 1 1 1 1 1 1 1 Method of Operation Method of Operation Method of Operation Method of Operation Method of Operation Gas from the process stream is fed through a sampl...

Page 6: ...onveniently located near the analyzer and installed in a fashion which permits easy removal for periodic cleaning or replacement 2 2 2 2 2 Scrubbers Scrubbers Scrubbers Scrubbers Scrubbers If the sample contains small quantities of acidic anhydrides SO2 etc or mercaptans H2 S etc they will react with the electrolyte or the cathode and must be removed A causticscrubberisusuallyeffective 3 3 3 3 3 P...

Page 7: ...de An exploded view of the cell is showm in Figure 5 1 The sample gas stream is passed directly over the cathode screens initiating an electrochemical reaction Four electrons are generated by the oxidation of the lead anode and are then used to reduce oxygen at the cathode The flow of electrons between the anode and cathode creates an electric current which is directly proportional to the oxygen c...

Page 8: ...ty control that is located on the panel of the control unit The amount of heating required depends on the sample flow rate the sample humidity and the specific heat of the sample The correct adjust ment for the operating conditions of any particular installation is obtained by checking the cell electrolyte level periodically and replenished when neces sary according to the instructions in Section ...

Page 9: ... yzer er er er er Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Teledyne Analytical Instruments Figure 2 1 Flow System Schematic Cell Pressure ATM b a b a b a Vent Reservoir Drain Throttle Valve Flowmeter Humidifier Column Water Sample In Cell Compartment ...

Page 10: ...r There will be a slight additional pressure in the top of the humidifier column depending on the flow rate the pressure needed to push the sample through the cell and associated tubing but at normal flow rates this merely slightly lowers the level in the humidifier column The sample bubbles through the water in the reservoir on its way to the outlet port Some of the water vapor will re condense s...

Page 11: ... the water level control system for the humidifier is gravity sensitive the water level control system for the humidifier is gravity sensitive the water level control system for the humidifier is gravity sensitive the water level control system for the humidifier is gravity sensitive THE ANALYZER MUST BE MOUNTED SO THAT THE BOTTOM OF THE ANALYZER MUST BE MOUNTED SO THAT THE BOTTOM OF THE ANALYZER ...

Page 12: ...through small leaks even when sample pressure is much greater than atmospheric pressure A 1 8 female NPT fitting is installed on the back of the instrument for making sample and vent line connections Thepurge line is fitted with a 1 4 tube fitting 1 Connectors Connectors Connectors Connectors Connectors Use straight tube connectors where possible This facilitates removal of the analyzer section fr...

Page 13: ...o the atmosphere a vent line to carry the sample to a suitable venting area will be required The sample leaves the vent connection of the analyzer saturated with water vapor at a temperature somewhat above ambient so a suitable trap to remove conden sate without plugging the vent line will be required The vent line should also be arranged so that it cannot become plugged by dirt or dust Figure 2 2...

Page 14: ...l 356W Model 356W Model 356W Model 356WA A A A A Teledyne Analytical Instruments Figure 5 Gas Connections to Back of Analyzer 18 1 4 17 9 16 2 15 7 15 16 17 9 5 16 Sample Purge Vent 115 V 50 60 Hz Power In Signal Out 1 4 Female NPT 7 8 dia holes for 1 2 conduit FIGURE 5 ANALYZER OUTLINE DIAGRAM ...

Page 15: ...r Cell Detector Cell Detector Cell Detector Cell Detector Cell The cell is located in the heated compartment on the left side of the analyzer case as shown in Figure 4 1 To open the compartment unscrew the captive knurled knobs at the top and bottom of the compartment and remove the plastic window 4 2 1 4 2 1 4 2 1 4 2 1 4 2 1 Cell Packaging Cell Packaging Cell Packaging Cell Packaging Cell Packag...

Page 16: ...carbonate and should be used when the CO2 level in the background gas is between 500 ppm and 1 This narrow range is rarely encountered It is however available from the factory Safety related information for this electrolyte can be found in the Appendix Type C electrolyte is a 20 solution w v of potassium bicarbonate and should be used when the CO2 level in the background gas is between 1 and 100 S...

Page 17: ...istilled water 2 Pour about half the furnished electrolyte into the cell and slosh until all components within the cell are wetted by the solution Drain and dispose of the solution 3 Wipe the top of the cell and the O ring with a clean disposable tissue to remove solution from the exterior DO NOT DO NOT DO NOT DO NOT DO NOT touch the interior of the cell 4 Carefully pour in electrolyte until it ju...

Page 18: ...Model 356W Model 356W Model 356W Model 356W Model 356WA A A A A Teledyne Analytical Instruments Figure 4 2 Cell Compartment Components Humidifier Column Heater Humidifier Column Cell Block Sample Flow Control Valve Cell Mounting Bolts Terminal Strip No 4 Flowmeter O Ring ...

Page 19: ...n and the float of the flowmeter should rise in its tube 2 Adjust the valve so that the flowmeter float is centered in the flow rate reference indicator CAUTION Open the throttle valve carefully Excessive flow rate may cause water in the humidifier column to be carried into the detector cell This can cause erratic readings and may require disassembly cleaning and refilling of the sensor 3 The flow...

Page 20: ...W Model 356WA A A A A Teledyne Analytical Instruments Figure 8 Calibrator Assembly Electrical Terminal Board Sub Assembly O Ring Outside Electrode Connected to Y Terminal Post Oxygen Generated Here Wick Saturated With KOH Electrolyte Solution Inside Electrode Connected to B Terminal Post Hydrogen Generated Here ...

Page 21: ...wer is turned on power is applied to the cell compartment heater The cell operates without applied power but its output will vary with changes in ambient temperature 4 6 4 6 4 6 4 6 4 6 Warm Up and Stabilization Warm Up and Stabilization Warm Up and Stabilization Warm Up and Stabilization Warm Up and Stabilization When the analyzer is initially put into operation the air in the lines and sample pa...

Page 22: ...t is centered in the flowmeter reference indicator Note the reading of the external recorder or meter 2 Turn the range selector switch to the range which encompases the oxygen concentration of the span gas The meter or recorder should move upscale and indicate the exact concentration of oxygen in the span gas 3 If the external recorder meter does not indicate the proper amount of oxygen adjust the...

Page 23: ...olyte Level 5 2 Cell Electrolyte Level 5 2 Cell Electrolyte Level 5 2 Cell Electrolyte Level 5 2 Cell Electrolyte Level The level of electrolyte in the cell must be checked daily and adjusted as necessary Refer to Section 4 2 3 Cell Installation The proper level for the electrolyte is when the bottom edge of the sensor screen is wetted but not immersed Approximately 3 32 of the silver electrode sh...

Page 24: ...s serviced or replaced calibrate the analyzer as outlined in Section 4 7 Calibration 5 5 2 Lead Electrode 5 5 2 Lead Electrode 5 5 2 Lead Electrode 5 5 2 Lead Electrode 5 5 2 Lead Electrode If electrode is discolored when new or has obviously deteriorated from use it may be necessary to clean or replace the electrode Use the following procedure while referring to Figure 5 1 If the lead electrode i...

Page 25: ...yz yz yz yzer er er er er Maintenance Maintenance Maintenance Maintenance Maintenance T T T T Tr r r r roub oub oub oub oubleshooting 5 leshooting 5 leshooting 5 leshooting 5 leshooting 5 Figure 5 1 Cell Assembly O Ring Cover Cathode Screen Assembly Lead Electrode Cell Block Terminal seal O rings 2 Cell Mounting Nuts 4 Mounting Bolts 4 ...

Page 26: ...Installationforcellinstallationinstructions 5 7 Reservoir and Humidifier Column 5 7 Reservoir and Humidifier Column 5 7 Reservoir and Humidifier Column 5 7 Reservoir and Humidifier Column 5 7 Reservoir and Humidifier Column Approximately once each year the reservoir and humidifier column should be drained and cleaned Use the following procedure a Reduce sample flow to approximately 50 cc min 50 cc...

Page 27: ...emovingtheHumidifier RemovingtheHumidifier RemovingtheHumidifier Column Column Column Column Column 1 Grasp the tube and with a twisting motion work it up into the top humidifier block until it clears the bottom block completely 2 Angle the bottom of the tube towards you and twist it free of the top block 3 The top and bottom O rings will remain captive in their blocks To Reinstall To Reinstall To...

Page 28: ...s 5 9 1 Leak Detection Procedure 5 9 1 Leak Detection Procedure 5 9 1 Leak Detection Procedure 5 9 1 Leak Detection Procedure 5 9 1 Leak Detection Procedure The procedure outlined here is based on the premise that the leak rate is independent of sample flow rate a Stop the sample flow to permit oxygen to accumulate at the point of the leak b After approximately one minute restart the sample flow I...

Page 29: ...y leaks locations are at the two terminal seal O rings or at the large O ring in the cell block mounting base Check that the terminals are screwed tightly into place Frequently when a leak occurs at a terminal connection a greenish crystalline deposit will be found inside the cell around the terminal mounting screw This is lead carbonate which is formed by carbon dioxide in the air reacting with l...

Page 30: ...ity control a Verify proper connection from the cell through the control unit to the external recorder or meter check for blown fuse Replace as necessary b Inspect electrolyte level and add as necessary See Section 4 2 3 item 4 c Remove cell and clean thoroughly See Section 4 2 3 d Correct short Refill with fresh electrolyte as needed e Check for excessive flow rate Check for excessive foam ing in...

Page 31: ...ile watching the voltmeter turn the humidifier control clock wise the meter reading should go from 0 50 milliamps If not replace the humidifier heater element or the humidifier heater control To deter mine which should be replaced see paragraph below If there is no current either the humidifier element or control is defective To determine which it is Turn the humidifier control knob fully ccw Disc...

Page 32: ... all power and remove the AC power cord from the power source Refer to wiring diagram C 18593 left hand side bottom of the cell com partment Pull out the block assem bly from the bottom of the humidifier column pull out the heater element and unsolder the wires Replace with new heater element P N R139 Solder wires turn the terminals down into the holder and replace the holder d Verify that the pow...

Page 33: ...Do Faulty triac Q6 in heater control or faulty triac driver A4 continued Cell lacks sensitivity contin ued Disconnect the thermo switch by removing one of the wires from TS4 terminal 3 Meter should show voltage If voltage shows short terminals 3 and 4 with a test jumper Meter reading should drop to about zero less than 10 VAC If power fails to go on and off as jumper is alter nately installed and ...

Page 34: ...s 5 12 5 Maintenance 5 Maintenance 5 Maintenance 5 Maintenance 5 Maintenance T T T T Tr r r r roub oub oub oub oubleshooting leshooting leshooting leshooting leshooting Model 356W Model 356W Model 356W Model 356W Model 356WA A A A A ...

Page 35: ...onse and Recovery Time Response and Recovery Time 90 in less than 1 minute for lowest range Operating Temperature Range Operating Temperature Range Operating Temperature Range Operating Temperature Range Operating Temperature Range 40 F to 120 F 5 C to 49 C SampleRequirement SampleRequirement SampleRequirement SampleRequirement SampleRequirement Flow 150cc min Pressure 1 to 150 psig Temperature 60...

Page 36: ...B6274 Flowmeter asm specify background gas 1 B30868 PC Board Proportional temp control For applications 10 PPM or higher 1 B36026 PC Board Proportional temp control 220V 1 C14449 PC Board Proportional temp control For applications less than 10 PPM 1 C41274 PC Board Proportional temp control 220V 1 B29600 PC Board E I converter isolated O option 1 A9309 PC Board Alarm comparator dual 2 opt optional...

Page 37: ...t to Teledyne Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Phone 626 934 1500 FAX 626 961 2538 TWX 910 584 1887 TDYANLY COID Web www teledyne ai com or your local representative Drawing List Drawing List Drawing List Drawing List Drawing List A 5855 Outline A 47143 Piping D 47142 Schematic B 30364 Schematic B 14718 Schematic B 15016 Schematic D 22297 Wiring D 47139 W...

Page 38: ...Electrolyte Type Electrolyte Type Electrolyte Type Type A 10 potassium hydroxide in distilled water Type B 10 potassium carbonate in distilled water Type C 20 potassium bicarbonate in distilled water Calibration Considerations Calibration Considerations Calibration Considerations Calibration Considerations Calibration Considerations In order to calibrate the Model 356 all that is required is to ce...

Page 39: ...sitioned on the flow tube The vent flow should be measured either with a volume displacement flow device e g a bubble o meter or a calibrated rotometer with correc tion factors for ambient temperature and pressure and sample gas density and viscosity When using a volume displacement flow device it will be necessary to correct the 150 cc min flow rate for ambient temperature and pressure It will al...

Page 40: ...or pressure of water at ambient temp in mm Hg By way of example suppose that the target s position on the flow tube is in question and it has been determined that the ambient temperature is 77 F and the altitude where the instrument is being used is 5000 ft above sea level This approximation is within 0 5 of the ICAO Standard Atmo sphere over the range 0 7500 ft above sea level Ref Fluid Mechanics...

Page 41: ...dix Teledyne Analytical Instruments From these computations the exit flow rate should be set to 189 cc min using an appropriate flow measuring device and the target respositioned if necessary so that the float is centered within the target opening Subsequently it should not be necessary to measure the exit flow unless another circumstance of the type listed above occurs ...

Page 42: ...t Temperature K Vapor Pressure of Water mm Hg Ambient Temperature K Vapor Pressure of Water mm Hg Ambient Temperature K Vapor Pressure of Water mm Hg Ambient Temperature K Vapor Pressure of Water mm Hg Ambient Temperature K Vapor Pressure of Water mm Hg 288 12 9 289 13 7 290 14 6 291 15 6 292 16 6 293 17 7 294 18 8 295 20 0 296 21 2 297 23 9 298 23 9 299 25 4 300 26 9 301 28 6 302 30 7 303 32 1 30...

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