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Trace Oxygen Analyzer

Maintenance

Teledyne

Analytical

Instruments

45

Maintenance

5.1 Routine Maintenance

Aside from normal cleaning and checking for leaks at the gas

connections, routine maintenance is limited to replacing the sensors and
fuses, and recalibration. For recalibration, see Section 4.4

Calibration

.

WARNING: SEE WARNINGS ON THE TITLE PAGE OF THIS

MANUAL.

5.2 Sensor Replacement

The ZrO

2

sensors are sealed transducers with no electrolyte to

change or electrodes to clean. When the sensor reaches the end of its
useful life, it is replaced. The spent sensor should be discarded
according to local regulations.

5.2.1 Removing the Sensor

The ZrO

2

sensors is located inside the nylon cell block behind the

front panel.

To remove an existing cell (refer to Figure 5-1):

CAUTION:

POWER IS APPLIED TO THE INSTRUMENT
CIRCUITRY WHENEVER THE INSTRUMENT IS
CONNECTED TO THE POWER SOURCE. THE RED
SWITCH ON THE FRONT PANEL IS FOR SWITCHING
POWER ON OR OFF TO THE DISPLAYS AND
OUTPUTS ONLY.

1.

Remove power to the instrument by unplugging the power
cord at the power source.

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Содержание 3000ZA-3X

Страница 1: ...stem 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...

Страница 2: ...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...

Страница 3: ...Instrument Serial Number _______________________ Options Included in the Instrument with the Above Serial Number 3000ZA C In addition to all the standard features this model also has separate ports f...

Страница 4: ...e used throughout the Instruction Manual These symbols are visual indicators of important and immediate warnings and when you must exercise CAUTION while operating the instrument See also the Safety I...

Страница 5: ...rocedures which if not followed could cause bodily Injury and or damage the instrument CAUTION HOT SURFACE WARNING This warning is specific to heated components within the instrument Failure to heed t...

Страница 6: ...zer Please read this manual and keep it available Occasionally some instruments are customized for a particular application or features and or options added per customer requests Please check the fron...

Страница 7: ...ensure that the principles of operation of this equipment is well understood by the user Misuse of this product in any manner tampering with its components or unauthorized substitution of any compone...

Страница 8: ...ry 7 2 1 Introduction 7 2 2 ZrO2 Sensor 7 2 2 1 Principles of Operation 7 2 3 Sample System 8 2 4 Zirconium Oxide Sensor Application Notes 9 2 5 Electronics and Signal Processing 9 Installation 13 3 1...

Страница 9: ...4 3 Menu Screen Structure 30 4 3 1 Analyze Screen 30 4 3 2 System Menu 30 4 3 3 Password routine 32 4 3 4 Logout Routine 33 4 3 5 Model Routine 33 4 3 6 Self Test Routine 34 4 3 7 Filter Routine 34 4...

Страница 10: ...al Range Select 44 4 7 3 Range Setpoints 44 Maintenance 45 5 1 Routine Maintenance 45 5 2 Sensor Replacement 45 5 2 1 Removing the Sensor 45 5 3 Fuse Replacement 47 5 4 System Self Diagnostic Test 48...

Страница 11: ...t Panel of the Model 3000TA 14 Figure 3 2 Required Front Door Clearance 14 Figure 3 3 Rear Panel of the Model 3000ZA 15 Figure 3 4 Equipment Interface Connector Pin Arrangement 18 Figure 3 5 Remote Pr...

Страница 12: ...ut Connections 19 Table 3 2 Alarm Relay Contact Pins 20 Table 3 3 Remote Calibration Connections 21 Table 3 4 Range ID Relay Connections 22 Table 3 5 Commands via RS 232 Input 25 Table 3 6 Required RS...

Страница 13: ...ment 1 2 Typical Applications A few typical applications of the Model 3000ZA are Monitoring inert gas blanketing Air separation and liquefaction Chemical reaction monitoring Semiconductor manufacturin...

Страница 14: ...to lock onto a specific range of interest Two adjustable concentration alarms and a system failure alarm Extensive self diagnostic testing at startup and on demand with continuous power supply monitor...

Страница 15: ...he cell block instead of upstream pressure The internal restrictor is located downstream from the cell block to support this configuration All other standard features are present in this model 1 5 Fro...

Страница 16: ...creen Up Down Arrows Increment or decrement values of functions currently displayed Enter Advances VFD display to the next screen in a series or returns to the Analyze screen if none remain Escape Bac...

Страница 17: ...or access to the ZrO2 sensors the front panel swings open when the latch in the upper right corner of the panel is pressed all the way in with a narrow gauge tool Accessing the main circuit board requ...

Страница 18: ...ntrol of analyzer calibration Calibration Contact To notify external equipment that instrument is being calibrated and readings are not monitoring sample Range ID Contacts Four separate dedicated rang...

Страница 19: ...rol subsystem simplifies operation of the analyzer and accurately processes the sampled data The microprocessor controls all signal processing input output and display functions for the analyzer 2 2 Z...

Страница 20: ...gned and fabricated to ensure that the oxygen concentration of the gas is not altered as it travels through the sample system The sample system for the standard instrument incorporates compression tub...

Страница 21: ...st be filtered before entering the cell The sensor will be damaged by the decomposition of Freon Gases containing SOx H2S silicone vapor and adhesives must not enter the sensor These components advers...

Страница 22: ...ntrolled by the microprocessor In the block diagram only one sensor is shown but in reality there are three separate amplifier circuits for each sensor The output of each sensor is then multiplexed to...

Страница 23: ...Trace Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 11 Figure 2 3 Component Location...

Страница 24: ...Operational Theory 3000ZA 3X Teledyne Analytical Instruments 12 Figure 2 4 Electronic Block Diagram...

Страница 25: ...agent 3 2 Mounting the Analyzer The Model 3000ZA is for indoor use in a general purpose area It is NOT for hazardous environments of any type The standard model is designed for flush panel mounting Fi...

Страница 26: ...he left edge and doubles as the door that provides access to the sensor and cell block inside the instrument The door latch is spring loaded and will swing open when the button in the center of the la...

Страница 27: ...Zero In and Span In ports are not included on the standard model but are available as options Figure 3 3 Rear Panel of the Model 3000ZA with Span and Zero Ports 3 3 1 Gas Connections Before using this...

Страница 28: ...hould face TOWARD the back of the unit against the direction of gas flow CAUTION OPERATING THE UNIT WITHOUT RESTRICTORS CAN CAUSE DAMAGE TO THE SENSOR The unit is manufactured with 1 4 tube fittings a...

Страница 29: ...y controlled only indirectly through the remote cal inputs as described below Note however that each sensor is calibrated separately Thus three span gas mixtures are needed It is recommended to leave...

Страница 30: ...proper fuse as part of installation See Fuse Replacement in Chapter 5 Maintenance 3 3 2 2 50 PIN EQUIPMENT INTERFACE CONNECTOR Figure 3 4 shows the pin layout of the Equipment Interface Connector The...

Страница 31: ...ound 24 ppm Range 0 1 VDC 7 ppm Range 0 1 VDC negative ground Alarm Relays The nine alarm circuit connector pins connect to the internal alarm relay contacts Each set of three pins provides one set of...

Страница 32: ...ing button to remove power to relay Then press again and any other button Up and Down simultaneously to resume Further detail can be found in Chapter 4 Section 4 6 Table 3 2 Alarm Relay Contact Pins P...

Страница 33: ...one A synchronous signal must open and close external span valve appropriately See Figure 3 5 Remote Probe Connector The C option internal valves operate automatically Cal Contact This relay contact i...

Страница 34: ...he sample is being analyzed Note The Remote Valve connections described below provides signals to ensure that the zero and span gas valves will be controlled synchronously If you have the C Internal v...

Страница 35: ...o span gas valves See Figure 3 5 Figure 3 5 Remote Probe Connections The voltage from these outputs is nominally 0 V for the OFF and 15 VDC for the ON conditions The maximum combined current that can...

Страница 36: ...ard 9 pin D connector The output data is status information in digital form updated every two seconds Status is reported in the following order The concentration in ppm or percent The range in use HI...

Страница 37: ...Parity none Stop Bits 1 Message Interval 2 seconds When CRC opens again zero and span are done and the sample is being analyzed Range ID Relays There are three dedicated Range ID relay contacts Three...

Страница 38: ...s will be packaged with their Teledyne Analytical Instruments part number marked on the bag When the ZrO2 sensor needs to be installed or replaced follow the procedures in Section 5 2 If sensors were...

Страница 39: ...sis as required Set alarm setpoints and modes of alarm operation latching failsafe etc Before you configure your 3000ZA these default values are in effect Ranges R1 100 ppm R2 1 00 R3 100 although sen...

Страница 40: ...be placed between the brackets If discussing a particular key it will be typed using all caps Example this is the ENTER key Screen Modes Times New Roman 12 pt italic Example Analysis Mode or Setup Mo...

Страница 41: ...al context sensitive ways 1 In an Item Selection Menu the ENTER key selects the line indicated by the arrow and enters the Item Modification Menu 2 In an Item Modification Menu the ENTER key accepts t...

Страница 42: ...more than 1 line It is important to read and understand the NAVIGATION AND DATA ENTRY section to fully understand the menu structure 4 3 1 Analyze Screen The ANALYSIS SCREEN displays the following Lin...

Страница 43: ...Trace Oxygen Analyzer Operation Teledyne Analytical Instruments 31 PASSWORD LOGOUT MODEL SELF TEST FILTER ANALOG OUT ADJUST AUTO CALIBRATION CHANGE STREAM Figure 4 1 Hierarchy of Available Functions...

Страница 44: ...rect password Pressing ENTER advances to the next letter When at the 3rd letter Pressing ENTER causes the letters to be compared to the actual password If the letters don t match the user is told Pass...

Страница 45: ...g the password to an unintended and perhaps unguessable password Password Mismatch The entered and re entered password did not match No change was made to the original password Password Changed The pa...

Страница 46: ...NTER causes the analyzer to run the same diagnostic that runs on start up See section 5 4 for results display 4 3 7 Filter Routine Digital Filter Index 5 Pressing ENTER causes the number after Index t...

Страница 47: ...ead the 4 20 madc output to have an offset 4 20mA Gain Pressing ENTER causes the number after Offset to start flashing Then pressing UP or DOWN selects a number ranging from 500 to 500 The analog outp...

Страница 48: ...as to be purged out by sample gas 4 3 9 Auto Calibration Timer This function sets the timer for auto calibration It is useful when control valves are available and the remote valve control outputs are...

Страница 49: ...om 200 ppm to 2 O2 Span gas that is near the top of this scale should be used to calibrate this sensor The low sensor covers ranges from 0 to 100 ppm O2 Span gas that is near the top of this scale sho...

Страница 50: ...she determines the sensor has settled on the span sample If the value is AUTO the analyzer will automatically countdown the time when the sensor has settled on the span sample and will proceed to cal...

Страница 51: ...med If the value is MANUAL then when the zero begins the user is prompted to press ENTER at the time he she determines the sensor has settled on the zero sample If the value is AUTO the analyzer autom...

Страница 52: ...O Pressing ENTER causes the screen to prompt to begin the zero routine as displayed above Pressing ENTER again causes the analyzer to commence the zero routine and begin analyzing in ZERO MODE 4 5 4 Z...

Страница 53: ...FE AL 2 NON LATCHING AL 2 50 00 ppm Note that alarm functionality explanation below applies to both AL 1 and AL 2 identically 4 6 1 Alarm Active AL 1 ACTIVE Pressing ENTER causes the word ACTIVE or DE...

Страница 54: ...non tripped state and de energized when tripped 4 6 4 Alarm Latching AL 1 LATCHING Pressing ENTER causes the word LATCHING or NON LATCHING to start flashing Then pressing UP or DOWN toggles between th...

Страница 55: ...chooses the least range that will accommodate the current O2 concentration The analyzer will switch to the next lower range if available when the concentration falls below 90 of the lower range setpoi...

Страница 56: ...ive range if the Range Select above is set to Man ual 4 7 3 Range Setpoints R1 0 1000 00 ppm Pressing ENTER causes the value to the right of Rn to start flashing Then pressing UP or DOWN adjusts the v...

Страница 57: ...h no electrolyte to change or electrodes to clean When the sensor reaches the end of its useful life it is replaced The spent sensor should be discarded according to local regulations 5 2 1 Removing t...

Страница 58: ...replace with your fingers or using small pliers Just pull the sensor straight out CAUTION SENSORS MIGHT BE HOT AFTER REMOVING POWER LET THE SENSORS COOL FOR A FEW MINUTES 5 Install the new sensors pay...

Страница 59: ...ce Teledyne Analytical Instruments 47 Figure 5 1 Sensor Block with Middle Sensor Installed 5 3 Fuse Replacement 1 Place small screwdriver in notch and pry cover off as shown in Figure 5 2 Figure 5 2 R...

Страница 60: ...elf 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 following Item...

Страница 61: ...cribed earlier Other internal components are accessed by removing the rear panel and sliding out the entire chassis See Figure 5 4 below The gas piping is illustrated in Figures 2 1 and Figure 2 2 and...

Страница 62: ...side surfaces with a soft cloth dampened slightly with plain clean water Do not use any harsh solvents such as paint thinner or benzene For panel mounted instruments clean the front panel as prescribe...

Страница 63: ...sensor Inaccurate zero operation i e user has zeroed the instrument using a gas concen tration much higher than normal for a zero gas Turn analyzer off then back on again Press the UP and DOWN key si...

Страница 64: ...Maintenance 3000ZA 3X Teledyne Analytical Instruments 52...

Страница 65: ...esponse Time 65 seconds at 25 C 77 F on 10 ppm range 100 seconds on 1 ppm range Ranges Three programmable ranges from 0 1 ppm to 0 100 oxygen note that the maximum concentration of analysis is 95 O2 A...

Страница 66: ...er operating temperature range except 0 1 ppm analysis range once thermal equilibrium is reached 0 2 ppm on 0 1 ppm analysis range once thermal equilibrium is reached Analog outputs 0 1 VDC percent of...

Страница 67: ...rconium oxide sensor for 0 200 ppm range 1 S1492 Zirconium oxide sensor for 0 2 range 1 S1442 Zirconium oxide sensor for 0 95 range 1 A68729 Restrictor kit A minimum charge is applicable to spare part...

Страница 68: ...ance 3000ZA 3X Teledyne Analytical Instruments 56 A 3 Drawing List D 77579 Final Assembly D 75738 Outline Drawing A 4 19 inch Relay Rack Panel Mount Figure A 1 Single and Dual 19 Rack Mounts dimension...

Страница 69: ...rate CELL PRESSURE CONCERNS The sensors used in 3000 series analyzers are optimized to function at atmospheric pressure At pressures other than atmospheric the diffusion rate of O2 will be different...

Страница 70: ...as vacuum service applications see manual for installation instructions The standard restrictor BLUE DOT is recommended for pressures between 5 and 50 PSIG For positive low pressure application 5 psig...

Страница 71: ...mple system including the cell will be approximately at atmospheric pressure provided the sample flow into the analyzer is not blocked BY PASS To improve the system response a by pass can be added to...

Страница 72: ...60 TAI PART NUMBERS Restrictor kit A68729 Union SS U11 LP Restrictor R2323 low pressure vac service Std Restrictor R2324 Blue dot Nut N73 Ferrule F73 Ferrule F74 Both ferrules are required CONVERSIONS...

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