Teledyne 3190 User's Manual
Contents
1. 5 2 5 2 1 When to Replace a 5 2 5 2 2 Ordering and Handling of Spare Sensors 5 3 5 2 3 Removing the Micro Fuel Cell 5 3 5 2 4 Installing a Micro Fuel Cell 5 4 5 2 5 Cell Warranty Conditions 5 5 Appendix A 1 AZ Spare Paris LS ana ads enten 2 AS Drawing ES A 3 A 4 Mis cala SOUS aci n A 3 A 5 Material Safety Data A 4 Teledyne Analytical Instruments vi Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 1 1 Introduction Overview The Teledyne Analytical Instruments TAI Model 3190 is a micropro cessor based trace oxygen analyzer for real time measurement of trace amounts 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 3190 are monitoring nitrogen generators and inert gas blanketing applications 1 2 Main Features of the Analyzer The main features of the analyzer include High resolution accurate readings of oxygen content from 0 10 ppm through 0 25 Large bright light emitting diode meterreadout Simple pushbutton controls Nylon cell holder Advanc2. 2 3 2 Signal Processing Figure 2 3 is a block diagram of the signal processing electronics described below Teledyne Analytical Instruments 2 5 2 Operational Theory Model 3190 TEMP GH AMPL COMP ADC E I CONV 4 20 mA dc THERM cnn 0 0 10 Vde DAC RANGE ID MICRO CONTROL LER RS 232 DIGITAL DEVICE KEYBOARD DISPLAY RELAYS ALARMS RELAYS ALARMS Figure 2 3 Block Diagram of the Signal Processing Electronics In the presence of oxygen the cell generates a current A current to voltage amplifier AMPL converts this current to a voltage The second stage amplifier TEMP COMP supplies temperature compensation for the oxygen sensor output The temperature compensation amplifier incorporates a thermistor THERM that is physically located in the cell block The thermistor is a temperature dependent resistance that changes the gain of the amplifier in proportion to the temperature changes in the block This change is inversely proportional to the change in the cell output due to the temperature changes As a result there is negligible net change in the signal due to temperature changes once the sensor comes to equilibrium See Specifications in the Appendix The output from the temperature compensation amplifier
3. OPERATING INSTRUCTIONS FOR Model 3190 Series Trace Oxygen Analyzer Model 3190 TELEDYNE ANALYTICAL INSTRUMENTS ALARM ALARM RANGE Li Li Li TRACE OXYGEN SPAN A paa V DANGER HIGHLY TOXIC AND ORFLAMMABLELIQUIDS OR GASESMAY BE PRESENTIN THIS MONITORING SYSTEM PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FORA TIMEEVENAFTERTHE POWERIS TURNED OFF AND DISCONNECTED ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND OR SERVICING BEFORE CONDUCTING ANY MAINTENANCE ORSERVICING CONSULT WITH AUTHORIZED SUPERVISOR MANAGER P NM64641 06 21 2000 00 0221 Teledyne Analytical Instruments Copyright O 1999 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 wit
4. condition OR unit is NOT POWERED condition AND unit IS POWERED Figure 3 2 Contact ID for FAILSAFE Relay Operation The specific descriptions for each type of alarm are as follows HI Alarm Configured as high alarm actuates when concentration is above threshold Can be set anywhere within the full range of the analyzer 0 9 999 ppm but must be set ABOVE the threshold set for the LO Alarm LO Alarm Configured as low alarm actuates when concentration is below threshold Can be set anywhere within the full range of the analyzer 0 9 999 ppm but must be set BELOW the threshold set for the HI Alarm Sensor Fail Actuates when the output of the Micro Fuel Cell sensor falls below the acceptable level RS 232 Port The digital signal output is a standard RS 232 serial communications port used to connect the analyzer to a modem or other digital device Only the output mode is implemented in this instrument The data is oxygen concentration and range information in serial digital form The RS 232 protocol allows some flexibility in implementation in the choice of values for certain parameters Table 3 1 lists the RS 232 values required by the 3190 implementation Table 3 1 Required RS 232 Options Parameter Setting Baud 2400 Byte 8bits Parity none Stop Bits 1 Message Rate 2 per second External Probe The receptacle for the analysis unit cable is located in the lower left hand corner of the rear pan
5. 3 1 Unpacking the Analyzer 4 2 3 1 3 2 Location and Mounting amaia ias 3 2 3 2 1 Control Unit 3 2 3 2 2 External Probe Installation 3 2 3 2 3 Installing the Micro Fuel Cell 3 3 3 3 Electrical Connections 3 3 3 4 E AA RE 3 7 3 5 Installation Checklist Ih Lo ette n bent 3 7 Operation 41 IOQUCUOD 1 et tt Laia 4 1 4 2 Using the Function and Data Entry Buttons 4 2 4 3 Setting the Analysis 4 2 RS Ll HERJE rrr 4 3 4 9 2 LOROS Marcas a eod ne 4 3 Asno CME WOES 4 3 iv Teledyne Analytical Instruments 4 4 Setting the Alarm 4 3 241 MAE ae Ad 4 3 442 LO AM as 4 3 4 4 3 Sensor Fail Alarm sicario 4 4 4 5 Selecting a Fixed Range or Autoranging 4 4 4 6 Calibration tte 4 4 4 7 Displaying Percent amp PPM on the LED Display 4 5 4 8 mode in the LED display 4 6 Maintenance 5 1 Replacing the Fuse oni deer nave saves 5 1 5 1 1 AC Powered On Seient tr deret oap Een 5 1 5 1 2 DG Powered Unis ence aeree 5 2 5 2 Sensor Installation or Replacement
6. Correctly installed the Sample and Exhaust gas lines e Opened the isolation valves Checked for leaks Set the sample pressure to 5 10 psig nominal Once the above checks have been made you can connect to the power source The instrument is now ready for operation Teledyne Analytical Instruments 3 7 3 Installation Model 3190 3 8 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 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 appli cation This involves setting the system parameters Definingthe user selectable analysis ranges Settingalarmsetpoints e Calibrating the instrument All of these functions are performed via the front panel controls shown in Figure 4 1 Analyzing for the trace oxygen level in the gas passing through the cell block is the default mode of operation As long as no front panel buttons are being pressed the Analyzer is analyzing Model 3190 4 TELEDYNE ANALYTICAL INSTRUMENTS JU LI LI TRACE OXYGEN SPAN Figure 4 1 Front Panel Controls and Indicators EEE 77 4 2 Using the Function and Data Entry Teledyne Analytical Instruments 4 1 4 Operation Model 3190 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 ga
7. and the sensor is reconnected When the concentration rises above a point between 2000 to 3000 ppm it changes from sensor to sensor there are a few seconds where the display freezes This is due to an automatic gain change to low gain When the concentration drops and crosses a point between 3000 and 1500 ppm it changes from sensor to sensor the display will show SetL and alternate with a countdown of 30 seconds This is due to an automatic gain change to high gain It takes longer for the electronics to settle when switching to the high gain than when switching to low gain that is the reason why the count down only appears when the sensor reading is going down and not up 4 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 Overvoltage Category II Maintenance Aside from normal cleaning and checking for leaks the Model 3190 should not require any maintenance beyond replacement of expended Micro Fuel Cells and perhaps a blown fuse Routine maintenance includes occa sional recalibration as described in chapter 4 Operation 5 1 Replacing the Fuse 5 1 1 AC Powered Units When a fuse blows check first to determine the cause then replace the fuse using the following procedure l Disconnect the AC power and place the power switch located on the rear panel in the O position Remove the power cord from the receptacle The fuse receptacle is located in the power cord receptacle assembly in
8. 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 appropri ate output signals are directed to the display alarm relays and RS 232 output The same digital information is also sent to a 12 bit digital to analog converter DAC that produces the 0 10 V dc analog concentration signal and the 0 10 V dc analog range ID output A current to voltage converter E I CONV produces the 4 20 mA dc concentration signal 2 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 Overvoltage Category II Installation Installation of the analyzerincludes 1 2 3 5 6 E Unpacking the system Mounting the Control Unit External Sample Block and Micro Fuel Cell sensor Making the electrical connections Making the gas connections Testing the installation CAUTIONS Read this chapter in its entirety before installing 3 1 the units The Model 3190 is for or indoor use only The sample must be free of entrained solids or water However a high humidity 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 vvith local regulatio
9. the upper left hand corner of the rear panel See Figure 5 1 Spare fuse compartment fu Fuse in use Figure 5 1 AC Fuse Replacement 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 The fuse in use is visible in the clip To Teledyne Analytical Instruments 5 1 5 Maintenance Model 3190 open the spare fuse compartment push on one end until it slides out 4 Remove the blown fuse and replace it with a 5x20 mm 0 5 A 250 VAC IEC time lag T fuse P N F1128 for AC units 5 Replace the fuse holder into its receptacle pushing in firmly until itclicks 5 1 2 DC Powered Units In units with DC power the fuse is located on the rear panel above the ON OFF switch 1 Open the fuse holder by unscrewing and removing the cap marked FUSE 2 The fuse is located inside the receptacle not inside the cap Both terminals are on the same end of the fuse Pull straight out without twisting to remove the old fuse from the receptacle and replace it with a 0 5 A 125 V dc very quick acting FF microfuse P N F51 3 Replace the cap by screwing it back into the receptacle 5 2 Sensor Installation or Replacement 5 2 1 When to Replace a Sensor There are several symptoms that may indicate sensor weakness other than the Sensor Failure Alarm Cellfailure in the 3190 is usually characterized very slo
10. 1 HI Range Setting the HT Range fullscale value defines the LEAST sensitive analysis range to be used To set the HI Range 1 Press the SET HI RANGE Function button once 2 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 fullscale concentration 4 3 2 LO Range Setting the LO Range fullscale value defines the MOST sensitive range to be used To set the LO Range 1 Press the SET LO RANGE Function button once 2 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 fullscale concentration 4 3 3 Settle Mode The Model 3190 has two programmable ranges as discussed previous Occasionally to maximize accuracy the microprocessor must make certain adjustments to the gain of the amplifier which converts the sensor current into a voltage When these adjustments are being made the outputs of the analyzer are frozen and the LED will flash SetL This condition will persist for approximately 35 seconds and then normal operation will resume 4 4 Setting the Alarm Setpoints The alarm setpoints can be adjusted over the full range of the analyzer 0 9 999 ppm oxygen content The setpoint values are expressed in ppm only Note For proper operation the HI Alarm setpoint should be set at a higher concentration than the LO Alarm setpoint 4 4 1
11. DOG LAI LA 2E Figure 3 1 Rear Panel Electrical Connectors for AC and DC Units Primary Input Power AC version The power cord receptacle fuse block and Power switch are located in the same assembly A 6 foot standard AC power cord is supplied with the Control Unit Insert the female plug end of the power cord into the power cord receptacle The universal power supply allows direct connection to any 100 240 V ac 50 60 Hz power source The fuse block to the right of the power cord receptacle accepts a 5 x 20 mm 0 5 A time lag T fuse See Fuse Re placement in chapter 5 Maintenance The Power switch is located on the right hand end of the power source input receptacle assembly Primary Input Power DC version The 10 36 V dc power is connected via the and terminals in the upper left corner of the panel The 34 9 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 fuse receptacle to the right of the povver terminal strip holds a 0 5 A very quick acting fuse See Fuse Replacement in chapter 5 Maintenance The Power switch is located below the fuse receptacle WARNING INSERT THE STRIPPED TIPS OF WIRES ENTIRELY INTO THE TERMINAL BLOCKS DO NOT LEAVE EXPOSED WIRE OUTSIDE OF THE HOLES IN THE BLOCKS CAUTION The control unit chassis must be isolated from the grounding system of the DC input power Analog Outputs There are three DC output signa
12. During the Installation and or Replacement of the MFC Membrane surface MUST ALLWAYS FACE DOWNWARD and the Contact side of the Membrane MUST be placed FIRST into Analysis Unit The reason for proper Installation Replacement is if any bubble that develops as the electrolyte dries out will be directed by the gravity away from the membrane To install or replace the Micro Fuel Cell follow the procedures in Chapter 5 Maintenance 3 3 Electrical Connections Figure 3 1 shows the two alternate Model 3190 rear panels The first illustration shows the AC powered version and the second illustration shows the DC powered version The difference between them is the power connec tions Both versions have identical connections for the External Probe the alarms and for the digital and analog concentration outputs For detailed pinouts see the wiring interconnection drawings in the Drawings section at the rear of this manual Teledyne Analytical Instruments 3 3 3 Installation Model 3190 RS 232 00000 0 10VDC 4 20mA O P RANGE ID RANGE ee es gel ES ES 100 240 50 60Hz 0 3 A MAX 250V O 5A T FUSE Ses pier LO ECT SEE FAIL REMOTE CAUTI PROBE A oe B EE El 5 ems um BIE LA LI Lopa RS 232 ee 560591 9 FF 99608 ee 4 20mA O P ES CAM RANGE RANGE ID D ESE HI ALARM LO ey SENSOR FAIL ses Sad one eee
13. HI Alarm Setting the HI Alarm sets the value ABOVE which the HI Alarm will activate To Set the HI Alarm 1 Press the SET HI ALARM Function button once Teledyne Analytical Instruments 4 3 4 Operation Model 3190 2 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 concentration 4 4 2 LO Alarm Setting the LO Alarm sets the value BELOW which the LO alarm will activate To set the LO Alarm 1 Press the SET LO ALARM Function button once 2 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 concentration 4 4 3 Sensor Fail Alarm The SENSOR FAIL alarm triggers 1f during calibration the raw cell output for the given oxygen level is too low See Calibration Characteristics in Chapter 2 Should this alarm trigger The ALARM indicator below the SET function buttons will start blinking Replace the cell before proceeding 4 5 Selecting a Fixed Range or Autoranging The Model 3190 can operate in fixed high fixed low or autoranging mode 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 LCD as desired After about three seconds the analyzer resumes monitoring in the selected range mode NOTE If t
14. NTAL 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 5 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 1 Disconnect the Power Source from the Control Unit 2 Remove the new Micro Fuel Cell from its protective bag 3 Examine the O ring at the base of the threaded portion of the cell retainer cap and replace it if it is worn of damaged 3 Replace the cell on the end of cell retainer cap vvhich is designed to fit snugly into the rim on the screen side of the cell 4 Careful insert the cap and cell into the block and screw the cap clockwise into the cell block until it is held firmly in the cell 5 Reconnect the cell block electrical connector plug 5 2 5 Cell Warranty Conditions The Class A 2C B 2C or Z 2C Micro Fuel cell is used in the Model 3190 These cells are warranted for 6 months with an expected life of 8 months from the date of shipment under specified 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 worki
15. View Bottom View Concentric Sensing 2 1 FollContact Surface Rings lt gt uu Figure 2 1 Micro Fuel Cell Refer to Figure 2 2 Cross Section of a Micro Fuel Cell which illus trates the following internal description Dress Ring Diffusion Membrane X Cathode Electrolyte EN Anode Contact Plate Flexible Membrane Figure 2 2 Cross Section of a Micro Fuel Cell simplified 2 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 At the top end of the cell is a diffusion membrane of Teflon whose thickness is very accurately controlled Beneath the diffusion membrane lies the oxygen sensing element the cathode with a surface area almost 4 cm The cathode has many perforations to ensure sufficient wetting of the upper surface with electrolyte and it is plated with an inert metal The anode structure is below the cathode It is made of lead and has a proprietary design which is meant to maximize the amount of metal avail able for chemical reaction At the rear of the cell just below the anode structure is a flexible membrane designed to accommodate the internal volume changes that occur throughout the life of the cell This flexibility assures that the sens ing membrane remains in its proper position keeping the electrical output constant The entire space between the diffusion membrane above the cathode and the flexible rear membrane beneath the anode is filled with e
16. ctrochemi cal transducer The active components of the Micro Fuel Cell are a cathode an anode and the 15 90 aqueous KOH electrolyte in which they are immersed The cell converts the energy from a chemical reaction into an electrical current through 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 Teledyne Analytical Instruments 2 1 2 Operational Theory Model 3190 stored within the cell vvhereas 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 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 a cylinder only 1 inches in diameter and 1 inch thick It is made of extremely inert plastic which can be placed confidently in practically any environment or sample stream It is effec tively sealed although one end is permeable to oxygen in the sample gas The other end of the cell is a contact plate consisting of two concentric foil rings The rings mate with spring loaded contacts in the sensor block assembly and provide the electrical connection to the rest of the analyzer Figure 2 1 illustrates the external features Top
17. ed Micro Fuel Cell for trace analysis has a six 6 months warranty and expected lifetime Unaffected by oxidizable gases Fast response and recovery time Microprocessor based electronics 8 bit CMOS microprocessor with on board RAM and 16 kB ROM Two user selectable ranges from 0 10 ppm through 0 9 999 ppm allow best match to users process and equipment Air calibration range for convenient spanning at 20 9 96 Operator can select Autoranging which allows the analyzer to automatically select the proper preset range for a given measurement or he can lock the analyzer onto a single range Teledyne Analytical Instruments 1 1 1 Introduction Model 3190 e Twoconcentration alarms with adjustable setpoints e Sensor failure alarm e RS 232 serial digital port for output of concentration and range data to a computer terminal or other digital device e Three analog outputs two for measurement 0 10 V dc and negative ground 4 20 mA dc and one for range identification 0 10 V dc Compact and rugged Control Unit with flush panel case Designed for indoor use Front panel NEMA 4 rated e External Probe can be located six feet or more away depending on the existing electromagnetic noise level 1 3 Front Panel Description All controls and displays except the power switch are accessible from the front panel See Figure 1 1 The front panel has seven pushbutton mem brane switches a digital meter and an alarm ind
18. el The 6 pin Mini FitTM connector 3 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 is Reyed to fit only one vvay into the receptacle Do not force it in The other end of the cable is made of four separate wires These should be connected to the terminal strip on the analysis unit as follows Red 1 Black 2 Green 3 The green and vvhite connectors be VVhite 4 interchanged but be consistent Refer to the Final Assembly Dwg C 64641 3 4 Gas Connections Gas connection instructions depend on the specific External Probe used and any special requirements of the process being monitored The standard Model 3190 External Probe has inlet and outlet fixtures only Calibration gasses must be tee d into the sample inlet through appropri ate valves 1 4 inch tube fittings are used For metric installations 1 4 inch to 6 mm adapters are supplied In general sample flow and pressure must not create significant backpressure past the sensor For the standard probe 2 scfh is the nominal recommended flowrate The pressure required will depend on the sampling system When venting into a constant pressure such as the atmosphere controlling input pressure is simple If you are venting into a system of varying pressure then some form of pressure regulation is required 3 5 Installation Checklist Before connecting the instrument to the power source and turning it on make sure you have e
19. ge output 4 20 mA dc concentration output negative ground 1 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 Alarm Connections HI Alarm LO Alarm and Sensor Failure Alarm connections e RS 232 Port Serial digital output of concentration and range signals e External Probe Connects to the Remote Probe or remote Analysis Unit Teledyne Analytical Instruments 1 5 1 Introduction Model 3190 1 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 Operational Theory 2 1 Introduction The analyzer is composed of two subsystems 1 Analysis Unit with Micro Fuel Cell Sensor 2 Control Unit with Signal Processing Display and Controls The Analysis Unit 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 Control Unit processes the sensor output and translates it into electrical concentration range and alarm outputs and a trace oxygen meter readout It contains a microcontroller that manages all signal pro cessing input output and display functions for the analyzer 2 2 Micro Fuel Cell Sensor 2 2 1 Principles of Operation The oxygen sensor used in the Model 3190 is a Micro Fuel Cell designed and manufactured by TAI It is a sealed disposable ele
20. he concentration exceeds 9 999 ppm oxygen the analyzer will automatically switch to the Calibration Range EVEN THOUGH INSTRUMENT IS IN THE FIXED RANGE MODE 4 6 Calibration Preliminary lf not already done Power up the Analyzer and allow the LED reading to stabilize Set the Alarm setpoints and the fullscale ranges to the desired values 4 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 Note Note Note Procedure 1 Expose the sensor to ambient air or instrument grade air 20 9 oxygen Allow time for the sampling system to purge and the analyzerto achieve equilibrium If the analyzer output goes above the high alarm setpoint or below the low alarm setpoint the front panel ALARM Indica tor beneath the SET Function buttons will blink When the SPAN key is pressed to enter SPAN mode Alarm indicator stops blinking 2 Press the SPAN button once 3 Within 5 seconds press either the A or V button until the display 1s stable and reads 20 9 The unit is now calibrated If you use a span gas other than air do not span in the 0 10 ppm range Calibration at this level is not dependable If you use a span gas other than air and the span gas oxygen concentration is less than 10 000 ppm the analyzer could take up to 65 seconds to to settle The lag is caused by a digital filter that is active only below 10 000 ppm 1 oxygen If the output of the sensor as measured by the 3190 out
21. hout charge except for transportation or at customer plant at our option 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 autho rized 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 ImportantNotice 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 instrumen tation related to it The safety of personnel is ultimately the responsibili
22. icator LED for operating the analyzer These features are described briefly here and in greater detail in Chapter 4 Operation Model 3190 4 TELEDYNE ANALYTICAL INSTRUMENTS A coo v ALEC E TRACE OXYGEN SPAN SET LO ALARM Figure 1 1 Front Panel Function Keys Seven pushbutton membrane switches are used to select the function performed by the analyzer 1 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 Set HI Alarm Set the concentration ABOVE vvhich an alarm activates e Set LO Alarm Set the concentration BELOW which alarm activates Set HI Range Set the high analysis range for the instrument up to 0 9999 ppm e Set LO Range Setthelow analysis range for the instrument down to 0 10 ppm Span Span calibrate the analyzer Data Entry Keys Two pushbutton 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 e Meter Readout As the meter readout it displays the oxygen concentration currently being measured e Measurement Parame
23. ity 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 THE SENSOR USED IN THE MODEL 3190 CON TAINS AN ELECTROLYTE WHICH INCLUDES SUBSTANCES THAT ARE EXTREMELY HARMFUL IF TOUCHED SWALLOWED OR INHALED AVOID CONTACT WITH ANY FLUID OR POWDER IN OH AROUND THE UNIT WHAT MAY APPEAR TO BE PLAIN VVATER 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 Removing the Micro Fuel Cell Refer to Figure 5 2 for an exploded view of the cell block and cell To remove a spent or damaged Micro Fuel Cell 1 Disconnect the Power Source at the Control Unit 2 Disconnect the connector from the cell block if possible Teledyne Analytical Instruments 5 5 3 5 Maintenance Model 3190 3 Unscrew the cell retainer cap from the cell block by turning it counterclockwise until it is free 47 Screen side of MFC Contact Nd side of MFC Figure 5 2 Exploded View of MFC and Cell Block 4 Slowly withdraw the cap from the block The cell should come out with the cap 5 Carefully pull the cell off of the cap DO NOT TOUCH THE SCREENED END OF THE CELL OR ANY FLUID THAT MAY BE LEAKING FROM IT 6 Dispose of the cell in a safe manner in accordance with all applicable ENVIRONME
24. l connectors with screw terminals on the panel There are two wires per output with the polar ity noted See Figure 3 3 The outputs are 0 10 V concentration Voltage rises with increasing oxygen concentra tion from 0 V at 0 oxygen content to 10 V at full scale oxygen content Full scale 100 of programmedrange 0 10 V Range ID 03 33 V Low Range 06 66 V High Range 10 V Air Cal Range 4 20 mA concentration Current increases with increasing oxygen concen tration from 4 mA at 0 oxygen content to 20 mA at full scale oxygen content Full scale 100 of programmed range 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 5 ampere at 125 V ac into a resistive load The alarm relay circuits are designed for failsafe operation meaning 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 Teledyne Analytical Instruments 3 5 3 Installation Model 3190 eee This side is closed when ALARM N This side is closed with NO ALARM
25. lectro lyte Cathode and anode are submerged in this common pool They each have a conductor connecting them to one of the external contact rings on the contact plate which is on the bottom 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 2H 0 4e gt 40H cathode Four electrons combine with one 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 2Pb 40H gt 2Pb 2H 0 4e7 anode Two electrons are transferred for each atom of lead that is oxidized TWO ANODE REACTIONS balance one cathode reaction to transfer four electrons The electrons released at the surface of the anode flovv to the cathode surface vvhen an external electrical path is provided The current is propor tional 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 Teledyne Analytical Instruments 2 3 2 Operational Theory Model 3190 2Pb O gt 2PbO These reactions will hold as long as no gaseous components capable of oxidizing lead such as iodine bromine ch
26. linearities Also since there is zero output in the absence oxygen the characteris tic curve has an absolute zero The cell itself does not need to be zeroed As the cell reaches the end of its useful life the slope seen in Figure 2 2 decreases In the Model 3190 the slope is monitored If the inverse of the slope Span Value ppm Cell Output nA 1s over 4 447 ppm nA a sensor failure alarm is triggered indicating that the cell should be replaced 2 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 80 7 2 e Cell Output uA A e 20 I 10 20 30 Oxygen Concentration percent Figure 2 2 Characteristic Input Output Curve for a Micro Fuel Cell 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 temperature compen sated 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
27. lorine and fluorine are present in the sample The only likely components are the halogens 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 no current is generated 2 2 4 The Effect of Pressure In order to state the amount of oxygen present in the sample as a specific portion of the gas 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 rela tively constant between calibrations 2 2 5 Calibration Characteristics Given that the total pressure of the sample gas on 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 of constant impedance is directly proportional to the rate at which oxygen molecules reach the cathode and this rate is directly proportional to the concentration of oxy gen 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 compen sate for non
28. nce can be more depending on the level of electromagnetic noise in the operating environment The standard Model 3190 includes the External Probe unit depicted in the Final Assembly Dwg C 64641 and the Analysis Unit probe Outline Dwg B 59610 Dimensions are also given in Specifications in the Appendix For special applications the type of External Probe unit supplied may vary depending on the specific process With these systems specific installa tion and interconnect information is given in a separate probe manual or in an addendum to this manual depending on the model External Probe used The addendum will reference the specific Outline and Interconnection Drawings in the Drawings section of this manual and provides any other appropriate information 32 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 For special applications the Micro Fuel Cell may also be of a different type than the standard A 2C B 2C or Z 2C unit If this is the case the pertinent cell specifications will be given in the addendum 3 2 3 Installing the Micro Fuel Cell Cell Block Orientation 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 Important Installation Note e e Membrane side of MFC MUST FACE DOWNWARD Contact side of MFC
29. ng 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 If it is determined that failure is due to faulty work manship 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 5 5 5 Maintenance Model 3190 5 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix Appendix A 1 Specifications Overvoltage Ranges Category II Signal Output Range ID Display Alarms System Operating Temp Accuracy Response Time System Power Requirement System Enclosure Twouser selectable ranges can be set between 0 10 ppm and 0 9 999 ppm oxygen Defaultranges are0 100 ppmand 0 1 000 ppm oxygen and a0 25 nomi nal AirCalibration Range Voltage 0 10 V dc negative ground Current 4 20 mA negative ground 0 10 V dc Lightemitting diode LED display Onehighalarmrelay adjustable one low alarmrelay adjustable one sensor failure relay Allare failsafe 0 50 C 2 of full scale at constant temperature 5 of full scale through operating tem perature range At 100 ppm and higher user defined ranges once temperature equilib riumisreached 1 ppm for 10 ppmra
30. nge under above conditions 90 in less than 65 seconds at 25 C 68 F AC 100 to 240 V ac 47 440 Hz or DC 10 36 V dc user specified Panel Mount 2 81 H x 6 0 W x 2 87 D 71 4 mmx 152 4 mmx 72 9 mm Face Plate 3 15 Hx 7 0 VV Teledyne Analytical Instruments A 1 Appendix Model 3190 95 3 mm H x 177 8 mm VV Face plate rated to NEMA 4 Sensor Type Class A 2C B 2C and Z 2C Analysis Unit 4 0 H x 6 0 W x 2 5 D 101 6 mm x 152 4 mm x 63 5 mm A 2 Spare Parts List QTY P N DESCRIPTION 1 C 65220 A PC Board Main 1 C 64586 PC Board Power Supply 1 C 6689 B 2C Micro Fuel Cell class B 2C 1 C 6689 Z 2C Micro Fuel Cell class Z 2C 2 F 1130 Fuse AC VA 250 VAC IEC Type T 5 x 20mm 1 F 51 Fuse DC VA 125 VDC Micro Fuse A 64678A Probe to Analyzer Cable 6 ft 1 C 6689 A 2C Micro Fuel Cell class A 2C Order one type only A 2C B 2C or Z 2C See Specific Model Informa tion in front of this manual for cell class supplied with your analyzer A minimum charge is applicable to spare parts orders 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 Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Telephone 626 934 1500 Web Site www teledyne ai com Fax 626 961 2538 626 934 1651 Technical Support 626 534 1673 Web
31. ns 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 vvill require cell replacement Prevent contact vvith membrane by any solid object Unpacking the Analyzer As soon as you receive the instrument carefully unpack and inspect Control Unit External Probe and any included accessories for damage Immediately report any damage to the shipping agent The analyzer is Teledyne Analytical Instruments 31 3 Installation Model 3190 shipped with all the materials you need to install and prepare the system for Operation CAUTION Do not disturb the integrity of the cell package until the cell is to be used immediately If the cell package is punctured prematurely and air is permitted to enter cell life will be shortened 3 2 Location and Mounting 3 2 1 Control Unit Installation The 3190 Control Unit is designed to be panel mounted in a general purpose indoor area away from moisture and the elements The unit should be installed at viewing level in a sheltered area CAUTION For the DC powered version the control unit chassis must be isolated from the input power ground Refer to the Outline Diagram C 64772 for the physical dimensions of theanalyzer 3 2 2 External Probe Installation The External Probe can be installed in the process any reasonable distance from the Control Unit The nominal maximum is 6 ft but the dis ta
32. porated in the instrument for which this manual is supplied are indicated by a check mark in the box Instrument Serial Number Options Included in the Instrument with the Above Serial Number Class A 2C Micro Fuel Cell For 0 100 CO background and General Purpose range 0 10 ppm O minimum Q Class B 2C Micro Fuel Cell For General Purpose and high hydrogen or helium backgrounds range 0 10 ppm O minimum Q Class Z 2C Micro Fuel Cell For faster recovery after air calibration range 0 200 ppm O minimum Class B 2C is the standard cell provided Teledyne Analytical Instruments iii Contents Introduction dob OVGIVIBW temes citat 1 1 1 2 Main Features of the Analyzer 1 1 1 8 Front Panel Description 1 2 1 4 Rear Panel Description 1 3 Operational Theory 2 1 it oa db ERE imd ees 2 1 2 2 Micro Fuel Cell Sensor 2 1 2 2 1 Principles of Operation 2 1 2 2 2 Anatomy of a Micro Fuel Cell 2 2 2 2 3 Electrochemical Reactions 2 3 2 2 4 The Effect of Pressure 2 4 2 2 5 Calibration Characteristics 2 4 2h39 EI CODI ec O 2 5 253211 Gere 2 5 2 3 2 Signal Processing sso oo oet rene 2 5 Installation
33. s that is flowing through the Remote Probe When one of the Function Buttons is being pressed the Analyzer is in the Setup mode or the Calibration mode The 4 Setup Mode buttons on the analyzer are SET HI ALARM SET LO ALARM SET HI RANGE SET LO RANGE The Calibration Mode button is 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 Increments the displayed value upwards V Increments the displayed value downwards Any of the functions can be selected at any time by holding down the appropriate button Each function will be described in the following sections Although the Operator can use any function at any time the order chosen in this manual is appropriate for an initial setup 4 3 Setting the Analysis Ranges The two user definable analysis ranges are both capable of being adjusted for from 0 10 ppm to 0 9 999 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 fullscale value and 1t switches back to the LO range when the oxygen concentration falls below the LO range fullscale value Note For proper operation the HI Range setpoint should be set at a higher concentration than the LO Range setpoint 4 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 4 3
34. side of the expected range due either to a Bad electrical connection between the unit and the sensor b Improperly analyzed or entered calibration gas value Electronics failure The unit will not accept the calibration attemped and flash 5000 on the LED display unit a valid calibration has been performed 4 7 Displaying Percent amp PPM on the LED Display The analyzer displays the concentration in percent whenever the read ing is over 9999 ppm When the reading changes to percent the LED display will alternate between flashing PC and the oxygen concentration On the other hand if the instrument is displaying ppm only the concentra tion reading will be shown Teledyne Analytical Instruments 4 5 4 Operation Model 3190 4 8 mode in the LED display When you turn on the unit it displays 8 8 8 8 for a couple of seconds This 1s to have an inspection that all segments of the display are all right After the first two seconds the LED display will show SetL and alternate with a countdown starting at 34 0 This countdown is to let the electronics settle and do a zero calibration of the electronics Flowing zero gas or a sensor is not needed for this instrument adjustment It is only an electronic zero calibration The sensor is automatically disconnected by the 3190 hardware during this mode As soon as the countdown reaches 0 00 the analyzer will go back to the normal mode of operation
35. ters Readout It also displays user definable alarm setpoints ranges and span calibration point when they are being checked or changed 1 4 Rear Panel Description The rear panel contains the electrical input and output connectors Separate rear panel illustrations are shown in Figure 1 2 for the AC and DC powered versions of the instrument The connectors are described briefly here and in detail in the Installation chapter of this manual Teledyne Analytical Instruments 1 3 1 Introduction Model 3190 F i 0 22 0 0 10VDC 4 20mA O P RANGE ID RANGE Ses es ss 100 240 50 60Hz E 1 AU E 5A T FUSE HI LO ar FAIL ON EN I pros poo poa LS LJ Lt A NN RS 232 FUSE 00000 FF O 00009 9 e PS 4 20mA O P RANGE ID AE RANGE id fef HI ALARM SES a SENSOR FAIL REMOTE PROBE Figure 1 2 Rear Panel AC and DC versions Power Connection AC version 100 240 V ac at 50 60 Hz The connector housing includes the fuse holder and the power switch DC version Requires between 10 and 36 V dc Fuse Holder Replacing the fuse is described in Chapter 5 Maintenance 1 0 Power Switch Turns the instrument power ON 1 or OFF 0 Analog Outputs 0 10 V dc concentration output 0 10 V dc range ID or optional overran
36. ty of those who control process conditions While this instrument may be able 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 Teledyne Analytical Instruments 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 incor
37. w response to changes in oxygen levels below 100 ppm This can cause errors in span calibration since the sensor may not have time to settle properly e If large adjustments are required to calibrate the instrument or calibration cannot be achieved within the range of the AV buttons the cell may need replacing Ifthe front panel Trace Oxygen Meter displays 00 0 when the unit is plugged in and the power switch is in the ON position CHECK to make sure the sensor is connected If it is replace the sensor 5 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance CAUTION CAUTION 5 2 2 Read the section Cell VVarranty Conditions belovy before replacing the cell After replacing the Micro Fuel Cell the analyzer must be recalibrated See Calibration in chapter 4 Ordering and Handling of Spare Sensors To have a replacement cell available vvhen it is needed TAI recom mends 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 to 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 N WARNING 5 2 3 Do not disturb the integr
38. www teledyne ai com or your local representative A 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix A 3 C 64772 C 64641 D 65666 B 65992 A 4 Dravving List Outline diagram Final Assembly and interconnection diagram Control Unit Assembly Analysis unit outline Miscellaneous The symbol is used on the rear panel of the model 3190 to signify volts alternating current V ac NOTE MSDS on this material is available upon request through the Teledyne Environmental Health and Safety Coordinator Contact at 626 934 1592 Teledyne Analytical Instruments A 3 Appendix Model 3190 A 4 Teledyne Analytical Instruments
Download Pdf Manuals
Related Search