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Teledyne OT-3, Operating Instructions Manual

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Trace Oxygen Analyzer

Teledyne Analytical Instruments

i

OPERATING INSTRUCTIONS FOR

MODEL OT-3

MODEL OT-3

Trace Oxygen Analyzer

DANGER

Toxic gases and or flammable liquids may be present in this monitoring system.

Personal protective equipment may be required when servicing this instrument.

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.

P/N M74173
10/28/2001
ECO#

Summary of Contents for OT-3

Page 1: ...ystem Personal protective equipment may be required when servicing this instrument 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 P N M74173 10 28 2...

Page 2: ...ht of any parts in so far as such alterations do not adversely affect our warranty Important Notice 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 involved in the use o...

Page 3: ...al was supplied may incorporate one or more options not supplied in the standard instrument Commonly available options are listed below with check boxes Any that are incorporated in the instrument for which this manual is supplied are indicated by a check mark in the box Instrument Serial Number _______________________ ...

Page 4: ...uction Manual for your visual and immediate warnings and when you have to attend CAUTION while operating the instrument STAND BY Instrument is on Stand by but circuit is active GROUND Protective Earth CAUTION The operator needs to refer to the manual for further information Failure to do so may compromise the safe operation of the equipment CAUTION Risk of Electrical Shock Note Additional informat...

Page 5: ...HOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL IF YOU USE THE ANALYZER IN A MANNER OTHER THAN THAT FOR WHICH IT WAS INTENDED UNPREDICTABLE BEHAVIOR COULD RESULT POSSIBLY ACCOMPANIED WITH HAZARDOUS CONSEQUENCES This manual provides information designed to guide you through the installation calibration and operation of your new analyzer Please read this manual and keep...

Page 6: ...es of Operation 6 2 2 2 Anatomy of a Micro fuel Cell 7 2 2 3 Electrochemical Reactions 8 2 2 4 The Effect of Pressure 9 2 2 5 Calibration Characteristics 9 2 3 Electronics 10 2 3 1 General 10 2 3 2 Signal Processing 11 Installation 13 3 1 Unpacking the Analyzer 13 3 2 Location and Mounting 14 3 2 2 Installing the Micro fuel Cell 14 3 3 Electrical Connections 14 3 3 1 Primary Input Power 15 3 3 2 A...

Page 7: ...ure Alarm 26 4 5 Alarm Delay 26 4 6 Keypad Lockout 27 4 7 Selecting a Fixed Range or Autoranging 28 4 8 Calibration 28 4 9 Displaying Percent PPM on the LED Display 29 4 10 Supplementary Information 29 Maintenance 31 5 1 Replacing the Fuse 31 5 2 Sensor Installation or Replacement 32 5 2 1 When to Replace a Sensor 32 5 2 2 Ordering and Handling of Spare Sensors 33 5 2 3 Removing the Micro fuel Cel...

Page 8: ...Micro fuel Cell 7 Figure 2 2 Characteristic MFC Input Output Curve 10 Figure 2 3 Block Diagram of the Signal Processing Electronics 11 Figure 3 1 Electrical Connectors for AC Control Unit 15 Figure 3 2 Contact ID for FAILSAFE Relay Operation 166 Figure 3 3 Gas Connections 19 Figure 3 4 OT 3 Sample System 21 Figure 4 1 Front Panel Control and Indicators 23 Figure 5 1 AC Fuse Replacement 32 ...

Page 9: ...compact rugged construction Typical applications of the Model OT 3 include monitoring natural gas pipelines wellheads and compressor blowers 1 2 Main Features of the Analyzer The main features of the analyzer include Insta Trace sensor technology Stainless steel sample system with PVC scrubber and Nylon cell block Pressure regulator Coalescing filter Acid gas scrubber clear rebuildable Flow contro...

Page 10: ... O2 concentration read out 7 button user interface keypad Alarm condition indicator LED 100 240 VAC 50 60 Hz power optional 9 36VDC 0 10 VDC output 4 20 mA output 0 10 VDC range ID output Electronic temperature compensation Optional RS323 interface Accuracy 2 of range at constant temp Response time 90 in 65 sec of less 25 degrees C Temperature range 0 50 degrees C 1 3 Front Panel Description All c...

Page 11: ... 0 9999ppm Set LO Range Set the low analysis range for the instrument down to 0 10ppm Set Span Span calibrate the analyzer Data Entry Keys Two push button membrane switches are used to manually change measurement parameters of the instrument as they are displayed on the LED meter readout Up Arrow Increment values of parameters upwards as they are displayed on the LED readout Down Arrow Increment v...

Page 12: ...d DC versions are different Figure 1 2 shows the AC version while Figure 1 3 shows the DC version Power Connection AC version 100 240 VAC at 50 60Hz The connector housing includes the fuse holder and AC Power cord receptacle Fuse Holder DC version Replacing the fuse is described in Chapter 5 Maintenance Analog Outputs 0 10 VDC concentration output 0 10 VDC range ID or optional overrange output 4 2...

Page 13: ...Trace Oxygen Analyzer Introduction Teledyne Analytical Instruments 5 Figure 1 2 Rear Panel AC Version Figure 1 3 Rear Panel DC Version ...

Page 14: ...play functions for the analyzer 2 2 Micro fuel Cell Sensor 2 2 1 Principles of Operation The oxygen sensor used in the Model OT 3 is a Micro fuel Cell designed and manufactured by TAI It is a sealed disposable electrochemical transducer The active components of the Micro fuel Cell are a cathode an anode and the aqueous electrolyte in which they are immersed The cell converts the energy from a chem...

Page 15: ...of the cell is a printed circuit board with concentric gold contacts Refer to Figure 2 1 Cross Section of a Micro fuel Cell which illustrates the following internal description Figure 2 1 Cross Section of a Micro fuel Cell At the sensing end of the cell is a diffusion membrane whose thickness is very accurately controlled Near the diffusion membrane lies the oxygen sensing element the cathode The ...

Page 16: ...rred for each atom of lead that is oxidized Therefore it takes two of the above anode reactions to balance one cathode reaction and transfer four electrons The electrons released at the surface of the anode flow to the cathode surface when an external electrical path is provided The current is proportional to the amount of oxygen reaching the cathode It is measured and used to determine the oxygen...

Page 17: ...ace of the Micro fuel Cell input is constant a convenient characteristic of the cell is that the current produced in an external circuit is directly proportional to the rate at which oxygen molecules reach the cathode This rate is directly proportional to the concentration of oxygen in the gaseous mixture In other words it has a linear characteristic curve as shown in Figure 2 2 Measuring circuits...

Page 18: ...er System power is supplied from a universal power supply module designed to be compatible with most international power sources The power supply circuitry is on the Power Supply PCB which is mounted vertically just behind the rear panel of the Control Unit The signal processing electronics including the sensor amplifier microcontroller analog to digital and digital to analog converters are locate...

Page 19: ...put is fed to a voltage amplifier The internal thermistor network provides temperature compensation of the sensor output The resistance of the network changes with temperature compensating for the changes of the Micro fuel Cell output to temperature The output from the temperature compensation amplifier is sent to an analog to digital converter ADC and the resulting digital concentration signal is...

Page 20: ...digital information is also sent to a 12 bit digital to analog converter DAC that produces the 0 10 V dc analog concentration signal and the 0 10 VDC analog range ID output A voltage to current converter E I CONV produces the 4 20 mA DC analog concentration signal ...

Page 21: ...THE MICRO FUEL CELL SENSOR ELECTROLYTE IS CAUSTIC DO NOT ATTEMPT TO OPEN IT LEAKING OR EXHAUSTED CELLS SHOULD BE DISPOSED OF IN ACCORDANCE WITH LOCAL REGULATIONS REFER TO THE MATERIAL SAFETY DATA SHEET IN THE APPENDIX ANY DAMAGE OR SCARRING OF THE DELICATE PERMEABLE MEMBRANE ON THE SENSING END OF THE CELL WILL REQUIRE CELL REPLACEMENT PREVENT CONTACT WITH MEMBRANE BY ANY SOLID OBJECT 3 1 Unpacking...

Page 22: ...l instrument response time If the analyzer is to be mounted in direct sunlight minimize the solar heating by orienting it in a north or south facing direction 3 2 2 Installing the Micro fuel Cell A Micro fuel Cell is included as a separate item It must be installed prior to instrument use Also once it is expended or if the instrument has been idle for a lengthy period the Micro fuel Cell will need...

Page 23: ...cepts two 5x20mm 0 5 A 250V IEC time lag T fuse See Fuse Replacement in chapter 5 Maintenance For DC powered units the customers DC power wiring is attached to the two pin terminal block located on the rear of the control unit See Figure 1 3 3 3 2 Analog Outputs There are three DC four on AC units output signal connectors with screw terminals on the panel There are two wires per output with the po...

Page 24: ... open and normally closed contact connections capable of switching up to 0 2 ampere at 125 VAC into a resistive load 0 9A for 30 VDC The alarm relay circuits are designed for failsafe operation In failsafe operation the relays are energized during normal operation If power fails the relays de energize alarms activated The contact connections are indicated diagrammatically on the rear panel as Norm...

Page 25: ...E COULD BE HAZARDOUS VOLTAGE AT THE ALARMS TERMINALS EVEN WHEN POWER IS REMOVED FROM THE INSTRUMENT 3 3 4 Relay Ratings The 3300 OT 3 has 2 relay ratings Higher rating established by the manufacturer DC Rating 0 30 VDC maximum 2 0 Amps resistive AC Rating 125 VAC maximum 0 5 Amps minimum reliable switching rating 10 µA 10mV Lower rating maximum safe rating for Cl 1 Div 2 Group C or D hazardous loc...

Page 26: ...300 OT 3 control unit is equipped with a SSR output on the rear panel This output provides 15 VDC and ground through a 689 ohm resistor during an alarm condition The output as configured is set for failsafe operation however it can be set to non failsafe by changing an internal jumper The output sends a command signal to drive external SSRs not provided during an alarm event Using external SSRs wi...

Page 27: ...e and cone over the tubing Mate the assembly back to the connector on the panel and tighten finger tight Use a wrench to tighten an additional 1 turn beyond finger tight You may have to hold the stationary fitting with another wrench to keep the entire fitting from turning Figure 3 3 shows the gas connection panel CAUTION TIE IN ONE LINE AT A TIME MAKE SURE THAT THE CORRECT GAS LINE IS MATED TO TH...

Page 28: ...ront of this manual for any additional information in the form of addenda that may apply to your custom system Sample gas enters the system at 5 2000 psig A shut off valve is installed and is used to switch gas flow on or off The sample gas is passed through a horizontal coalescing filter to remove moisture and debris This filter is designed to handle inlet gas pressure up to 2000 psig It is impor...

Page 29: ...n does not restrict the sample flow The sensor is designed to operate at atmospheric pressure Restricting the sample vent line will pressurize the sensor alter the O2 reading and reduce the sample flow Sample and Span pressure should not exceed 2000 psig 13 8 Mpa Figure 3 4 OT 3 Sample System 3 6 Installation Checklist Before connecting the instrument to the power source and turning it on make sur...

Page 30: ...Installation OT 3 Teledyne Analytical Instruments 22 ...

Page 31: ...volves setting the system parameters Defining the user selectable analysis ranges Setting alarm setpoints Calibrating the instrument All of these functions are performed via the front panel controls shown in Figure 4 1 Analyzing for the trace oxygen level in the gas passing through the cell block is the default mode of operation As long as no front panel buttons are being pressed the unit is analy...

Page 32: ... the displayed value upwards DOWN arrow increments the displayed value downwards Any of the functions can be selected at any time by holding down the appropriate button Each function will be described in the following sections Although the operator can use any function at any time the order chosen in this manual is appropriate for an initial setup 4 3 Setting the Analysis Ranges The two user defin...

Page 33: ... full scale percent concentration 4 4 Setting the Alarm Setpoints The alarm setpoints can be adjusted over the full range of the analyzer 0 9999 ppm oxygen content The set point values are expressed in ppm only 4 4 1 Set Alarm 1 Alarm 1 can be set either as a high or low alarm To configure this alarm to your preferences 1 Press the SET ALARM 1 function button once 2 The display will flash either H...

Page 34: ...return to the sample mode and display oxygen concentration 3 To change the setting at which the alarm will be actuated press the SET ALARM 2 function button once more The alarm setpoint will flash on the LED display Press either the Up or Down keys to raise or lower the displayed value as required until the display reads the desired percent concentration If within 5 seconds no key is pressed the i...

Page 35: ...ough the DELAY function To set the alarm delay 1 Press the UP and DOWN arrow keys simultaneously The display will indicate either PASS CODE or DELAY If the display indicates PASS CODE then to set the delay press both arrow keys simultaneously again to toggle to DELAY 2 While the display is blinking the word PASS DELAY press the UP arrow key to increase the delay To decrease the delay press the DOW...

Page 36: ...on exceeds 9999 ppm oxygen the analyzer will automatically switch to the Calibration Range EVEN THOUGH INSTRUMENT IS IN THE FIXED RANGE MODE 4 8 Calibration Preliminary If not already done Power up the Analyzer and allow the LED reading to stabilize Set the Alarm setpoints and the full scale ranges to the desired values Procedure Note This procedure requires a suitable span gas with pressure regul...

Page 37: ...isplay will flash the oxygen concentration on and off On the other hand if the instrument is displaying ppm only the concentration reading will be shown 4 10 Supplementary Information If during the Span Procedure you pressed the SPAN button by mistake you must wait five minutes for the analyzer to resume analysis or you can press the UP button and then the DOWN button Pressing the UP and DOWN butt...

Page 38: ...Operation OT 3 Teledyne Analytical Instruments 30 OR ALARM BUTTONS ARE PRESSED DURING SPAN THIS MAY RESULT IN FALSE ALARMS IF THE SPAN GAS HAS NOT BEEN FULLY PURGED FROM THE CELL AND SAMPLE LINES ...

Page 39: ...rst to determine the cause then replace the fuse using the following procedure AC Units 1 On AC units disconnect the power Remove the power cord from the receptacle 2 The fuse receptacle is located in the power cord receptacle assembly in the upper left hand corner of the rear panel See Figure 5 1 3 Insert a small flat blade screwdriver into the slot in the receptacle wall nearest the fuse and gen...

Page 40: ...gen with less than 1 ppm O2 To do this you should connect a pressure regulated zero gas source to the instrument at the span gas port This can be done by either shutting off the span gas and replacing it with the zero gas supply or by teeing into the span gas line using a selector valve which can then feed either span or zero gas to the instrument It may take several hours for the sample system an...

Page 41: ...ct to large variations in ambient temperature 75 F nominal and in such a way as to eliminate the possibility of incurring damage CAUTION DO NOT DISTURB THE INTEGRITY OF THE CELL PACKAGE UNTIL THE CELL IS TO ACTUALLY BE USED IF THE CELL PACKAGE IS PUNCTURED AND AIR IS PERMITTED TO ENTER CELL LIFE WILL BE COMPROMISED WARNING THE SENSOR USED IN THE MODEL OT 3 CONTAINS AN ELECTROLYTE WHICH INCLUDES SU...

Page 42: ...o install a new Micro fuel Cell CAUTION DO NOT SCRATCH PUNCTURE OR OTHERWISE DAMAGE THE SENSING MEMBRANE OF THE MICRO FUEL CELL IF THE MEMBRANE IS DAMAGED THE CELL MUST BE REPLACED 1 Examine the O ring at the base of the cell retainer cap and replace it if it is worn of damaged 2 Disconnect the Power Source from the Control Unit 3 Set the flow rate to a high level 5 1 SCFH 4 As rapidly as possible...

Page 43: ...ipment The customer should stock only one spare cell per instrument at a time Do not attempt to stockpile spare cells If a cell was working satisfactorily but ceases to function before the warranty period expires the customer will receive credit toward the purchase of a new cell If you have a warranty claim you must return the cell in question to the factory for evaluation Note When returning cell...

Page 44: ...alarms with user adjustable programmable 0 20 min delay one power failure relay All are failsafe System Operating Temp 0 50 C Accuracy 2 of full scale at constant temperature 5 of full scale through operating temperature range At 100 ppm and higher user defined ranges once temperature equilibrium is reached 1 ppm for 10 ppm range under above conditions Response Time 90 in less than 65 seconds at 2...

Page 45: ...ictor 0 4 SCFH 4 psig 1 R2588 Regulator 1 O182 O Ring std OT 3 Cell Holder 1 C74050A Acid Gas Scrubber 1 C73514A 3300 OT 3 Control Unit AC std 1 C73514B 3300 OT 3 Control Unit AC RS232 1 C73514C 3300 OT 3 Control Unit DC std 1 C73514C 3300 OT 3 Control Unit DC RS232 1 F51 Fuse DC Units 1 2 Amp Micro Depends on options chosen at time of purchase IMPORTANT Orders for replacement parts should include...

Page 46: ...gram B 74106 Piping Diagram D 65305 Schematic main PCB D 70739 Schematic AC Power Supply PCB D 74161 Schematic DC Power Supply PCB B 74224 Wiring diagram 3300 OT 3 ext SSR drive A 4 Miscellaneous The symbol is used on the rear panel of the Model OT 3 to signify volts alternating current VAC ...

Page 47: ...onfiguring the OT 3 23 contaminants 8 13 20 control unit 6 copyright ii current generation 11 current output See output data entry buttons 24 data entry keys 3 DELAY 27 DELAY function 27 diffusion membrane 7 digital display 3 digital meter 2 digital to analog converter 10 12 display 36 drain filter 19 drain valve 20 drawing list 38 E to I converter See voltage to current electrical connections 14 ...

Page 48: ...wer supply 15 power connection 4 power cord 15 power failure alarm See alarm power supply module 10 pressure 21 pressure effects 9 pressure regulator 1 RAM 10 range 2 24 36 range ID 36 reaction 8 rear panel 4 AC version 5 DC version 5 recovery time 32 reduction 8 regulator 20 relay contacts 16 DC SSR 18 failsafe operation 16 rating 17 solid state relay SSR 18 replacement cell 33 response time 2 14...

Page 49: ...s 41 terminal block 14 15 thermistor 11 universal power supply See power supply module VAC symbol 38 vent 19 20 voltage amplifier 11 voltage to current converter 12 warranty ii 35 web address 37 website address v zero absolute 9 zero gas 19 32 zero offset 9 32 ...

Page 50: ...Index OT 3 Teledyne Analytical Instruments 42 ...

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