Teledyne OT-3 User's Manual
Contents
1. Analyzer OPERATING INSTRUCTIONS FOR MODEL OT 3 Trace Oxygen Analyzer P N M74173 10 28 2001 ECO N 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 4 Teledyne Analytical Instruments Model OT 3 Copyright 2000 Teledyne Analytical Instruments All Rights Reserved No part of this manual may be reproduced transmitted transcribed stored in a retrieval system or translated into any other language or computer language in whole or in part in any form or by any means whether it be electronic mechanical magnetic optical manual or otherwise without the prior written consent of Teledyne Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Warranty This equipment is sold subject to the mutual agreement that it is warranted by us free from defects of material and of construction and that our liability shall be limited to replacing or repairing at our factory without charge except for transportation or at customer plant at our opti2. 4 Withdraw the cap from the block The cell should come out with the cap 5 Carefully pull the cell off of the cap WARNING DO NOT TOUCH THE SCREENED END OF THE CELL FLUID THAT MAY LEAKING FROM 6 Dispose of the cell in a safe manner in accordance with all applicable ENVIRONMENTAL AND SAFETY laws 5 2 4 Installing a Micro fuel Cell To 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 Disconnect the Power Source from the Control Unit Set the flow rate to a high level 5 1 SCFH As rapidly as possible complete steps 5 7 Remove the new Micro fuel Cell from its protective bag AS RE OG 49 Place the cell on the end of cell retainer cap with the concentric gold rings facing up 7 Careful insert the cap and cell into the block and screw the cap clockwise into the cell block until it is fully closed 8 Reconnect the electrical power Teledyne Analytical Instruments 34 Analyzer Maintenance 5 2 5 Cell Warranty Conditions The B 2C A 2C and Insta Trace Class Micro fuel Cells are used in the Model OT 3 These cells are warranted for 6 months with an expected life of 8 months from the date of shipment under specifi
3. Alarm Power Failure Alarm 1 Alarm 2 Figure 3 1 Electrical Connectors for AC Control Unit 3 3 1 Primary Input Power A detachable power cord is installed directly into the Control Unit and connects to a three pin terminal block on the rear panel The terminal block is provided for customer AC wiring The universal power supply allows direct connection to any 100 240 VAC 50 60Hz power source The fuse block to the right of the power cord receptacle accepts 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 polarity noted See Figure 3 1 The outputs are 0 10 V Range Voltage rises with increasing oxygen concentration from 0 V at 0 percent oxygen to 10 V at full scale percent oxygen Full scale 100 of programmed range 0 10 V Range ID 3 33 V Low Range 6 66 High Range 10 V Air Cal Range Teledyne Analytical Instruments 15 Installation OT 3 4 20 mA Range Current increases with increasing oxygen concentration from 4 mA at 0 percent oxygen to 20 mA at full scale percent oxygen Full scale 100 of programmed range SS
4. concentration 29 calibration 9 28 calibration mode 24 cathode 6 7 8 9 cell block 1 18 cell failure 32 cell output 8 cell warranty 35 Class 1 Div 1 18 coalescing filter See filter company address 37 configuring 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 electrical potential 6 electrochemical device 6 electrochemical transducer 6 electrolyte 6 7 13 33 electron transfer 9 failsafe operation 16 18 false alarms 30 features 1 filter bypass 1 coalescing 1 19 20 flow restrictor 1 21 flowmeter 1 20 forced time out 29 front panel 2 23 function keys 3 fuse block 15 fuse holder 4 31 fuse replacement procedure 31 gas connection 18 gas selector switch 20 half reaction See reaction hazardous location 17 HI Range 25 hydroxyl ion 8 installation 13 installation checklist 21 Insta Trace 1 Teledyne Analytical Instruments 39 Index international power 10 jumper 18 keypad lockout 2 27 lead 7 8 linear curve 9 LO Range 25 location 14 maintenance 31 manuals additional v membrane 8 9
5. 13 14 microcontroller 6 10 11 Micro fuel Cell 6 9 anatomy 7 characteristic curve 10 contacts 7 14 cross section 7 installation 14 installing 34 removing 33 temperature compensation 11 model information iii NEMA 4 1 36 NO PASS 28 operating temperature 36 operation 23 output 2 9 15 analog 4 connectors 15 current 16 range ID 2 15 sensor 11 solid state relay 18 specifications 36 oxidization 8 oxygen concentration 9 15 oxygen sensor See Micro fuel Cell packaging 14 33 PASS CODE 27 PCB main 10 power supply 10 percent concentration 29 permeable membrane 7 power 2 10 power supply 15 power connection 4 power cord 15 power failure alarm See alarm power supply module 10 pressure 21 OT 3 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 36 restrictor See flow restrictor ROM 10 sample pressure 20 sample system 18 20 scrubber 1 18 20 sensor amplifier 10 sensor connector 4 sensor installation 32 serial number iii setup function buttons 24 setup mode 24 shut off valve 1 20 signal output 36 signal processing 6 10 slope 9 solid state relay 2 4 See relay span 29 span adjustment
6. 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 important to periodically drain the condensate by opening the drain valve If appropriate the drain line should be connected to a suitable receptacle for handling contaminated waste liquid A 0 10 psig pressure regulator is installed downstream from the filter and controls the sample pressure through the analyzer In conjunction with the flowmeter it provides a stable mass flow even at low volume over the rated temperature range of the instrument Set the pressure regulator to provide a flow rate of 0 4 SCFH approximately 4 psig A clear PVC acid gas scrubber is installed between the regulator and the sample span gas selector switch The clear housing permits a visual analysis regarding the condition of the scrubber medium and allows the user to predict service intervals A switching valve is provided to feed the analysis unit with either sample or span gas 4 Teledyne Analytical Instruments 20 Analyzer Installation A flowmeter and flow restrictor are parts of the sample system and assist in setting the flow of the gas The restrictor is installed upstream of the analyzer while the flowmeter is installed on the vent side Adjust the sample pressure at the
7. Cell 5 2 4 Installing a Micro fuel Cell 5 2 5 Cell Warranty Conditions A 1 Specifications A 2 Spare Parts List A 3 Reference Drawing A 4 Miscellaneous Teledyne Analytical Instruments 18 20 21 23 23 24 24 25 25 25 25 26 26 26 27 28 28 29 29 31 31 32 32 33 33 34 35 36 37 38 38 Model OT 3 List of Figures Rm 29 959 40002522222222222222 Figure 1 1 Figure 1 2 Figure 1 3 Figure 2 1 Figure 2 2 Figure 2 3 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 4 1 Figure 5 1 PROMI oen eer ees 3 Rear Panel AC 5 Rear Panel DC 5 Cross Section of a Micro fuel Cell 7 Characteristic MFC Input Output Curve 10 Block Diagram of the Signal Processing Electronics 1 1 Electrical Connectors for AC Control Unit 15 Contact ID for FAILSAFE Relay Operation 166 e IRoe aee Mta M 19 OT 3 Sample 21 Front Panel Control and Indicators 23 Fuse Replacement ind 32 Teledyne Analytical Instruments viii Analyzer Introduction Introduction 1 4 Overview The T
8. 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 regulation The O concentration of the span gas should be 80 90 of the principle range of use typically 8 9 ppm or 80 90 ppm 1 Attach the pressure regulated span gas to the to the span port on the bottom of the analyzer as described in Section 3 4 2 Move the gas selector valve to the SPAN position 3 Adjust the pressure on the span gas to produce a 0 4 0 5 SCFH flow and allow the analyzer to stabilize before setting the span 4 The analyzer reading should be stable prior to setting the span 4 Teledyne Analytical Instruments 28 Analyzer Operation Note If the analyzer output goes above the high alarm setpoint or below the low alarm setpoint the display will go blank and the front panel ALARM Indicator beneath the SET Function buttons will blink Hold down the SPAN button until the ALARM Indicator stops blinking To set the span 1 Press the SPAN button once 2 Within 5 seconds press either the A or V button until the display is stable and matches the known span gas concentration The unit is now calibrated 4 9 Displaying Percent amp PPM on the LED Display The analyzer displays the
9. ONE LINE AT A TIME MAKE SURE THAT THE CORRECT GAS LINE IS MATED TO THE PROPER ji FITTING ON THE INSTRUMENT For maximum performance the system should be installed in a manner to minimize the sample line length 4 Teledyne Analytical Instruments 19 Installation OT 3 een The vent line must be installed in a manner which will prevent dirt and water from accumulating within the line It must return sample to atmospheric pressure The vent line should be 1 4 diameter tubing or larger and be at least 24 long This will help to prevent the back diffusion of into the sample system 3 5 Sample System The sample system used in the OT 3 Trace Oxygen Analyzer is a robust gas handling and conditioning system designed for low flow rate trace oxygen analysis in a natural gas or other low oxygen gas environment It uses stainless steel tubing and fittings throughout and a special 0 10 psig regulator designed to provide stable sample flow at low volumes over wide temperature extremes The incoming sample gas is conditioned using a coalescing filter and an acid scrubber to remove moisture and contaminants which would otherwise interfere with the accurate trace analysis and or reduce the lifetime of the sensor Refer to Figure 3 4 for the following discussion Note Check the front 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
10. concentration in percent whenever the reading is over 9999 ppm When the reading changes to percent the LED display 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 buttons causes the analyzer to time out in five seconds instead of five minutes If during the span procedure you press the RANGE or ALARM buttons either the range or alarm routine will be activated any changes to span will be rejected the 60 second alarm delay will not occur i e the alarms will be responsive immediately CAUTION CONSIDERS THE ACTION OF PRESSING THE ALARM OR RANGE BUTTONS TO BE AT YOUR THE USER S DISCRETION BE AWARE THAT THE ALARMS WILL BECOME ACTIVE WITHIN 5 FIVE SECONDS IF THE RANGE 4 Teledyne Analytical Instruments 29 Operation OT 3 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 Teledyne Analytical Instruments 30 Analyzer Maintenance Maintenance Aside from normal cleaning and checking for leaks at the gas connections the M
11. 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 values of parameters downwards as they are displayed on the LED readout Digital LED Readout The digital display is a LED device that produces large bright 7 segment numbers that are legible in any lighting environment It has two functions Teledyne Analytical Instruments 3 Introduction OT 3 1 4 Meter Readout As the meter readout it displays the oxygen concentration currently being measured Measurement Parameters Readout It also displays user definable alarm setpoints ranges and span calibration point when they are being checked or changed Rear Panel Description The rear panel contains the electrical input and output connectors The connectors are described briefly here and in detail in the Installation chapter of this manual The rear panels for the AC and 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 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
12. output 4 20 mA DC concentration output negative ground Alarm Connections Alarm 1 Alarm 2 and Power Failure Alarm connections Sensor Connector Internal Sampling System Sensor Connector RS 232 Port Serial Digital Output of concentration and range signals SSR POWER AC POWER UNITS ONLY 15 VDC power output for powering Solid State Relays 4 Teledyne Analytical Instruments 4 Analyzer Introduction Fuse Compartment RS 232 Port Power LOTMA P Range ID 0 10VDC Concentration 0 10 VDC Alarm Power Failure Remote Alami Probe Alam Figure 1 2 Rear Panel AC Version Fuse Holder RS 232 Port Output DC Power AJOA 10 36 VDC Range ID 0 10VDC Concentration 0 10 VDC Alarm Power Failure Remote LO Alarm Probe HI Alarm Figure 1 3 Rear Panel DC Version Teledyne Analytical Instruments 5 Installation OT 3 een Operational Theory 21 Introduction The analyzer is composed of two subsystems e 3300 3 control unit e OT 3 sample sys The OT 3 sample system is designed to accept the sample gas and direct it to the sensitive surface of the Micro fuel Cell sensor The Micro fuel Cell is an electrochemical galvanic device that translates the amount of oxygen present in the sample into an electrical current The 3300 OT 3 control unit processes the sensor output and translates it into electrical concentration range and alarm outp
13. regulator to provide a flow rate of 0 4 0 5 SCFH It is important that the sample vent connection 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 O reading and reduce the sample flow Sample and Span pressure should not exceed 2000 psig 13 8 Mpa Sample Coalescing Pressure Acid Flow Filter Regulator Scrubber Sample In 5 2000 psig Sample Span Drain Span Gas Selector In Sample Return Vent to Atmospheric Pressure Flowmeter Cell Flow Restrictor Figure 3 4 OT 3 Sample System 3 6 Installation Checklist Before connecting the instrument to the power source and turning it on make sure you have e Correctly installed the Sample and Exhaust gas lines Checked for leaks Set the flow Once the above checks have been made you can connect to the power source The instrument is now ready for operation 4 Teledyne Analytical Instruments 21 Installation OT 3 ee 5 7 4 Teledyne Analytical Instruments 22 Analyzer Operation Operation 4 1 Introduction Once the analyzer has been mounted the gas lines connected and the electrical connections made the Analyzer can be configured for your application This involves setting the system parameters e Defining the user selectable analysis ranges e Setting alarm setpoints e Calibrating the instrument
14. to provide early warning of imminent danger it has no control over process conditions and it can be misused In particular any alarm or control systems installed must be tested and understood both as to how they operate and as to how they can be defeated Any safeguards required such as locks labels or redundancy must be provided by the user or specifically requested of Teledyne at the time the order is placed Therefore the purchaser must be aware of the hazardous process conditions The purchaser is responsible for the training of personnel for providing hazard warning methods and instrumentation per the appropriate standards and for ensuring that hazard warning devices and instrumentation are maintained and operated properly Teledyne Analytical Instruments the manufacturer of this instrument cannot accept responsibility for conditions beyond its knowledge and control No statement expressed or implied by this document or any information disseminated by the manufacturer or its agents is to be construed as a warranty of adequate safety control under the user s process conditions 4 Teledyne Analytical Instruments ii Analyzer Specific Model Information The instrument for which this manual 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 manua
15. 9 span gas 18 20 concentration 28 flowrate 28 spare parts listing 37 specifications 36 SSR See solid state relay stainless steel 20 stockpiling MFCs 33 switches membrane 2 temperature compensation 2 11 temperature range 2 14 Teledyne Analytical Instruments 40 Analyzer Index terminal block 14 15 warranty ii 35 thermistor 11 web address 37 universal power supply See power website address v supply module Zero VAC symbol 38 absolute 9 vent 19 20 Zero gas 19 32 voltage amplifier 11 zero offset 9 32 voltage to current converter 12 4 Teledyne Analytical Instruments 41 Index OT 3 4 Teledyne Analytical Instruments 42
16. ARMS ALARMS Figure 2 3 Block Diagram of the Signal Processing Electronics In the presence of oxygen the cell generates a current The sensor has an internal thermistor compensation network The output of the sensor is converted to voltage millivolt range This output 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 sent to the microcontroller The digital concentration signal along with input from the front panel buttons KEYBOARD is processed by the microcontroller and appropriate output signals are directed to the display and alarm relays 4 Teledyne Analytical Instruments 11 Installation OT 3 The same digital information is also sent to a 12 bit digital to analog converter DAC that produces the 0 10 V 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 Teledyne Analytical Instruments 12 Analyzer Installation Installation E Installation of the analyzer includes CAUTION Unpacking the system Installing t
17. C e Large 3 gt digit LED O2 concentration read out 7 button user interface keypad e 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 e Electronic temperature compensation e Optional RS323 interface e Accuracy 2 of range at constant temp e Response time 90 in 65 sec of less 25 degrees C Temperature range 0 50 degrees 1 3 Front Panel Description controls are accessible from the front panel See Figure 1 1 The front panel has seven push button membrane switches a digital meter and an alarm indicator LED for operating the analyzer These features are described briefly here and in greater detail in Chapter 4 Operation 4 Teledyne Analytical Instruments 2 Analyzer Introduction 4 Teledyne Analytical instruments A V Figure 1 1 Front Panel Function Keys Seven push button membrane switches are used to select the function performed by the analyzer Set Alarm 1 Set Alarm 1 Hi or Low and the concentration at which alarm 1 activates Set Alarm 2 Set the Alarm 2 Hi or Low and the concentration to which alarm 2 activates Set HI Range Set the high analysis range for the instrument up to 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
18. R POWER AC units only Provides 15vdc at 698 ohm impedance to power external Solid State Relays 3 3 3 Alarm Relays The three alarm circuit connectors are screw terminals for making connections to internal alarm relay contacts There is one set of contacts for each type of alarm Contacts are Form C with normally 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 Normally Closed Common and Normally Open Figure 3 2 explains how these act in failsafe operation Alarm 1 and Alarm 2 can both be configured as either HI or LO A HI alarm will activate when concentration is above threshold while a LO alarm will activate when concentration is below threshhold 3 This side is closed This side is closed when IN ALARM with NO ALARM condition OR unit condition AND unit is NOT POWERED IS POWERED Figure 3 2 Contact ID for FAILSAFE Relay Operation Teledyne Analytical Instruments 16 Analyzer Installation The specific descriptions for each type of alarm are as follows Power Fail Alarm This alarm c
19. and mounted so it won t be subject to vibration The ambient temperature should be within the range of 0 50 C 32 122 F For the best performance do not exceed 40 104 F In choosing a location for the analyzer select a site that is as close as possible to the sample extraction point This will enhance the overall 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 to be replaced During the Installation and or Replacement of the the membrane surface MUST ALLWAYS FACE DOWNWARD TOWARD THE CELL CAP The concentric gold contacts must face up To install or replace the Micro fuel Cell follow the procedures in Chapter 5 Maintenance 3 3 Electrical Connections Figure 3 1 shows the Model 3300T OT 3 rear panel of the control unit See Figure 1 3 for DC version To gain access to the terminal blocks the analyzer door screws must be loosened and the door opened Teledyne Analytical Instruments 14 Trace Oxygen Analyzer Installation Output SSR AC Power 4 20 mA Range ID 0 10VDC Concentration 0 10 VDC Fuse Compartment RS 232 Port
20. aui a alo Es ine ar 1 1 Overview 1 2 Main Features of the Analyzer 1 3 Front Panel Description 1 4 Rear Panel Description Operational Theory circi nie rne nni vas aec 2 1 Introduction 2 2 Micro fuel Cell Sensor 2 2 1 Principles of Operation 2 2 2 Anatomy of a Micro fuel Cell 2 2 3 Electrochemical Reactions 2 2 4 The Effect of Pressure 2 2 5 Calibration Characteristics 2 3 Electronics 2 39 4 General 2 3 2 Signal Processing Installation a 3 1 Unpacking the Analyzer 3 2 Location and Mounting 3 2 2 Installing the Micro fuel Cell 3 3 Electrical Connections 3 3 1 Primary Input Power 3 3 2 Analog Outputs 3 3 3 Alarm Relays 3 3 4 Relay Ratings 3 3 5 Solid State Relay Output Teledyne Analytical Instruments Model OT 3 vi Operation Maintenance Appendix Trace Oxygen Analyzer 3 4 Gas Connections 3 5 Sample System 3 6 Installation Checklist 4 1 Introduction 4 2 Using the Function and Data Entry Buttons 4 3 Setting the Analysis Ranges 4 31 Range 4 32 LO Range 4 4 Setting the Alarm Setpoints 4 4 1 Set Alarm 1 4 4 2 Set Alarm 2 4 4 8 Power Failure Alarm 4 5 Alarm Delay 4 6 Keypad Lockout 4 7 Selecting a Fixed Range or Autoranging 4 8 Calibration 4 9 Displaying Percent amp PPM on the LED Display 4 10 Supplementary Information 5 1 Replacing the Fuse 5 2 Sensor Installation or Replacement 5 2 1 When to Replace a Sensor 5 2 2 Ordering and Handling of Spare Sensors 5 2 3 Removing the Micro fuel
21. 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 2 Press the SET ALARM 1 function button once The display will flash either HI or LO depending on what the alarm was configured in the last time If the alarm configuration must be changed use the Up or Down keys to toggle the alarm from HI to LO or vice versa if within 5 seconds no key is pressed the instrument will return to the sample mode and display oxygen concentration To change the setting at which the alarm will be actuated press the SET ALARM 1 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 4 Teledyne Analytical Instruments 25 Operation OT 3 until the display reads the desired percent concentration if within 5 seconds no key is pressed the instrument will return to the sample mode and display oxygen concentration After setting the value wait for the unit to time out of this mode approximately 5 seconds and return to displaying oxygen concentration 4 4 2 Set Alarm 2 Alarm 2 can be set either as a high or low alarm To configure this alarm to your preferences 1 Press the SET ALARM 2 function button once 2 The display will flash eith
22. ed operating conditions see Appendix Note any Addenda attached to the front of this manual for special information applying to your instrument Note that the warranty period begins on the date of shipment 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 cells for evaluation do not install the shorting pin on the rear of the cell If it is determined that failure is due to faulty workmanship or material the cell will be replaced at no cost to you Note Evidence of damage due to tampering or mishandling will render the cell warranty null and void Teledyne Analytical Instruments 35 Appendix OT 3 Appendix A 1 Specifications Ranges Signal Output Range ID Display Alarms System Operating Temp Accuracy Response Time Two user selectable ranges can be set between 0 10 ppm and 0 9999 ppm oxygen and a 0 25 nominal Air Calibration Range Voltage 0 10 VDC negative ground Current 4 20 mA negative ground 0 10 VDC Light emitting diode LED display Two user settable non latching alarms with user adjustable programmable 0 20 min delay
23. eledyne Electronic Technologies Analytical Instruments TET AI Model OT 3 is a microprocessor based trace oxygen analyzer for real time measurement of the parts per million of oxygen in inert gases or in a wide variety of gas mixtures It features simple operation fast response and a 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 e The main features of the analyzer include Insta Trace sensor technology e Stainless steel sample system with PVC scrubber and Nylon cell block e Pressure regulator e Coalescing filter Acid gas scrubber clear rebuildable e Flow control restrictor Sample shut off valve Bypass filter drain valve e Flowmeter e Viewing window Sample Span selector valve NEMA 4 enclosure 15 8 x 11 8 x 8 1 e Viewing window 3300 OT 3 Control Unit 4 Teledyne Analytical Instruments 1 Introduction OT 3 The Model 3300 OT 3 Control Unit has its own long list of features including e Keypad lockout feature Two user settable fail safe alarms with a user settable 0 20 min time delay Two user settable ranges from 0 10 0 9999PPM with user selectable auto ranging e Power fail alarm e SSR power output Solid State Relay power available on control units Micro processor based electronics 8 bit ADC amp 18 bit DA
24. er HI or LO depending on how the alarm was last configured If the alarm configuration must be changed use the Up or Down keys to toggle the alarm from HI to LO or vice versa If within 5 seconds no key is pressed the instrument will 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 instrument will return to the sample mode and display oxygen concentration After setting the value wait for the unit to time out of this mode approximately 5 seconds and return to displaying oxygen concentration 4 4 3 Power Failure Alarm The power failure alarm provides a set of form C contacts and are configured for failsafe operation The contacts remain energized when the whenever power is applied to the instrument 4 5 Alarm Delay The alarms have a user settable delay feature which can delay the onset of an alarm The delay can be set from 0 20 minutes in 1 minute increments 4 Teledyne Analytical Instruments 26 Analyzer Operation When the alarms are set for delay and an alarm condition exists the display will alternate between the O reading and the time in min
25. hanges state when the AC or DC system power is lost Alarm 1 Programmable as high or low alarm actuates when concentration is above threshold Can be set anywhere between 0 and 9999ppm but must be set ABOVE the threshold set for Alarm 2 Alarm 2 Programmable as high or low alarm actuates when concentration is below threshold Can be set anywhere from 0 to 9999ppm CAUTION THERE 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 uA 10mV e Lower rating maximum safe rating for Cl 1 Div 2 Group C or D hazardous location DC Rating 0 30 VDC maximum 0 9 Amps maximum AC Rating 125 VAC maximum Q 0 2 Amps maximum minimum reliable switching rating 10 uA 10mV To safely use the alarm relays in a hazardous location the characteristics of both the switched voltage and the components or load being operated must be known The alarm relays must not be attached to 4 Teledyne Analytical Instruments 17 Installation OT 3 any unknown power source or any load or device that may exceed the safe use ratings for Cl 1 Div 2 Group amp D as listed above It should also be understood that that these alarm relays can not be used to ope
26. he Micro fuel Cell Making the electrical connections Making the gas connections Testing the installation READ THIS ENTIRE CHAPTER BEFORE INSTALLING THE UNITS SAMPLE MUST BE FREE OF ENTRAINED SOLIDS OR WATER HOWEVER A HIGH HUMIDITY NON CONDENSING SAMPLE IS IDEAL SINCE IT WILL PREVENT WATER LOSS FROM THE CELL ELECTROLYTE 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 14 Unpacking the Analyzer As soon as you receive the instrument carefully unpack and inspect the Unit and any included accessories for damage Immediately report any damage to the shipping agent The analyzer is shipped with all the materials you need to install and prepare the system for operation Teledyne Analytical Instruments 13 Installation OT 3 een 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 3 2 Location and Mounting This instrument should be installed at viewing level either indoors or sheltered from the moisture and the elements
27. hen it is needed TAI recommends that one spare cell be purchased when the current cell s warranty period is approximately two thirds over CAUTION DO NOT STOCKPILE CELLS THE WARRANTY PERIOD STARTS ON THE DAY OF SHIPMENT FOR BEST RESULTS DO NOT ORDER A NEW SPARE CELL TOO SOON The spare cell should be carefully stored in an area that is not subject 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 SUBSTANCES THAT ARE EXTREMELY HARMFUL IF TOUCHED SWALLOWED OR INHALED AVOID CONTACT WITH ANY FLUID OR POWDER IN OR AROUND THE UNIT WHAT MAY APPEAR TO BE PLAIN WATER COULD CONTAIN ONE OF THESE TOXIC SUBSTANCES IN CASE OF EYE CONTACT IMMEDIATELY FLUSH EYES WITH WATER FOR AT LEAST 15 MINUTES CALL A PHYSICIAN SEE APPENDIX Material Safety Data Sheet MSDS 5 2 3 Removing the Micro fuel Cell To remove a spent or damaged Micro fuel Cell 1 Disconnect the Power Source from the instrument 4 Teledyne Analytical Instruments 33 Maintenance OT 3 2 Open the analyzer door 3 Unscrew the cell retainer cap from the cell block by turning it counterclockwise until it is free
28. ized substitution of any component may adversely affect the safety of this instrument Since the use of this instrument is beyond the control of Teledyne no responsibility by Teledyne its affiliates and agents for damage or injury from misuse or neglect of this equipment is implied or assumed CAUTION THE ANALYZER SHOULD 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 it available Occasionally some instruments are customized for a particular application or features and or options added per customer requests Please check the front of this manual for any additional information in the form of an Addendum which discusses specific information procedures cautions and warnings that may be peculiar to your instrument Manuals do get lost Additional manuals can be obtained from Teledyne at the address given in the Appendix Some of our manuals are available in electronic form via the internet Please visit our website at www teledyne ai com Teledyne Analytical Instruments Table of Contents List of Figures scan iind dae iura 7 0
29. l is supplied are indicated by a check mark in the box Instrument Serial Number 4 Teledyne Analytical Instruments iii Model OT 3 Important Notice Model OT 3 complies with all of the requirements of the Commonwealth of Europe CE for Radio Frequency Interference Electromagnetic Interference RFI EMI and Low Voltage Directive LVD The following International Symbols are used throughout the Instruction 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 gt gt OC Note Additional information in the form of notes are Symbol included which emphasize specific topics regarding the present discussion Teledyne Analytical Instruments iv Trace Oxygen Analyzer This instrument is designed for CL1 DIV hazardous locations It is the customer s responsibility to ensure safety especially when combustible gases are being analyzed since the potential of gas leaks always exist The customer should ensure that the principles of operating this equipment are well understood by the user Misuse of this product in any manner tampering with its components or unauthor
30. l setup 4 3 Setting the Analysis Ranges The two user definable analysis ranges are both capable of being adjusted for from 0 10ppm to 0 9999 ppm oxygen concentration Whatever values are selected the analyzer automatically switches from the LO range to the HI range when the oxygen concentration reaches the LO range full scale value and it switches back to the LO range when the oxygen concentration falls below of the LO range full scale value Note The HI Range setpoint MUST be set at a higher concentration percentage than the LO Range setpoint Teledyne Analytical Instruments 24 Analyzer Operation 4 3 1 HI Range Setting the HI Range full scale value defines the LEAST sensitive analysis range to be used To set the HI Range 1 2 4 3 2 Press the SET HI RANGE Function button once Immediately within 5 seconds press either the A or V button to raise or lower the displayed value as required until the display reads the desired full scale percent concentration LO Range Setting the LO Range full scale value defines the MOST sensitive range to be used To set the LO Range 1 2 4 4 Press SET LO RANGE Function button once Immediately within 5 seconds press either the UP or DOWN arrow button to raise or lower the displayed value as required until the display reads the desired full scale percent concentration Setting the Alarm Setpoints The alarm setpoints can
31. mixture it is necessary that the sample diffuse into the cell under constant pressure If the total pressure increases the rate that oxygen reaches the cathode through the diffusing membrane will also increase The electron transfer and therefore the external current will increase even though the oxygen concentration of the sample has not changed It is therefore important that the sample pressure at the fuel cell usually vent pressure remain constant between calibrations 2 2 5 Calibration Characteristics Given that the total pressure of the sample gas at the surface 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 do not have to compensate for nonlinearity In addition since there is zero output in the absence oxygen the characteristic curve is close to an absolute zero The cell itself does not need to be zeroed on ranges as sensitive as 0 10 ppm The electronics are zeroed to compensate for zero offsets in the electronics The electronics is zeroed automatically when the instrument power is turned on during the Self Test As the cell reaches the end of its useful life the slope see
32. n in Figure 2 2 decreases As this occurs the span adjustments will become larger 4 Teledyne Analytical Instruments 9 Installation OT 3 500 375 250 Cell Output uA 125 50k 100k 150k 200k Oxygen Concentration ppm Figure 2 2 Characteristic MFC Input Output Curve 2 3 Electronics 2 3 1 General The signal processing uses an Intel microcontroller with on board RAM and ROM to control all signal processing input output and display functions for the analyzer 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 located on the Main PCB which is mounted vertically just behind the front panel of the Control Unit j Teledyne Analytical Instruments 10 Analyzer Installation 2 3 2 Signal Processing Figure 2 3 is a block diagram of the signal processing electronics described below Milliv olt Output TEMPERATURE COMPENSATION SENSOR SER AMPLIEIER C E CONV 4 20 mA DC Concentrati lt 0 10 VDC NETWORK ON SENSOR PCB Microamp Output B 2C Sensor RANGE ID MICRO CONTROL L KEYBOARD AL
33. ne oxygen molecule in the presence of water from the electrolyte to produce four hydroxyl ions When the oxygen is reduced at the cathode lead is simultaneously oxidized at the anode by the following half reaction Pb 20H gt H20 2 anode In this reaction two electrons are transferred 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 concentration in the gas mixture The overall reaction for the fuel cell is the SUM of the half reactions above or 2Pb O2 gt 2PbO These reactions will hold as long as no gaseous components capable of oxidizing lead such as iodine bromine chlorine and fluorine are present in the sample The output of the fuel cell is limited by 1 the amount of oxygen in the cell at the time and 2 the amount of stored anode material In the absence of oxygen or any gases capable of oxidizing lead no current is generated Teledyne Analytical Instruments 8 Analyzer Installation 2 2 4 The Effect of Pressure In order to state the amount of oxygen present in the sample as a percentage of the gas
34. odel OT 3 should not require any maintenance beyond replacement of expended Micro fuel Cells and perhaps a blown fuse Routine maintenance includes occasional recalibration as described in chapter 4 Operation 5 1 Replacing the Fuse CAUTION ON AC UNITS REMOVE THE POWER TO THE UNIT j BEFORE REPLACING THE FUSE When a fuse blows check first to determine the cause then replace the fuse using the following procedure AC Units 1 On 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 gently pry open the fuse receptacle The fuse holder will slide out There are two fuses in use and are visible in the clip 4 Remove the bad fuse and replace it with a 5x20mm 0 5 A 250 VAC IEC time lag T fuse P N F1130 5 Replace the fuse holder into its receptacle pushing in firmly until it clicks Teledyne Analytical Instruments 31 Maintenance OT 3 FUSE Figure 5 1 AC Fuse Replacement DC Units On DC units the fuse is located in a fuse holder on the rear panel See Figure 1 3 Unscrew the cap on the fuse holder and remove the blown fuse Replace the fuse with a 1 2 A micro fuse P N F91 5 2 Sensor Installation or Replacement 5 2 1 When to Replace a Sens
35. 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 analyzing 4 Teledyne Analytical Instruments A V Figure 4 1 Front Panel Control and Indicators Teledyne Analytical Instruments 23 Operation OT 3 4 2 Using the Function and Data Entry Buttons When no buttons on the Analyzer are being pressed the instrument is in the Analyze mode It is monitoring the amount of oxygen in the sample gas that is flowing through the sampling system When one of the Function Buttons is being pressed the Analyzer is in the Setup mode or the Calibration mode The 4 Setup function buttons on the analyzer are e SET ALARM 1 e SET ALARM 2 e SET HI RANGE e SET LO RANGE The Calibration mode button is e SET SPAN The Data Entry buttons A and V increment the values displayed on the TRACE OXYGEN meter while one of the Function buttons is being held down A UP arrow increments 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 initia
36. on any material or construction in which defects become apparent within one year from the date of shipment except in cases where quotations or acknowledgements provide for a shorter period Components manufactured by others bear the warranty of their manufacturer This warranty does not cover defects caused by wear accident misuse neglect or repairs other than those performed by Teledyne or an authorized service center We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage which may result from its use or misuse We reserve the right to employ any suitable material in the manufacture of our apparatus and to make any alterations in the dimensions shape or weight 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 of the instrument or its interface with the process being measured be properly trained in the process itself as well as all instrumentation related to it The safety of personnel is ultimately the responsibility of those who control process conditions While this instrument may be able
37. one power failure relay All are failsafe 0 50 C 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 90 in less than 65 seconds at 25 C 68 F System Power Requirement Weight System Enclosure AC 100 240 VAC 50 60Hz 2 8W or DC 10 36 VDC 2 8W 30 9Lbs 14 Kg NEMA 4 enclosure 40 cm x 30 cm x 20 6 cm 15 8 x 11 8 x 8 17 Teledyne Analytical Instruments 36 Analyzer Appendix A 2 Spare Parts List QTY P N DESCRIPTION 1 C65220 A PC Board Main std 1 C70740 A PC Board Power Supply AC std 1 C6689 B 2C Micro Fuel Cell class B 2C or 1 C6689 A 2C Micro Fuel Cell class A 2C CO type or 1 B 71875 Micro fuel Cell Insta Trace B 2C type or 1 B 73016 Micro fuel Cell Insta Trace A 2C CO type 2 F1130 Fuse AC 250 VAC IEC Type T 5 20mm 1 C 74162 A Board Power Supply DC std 1 F1605 Filter Elements 5 elements 1 R2533 Restrictor 0 4 SCFH 4 psig 1 R2588 Regulator 1 O182 O Ring std OT 3 Cell Holder 1 74050 Acid Gas Scrubber 1 C73514A 3300 OT 3 Control Unit AC std I C73514B 3300 OT 3 Control Unit AC RS232 1 C73514C 3300 OT 3 Control Unit DC std 1 73514 3300 OT 3 Control Unit DC RS232 1 5 Fuse DC Units 1 2 Amp Mic
38. or On trace analyzers the Micro fuel Cell will typically fail due to excessive zero offset caused by loss of water Large zero offsets will result in inaccurate SPAN settings To test for this condition purge the sensor and sample system with ZERO gas typically nitrogen with less than 1 ppm 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 and cell to return to a stable low level of O if it has been exposed to higher levels of O If the instrument will not come down to an acceptably low reading on zero gas then a depleted cell or a sample system leak should be suspected Typically offsets of 1 0 ppm or less are acceptable A cell failure may also be indicated by an inability to SPAN or slow response to changes in O concentration at levels below 100 ppm Teledyne Analytical Instruments 32 Trace Oxygen Analyzer Maintenance CAUTION READ THE SECTION CELL WARRANTY CONDITIONS BELOW BEFORE REPLACING THE CELL After replacing the Micro fuel Cell the analyzer must be recalibrated See Calibration in Chapter 4 5 2 2 Ordering and Handling of Spare Sensors To have a replacement cell available w
39. rate any inductive components such as mechanical relays or motors if this instrument is used in a hazardous location The higher contact ratings are applicable only when this system is installed in a general purpose non hazardous location It is possible to switch loads that exceed the above ratings by using an external solid state relay SSR This type of relay is a fully potted semiconductor device with no moving parts They are non inductive and typically require 3 30 VDC at 5 mA to operate These devices can safely control loads in excess of 6 amperes in both non hazardous and hazardous areas SSRs are available to handle either AC or DC loads 3 3 5 Solid State Relay Output The AC version of the 3300 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 will allow the 3300 OT 3 Control Unit to operate loads which exceed the safe use limits listed above for both non hazardous and hazardous applications For DC versions of the 3300 OT 3 Control Unit the DC service power can be switched through the alarm relays to operate a DC external SSR 3 4 Gas Connections The standard Model OT 3 incorpo
40. rates a stainless steel sample system with a PVC scrubber and nylon cell block All gas connections are made using the 1 8 stainless steel tube fittings provided on the bottom of the enclosure 4 on the drain There are three separate gas connections to be made plus a liquid drain connection e Sample gas Span gas recommended concentration of 80 90 of the primary range of interest balance N typically 8 9 ppm or 80 90 ppm in Teledyne Analytical Instruments 18 Analyzer Installation e Vent connection e Coalescing filter drain Note Zero gas is not required however see Section 5 2 1 Control Unit Power In Flow Signal Alarm Restrictor Connections Cell Holder Regulator Selector Coalescing Valve Filter Flowmeter Scrubber Span In m Filter Drain Sample Return Sample In vent Figure 3 3 Gas Connections To connect the gas lines remove the fitting and ferrule and cone at the bottom panel Insert the tubing into the fitting then place the ferrule 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
41. rmeable membrane At the permeable end a screen retains a diffusion membrane through which the oxygen passes into the cell At the other end 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 Dress Ring Diffusion Membrane Electrolyte Cathode Anode Contact Plate Flexible Membrane 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 anode structure is larger than the cathode It is made of lead and is designed to maximize the amount of metal available for chemical reaction The space between the active elements is filled by a structure saturated with electrolyte Cathode and anode are wet by this common pool They each have a conductor connecting them through some 4 Teledyne Analytical Instruments 7 Installation OT 3 een electrical circuitry to one of the external contacts in the connector receptacle which is on the top of the cell 2 2 3 Electrochemical Reactions The sample gas diffuses through the Teflon membrane Any oxygen in the sample gas is reduced on the surface of the cathode by the following half reaction O 2 0 4e gt 40H cathode In this reaction four electrons combine with o
42. ro Depends on options chosen at time of purchase IMPORTANT Orders for replacement parts should include the part number and the model and serial number of the system for which the parts are intended Send orders to TELEDYNE ELECTRONIC TECHNOLOGIES Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580Telephone 626 934 1500 Fax 626 961 2538 or your local representative Web www teledyne ai com Teledyne Analytical Instruments 37 Appendix OT 3 A 3 Reference Drawing D 74110 B 74106 D 65305 D 70739 D 74161 B 74224 Outline Diagram Piping Diagram Schematic main PCB Schematic AC Power Supply PCB Schematic DC Power Supply PCB 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 Teledyne Analytical Instruments 38 Analyzer Index Index accuracy 2 36 address See company address alarm connection 16 delay 26 HI 16 LO 16 power failure 2 26 SET ALARM 1 25 SET ALARM 2 26 specifications 36 alarm 1 17 alarm 2 17 alarm indicator 27 alarm indicator LED 2 analog concentration signal 12 analog to digital converter 10 11 analysis mode 23 24 analysis range See range analysis ranges See range anode 6 7 8 autoranging 28 auto ranging 2 back diffusion 20 blinking alarm indicator 29 blinking display 27
43. utes and seconds before the alarm will trigger The alarm indicator on the front panel will blink on and off The delay time will continue to count down until it reaches zero then the alarm relay will close At this point the display will stop blinking and the O concentration will display continuously If a second alarm is reached after the delay time has elapsed it will trigger immediately without any delay If the O level drops to below the alarm condition during the delay the delay timer will reset to the full delay If the alarm delay is set to 0 and an alarm condition exists the alarm indicator will blink and the alarm relay will close immediately When the level drops out of the alarm condition the alarm relay will drop out accordingly The alarm delay can be toggled on or off and the timing set through 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 DOWN arrow key After three seconds the delay feature will time out and return to the analyze mode 4 6 Keypad Lockout The Model OT 3 has a keypad lockout feature which is designed to prevent unauthorized changes to the analy
44. uts and a trace oxygen meter readout It contains a microcontroller that manages all signal processing input output and display functions for the analyzer 2 2 MMicro 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 chemical reaction into an electrical potential that can produce a current in an external electrical circuit Its action is similar to that of a battery There is however an important difference in the operation of a battery as compared to the Micro fuel Cell In the battery all reactants are stored within the cell whereas in the Micro fuel Cell one of the reactants oxygen comes from outside the device as a constituent of the sample gas being analyzed The Micro fuel Cell is therefore a hybrid Teledyne Analytical Instruments 6 Analyzer Installation between a battery and a true fuel cell All of the reactants are stored externally in a true fuel cell 2 2 2 Anatomy of a Micro fuel Cell The Micro fuel Cell is made of extremely inert plastic which can be placed confidently in practically any environment or sample stream It is effectively sealed though one end is a gas pe
45. zer This feature is toggled on or off via the PASS CODE function To enable the keypad lockout 1 Press the UP and DOWN arrow keys simultaneously The display will indicate either PASS CODE or DELA Y If the display indicates DELAY then to set the lockout feature press both arrow keys simultaneously again to toggle to PASS CODE 2 While the display is blinking the word PASS CODE press the up or down arrow key to alter the code number Any number except 10 will lock the keypad 3 After three seconds the control unit will time out and return to analyze mode With the keypad locked pressing the keys 4 Teledyne Analytical Instruments 27 Operation OT 3 will cause the display to flash NO PASS and the keys will have no effect 4 To unlock the keypad repeat steps 1 and 2 Enter the number 10 when the word PASS CODE blinks on the display 4 7 Selecting a Fixed Range or Autoranging The Model OT 3 can operate in fixed high fixed low or autoranging mode These modes are user selectable To change modes 1 Press and then release the SET HI RANGE and the SET LO RANGE buttons simultaneously 2 Within 5 seconds press either the A or V button until Auto Lo or Hi displays on the LED as desired After about three seconds the analyzer resumes monitoring in the selected range mode Note If the concentration exceeds 9999 ppm oxygen the analyzer will automatically switch to the Calibration Range EVEN THOUGH INSTRUMENT
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