SERVICE MANUAL MANUAL Model 9060 Zirconia Oxygen Analyser
Contents
1. Tr 26 6 m s s E Teledyne Analytical Instruments E ee 0090000000 se E LI 17 9060 Service Manual 3 1 4 The DC to DC converter PS1 that powers the output 4 20mA channel 2 can be damaged if n 18 a power supply is connected in an attempt to loop power the output circuit The isolated 4 20mA outputs are active outputs on the 9060 series of analysers When the DC to DC converter is damaged due to loop powering it will overload the 5V rail causing the component to rise in temperature Replace the DC to DC converter PS1 with an HPR 104 5V to 12V UN a HPR 104 DC to DC Converter Teledyne Analytical Instruments 9060 Service Manual 3 2 FILTER REPLACEMENT PROCEDURE ON 9060 OXYGEN PROBES PROCEDURE 3 2 1 To dismantle the filter assembly loosen the two 4mm grub screws the end 19 Teledyne Analytical Instruments 9060 Service Manual 3 2 2 Slide the end cap filters and spacer from the probe 20 Teledyne Analytical Instruments 9060 Service Manual 3 2 3 Use clean compressed air to dislodge any particulate that may have accumulated inside the filter assembly If particulate build up is excessive then consider using the 15 micron filters The finer filters will considerably dampen the response time of the2. 72 79 Teledyne Analytical Instruments 9060 Service Manual 5 5 4 20 mA Output Drivers dS0009r HH PIC HEH 161270 SISED0T F ZAC 73 Teledyne Analytical Instruments 9060 Service Manual 5 6 Digital Input Output E 3 8 121 55 ee Bim CERESE ST SSS He amp H OW od bus i ET Vee Latch 2 plouajos ser 5 asung 4 13H 6 L NEN gt 5 BS ser 9 t 07971 SI 565 OHTZ 9g yore oe L la uiu OU 9 cg BD OTF OC F eja NEST I Ap o1 Wwuely NCC 1 uure v RI S6SDHPL Ve Digital output latch Digital output data Clock P64 6 1 26 1 74 Teledyne Analytical Instruments 9060 Service Manual Input MUX s ADC amp RH sensor 5 7 meL 19191 62 yuppeo 4 218 94 zp dt 9 94 mop 421 d o oo otf 5 dvo 8101 94 1emod zopeuy PTD 1 94 ES S8t SU 8 5 TS XL S TET SU Cie asup ajqena djo peues lt
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5. It is recommended that before the probe is disassembled it should be tested in a workshop For the probe to be tested completely 1 26 Power must be applied to the heater and controlled to maintain about 720 C at the sensor Expected result The SENSOR TEMP should rise to 720 C 15 C within 15 minutes The display of SENSOR TEMP should fluctuate less than 2 C A certified gas connected to the CAL port of the probe 2 liters per minute and the sensor EMF Oxygen measured Expected result The oxygen reading from the probe should agree with the gas bottle s certified value The impedance of the sensor measured Expected result The impedance of the zirconia sensor as read on the analyser should be less than 7kW when the sensor is 720 C 15 The easiest way to do these tests is to use a Teledyne oxygen analyser This provides all the facilities to do a complete electrical test of the probe Alternatively a common temperature controller and a 110VAC transformer could be used to control the temperature A digital multimeter and the oxygen EMF tables could be used to determine the oxygen level This does not give you the impedance of the sensor Teledyne Analytical Instruments 9060 Service Manual 3 3 3 DISASSEMBLY PROCEDURE 3 3 3 1 Hold probe vertically and securely by the hexagonal body in a vice with the probe connector at the rear 99 9 2 Open the probe s screwed head cover by tu
6. C 210 to 2550 F in 100 degree steps Log Oxygen 0 1 2 Fixed 20 O2 Fixed Reducing Oxygen 10 2 10096 to 10 10 oxygen in one 1073 to 10790 Oxygen decade steps non overlapping in one decade steps Min span two decades Linear Oxygen probe 2 0 oxygen fixed 1 to 10096 Combustibles 96 Probe 1 0 combustibles fixed 0 5 to 2 0 96 Linear Probe 1 and 2 averaged 0 oxygen fixed 1 to 10096 If 2 probes are used Teledyne Analytical Instruments 9060 Service Manual Range of Indication Upper Line e Auto ranging from 10 39 to 100 02 Indication Choice Lower Line Any or all of the following can be selected for lower line display e Date time Run Hours since last service Date of last service Probe 1 oxygen Probe 2 oxygen Probe 1 EMF Probe 2 EMF Probe 1 Temperature Auxiliary Temperature Probe 2 Temperature Probe 1 Impedance Probe 2 Impedance Ambient Temperature Ambient Relative Humidity Carbon Dioxide Combustibles Oxygen Deficiency The oxygen deficiency output can be used in the same way as a combustibles transmitter to signal the extent of reducing conditions of combustion processes Accuracy 1 of actual measured oxygen value with a repeatability of 0 5 of measured value Relay Contacts e 0 5A 24 VAC 1A 36 VDC Environmental Rating e Operating Temperature 25 to 55 C 15 to 130 F e Relative Humidity 5 to 95 non condensing e Vibration 10 to 150Hz 2g peak Power Requi
7. SAL ATI 015 01 4 ex cum NI I 089 ogy BL 1001 SI WET Jno 012 M10 yw L qn 62 4110 91 4n Lt t IPAP Apetps TAS 1126 44 1 YUISWOY euis 42171 9 oS B gt wid Age OCC oO 005 205 EN COS CDE 31000 po1ospuq v1 ASE ANOZZ ryg 621 si 4 BEH IEN pea ENE 54 cU 0121 01 I OrarSsWm cro cA 29 6 05 nid 2 821 tOM Java pa v POAN TAL 55 2520 2900 2 XI cri mol SCNT yams ssed amp g umg Ca Wo Jauing 4 suey N y 69 Teledyne Analytical Instruments 9060 Service Manual 5 2 Main Board Block Diagram ADC MICRO ADC SCH MICRO SCH D A L4 3 d 2 558 9 RI 5 L iu 8 E 70 Teledyne Analytical Instruments 9060 Service Manual Ag AC Semi 5 3 Main Board Terminal Allocation Block Diagram zepjos dunp 5qr uid oz NOFT INTTOO Atrum O 519 E IND IND NEE ET BIS ATddNsS 05528 EE em CHI DA 05508 4 001 i ud i i CHI
8. What to do if the oxygen reading does not match the certified gas 9o Teledyne Analytical Instruments 99 4 1 4 2 60 9060 Service Manual Question Sometimes see a symbol and on the LCD of the O2 analyser what does it mean Answer Four symbols periodically flash on the right hand side of the display during normal operation each indicates that a specific function is currently being performed by the analyser Checking for timed events 30 second interval Purge and calibration sequences updates run time checks that the BBRAM is okay reads the ambient RH updates the O2 value of the reference air with respect to the RH value li The heartbeat means the software is running correctly 1 5 second interval Auto calibration of the analyser s electronics with respect to the four reference voltages 60 second interval Z Sensor Impedance Check 24 hour interval when the impedance is normal at 11 30pm 60 second interval when the impedance is high Question How do set my 9060 oxygen analyser to transmit 0 21 linear oxygen from probe 1 on channel 1 and from probe 2 on channel 2 Answer 1 First make sure that two probes have been selected in set up step 1 2 Enter the set up mode and go to set up step 26 Chan1 Scale Using the OPTION up or down buttons select Linear Sensor1 and push ENTER 3 Go to set up step 27 Chan1 Span and push the OPTION up or down
9. be more appropriate where incomplete combustion is possible Also read the probe or sensor electrical shock caution in Section 2 5 and the probe or sensor heater interlock caution in Section 3 6 CAUTION 5 If an external pressure transducer is used to feed the process pressure to the transmitter for pressure compensation it is essential that the pressure transducer is accurate and reliable An incorrect reading of pressure will result in an incorrect reading of oxygen It is therefore possible that an explosive level of fuel could be calculated in the transmitter as a safe mixture CAUTION 6 FIL 3 filter If the optional FIL 3 has been fitted to the 1231 probe in this installation please read the Important Notice in section 1 2 Teledyne Analytical Instruments 9060 Service Manual SPECIFICATIONS Teledyne Analytical Instruments 9060 Service Manual 1 1 MODEL 9060 OXYGEN ANALYSER FOR TWO OXYGEN PROBES DESCRIPTION The Teledyne Model 9060 oxygen analyser transmitter provides in situ measurement for two oxygen probes in furnaces kilns and boilers and flue gases with temperatures from ambient up to 1400 C 2550 F The transmitter provides local indication of oxygen plus thirteen other selectable variables One or two probes or sensors in one process can be controlled from one transmitter providing an average and or individual sensor signals Two linearised and isolated 4 to 20 mA output signals are provided Alarms are
10. in CAL port filter blockage Is there any ADC Cal Fail Alarm Check Ref Ref Voltages The should be close to 27 8 YES 196 00 1200 amp 2500 33 2 5 V DC IC 36 37 output 5V amp 5V and IC 23 26 32 and C54 NO Is Check SSR1 5 Check terminal 51 52 amp 53 54 output voltage mains voltage to heaters YES If it is OK then check probe amp cable there any Heater YES LED4 amp LED 8 Flashing The correct heater resistance is 110 Q The correct thermocouple resistance is 10 Q at ambient temperature Fail Alarm NO NO Check Burner Bypass Switch Terminals 18 19 link LED4 LED8 RL7 Teledyne Analytical Instruments 9060 Service Manual LAJA DAI Y WARNING Mains mil Oniv arthoriced nare alchould work on y authorised pe st ould W on Vin Is there any DAC fail Alarm YES Check LED1 LED2 RL4 IC5 IC6 PS1 TR1 TR2 on 1600 2 board Check 1630 1 amp 1630 2 PCB cable connection and OP1 OP2 OP3 OP4 IC7 IC3 IC37 on the 1600 1 board NO Is there When the probe is at YES 720 C amp in air you can measure the sensor impedance with a multimeter from terminals 1 amp 2 YES Oxygen probe any sensor fail Alarm Suspected NO NO Check CN7 connector and probe EMF input Check probe cable Is Sensor TIC OK OR Open YES Check thermocouple input from
11. long nose pliers carefully remove the sensor gland and the sensor from the probe sheath a Inspect for damage b Check the state of the sensor s catalytic electrode material Reverse this procedure for reassembly Note Wipe a small amount of o ring grease such as Molykote FS3451 around the top of the sensor and outer o ring on the sensor gland before re installing the sensor and gland 48 es Teledyne Analytical Instruments 9060 Service Manual 3 5 HEATER REMOVAL PROCEDURE ON 9060 OXYGEN PROBE NEW VERSION AFTER JAN 2007 ONWARDS Procedure Refer to service note 3 3 Disassembly Repair for instructions to dismantle the probe to its basic components 3 5 1 Secure the inner sheath in a vice 49 Teledyne Analytical Instruments 9060 Service Manual 3 5 2 Remove the split pin 50 Teledyne Analytical Instruments 9060 Service Manual 3 5 3 Remove the heater insulation retainer 3 5 4 Remove the heater insulation i 7 51 Teledyne Analytical Instruments 9060 Service Manual 3 5 5 Gently twist the heater to and fro while sliding it off the sheath 52 Teledyne Analytical Instruments 9060 Service Manual 3 5 6 Re installation is simply a reversal of this procedure 53 Teledyne Analytical Instruments 9060 Service Manual 3 6 HEATER REMOVAL PROCEDURE ON 9060 OXYGEN PROBE OLD VERSION BEFORE JAN 2007 Procedure Refer to servic
12. the Teledyne Analytical Instruments analyser will raise a Sensor Fail alarm when the sensor is over 9kO when the sensor temperature is 720 C Summary An oxygen probe will fail through a number of failure modes only one of which has a measurable quantity related to the potential failure Although most probes are taken out of service because the sensor electrode has deteriorated the impedance changes must be taken as a series of readings over a period of several weeks The best indication of an impending probe failure is in a series of impedance readings showing a definite and rapid increase 64 Teledyne Analytical Instruments 4 7 9060 Service Manual What is Oxygen Deficiency Scale Answer The negative oxygen deficiency scale of the Teledyne Analytical Instruments 9060 oxygen analyser is a measure of the amount of oxygen that would be required to bring the combustion back to the perfect balance As a result of the burning of the fuel and air in the boiler there is a mixture of gasses These gasses are mainly e Carbon dioxide Carbon monoxide Oxygen Water vapour Hydrogen When a boiler is FUEL RICH there is a balance established between all of these gasses that is dependent on the temperature and the air fuel ratio before the combustion In these conditions the free oxygen will be very small less than 0 000 000 001 A zirconia sensor can measure down to less than 0 000 000 000 000 000 000 000 000 000
13. the velocity of the process gas The probe should protrude almost halfway across small diameter flues and about 750mm into large ducts Higher flue gas flow rates reduce the depth of tramp air ingression at the boundary of the duct and can therefore use a shorter probe In high temperature processes with high velocities the appropriate insertion depth can be determined by inserting an inconel or 253MA tube into the gas stream longer than the estimated or guessed insertion depth Leave the tube in the process for a week and then remove it The affect of heat and available oxygen will discolor the sheath proportional to the amount of heat and oxygen The correct insertion depth is the length required to reach the point where the discoloration or oxidation of the tube is uniform Teledyne Analytical Instruments 4 9 9060 Service Manual What to do if the oxygen reading does not match the certified gas 96 Answer 1 Check the setting of the reference voltages in the analyser 2 Check that the calibration gas pipe work connections are not leaking 3 Confirm that the readings were taken within 1 minute especially at high flow rates 4 Confirm the accuracy of the gas bottle READING LOW If the probe appears to be reading low this can be caused by a build up of hydrocarbons at the sensor running at 720 C and consuming the oxygen that should be measured due to combustion A solution to this is to pump air into the calibration port to ac
14. 0 If installed remove the weatherproof plug head connector by unscrewing anti clockwise Avoid twisting the wires while unscrewing the connector Head Connector 31 Teledyne Analytical Instruments 9060 Service Manual 3 3 3 11 Removed both circuit board retaining nuts PCB Retaining Nuts des o a E oF j j r J x m F gt d EG wok NIC KE i i i m H 3 33 12 Lift the circuit board over the heater O2 ve T C ve and T C ve wires DANGER 32 Teledyne Analytical Instruments 3 33 13 3 3 3 14 3 3 3 15 9060 Service Manual Gently lift the ceramic four bore straight up avoid bending until clear of the probe body oet aside the four bore in a safe place to avoid damage and contamination Remove the sensor compression spring by gently working it from the sensor gland 33 Teledyne Analytical Instruments 9060 Service Manual 3 3 3 16 Remove the sensor by holding the sensor gland with pliers and gently lifting it straight up avoid bending until clear of the probe body Resistance will be felt removing the sensor due to the sensor gland o ring seal The sensor must not be forced as it is brittle and easily broken 3 3 3 17 Set aside the sensor in a safe place to avoid damage and contamination 3 3 3 18 Remove the probe head from the probe body by unscrewing the two retaining scr
15. 001 If the oxygen and the temperature of the oxygen sensor are measured the percentage of oxygen required to bring the combustion back to the perfect balance can be calculated This can be very useful in the operation of a power station boiler because it gives the operator a way of recording both 1 The oxygen level when the boiler is under normal AIR EXCESS conditions 2 How far and for how long the boiler was in FUEL RICH Both of these scales are transmitted on one 4 20 mA output channel The normal scale will be from 5 oxygen deficiency to 10 air excess but both ends of the scale can be set in the field 65 Teledyne Analytical Instruments 4 8 66 9060 Service Manual Can you provide some tips on In Site type Applications Answer For flue gas applications Location On coal fired boilers the best mounting position for a 1231 probe is vertically downwards The probe can be used without filters but the purge facility should still be utilized Locate the probe where the process temperature is between 300 C and 700 C Below 200 C the inner sheath outer sheath and heater can be corroded by concentrated acids condensing on the S S and inconel Above 800 C the heavy metals and many compounds are hostile to the electrode material used on the surface of the zirconia sensor Silica will also attack the grain boundary layer of the sensor The probe should be located at least five flue duct diamete
16. 9060 Service Manual SERVICE MANUAL MANUAL Model 9060 Zirconia Oxygen Analyser 9060 2006 9060 Service Manual CONTENTS SPECIFICATIONS CALIBRATION PROCEDURES SERVICE NOTES amp MAINTENANCE FREQUENTLY ASKED QUESTIONS SCHEMATICS Trouble Shooting M D Note This manual includes software modifications up to Version 2 25 October 2005 Copyright TELEDYNE ANALYTICAL INSTRUMENTS 1996 2006 Neither the whole nor any part of the information contained in or the product described in this manual may be adapted or reproduced in any material form except with the prior written approval of Teledyne Analytical Instruments Teledyne Analytical Instruments The product described in this manual and products for use with it are subject to continuous developments and improvement All information of a technical nature and particulars of the product and its use including the information in this manual are given by Teledyne Analytical Instruments in good faith However it is acknowledged that there may be errors or omissions in this manual A list of details of any amendments or revisions to this manual can be obtained upon request from Teledyne Analytical Instruments Technical Enquires Teledyne Analytical Instruments welcome comments and suggestions relating to the product and this manual All correspondence should be addressed to Technical Enquires Teledyne Analytical Instruments 16830 Chestnut Street City of
17. Answer The temperature of the 1234 oxygen sensor must be maintained between 650 and 800 C The recommended running temperature is 720 C The temperature should be stable to within 10 C per minute Control of the temperature can be achieved with proportional and integral action with a time proportioning cycle of 2 5 seconds The proportional band should be set to 15 150 C proportional range The integral action should be set to 200 seconds 4 5 62 Output EMF 2 154 x 10 2 x T x loge 0 2095 oxygen level of the sample T Temperature in K Question How long will the CM 15 reference air pump last Answer The life of a CM 15 pump can vary greatly from site to site If the analyser is located in an air conditioned control room then several years would be the expected life if it were located in a hot and dirty heat treat shop then the life could be as short as six months There are three factors that reduce the life of the CM 15 pump 1 Operating ambient temperature As this increases the pump life decreases If the internal temperature exceed 35 C the analyser will turn off the backlight display and cycle the pump on and off to assist reducing the temperature and extending the life of the pump 2 Particulate loading of the air being pumped This is mainly a problem on heat treatment sites the grit in these places gets lodged in the diaphragm increasing the load on the pump The analysers are fitted with a
18. Industry Phone 626 934 1500 CA 91748 USA Fax 626 961 2538 All maintenance and service on the product should be carried out by Teledyne Analytical Instruments authorised dealers Teledyne Analytical Instruments can accept no liability whatsoever for any loss or damage caused by service or maintenance by unauthorised personnel This manual is intended only to assist the reader in the use of the product and therefore Teledyne Analytical Instruments shall not be liable for any loss or damage whatsoever arising from the use of any information or particulars in or any error or omission in this manual or any incorrect use of the product Teledyne Analytical Instruments 9060 Service Manual USING THIS MANUAL The Teledyne 9060 Oxygen Transmitter has a variety of user selectable functions They are simple to use because each selection is menu driven For options you are not sure about read the manual on that particular item Please read the safety information below and the Installation section before connecting power to the transmitter CAUTION 1 The probe or sensor heater is supplied with mains voltage This supply has electrical shock danger to maintenance personnel Always isolate the transmitter before working with the probe or sensor gas solenoids or the transmitter The EARTH wire green from a heated probe or sensor must ALWAYS be connected to earth CAUTION 2 Combustion or atmosphere control systems can be d
19. alled in power stations petrochemical plants heat treatment hardening furnaces and annealing furnaces and a variety of incinerators cement plants and drying ovens All of these processes have different requirements and pose different conditions to the components of the probe exposed to the process Failure modes The useful life of the probe is limited by the first component of the probe to fail The failure may be a slow deterioration or a sudden change of the working condition of one of the vital components Components that may have a sudden failure are The heater in heated probes open circuit or short circuit to ground The thermocouple cracking thermal junction causing an open circuit Outer metal sheathing breakage through corrosion or abrasion or chemical attack The ceramic components of the probe physical or thermal shock Components that will slowly deteriorate are he electrode coating of the zirconia sensor The thermocouple oxidation grain growth he internal electrode conductor oxidation grain growth Out of all of these component failures only the zirconia electrode material loss can be measured in an attempt to determine the remaining life of the probe Unfortunately this failure can only be predicted with the experience of the process it is being used The Teledyne Analytical Instruments analysers measure the impedance of the zirconia sensor automatically Without interfering with the pr
20. angerous Burners must be mechanically set up so that in the worst case of equipment failure the system cannot generate explosive atmospheres This danger is normally avoided with flue gas trim systems by adjustment so that in the case of failure the appliance will not generate CO in excess of 400 ppm in the flue The CO level in the flue should be measured with a separate CO instrument normally an infrared or cell type CAUTION 3 The oxygen sensor which is heated to over 700 C 1300 F and is a source of ignition Since raw fuel leaks can occur during burner shutdown the transmitter has an interlocking relay that removes power from the probe or sensor heater when the main fuel shut off valve power is off If this configuration does not suit or if it is possible for raw fuel to come into contact with a hot oxygen probe or sensor then the Model 9060 Analyser with a heated probe or sensor will not be safe in your application An unheated probe can be utilised in such applications however the oxygen readings are valid only above 650 C 1200 F CAUTION 4 The reducing oxygen signal from the transmitter and the associated alarm relay can be used as an explosive warning or trip This measurement assumes complete combustion If incomplete combustion is possible then this signal will read less reducing and should not be used as an alarm or trip A true excess combustibles transmitter normally incorporating a catalyst or thermal conductivity bridge would
21. away from the oxygen sensor during the gas calibration checking procedure Equipment required Certified gas supply bottle generally between 2 and 8 oxygen in nitrogen Pressure regulator Needle valve Flow meter 0 5 to 5 The procedure Gas calibration check while the probe is in the process Setting the probe offset 1 Make sure that the reference air supply is connected to the probe and is operating normally 50 cc m 2 Setthe Damping Factor on the analyser to 0 or No Damping 3 Setthe lower line display to be showing the probe EMF mV and probe Impedance in Set up step 33 4 Note the mV reading on the analyser 5 Connect a supply of clean fresh air to the CAL port of the probe from the regulator needle valve and flow meter 6 Adjust the needle valve until about 0 5 l m is flowing into the probe If the connecting pipe is less than 5m the mV reading should move towards OmV within 5 seconds and stabilize within 10 to 15 seconds Note the mV reading As soon as the reading is stable and noted change the flow rate to 1 I m Wait for a stable reading and note the mV reading Repeat this for flow rates of 2 4 and and then close the needle valve 0 Check the results and pick the average mV reading disregarding sudden variations at low and high flow levels 11 Enter this reading into the Probe Offset of the analyser 11 Teledyne Analytical Instruments 9060 Service Ma
22. buttons until the lower line reads 20 9 and push ENTER Channel 1 has now been scaled 4 Go to set up step 28 Chan2 Output and use the OPTION up or down buttons to select Linear Sensor2 and push ENTER 5 Go to set up step 29 Chan2 Zero and push the OPTION up or down buttons until the lower line reads Zero 0 and push ENTER 6 Go to set up step 30 Chan2 Span and push the OPTION up or down buttons until the lower line reads Span 21 and push ENTER Channel 2 has now been scaled Teledyne Analytical Instruments 4 3 9060 Service Manual Question What does the Htr SSR Fail alarm mean Answer The power to the heater 9060H probe is powered through a solid state relay SSR SSR1 controls heater 1 and SSR5 controls heater 2 The electromechanical relay RL7 Burner on Relay switches the active and neutral lines to both SSRs and is used to disable power to the sensors heaters if 1 The terminals 18 and 19 Burner On Switch are open circuit 2 The probe or sensor temperature is greater than 735 C 4 IB er et mas Pere 1 P uii QUEUE i Heater 2 SSR Heater 1 558 Relay The most common mode of failure for a solid state relay is a short circuit This will result in 100 power applied to the probe or s
23. celerate the burning process to consume and eliminate the hydrocarbons Having an excessive flow of reference air can also cause a low reading this causes a cooling affect on the zirconia sensor Reference airflow should be approximately 50cc min READING HIGH If the probe appears to be reading high then the reference air should be checked remove the cap on the probe and pull the hypodermic from the four bore insulator place the hypodermic in a glass of water to observe air flow If the process operates under a negative pressure then check that the 1 8 inch plug screwed into the calibration port on the probe is not leaking If the problem persists then replace or return the probe to Teledyne Analytical Instruments 67 Teledyne Analytical Instruments 9060 Service Manual Schematics 5 1 5 2 5 3 5 4 9 9 5 6 et 5 8 68 POWER SUPPLY REFERENCE AIR PUMP 9060 MAIN BOARD BLOCK DIAGRAM MAIN BOARD TERMINAL ALLOCATION BLOCK DIAGRAM MICROPROCESSOR BD DISPLAY amp KEYPAD 4 20 mA OUTPUT DRIVERS DIGITAL INPUT OUTPUT INPUT MUX s ADC amp RH SENSOR SERIAL INTERFACE amp D A CONVERTERS Teledyne Analytical Instruments 9060 Service Manual Power Supply Reference air pump 5 1 lt VATA VATA PA ZH AS 0 dund joy 0 XI Jvd g 2909 05 6NO
24. displayed at the transmitter and relay contacts activate remote alarm devices The transmitter which is available for heated or unheated zirconia oxygen probes provides automatic on line gas calibration check of the probe and filter purging The electronics self calibrates all inputs every minute The 9060 has a keyboard for selecting the output range thermocouple type etc as well as maintenance and commissioning functions The instrument is microprocessor based and all adjustments are made using the keyboard e Used for air fuel ratio combustion control to provide fuel savings e Used for product quality control in ceramic and metal processing industries e Simple to install e Linear output of oxygen for recording or control e Built in safety features e 26 different alarm conditions that warn the operator of combustion probe or transmitter problems isolated RS 232 C printer computer interface and an RS 485 MODBUS network interface e Safety interlock relay for heated probes Teledyne Analytical Instruments 9060 Service Manual 9060 Oxygen Transmitter Zirconia Oxygen Probe 5 Reference Air Alarm Dry Inst Air Purge Solenoid Flowmeter Recorder Controller NL Calibration Solenoid a E VENNRNNNNE e m seg CN UI O Computer and or Checking Gas Printer Optional Calibration Oxygen Probe and Transmitter System Teledyne A
25. e note 3 3 Disassembly Repair for instructions to dismantle the probe to its basic components 3 6 1 Secure the inner sheath in a vice 54 Teledyne Analytical Instruments 9060 Service Manual 3 6 2 Use a 3 8 drill to break the weld on the heater insulation retainer ALE 55 Teledyne Analytical Instruments 9060 Service Manual 3 6 3 Use multi grips to remove the heater insulation retainer 56 es Teledyne Analytical Instruments 9060 Service Manual 3 6 4 Remove the heater insulation 3 6 5 Gently twist the heater to and fro while sliding it off the sheath 57 Teledyne Analytical Instruments 9060 Service Manual 3 6 6 Re installation is simply a reversal of this procedure 58 Teledyne Analytical Instruments 9060 Service Manual FREQUENTLY ASKED QUESTIONS 4 1 4 2 4 3 4 4 4 5 4 6 4 4 8 4 9 Sometimes see a symbol and on the LCD of the O2 analyser what does it mean How do set my 9060 oxygen analyser to transmit 0 21 linear oxygen from probe 1 on channel 1 and from probe 2 on channel 2 What does the Htr SSR Fail alarm mean What is Control of 1234 OR Extractive type Oxygen Sensor How long will the CM 15 reference air pump last What is the Probe Life Expectancy What is Oxygen Deficiency Scale Can you provide some tips on In Site type Applications
26. en reading 3 596 Certified calibration gas 5 0 0 05 If the oxygen probe has filters fitted the results will be very similar except that the readings at the lower flow rates will be closer to the calibration gas level Gas calibration check while the probe is out of the process The procedure for checking a probe that is out of the process is the same as checking it when it is in the process except that a small muffle of a high temperature insulating cloth or a high temperature glove should be placed loosely around the end of the probe in high wind conditions The reference air must also be still operating during the test 12 Teledyne Analytical Instruments 9060 Service Manual SERVICE NOTES amp MAINTENANCE 3 1 3 2 3 3 3 4 3 9 3 6 5VDC RAIL ISSUE IN 9060 SERIES ANALYSERS FILTER REPLACEMENT PROCEDURE ON 9060 OXYGEN PROBES DISASSEMBLY SERVICE amp ASSEMBLY OF HEATED OXYGEN PROBE DISASSEMBLY amp SERVICE OF UN HEATED OXYGEN PROBE HEATER REMOVAL PROCEDURE ON 9060 OXYGEN PROBE NEW VERSION AFTER JAN 2007 ONWARDS HEATER REMOVAL PROCEDURE ON 9060 OXYGEN PROBE OLD VERSION BEFORE JAN 2007 13 Teledyne Analytical Instruments 9060 Service Manual 3 1 5VDC RAIL ISSUE IN 9060 SERIES ANALYSERS The 5V rail in a 9060 series analyser can cause the microprocessor to reset if the rail drops to 4 93V This note lists the Known common causes and cures for a poor quality 5V ra
27. ensor s heater that will destroy the heater due to excessive temperature The 9060H Control unit turns off the electromechanical burner relay when the sensor temperature reaches 735 C If the temperature is caused by the process then heater power is not required if the temperature is caused by a shorted SSR then heater power is not desired The electromechanical burner relay is turned off When the probe or sensor temperature drops below 735 C the electromechanical burner relay is re energised If the SSR is shorted and the process temperature is above 715 C then the shorted SSR is not a threat to the heater because the heater will be powered for a relatively short time before it reaches 735 C again If the process is considerably lower than 715 C then the 100 power applied to the heater will be significantly longer and detrimental to the heater before the temperature reaches 735 C again If the temperature cycles between 735 C and 715 C three times then the instrument raises the Htr SSR Fail alarm and shuts power off to the heaters until a warm start is initiated power off then back on The number of cycles that will cause the alarm is selectable in the Extended Menu set up under SSR fail Alrm The alarm can be disabled if Disabled is selected for this menu item 61 Teledyne Analytical Instruments 4 4 9060 Service Manual Question What is Control of 1234 OR Extractive type Oxygen Sensor
28. eplace the O2 ve orange ve yellow T C ve red into the three way terminal block The terminals are marked and 3 3 5 11 Replace the heater wires into the two way terminal block These leads are not polarized gt 1 T 1 amd _ Loo m be Heater Tails Terminals 42 Teledyne Analytical Instruments 9060 Service Manual 3 3 5 12 Plug in the two wire heater connector and four way sensor T C connector SN 4 Probe Signals Connector 2 Way Heater Connector 4 d a i 3 3 5 13 Before screwing the reference air male connector into the head be sure the hypodermic is inserted into the barb s hole Tighten the male connector and then slide the silicon sleeve over the barb connector to form a seal 3 3 5 14 Install the screw top lid and tighten using the castellated slots on the lid The probe can now be tested as in section 2 0 Ref Air Connector Silicon Tube 43 Teledyne Analytical Instruments 9060 Service Manual 3 4 DISASSEMBLY amp SERVICE OF UN HEATED OXYGEN PROBE 3 4 1 9060 500mm 253MA Oxygen Probe Weatherproof Connector Optional gt i x External Reference Air a 44 Teledyne Analytical Instruments 9060 Service Manual 3 4 1 DISASSEMBLY PROCEDURE 3 4 1 1 Remove the calibration port fitting Thi
29. ews 7 Head Retaining Screw 34 Teledyne Analytical Instruments 9060 Service Manual 3 3 3 19 Lift the inner sheath straight up and out of the outer sheath Resistance will be felt removing the inner sheath due to the o ring seal inside the hexagonal nipple Once the o ring is clear of the hexagonal nipple care must be taken removing the inner sheath It must not be forced but gently worked until clear of the outer sheath 3 3 3 20 Set aside the inner sheath a safe place The heater insulation must be protected from damage and contamination The probe is now disassembled to the major subassemblies 35 Teledyne Analytical Instruments 9060 Service Manual 3 3 4 0 INSPECTION 3 3 4 1 Outer Sheath Check for corrosion inside and outside especially near the hex nipple This is where the condensation of process gasses will cause the worst corrosion 3 3 4 2 Inner Sheath Heater Check the heater continuity approx 110W Check the heater insulation resistance greater than 10MW Check for signs of corrosion along the heater sheath Check the o ring for damage or wear Check the tubular heater insulation for damage and degradation 3 3 4 3 Zirconia Sensor and Alumina tube Inspect the oxygen sensor for physical damage and loss of electrode paste Check the o rings for damage or wear If the sensor is to be replaced use a flat faced drill 8mm to remove any scale from the sensor seat to ens
30. filter on the reference air inlet to the analyser to extend the pumpss life 3 amount of restriction in the reference air line to the probe The greater the restriction the greater the load is on the pump s phosphor bronze bearings The normal flow range from a CM 15 pump connected to an oxygen probe is 100 to 120 cc per minute The zirconia sensor will work properly with a reference air flow rate as low as 10 cc per minute The common mode of failure for the CM 15 is a worn phosphor bronze bearing eventually causing the motor to pole out thereby greatly increasing the current drain The 9060 analyser monitors the current consumption of the pump and will raise a Reference Air Fail alarm if the current consumption exceeds a set level 250mA The alarm is also raised if the current falls below set level 15mA if the pump goes open circuit or is unplugged Teledyne Analytical Instruments 4 6 9060 Service Manual What is the Zirconia Probe Life Expectancy Answer Introduction The deterioration of a zirconia oxygen probe is of interest to maintenance engineers trying to maintain instrumental reliability and project planners budgeting for maintenance expenses Unfortunately the degradation does not follow a predictable formula Background Zirconium oxygen probes are the most common method of controlling combustion and heat treatment processes Teledyne Analytical Instruments have thousands of systems inst
31. il 3 1 1 The CM 15 reference air pump is worn and is drawing a higher than normal current from the 5V rail This normally results in the analyser constantly resetting it self when the pump is turned on at the end of the start up sequence If this stops when the pump cable is unplugged then the pump requires replacement PROBE _ PROBE PROBE TG 3 PROBE TC TC2 AUxX 2 AUX 120 GC 8 SC 5 TET 2 11 PURGE FL 12 SHITCH 14 Jana 7 4 F P 1 2 REN ALARNIE NOUATECH gt RESET 17 z TN i mE 8 BURNER ONIE SH E amp 1 L d ry i 3 E PURGE SOLENOID 05 232 20 RS 232 Tx y 5 232 21 She a CALI SOLENOID NETLIORK 22 NETWORK 23 ay LED ALE es MED 1 all i OUTPUT 14 25 Ho gi jt BURNER ON AX 1 1 7 i et EQS a BYPASS OUTPUT 1 26 SUPPLY OUTPUT 2427 ey _ EN E i 1 ho amp 3 i ri hd a Th oe N OUTPUT 2 28 14 Teledyne Analytical Instruments 9060 Service Manual 3 1 2 The bridge rectifier BR3 has an open circuit diode reducing the available power from the 5V rail This can be confirmed measuring the pre regulated DC voltage on pin 1 of IC12 this should be between 14 amp 18VDC
32. nalytical Instruments 78 Analyser not Operating Correctly LDA t rl in th m WA R NI N G n terminais g re BAI eda in Ic ic ana V se ie hy atritharicad narcanna Only authorised personn Check Fuse FS1 FS2 and PCB fuse FS3 Mains supply NO connections power switch transformer mains voltage selector switch Heater short circuit to ground Correct heater resistance is around 110 Q Display back light ON YES Is Check 5V Regulator 12 Dig 5V must be gt 4 97v Rectifiers bright BR3 BR1 BR2 BR4 and 26 C14 C14 is critical C26 C27 C19 C20 C21 Check Air Pump It should not be very hot 5 VDC Voltage NO Disconnect the display BD and check DC voltages on power board YES there any Text on the Display NO Check connection OK Check Display amp if still it is not between Display Board th Repl Display PCB amp Power Supply BD cee een eee YES Is Probe Is the probe heater OK 110 Q NO Is the BURNER ON switch SW1 on Or link terminals 188 19 Also check LED4 LED8 SSR1 SSR5 RL7 amp probe cable connection Temperature OK i e Approx 720 C Is there YES Check amp Ensure That both NO Analyzer amp Probe Working Oxygen Reading any Alarm correctly OK YES NO Check 4 20mA outputs 1 amp 2 Cable Reference air connection Gas leakage
33. nalytical Instruments 9060 Service Manual SPECIFICATIONS Inputs Zirconia oxygen probe heated or unheated Furnace kiln or flue thermocouple field selectable as type K or R Main flame established safety interlock for heated probes only Purge pressure switch Dual Fuel selector Remote alarm accept Outputs e Two linearised 4 to 20 mA DC outputs max load 10000 e Common alarm relay e Three other alarm relays with selectable functions Computer e RS 232 C or RS 485 for connection of a computer terminal or printer for diagnostics of the transmitter probe sensor or combustion process This connection is suitable for network connection to computers DCSs or PLCs using MODBUS protocol Range of Output 1 Field selectable from the following Output Selection Range Linear Probe 1 0 to 1 oxygen to 0 to 100 oxygen Linear Probe 1 and 2 averaged 0 to 1 oxygen to 0 to 100 oxygen If 2 probes are used Log 0 1 to 20 9 oxygen fixed Reducing 100 to 10 4 oxygen fixed Reducing 1071 to 10 25 oxygen fixed Linear probe 1 very low range to 0 001 to O to 2 0 oxygen 10ppm to 20 000ppm Range of Output 2 Field selectable from the following Output Zero Range Span Range Sensor EMF 0 to 1100 mV in 100 mV steps 1000 to 1300 mV in 100 mV steps Carbon Dioxide 010 10 96 2 to 20 96 Oxygen Deficiency 0 to 20 O deficiency 0 to 100 O2 excess Aux Temperature to 100 C 32 to 210 F in 1 degree steps 100 to 1400
34. ntact the o ring grease or the sensor will become contaminated Use long nosed pliers to work the sensor gland and o ring into the seal do not use excessive force as this could damage the sensor Replace the sensor compression spring onto the sensor gland Teledyne Analytical Instruments 3 3 5 5 9060 Service Manual Carefully insert the four bore assembly into the sensor 39 Teledyne Analytical Instruments 9060 Service Manual 3 3 5 6 Feed the four bore wires through the circuit board centre hole and the heater wires through the hole adjacent to the three way connector Install the reference air hypodermic into the four bore insulator While pushing the circuit board into position take extreme care lining up the four bore spring and sensor compression spring to avoid breaking the four bore insulator 220 Replace both circuit board retaining nuts flat washers PCB Retaining Nuts NS 40 Teledyne Analytical Instruments 9060 Service Manual 2 9220 Replace the weatherproof plug head connector Avoid twisting the wires while screwing in the connector Head Connector 3 3 5 9 Pass a Philips head screwdriver through the reference air male connector port and attache the earth lead wire to the opposite side of the head with the M4 screw Tighten securely Earthing Screw 41 79 Teledyne Analytical Instruments 9060 Service Manual 3 3 5 10 R
35. nual If the air is from an instrument air supply or a gas bottle compressed supply add 0 4mV to the reading before entering it into Probe Offset This will compensate for the ambient humidity in the atmosphere If a diaphragm or aquarium pump is used to supply the CAL port enter the mV reading as read from the lower line of the analyser The analyser monitors and compensates for the ambient relative humidity Certified calibration gas check 12 Disconnect the air supply and connect the gas supply to the CAL port of the probe through the gas regulator needle valve and the flow meter 13 Close the needle valve and set the gas regulator to about 50 kPa 14 Turn on the needle valve until about 0 5 l m is flowing into the probe The oxygen reading should move towards the certified oxygen concentration within 5 seconds and stabilize within 10 to 15 seconds Note the oxygen reading 15 As soon as the reading is stable and noted change the flow rate to 1 I m 16 Wait for a stable reading and note the oxygen reading 17 Repeat this for flow rates of 2 3 4 and 5 and then close the needle valve The oxygen readings should look like this Flow Rate LPM Analyser Oxygen Reading o Note The next time a gas calibration check 15 done it will not be necessary to vary the flow rate but simply use a flow rate in the centre of the flat area of the curve Oxygen probe Model 1231 without filters Process oxyg
36. ocess measurement the analyser allows an operator to read the impedance measurement and will automatically raise an alarm if the impedance is high enough to require attention 63 Teledyne Analytical Instruments 9060 Service Manual Oxygen Sensor Impedance 10 Impedance 2 Time yrs 1 2 3 Typical deterioration rate of a Teledyne Zirconia sensor There is not a definite impedance at which a sensor can be said to have failed As the electrode deteriorates the impedance will rise However the sensor oxygen reading is not affected by the loss of electrode material over a wide range if impedances up to tens of In fact if the temperature of the sensor is over 850 C the sensor will read the correct oxygen concentration without any electrode material as long as there is no other deterioration of the electrode connections The response time will usually increase as the electrode ages The above graph shows how sensor impedance will typically vary with use The sensor impedance is the sum of the electrode impedance and the electrolyte impedance The electrode impedance is the part that will increase as the probe ages Complicating the interpretation of the sensor impedance measurement is that the electrolyte impedance will be markedly lower at higher sensor temperatures This is taken into account in the determination of the alarm status of the Teledyne Analytical Instruments analysers As an indication of probe life
37. or by using a CRO Replace BR3 and make sure the component is installed so there is at least 3mm between the component and the circuit board This helps the component to dissipate heat Pin 1 1C12 15 Teledyne Analytical Instruments 9060 Service Manual 3 1 3 On analysers with version 1 6 or earlier 1630 2 boards the 40 way ribbon cable is worn or damaged Measure the 5V rail on the 1630 2 PSU board and then on the 1630 1 board If the value measured on the 1630 1 board is less than the value measured on the 1630 2 then the ribbon cable is causing excessive voltage drop al ad ad ad ad va oe 1632 V219 Iw 18 07 04 ER 9 9995 9595 55 55e n az Li Mmummmurr Str nt rere eee 3l EDEN d ma ee attr Tr CREO Ree Eee 16 Teledyne Analytical Instruments 9060 Service Manual There are spare conductors in the ribbon cable that can be utilized for the 5V rail and the common of the power supply Solder two jumpers to each of the headers as shown below i A 5 0 0 8 qme f SCIAP 0
38. probe 21 Teledyne Analytical Instruments 9060 Service Manual 3 2 4 Clean the steel surfaces of the filter retainer spacer and filter collar especially where the filters make contact with the retainer spacer and collar 22 Teledyne Analytical Instruments 9060 Service Manual 3 2 5 Reassemble the filter assembly The grub screws on the filter retainer should engage the grub screw locking holes at the end of the outer sheath 23 Teledyne Analytical Instruments 9060 Service Manual 3 3 DISASSEMBLY SERVICE amp ASSEMBLY OF HEATED OXYGEN PROBE INTRODUCTION The 9060 Heated oxygen probe is made up of 5 major parts 1 Alumina four bore assembly and compression spring 4 Filter outer sheath amp nipple assembly 5 Termination Head amp circuit board 24 Teledyne Analytical Instruments 9060 Service Manual This service note describes how to disassemble inspect repair or replace components and reassemble the oxygen probe 3 3 1 TOOLS REQUIRED To carry out these procedures the following tools are necessary vice with an 80mm opening and soft jaws 71 16 x 1 2 AF open end spanner mm open end spanner 7 mm nut driver 6 5 mm x 1 5 mm flat bladed screwdriver 2 5 mm x 1 0 mm flat bladed screwdriver 2mm Allen key 100 mm long nosed pliers 92 DU 25 Teledyne Analytical Instruments 9060 Service Manual 3 3 2 TESTING
39. rements e 240 or 110V 50 60 Hz 105 VA heated probe e 240 or 110V 50 60 Hz 5 VA unheated probe Weight e Transmitter 3 75 kg 10 lbs Dimensions Teledyne Analytical Instruments 9060 Service Manual 280mm 11 W x 180mm 7 H x 95mm 3 75 D Degree of Protection P65 without reference air pump P54 with reference air pump Mounting e Suitable for wall or surface mounting Teledyne Analytical Instruments 9060 Service Manual CALIBRATION PROCEDURES 2 1 GAS CALIBRATION CHECK FOR A MODEL 9060HEATED OXYGEN PROBE 10 Teledyne Analytical Instruments 9060 Service Manual 2 1 GAS CALIBRATION CHECK FOR A MODEL 9060HEATED OXYGEN PROBE Background The sensor that is used in all Teledyne probes is extremely predictable stable and reliable For this reason the calibration of a Teledyne oxygen system does not require the use of calibration gases However all Teledyne oxygen probes have a built in gas connection that does allow the accuracy of the probe to be checked This technical note describes the way to do this and gives some typical results Dust filter The 1231 oxygen probe can be supplied with or without a sintered dust filters The filter not only stops dust build up in the probe when the probe is used in dusty processes but also provides a partial gas barrier when a gas calibration check is being performed This allows the process gas to be more easily kept
40. rning the cap anti clockwise LM Ref Air Connector Silicon Tube E hus 3 9 9 9 Hold the reference air hypodermic silicon tube while unscrewing the reference air male tube connector from the head to avoid twisting the silicon tube 3 3 3 4 When the reference air male connector is unscrewed from the head gently remove it from the silicon tube 2f Teledyne Analytical Instruments 3 3 3 5 28 9060 Service Manual Ref Air Hypodermic Remove the reference air hypodermic by lifting straight up Do not bend Sharp bends could cause a blockage in the tube Teledyne Analytical Instruments 9060 Service Manual 3 3 3 6 From the circuit board lift out the two way heater wire connector and the 4 way O2 ve O2 ve T C ve and T C ve connector Both connectors can be folded back outside the head for clearance 4 Way Probe Signals Connector 2 Way Heater Connector A 3 3 3 7 Remove the heater tail wires from the two way terminal by loosening the two screws Heater Trails Terminals 29 Teledyne Analytical Instruments 9060 Service Manual 3 3 3 8 Remove the O2 ve T C ve and T C ve wires from the three way terminal by loosening the three screws Signals Wires Terminals 3 3 3 9 Remove the earth lead wire Access the M4 screw through the reference air male connector port Earthing Screw 30 Teledyne Analytical Instruments 9060 Service Manual 3 3 3 1
41. rs downstream of any bends and three diameters upstream of any bends Gas Velocity The gas velocity passing the end of the probe should be greater than 5 meters per second Low gas velocities result in slow refresh times of the process gas around the sensor causing a gradual depletion of the oxygen reading any hydrocarbons in the gas will accelerate the oxygen depletion rate at the sensor s surface Dust If the particulate loading is less than 500 mg Nm3 then filters are not required Use the sintered filters for particulate loadings in the range of 0 5 to 10 g Nm3 30 micron filters are used on most applications but 15 micron filters are available if required Remember that the response time to changes in oxygen levels dramatically increase with the finer pored filters For dust levels up to 200 g m3 on coal fired boilers the fly ash can be abrasive A protection shield may be required to prevent the probe from being prematurely destroyed In higher dust levels than 200 g m3 do not use filters but the probe must be mounted vertically downwards and purged frequently Process Pressure Teledyne Analytical Instruments in situ oxygen probes can operate over the process pressure range of 60kPa to 250kPa The analyser can compensate for a fixed process pressure or accept an analogue input signal from a pressure transducer for varying process pressures Probe Length The insertion depth required is dictated by the size of the flue or duct and
42. s could be 1 8 NPT plug or male connector if purge air or calibration gas is used Calibration Port 3 4 1 2 Remove the castellated lid on the probe head Use the shank of a suitable spanner or a square cross section bar Castellated Lid 45 Teledyne Analytical Instruments 9060 Service Manual 3 4 1 3 Unplug the wiring from the head connector These are the probe positive thermocouple positive and thermocouple negative The thermocouple is optional in the 1232 probe Plugged Wirina 3 4 1 4 Remove the silicon tube from the hypodermic that runs through the head connector or from the barb on the external reference air connector Gently work the silicon tube to get this off Silicon Tube Silicon Tube 46 Teledyne Analytical Instruments 9060 Service Manual 3 4 1 5 Remove the earthed wire inside the head O2 ve and remove the head connector 3 4 1 6 Evenly remove the two Nylok nuts holding down the compression plate This will remove the spring loading on the four bore insulator and the sensor Nylock Nuts 47 79 Teledyne Analytical Instruments 9060 Service Manual 3 4 1 7 Carefully remove the four bore insulator containing the thermocouple and probe positive conductor a Inspect for damage to the ceramic insulator b Check the conductors for damage or oxidation 3 4 1 8 Remove the sensor compression spring from the gland on top of the sensor 3 4 1 9 Using
43. terminal 3 4 or cable connection Check probe thermocouple resistance The resistance about 10 Q at ambient temperature NO Is AUX TIC OK OR Open if connected YES Check analyser setup and AUX TC input from terminal 5 6 NO Is Reference air Pump OK OR Failed Check that the pump is not hot YES Check reference air pump connection and the analyser setup and power supply amp ICA NO Main Freq YES Turn Burner Bypass switch off and link terminal 18 19 Check failed NO Is Watchdog there NO Heater By pass NO NO Timer Resetting any CAL gua Switch ON Error YES YES YES Turn Burner Bypass Check IC21 Check Cal Gas amp Check switch OFF and link amp Dig 5V terminal 18 19 9060 Service Manual Probe Filter NO Oxygen Deviation Blocked High YES YES analyser setup Check setup amp probe flow rate amp setup amp Probe filter blockage installation position Teledyne Analytical Instru 79 ments
44. ure a good electrical contact between the sensor and seat O2 ve 3 3 4 4 Thermocouple 4 bore Inspect the 4 bore for physical damage Check the thermocouple and O2 ve conductor for continuity and brittleness or oxidation of the wires 3 3 4 5 Head Assembly Check the reference air hypodermic for blockages 36 Teledyne Analytical Instruments 9060 Service Manual 3 3 5 0 RE ASSEMBLY 3 3 5 1 Wipe a small amount of o ring grease such as Molykote FS3451 around the o ring on the gland body Push the inner sheath straight into the outer sheath aligning the holes in the inner sheath assembly with the threaded holes in the outer sheath s hexagonal nipple Resistance will be felt replacing the inner sheath due to the o ring seal inside the hexagonal nipple Care must be taken replacing the inner sheath to prevent damaging the heater insulation and o ring It must not be forced but gently worked into position 3 5 0 2 Align the reference air male connector port in the head opposite the 1 8 NPT calibration port on the inner sheath assembly screw the probe head to the probe body with the two retaining screws 3 Teledyne Analytical Instruments 3 3 5 3 3 3 5 4 38 9060 Service Manual Wipe a small amount of o ring grease such as Molykote FS3451 around the top of the sensor and outer o ring on the sensor gland Carefully insert the sensor into the inner sheath Do not allow the tip of the sensor to co
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