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Teledyne 3020T User's Manual

1. Std 564804644 4 6 AS Ma UT mmn mon men E g g Li 60 50000000 609996 99 11111111 8 41 5 6 7 118 230 V ae 50 60 Hz UA e 90090904 O IVO P O P 4 20mA 4 20 RANGE ID RANGE RANGE ID RANGE iw z EI DES EI Figure 3 3 Electrical Connector Panel Teledyne Analytical Instruments 3 3 3 Installation Model 3020T For safe connections ensure that no uninsulated wire extends outside of the connectors they are attached to Stripped wire ends must insert com pletely into terminal blocks No uninsulated wiring should be able to come in contact with fingers tools or clothing during normal operation 3 3 1 Primary Input Power The universal power supply requires a 115 or 230 V ac 50 or 60 Hz power source The actual input voltage used must show in the window of the VOLTAGE SELECTOR switch before the power source is connected See Figure 3 4 for detailed connections DANGER Power is applied to the instrument s circuitry as long as the instrument is connected to the power source The Standby function switches power on or off to the displays and outputs only Ground Neutral Turn cw to hold 5 loosen wire Insert wi
2. 1 1 1 4 Model Designations 1 2 1 5 Operator Interface o nae 1 3 1 5 1 UP DOWN Switch 1 4 1 5 2 ESCAPE ENTER Switch 1 4 1 5 3 gt 1 5 1 6 Recognizing Difference Between LCD amp VFD 1 5 1 7 Rear Panel Equipment Interface 1 5 1 7 1 Electrical Connector Panel 1 5 1 7 2 Gas Connector 1 7 Operational Theory 2X MN EI 2 1 2 2 Micro Fuel 444 1 2 1 2 2 1 Principles of ODOratiOr e 2 1 2 2 2 Anatomy of a Micro Fuel 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 2 3 eu BE 2 5 2 4 Electronics and Signal Processing 2 6 2 5 Temperature Controle 2 8 Installation 3 1 Unpacking the Analyzer 0222 41 11 3 1 3 2 Mounting the Analyzer ee 3 1 3 3 Electrical Connections o ce toic 3 3 3 9 T Primary Input POWBL oe erroe pec tune 3 4 3 3 2 Puse Installaligi iiic cett sait 3 4 33 3 Analog OUIDUIS er there 3 4 3 3 4 Alarm elei eebe
3. 4 10 4 8 1 2 Manual Mode 2 4 11 4 8 1 3 Cell Failure text 4 11 48 2 pan Gal si ees nla ptos dogs 4 12 4 8 2 1 Auto Mode Spanning 4 12 4 8 2 2 Manual Mode Spanning ssssseeeeeeeeeeeeeeeenene 4 13 49 ALARMS Function 4 14 4 10 The RANGE Function 4 16 4 10 1 Setting the Analog Output Ranges 4 16 4 10 2 Fixed Range Analysis 4 17 4 11 The CONTRAST Function 4 18 4 12 The STANDBY Function 4 18 4 13 The Analysis Mode oce etes 4 19 Maintenance 5 1 Routine Maintenance 5 1 5 2 Major Internal 5 1 5 3 Cell Replacement 00 5 2 5 3 1 Storing and Handling Replacement Cells 5 3 5 3 2 When to Replace a Cell 5 3 5 3 3 Removing the Micro Fuel Cell 5 4 Teledyne Analytical Instruments V Model 3020 5 3 4 Installing a New Micro Fuel Cell 5 6 5 29 2 aan adeb band 5 6 5 4 F se Replacemeli iode 5 7 5 5 System Self Diagnostic 5 7 Appendix Specifications cacao rati cet o nee taie A 1 A 2 Recommended 2 Year Spare Parts List A 3 A3 Drawing EISE ceo oio Creta A 4 A 4 Application Note
4. teas 3 6 3 3 5 Digital Remote Cal Inputs 3 7 3 3 6 Range ID Belayso uice eder e e etti 3 9 3 07 NetWork siio idea acit es Ee ed c peace 3 9 3 9 8 RS 232 assise nt at as duds 3 9 3 3 9 Remote Sensor and Solenoid Valves 3 10 3 4 Installing the Micro Fuel Cell 3 11 Teledyne Analytical Instruments Trace Oxygen Analyzer 3 5 Gas EIERE 3 12 2 6 Testing the Sy E 3 14 4 Operation Introduction ee nain 4 1 4 2 Using the Controls aoro at 4 1 4 2 1 Mode Function Selection 4 2 4 2 1 1 Analysis 4 2 4 2 1 2 Setup MOdOG Mn 4 2 4 22 Data oo to Rep qu Rie pv qvum 4 4 42 2 pedit na oria 4 4 4222 ESCAPE seen as iota 4 4 4 3 The AUTO CAL Function 4 5 44 PWD Function cepe eoe e eene 4 5 4 4 1 Entering the Password 4 6 4 4 2 Installing or Changing the Password 4 7 4 5 The LOGOUT Function 4 8 4 6 The VERSION Screen esses 4 8 4 7 The SELF TEST FUDCUOD iore tet rens 4 9 4 8 The ZERO SPAN Functions 4 9 Zero e oh en Een 4 10 4 8 1 1 Auto Mode Zeroing
5. 50 k 100 k 150 k 200 k Oxygen Concentration ppm Figure 2 3 Characteristic Input Output Curve for a Micro Fuel Cell 2 3 Sample System The sample system delivers gases to the Micro Fuel Cell sensor from the analyzer gas panel inlets Depending on the mode of operation either sample or calibration gas is delivered The Model 3020T sample system is designed and fabricated to ensure that the oxygen concentration of the gas is not altered as it travels through the sample system The sample encounters almost no dead space This mini mizes residual gas pockets that can interfere with trace analysis The sample system for the standard instrument incorporates 1 4 inch tube fittings for sample inlet and outlet connections at the rear panel For metric system installations 6 mm adapters are supplied with each instrument to be used if needed The sample or calibration gas flowing through the system is monitored by a flowmeter downstream from the cell Teledyne Analytical Instruments 2 5 2 Operational Theory Model 3020 Figure 2 4 is the flow diagram for the sampling system In the standard instrument calibration gases zero and span can be connected directly to the Sample In port by teeing to the port with appropriate valves The shaded portion of the diagram shows the components added when the C and or F options are ordered The valves when supplied are installed inside the 3020T enclosure and are regulated by the ins
6. If you cannot read anything on the display after first powering up 1 Observe LED readout a If LED meter reads all eights and dots go to step 3 b If LED meter displays anything else go to step 2 2 Disconnect power to the Analyzer and reconnect again LED meter should now read all eights and dots 4 12 The STANDBY Function In STANDBY the analyzer s internal circuits are powered but there are no displays or outputs from the analyzer WARNING THE POWER CABLE MUST BE UNPLUGGED TO FULLY DISCONNECT POWER FROM THE INSTRU MENT WHEN THE ACCESS DOOR IS OPEN AND THE POWER CABLE IS CONNECTED EXTRA CARE IS REQUIRED TO AVOID CONTACT WITH LIVE ELECTRICAL CIRCUITS CAUTION If you disconnect the primary power source from the analyzer then on re energizing you will be required to choose to keep the configuration you previously programmed into your instrument in the Setup Mode or it will reset to factory defaults Use this function whenever you want to power down without loosing all of the configuration you programmed into your instrument in the Setup Mode 4 18 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 4 13 The Analysis Mode This is the normal operating mode of the analyzer In this mode the analyzer is monitoring the sample measuring and displaying the amount of oxygen and reporting alarm conditions Normally all of the functions automatically switch back to the Analysis Mode ANALYZE
7. Power Connection 115 or 230 V dc 50 or 60 Hz Analog Outputs 0 1 V dc concentration plus 0 1 V dc range ID and isolated 4 20 mA dc plus 4 20 mA dc range ID Ss Teledyne Analytical Instruments 1 5 1 Introduction Model 3020 Alarm Connections 2 concentration alarms and 1 system alarm e RS 232 Port Serial digital concentration signal output and control input Remote Valves Used for controlling external solenoid valves if desired E ns Teledyne Analytical Instruments DIGITAL INPUT e SOOO 8600606000 d d 6240 M elo 50206000 S 6106 05 0 00 D e eee WM lef sl AT lat als l l7 SAM Loc Sg 90006000 3 0 A MAX USE 250 V 4 0 ATFUSE p CAUTION NO USER SERVICEABLE PARTS INSIDE SERVICE ONLY BY QUALIFIED PERSONNEL VOLTAGE Figure 1 2 Electrical Connector Panel 1 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 e Remote Sensor Used for external sensor and thermocouple if desired e Remote Span Zero Digital inputs allow external control of analyzer calibration Calibration Contact notif
8. 4 1 Introduction Once the analyzer has been installed it can be configured for your application To do this you will Establish and start an automatic calibration cycle if desired Electrically operated valves required Define the three user selectable analysis ranges Then choose autoranging or select a fixed range of analysis as required e Calibrate the instrument e Set alarm setpoints and modes of alarm operation latching failsafe etc e Establish a security password if desired requiring Operator to log in Before you configure your 3020T these default values are in effect Ranges LO 100 ppm MED 1000 ppm HI 10 000 ppm Auto Ranging ON Alarm Relays Defeated 1000 ppm HI Not failsafe Not latching Zero Auto every 0 days at 0 hours Span Auto at 209 000 ppm every 0 days at 0 hours If you choose not to use password protection the default password is displayed on the VED screen only if you have entered the logout or pass word function as explained later Then you must enter the default password for access 4 2 Using the Controls To get the proper response from these controls turn the control toward the desired action ESCAPE or ENTER DOWN or UP and then release it Turn and release once for each action For example turn and release twice 29 Teledyne Analytical Instruments 4 1 4 Operation Model 3020 toward UP to move the screen two selections upwards on the list of
9. OPERATING INSTRUCTIONS FOR Model 3020 Trace Oxygen Analyzer TION HIGHLY AND OR FLAMMABLE LIQUIDS GASES MAY PRESENT THIS MONITORING SYSTEM PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PER SIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND OR SERVICING BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR MANAGER P N M65908 11 22 99 ECO 99 0459 Teledyne Analytical Instruments Model 3020 Copyright 1999 Teledyne Analytical Instruments Rights Reserved No part of this manual may be reproduced transmitted tran scribed 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 custome
10. 0 250 000 ppm range even though all concentration data outputs change from ppm units to percent when the concentration is above 10 000 ppm After defining your analysis ranges set Mode to either AUTO or one of the fixed ranges as described below 4 10 2 Fixed Range Analysis The autoranging mode of the instrument can be overridden forcing the analyzer DC outputs to stay in a single predetermined range To switch from autoranging to fixed range analysis ENTER the RANGE function by selecting RANGE from the MAIN MENU Use the DOWN UP control to move AUTO between the arrows Use DOWN UP control to switch from AUTO to FX LO FX MED or FX HI to set the instrument on the desired fixed range low medium or high L 100 1000 10000 Mode FX LO or L 100 M 1000 10000 or L 100 1000 10000 ESCAPE to re enter the ANALYZE screen using the fixed range NOTE When performing analysis on a fixed range if the oxygen concentration rises above the upper limit as established by the setup for that particular range the output saturates at 1 V dc or 20 mA However the digital readout and the RS 232 29 Teledyne Analytical Instruments 4 17 4 Operation Model 3020 output continue to read the true value of the oxygen tration regardless of the analog output range 4 11 The CONTRAST Function Contrast Function is DISABLED Refer to Section 1 6
11. different diffusion rate Cell pressures below 2 3 atmospheric are not recom mended because as they tend to cause excessive internal expansion which may resultin seal failure For operation at cell pressures other than atmospheric care must be taken not to change the sample pressure rapidly or cell damage may occur For cell pressures above atmospheric caution must be exercised to avoid over pressuring the cell holder percent analyzers will require some type of cell retainer to prevent the cell from being pushed out by the pressure For opera tion at pressures below atmospheric pressure a suffix C clamped cell is required RESTRICTION DEVICES For proper operation all 3000 series analyzers require a flow restriction device This device is typically arestrictor or a valve This restriction device serves two functions inthe sample path The first function is to limit the flow rate of the sample through the analyzer A restrictor is chosen to operate over arange of pressures and provide a useable flow rate over that range Teledyne Analytical Instruments A 5 Appendix Model 3020 The second function that the restriction device provides is a pressure drop This device is selected to provide the only significant pressure drop in the sample path RESTRICTOR KIT The current revision of the 3000 series analyzers are supplied with a kit containing two restrictors and a union which are user installed These parts suppliedto
12. In the automatic mode an internal algorithm com pares consecutive readings from the sensor to determine when the output is within the acceptable range for zero In the manual mode the operator determines when the reading is within the acceptable range for zero Make sure the zero gas is connected to the instrument If you get a CELL FAILURE message skip to section 4 8 1 3 4 8 11 Auto Mode Zeroing Select ZERO to enter the ZERO function The ZERO screen allows you to select whether the zero calibration is to be performed automatically or manually Use the DOWN UP control to toggle between AUTO and MAN zero Settling Stop when AUTO appears on the display Zero Settling AUTO lt ENT gt To Begin ENTER to begin zeroing THHHE PPM Zero Slope IHHHE ppm s 4 10 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 The beginning zero level is shown in the upper left corner of the dis play As the zero reading settles the screen displays and updates information on Slope unless the Slope starts within the acceptable zero range and does not need to settle further Then and whenever Slope is less than 0 08 for at least 3 minutes instead of Slope you will see a countdown 1 Left O Left and so fourth These are two steps in the zeroing process that the system must complete AFTER settling before it can go back to ANALYZE JHHHF PPM Zero 1 Left HHE ppm s The zeroing process will automatically conclude wh
13. Inputs to the Model 3020T Analyzer the customer s controller must monitor the CAL CONTACT relay When the contact is OPEN the analyzer is analyzing the Remote Cal Inputs are being polled and a zero or span command can be sent When the contact is CLOSED the analyzer is already calibrating It will ignore your request to calibrate and it will not remember that request Once a zero or span command is sent and acknowledged contact closes release it If the command is continued until after the zero or span is complete the calibration will repeat and the Cal Relay Contact CRC will close again Forexample Testthe CRC When the CRC is open Send a zero command until the CRC closes The CRC will quickly close 2 When the CRC closes remove the zero command 3 When CRC opens again send a span command until the CRC closes The CRC will quickly close 4 When the CRC closes remove the span command When CRC opens again zero and span are done and the sample is being analyzed 3 8 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 Note The remote probe connections paragraph 3 3 9 provide signals to ensure that the zero and span gas valves will be controlled synchronously If you have the C Internal valve option which includes additional zero and span gas inputs the 3020T automatically regulates the zero span and sample gas flow 3 3 6 Range ID Relays There are four ded
14. PHYSI CIAN SEE APPENDIX MATERIAL SAFETY DATA SHEET 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 the cell will require an excessively long time to reach zero after installation 1 2 weeks 5 3 2 When to Replace a Cell The characteristics of the Micro Fuel Cell show an almost constant output throughout its useful life and then fall off sharply towards zero at the end Cell failure in the 3020T is usually characterized inability to zero the instrument down to a satisfactorily low ppm reading When this occurs the 3020T system alarm trips and the screen displays a failure message dt ppm Anlz CELL FAIL ZERO HIGH Teledyne Analytical Instruments 9 3 5 Maintenance Model 3020 Before replacing the cell a b Check your span gas to make sure it is within specifications Check for leaks downstream from the cell where oxygen may be leaking into the system If there are no leaks and the span gas is OK replace the cell 5 3 3 Removing the Micro Fuel Cell The Micro Fuel Cell is located inside the stainless steel cell block behind the front panel see Figure 5 1 To remove an existing cell 1 5 4 Remove power to the instrument by unplugging the power cord at the power source Open the front panel door by unbolting it and swinging it open onits hinges Leave the cell block inst
15. See Figure in Chapter 3 Installation and or the Interconnection Diagram included at the back of this manual for relay terminal connections The system failure alarm has a fixed configuration described in chapter 3 Installation The concentration alarms can be configured from the front panel as either high or low alarms by the operator The alarm modes can be set as latching or non latching and either failsafe or non failsafe or they can be defeated altogether The setpoints for the alarms are also established using this function Decide how your alarms should be configured The choice will depend upon your process Consider the following four points 1 Which if any of the alarms are to be high alarms and which if any are to be low alarms Setting an alarm as HIGH triggers the alarm when the oxygen concentration rises above the setpoint Setting an alarm as LOW triggers the alarm when the oxygen concentration falls below the setpoint Decide whether you want the alarms to be set as e Both high high and high high alarms or e One high and one low alarm or Both low low and low low alarms 2 Are either or both of the alarms to be configured as failsafe In failsafe mode the alarm relay de energizes in an alarm condition For non failsafe operation the relay is energized in an alarm condition You can set either or both of the concentration alarms to operate in failsafe or non failsafe mode 3 Are either of the alarm
16. calibration gases These valves are com pletely under control of the 3020T Electronics They can be externally controlled only indirectly through the Remote Cal Inputs described below Pressure flow and safety considerations are the same as prescribed for the SAMPLE IN inlet above EXHAUST OUT Exhaust connections must be consistent with the hazard level of the constituent gases Check Local State and Federal laws and ensure that the exhaust stream vents to an appropriately controlled area if required Teledyne Analytical Instruments 3 13 3 Installation Model 3020T Note If the unit is for vacuum service see Sample In above for gas pressure flow considerations 3 6 Testing the System Before plugging the instrument into the power source e Check the integrity and accuracy of the gas connections Make sure there are no leaks e Check the integrity and accuracy of the electrical connections Make sure there are no exposed conductors Check that sample pressure is between 3 and 40 psig according to the requirements of your process e Check that the voltage selector switch on the Electrical Connector Panel is in the appropriate position for your power source Power up the system and test it by performing the following operations 1 Repeat the Self Diagnostic Test as described in chapter 4 section 4 3 5 3 14 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 Operation
17. givetheenduser more flexibility wheninstalling the analyzer The restrictor kitis suitableforhigh and low positive pressure applications as well as vacuum service atmospheric pressure sample applications see manual for installation instructions The standard restrictor BLUE DOT is recommended for pressures between 5 PSIG and 50 PSIG For positive low pressure appli cation 5 psig or less the un marked restrictor is better suited For none pressurized sample applications the marked restrictor should be used and configured for vacuum service Note for extremely low positive pressure appli cations less then 2 psig the vacuum service configuration should provide higher performance higher flow rates For vacuum service the end user must supply a vacuum pump and a by pass valve for the pump A vacuum level of 5 10 inches of mercury should provide the optimum flow rate CAUTION flow restrictors have very small orifices and may be plugged by small par ticles 005 dia or larger A sample filter must be included in the sample line prior to the restrictor a 60 micron filter is recommended 3020T EXAMPLES Example 1 withaincoming pressure of 10 psig the std restrictor blue dot will provide a flow rate of 76 SLPM Up stream of the restrictor the sample line pressure will be 10 psig while down stream including the cell the pressure will be at atmospheric pressure analyzer vented to atmospheric pressure Note all other pressure dr
18. of alarm Each has both normally open and normally closed contact connections The contact connections are indicated by diagrams on the connector panel They are capable of switching up to 3 amperes at 250 V ac into a resistive load See Figure 3 6 3 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 ts Normally closed a Norm Normally open Moving contact B o e e Tei Movit Figure 3 6 Types of Relay Contacts The connectors are Threshold Alarm 1 be configured as high actuates when concen tration is above threshold or low actuates when concentration is below threshold Can be configured as failsafe or nonfailsafe Can be configured as latching or nonlatching Can be configured out defeated Threshold Alarm 2 be configured as high actuates when concen tration is above threshold or low actuates when concentration is below threshold Can be configured as failsafe or nonfailsafe Can be configured as latching or nonlatching Can be configured out defeated System Alarm Actuates when DC power supplied to circuits is unacceptable in one or more parameters Permanently configured as failsafe and latching Cannot be de feated Actuates if self test fails Toreset a System Alarm during installation discon nect power to the instrument and then reconnect it Further detai
19. options menu The item that is between arrows on the screen is the item that is cur rently selectable by choosing ENTER turn and release toward ENTER with the ESCAPE ENTER control these instructions to ENTER means to turn and release toward ENTER and To ESCAPE means to turn and release towards ESCAPE To scroll UP or scroll DOWN means to turn and release toward UP or DOWN as many times as necessary to reach the required menu item 4 2 1 Mode Function Selection When the analyzer is first powered up and has completed its initializa tion and self diagnostics ESCAPE toggles the instrument between the ANALYZE screen Analysis Mode and the MAIN MENU screen Setup Mode The ANALYZE screen is the only screen of the Analysis Mode The MAIN MENU screen is the top level in a series of screens used in the Setup Mode to configure the analyzer for the specific application The DOWN UP commands scroll through the options displayed on the VFD screen The selectable option appears between arrows When you reach the desired option by scrolling ENTER the selection as described below ESCAPE takes you back up the hierarchy of screens until you reach the MAIN MENU again ESCAPING any further just toggles between the MAIN MENU and the ANALYZE screen 4 2 1 1 Analysis Mode This is the normal operating mode The analyzer monitors the oxygen content of the sample displays the percent of oxygen and warns of any alarm conditions Either
20. percent of range output and in the range ID outputs will be noticed The autoranging feature can be overridden so that analog output stays on a fixed range regardless of the oxygen concentration detected If the concentration exceeds the upper limit of the range the DC output will saturate at 1 V dc 20 mA at the current output However the digital readout and the RS 232 output of the concentra tion are unaffected by the fixed range They continue to read accurately with full precision See Front Panel description in Chapter 1 The automatic air calibration range is always 0 25 and is not pro grammable 4 10 1 Setting the Analog Output Ranges To set the ranges ENTER the RANGE function mode by selecting RANGE from the MAIN MENU The RANGE screen appears L 100 1000 10000 Mode AUTO Use the DOWN UP control to the range to be set low L medium or high H 4 16 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 Use the DOWN UP control to enter the upper value of the range all ranges begin at ppm Repeat for each range you want to set ENTER to accept the values and return to the Analysis Mode See note below Note The ranges must be increasing from low to high for example if range 1 is set as 0 100 ppm and range 2 is set as 0 1 000 ppm range 3 cannot be set as 0 500 ppm since it is lower than range 2 Ranges alarms and spans are always set in ppm units over the entire
21. screen when they have completed their assigned opera tions After four or five minutes in the MAIN MENU without any action by the operator the analyzer automatically switches itself back to the ANA LYZE screen ESCAPE asserted one or more times depending on the starting point also switches the analyzer back to the ANALYZE screen IMPORTANT the event of loss of flow through the analyzer if the vent is vented to a location of high oxygen content oxygen will back diffuse through the vent line and in most cases quickly saturate the cell with oxygen which can then require a quite long purge down time for the sensor when then exposed to low oxygen concentra tions In the event that flow is to be interrupted into the analyzer it is suggested that the user do one of the following 1 Bag the sensor in nitrogen during this time 2 Install a shut off valve on the vent port of the ana lyzer or somewhere within the users sample system Teledyne Analytical Instruments 4 19 4 Operation Model 3020 4 20 Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 Maintenance 5 1 Routine Maintenance Aside from normal cleaning and checking for leaks at the gas connec tions routine maintenance is limited to replacing Micro Fuel cells and fuses and recalibration For recalibration see Section 4 4 The Zero and Span Functions WARNING SEE WARNINGS ON TITLE PAGE OF THIS MANUAL 5 2 Major Internal Comp
22. 0 00 lt ENT gt Span lt UP gt Mod Use DOWN UP to start changing the oxygen concentration Use ESCAPE ENTER to blink the digit you are going to modify Use DOWN UP again to change the value of the selected digit When you have finished 4 12 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 typing the concentration of the span gas you are using repeatedly select ENTER until the rightmost digit is reached then the next ENTER will exit the Span Val field One more ENTER will enter the new span value bring up the next screen and start the span calibration THHHE ppm Span Slope iHHHE ppm s The beginning span value is shown in the upper left corner of the display As the span reading settles the screen displays and updates informa tion on Slope Spanning automatically ends when the span output corre sponds within tolerance to the value of the span gas concentration Then the instrument automatically returns to the ANALYZE mode 4 8 2 2 Manual Mode Spanning ENTER SPAN from the MAIN MENU to start the SPAN function The screen that appears allows you to select whether the span calibration is to be performed automatically or manually Span Settling MAN lt ENT gt For Next Use DOWN UP to toggle between AUTO and MAN span settling Stop when MAN appears on the display Use ENTER to move to the next screen Span Val 209000 00 lt ENT gt Span lt UP gt Mod Use UP to permit modification Mod
23. 5 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 5 3 5 Cell Warranty The Class L 2C Micro Fuel cell is used in the Model 3020T This cell is a long life cell and is warranted for 1 year from the date of shipment If any other cell is supplied with your instrument check the front of this manual for any special information applying to your cell With regard to spare cells warranty period begins on the date of ship ment The customer should purchase only one spare cell per section 5 3 1 Do not attempt to stockpile spare cells The L 2C cell is not designed for applications where CO is a major component in the sample however concentrations of 1 000 ppm or less will not adversely effect the cell performance Consult Analytic Instru ments for available options for either intermittent or continuous CO expo sure 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 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 5 4 Fuse Replacement The 3020T requires two 5 x 20 mm 4 A T type Slow Blow fuses The fuses are located
24. 5911 Wiring Diagram A 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix A 4 3000 SERIES ANALYZERS APPLICATION NOTES ON RESTRICTORS PRESSURES AND FLOW RECOMMENDATIONS 3000 series analyzers require reasonably regulated sample pressures While the 3000 analyzers are not sensitive to variations of incoming pressure provided they are properly vented to atmospheric pressure the pressure must be maintained as to provide auseable flow rate trough the analyzer Any line attached to sample vent should be 1 4 or larger in diameter FLOW RATE RECOMMENDATIONS Ausable flow rate for a 3000 series analyzer is one which can be measured on the flowmeter This is basically 2 2 4 SLPM The optimum flow rateis 1 SLPM mid scale Note response time is dependent on flow rate low flow rate will result in slow response to O2 changes in the sample stream The span flow rate should be the approximately same as the sample flow rate CELL PRESSURE CONCERNS The sensors used in 3000 series analyzers are optimized to function at atmospheric pressure At pressures other than atmospheric the diffusion rate of O2 will be different than optimum value Higher pressures will produce faster O2 diffusion rates resulting in higher O2 reading and shorter cell life To use a 3000 series analyzer at a cell pressure other than atmospheric the analyzer must be calibrated with a known calibration gas at the new cell pressure to adjust for the
25. al is analyzed and at the end of the test the status of each function is displayed on the screen either as OK or as a number between 1 and 3 See System Self Diagnostic Test in chapter 5 for number code The self diagnostics are run automatically by the analyzer whenever the instrument 15 turned on but the test can also be run the operator at will To initiate SELF TEST during operation Use the DOWN UP control to scroll through the MAIN MENU to SELF TEST The screen will follow the running of the diagnostic RUNNING DIAGNOSTIC Testing Preamp 83 During preamp testing there is a countdown in the lower right corner of the screen When the testing is complete the results are displayed Power OK Analog OK Preamp 3 The module is functioning properly if it is followed by OK number indicates a problem in a specific area of the instrument Refer to Chapter 5 Maintenance for number code information The results screen alternates for a time with Press Any Key To Continue Then the analyzer returns to ANALYZE screen 4 8 The ZERO and 5 Functions Zeroing is not required in order to achieve the published accuracy specification of this unit Zeroing will eliminate offset error contributed by sensor elec tronics and internal and external sampling system and im prove performance beyond published specification limits The analyzer is calibrated using zero and span gases Any suitable oxygen free gas c
26. alled Place one hand underneath the cell block ready to catch the cell holder and Micro Fuel Cell Lift up on the stainless steel gate in front of the cell block This releases the cell and cell holder from the block The cell and holder will fall out in your hand Ss Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 NNNS N NAN N O Teledyne Analytical Instruments Q o QC eee N N SIS SS SIS Q N Gere EEE 1 O N CRETE M N N O 4 o E Ne Figure 5 2 Exploded View of Cell Block and Micro Fuel Cell Teledyne Analytical Instruments 9 9 5 Maintenance Model 3020 5 3 4 Installing a New Micro Fuel Cell It is important to minimize the amount of time that a Teledyne Trace Oxygen Sensor is exposed to air during the installation process The quicker the sensor can be installed into the unit the faster your TAI O sensor will recover to low O measurement levels CAUTION Do not touch the sensing surface of the cell It is cov AN Before installing a new cell check the O ring in the base of the cell holder Replace if worn or damaged Note ered with a delicate Teflo
27. an be used for zero gas as long as it is known to be oxygen free and does not react adversely with the sample system Teledyne Analytical Instruments 4 9 4 Operation Model 3020 Although the instrument can be spanned using air span gas with a known oxygen concentration in the range of 70 90 of full scale of the range of interest is recommended Since the oxygen concentration in air is 209 000 ppm the cell can take a long time to recover if the instrument is used for trace oxygen analysis immediately following calibration in air Connect the calibration gases to the analyzer according to the instruc tions given in section 3 5 Gas Connections observing all the prescribed precautions Shut off the gas pressure before connecting it to the analyzer and be sure to limit the pressure to 40 psig or less when turning it back on Readjust the gas pressure into the analyzer until the flowrate as read on the analyzer s SLPM flowmeter settles between 0 5 and 2 4 SLPM ap proximately 1 5 scfh If you are using password protection you will need to enter your password to gain access to either of these functions Follow the instructions in section 4 4 to enter your password Once you have gained clearance to proceed you can ENTER the ZERO or SPAN function 4 8 1 Zero Cal The ZERO function on the MAIN MENU is used to enter the zero calibration function Zero calibration can be performed in either the auto matic or manual mode
28. and in the fitting This may require an additional s turn beyond finger tight 2 Hold the fitting body steady with a backup wrench and with another wrench rotate the nut another 17 4 turns 3 12 7 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 Teledyne Analytical Instruments 3020T Series A FLOW 1 4 TUBE NN SAMPLE 1 4 TUBE SPAN IN 1 4 TUBE CONN ZERO IN EXHAUST 1 4 TUBE CONN Figure 3 9 Gas Connector Panel SAMPLE IN In the standard model gas connections are made at the SAMPLE IN and EXHAUST OUT connections Calibration gases must be Tee d into the Sample inlet with appropriate valves The gas pressure in should be reasonably regulated Pressures between 3 and 40 psig are acceptable as long as the pressure once established will keep the front panel flowmeter reading in an acceptable range 0 1 to 2 4 SLPM Exact figures will depend on your process If greater flow is required for improved response time install a bypass in the sampling system upstream of the analyzer input Note If the unit is for vacuum service the above numbers apply instead to the vacuum at the EXHAUST OUT connector de scribed below with minus signs before the pressure readings ZERO IN and SPAN IN These are additional ports for inputting span gas and zero gas There are electrically operated valves inside for automatic switching between sample and
29. art azerocalibration ALARMS Used to set the alarm setpoints and determine whether each alarm will be active or defeated HI or LO acting latching or not and failsafe or not 29 Teledyne Analytical Instruments 4 3 4 Operation Model 3020 9 RANGE Used to set up three analysis ranges that be switched automatically with auto ranging or used as individual fixedranges 10 STANDBY Remove power to outputs and displays but maintain power to internal circuitry Any function can be selected at any time Just scroll through the MAIN MENU with the DOWN UP control to the appropriate function and ENTER it The analyzer will immediately start that function unless password restrictions have been assigned Password assignment is explained further on All of these functions are described in greater detail in the procedures starting in section 4 3 The VFD screen texts used to illustrate the procedures are reproduced in a Monospaced type style 4 2 2 Data Entry 4 2 2 1 ENTER When the item you want from the VFD screen appears between the arrows on the screen ENTER it using the ESCAPE ENTER control When the selected option is a function or subfunction ENTER moves to the VFD screen for that function or subfunction When the selected option is a modifiable item the DOWN UP control can be used to increment or decrement that modifiable item to the value or action you want Then you ENTER the item ENTER then puts yo
30. as pressure must be adjusted to achieve the proper flow rate OPERATION WITHOUT A RESTRICTOR DEVICE Operation without a restrictor device is not recommend as mentioned above 3020T without any flow restrictor device was tested on 11 19 97 This results ina flow rate of 2 4SLPM 1 PSIG This is of 0 023 for the standard sample sys REFERENCE FLOW_1 XLS amp FLOW 2 XLS for information on flow rates at various pressures TAI PART NUMBERS RESTRICTOR KIT A68729 UNION SS U11 LP RESTRICTOR R2323 LOW PRESSURE VAC SERVICE STD RESTRICTOR R2324 BLUEDOT NUT N73 FERRULE F73 FERRULE F74 BOTHFERRULES ARE REQUIRED CONVERSIONS 1 PSI 2 04 INCHES OF MERCURY in Hg 1 SCFH 0 476 SLPM Teledyne Analytical Instruments A 7
31. cal connections are made via cables which enter the explo sion proof housing through ports in its side No conduit fittings are supplied The installer must provide two 3 4 NPT and two 1 NPT adapters and the appropriate sealing conduit Teledyne Analytical Instruments 3 1 3 Installation Model 3020 12 94 3 4 CONDUIT ALARM oureurs CONCENTRATION DIGTAL INPUT SPAN ZERO CAL CONTACT RANGE ID CONTACTS RS 232 AC POWER IN 50 60 HZ 115 230 V SOLENOID RETURN ANALOG OUTPUTS LY AUTHORIZED PERSONNEL SHOULD REMOTE SENSOR PERSONAL PROTECTION EQUIPMENT MAY BE NET WORK w REQURED WHEN SERVING THIS SYSTEM BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISORMANAGER FLOWME 1 4 TUBE CONN SAMPLE IN Figure 3 1 Front View of the Model 3020T Simplified 3 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 Figure 3 2 Required Front Door Clearance 3 3 Electrical Connections Figure 3 3 shows the Model 3020 Electrical Connector Panel There are terminal blocks for connecting power communications and both digital and analog concentration outputs DIGITAL INPUT RELAY OUTPUTS Xy X l e N
32. control switches you to Setup Mode Setup Mode switches back to Analyze Mode if no controls are used for more than 5 s 4 2 1 2 Setup Mode The MAIN MENU consists of 11 functions you can use to customize the operations of the analyzer Figure 4 1 shows the functions available with the Model 3020T They are listed here with brief descriptions 1 AUTO CAL Used to define and or start an automatic calibration sequence 4 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 Setup Mode Auto Cal On Off Span Zero Timing Auto Cal Start Establish or Change a Password Contrast Function is DISABLED Refer to Section 1 6 N Log Out and Enable Security Set Instrument Zero Display Soft ware Version Set Alarm Setpoints Set Alarm Modes of Operation Perform Self Diagnostic Routine Set Instrument Defi Span Figure 4 1 Modes and Functions PWD Used to establish password protection or change the existing password LOGOUT Logging out prevents unauthorized tampering with the analyzer settings VERSION Displays Manufacturer Model and Software version of the instrument SELF TEST The instrument performs a self diagnostic routine to check the integrity of the power supply output boards and amplifiers SPAN Set up and or start a span calibration ZERO st
33. current that can be pulled from these output lines is 100 mA If two lines are ON at the same time each must be limited to 50 mA etc If more current and or a different voltage is required use a relay power amplifier or other matching circuitry to provide the actual driving current In addition each individual line has a series FET with a nominal ON resistance of 5 ohms 9 ohms worst case This could limit the obtainable voltage depending on the load impedance applied See Figure 3 8 LOAD Figure 3 8 FET Series Resistance 3 4 Installing the Micro Fuel Cell The Micro Fuel Cell is not installed in the cell block when the instrument is shipped It must be installed before the analyzer is placed in service Once it is expended or if the cell is exposed to air for too long the Micro Fuel Cell will need to be replaced The cell could also require replace ment if the instrument has been idle for too long Teledyne Analytical Instruments 3 11 3 Installation Model 3020T When the micro Fuel Cell needs to be installed or replaced follow the procedures in chapter 5 Maintenance for removing and installing cells 3 5 Gas Connections Before using this instrument it should be determined if the unit will be used for pressurized service or vacuum service and low pressure applica tions Inspect the restrictor kit that came with the unit The kit consist of two restrictors and a union for 1 4 diameter
34. e ID outputs Signals from the power supply are also monitored and through the microprocessor the system failure alarm is activated if a malfunction is detected 2 5 Temperature Control For accurate analysis this instrument is temperature controlled not to fall beneath a certain temperature This temperature is 22 F This is to prevent the sensor from freezing in cold environments 2 8 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 Installation E Installation of the 13020 Analyzer includes 1 Unpacking 2 Mounting 3 Gas connections 4 Electrical connections 5 Installing the Micro Fuel Cell 6 Testing the system 3 1 Unpacking the Analyzer The analyzer is shipped with all the materials you need to install and prepare the system for operation Carefully unpack the analyzer and inspect it for damage Immediately report any damage to the shipping agent 3 2 Mounting the Analyzer The Model 3020T is designed for bulkhead mounting in hazardous environments There are four mounting lugs one in each corner of the enclosure as shown in Figure 3 1 The outline drawing at the back of this manual gives the mounting hole size and spacing The drawing also con tains the overall dimensions Do not forget to allow an extra 13 8 for the hinges Be sure to allow enough space in front of the enclosure to swing the door open a 16 4 radius as shown in Figure 3 2 All electri
35. e 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 concen tration of the sample has not changed It is therefore important that the sample pressure at the fuel cell usually vent pressure remain relatively 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 is directly proportional to the rate at which oxygen molecules reach the cathode and 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 3 Measuring circuits do not have to compensate for nonlinearities In addition since there is zero output in the absence oxygen the charac teristic curve has close to an absolute zero within 1 ppm oxygen In practical application zeroing may still used to compensate for the combined zero offsets of the cell and the electronics The electronics is zeroed auto matically when the instrument power is turned on 2 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 500 375 Cell Output uA 250 125
36. elf Test Runs internal diagnostic program displays results e Span Span calibrate the analyzer e Zero Zero calibrate the analyzer Alarms Setthealarm setpoints and attributes Range Setup the 3 user definable ranges for the instrument e Contrast Allows adjustment of LCD contrast Contrast Function is DISABLED Standby Leaves analyzer powered but no outputs or displays Persons WARNING THE POWER CABLE MUST BE DISCONNECTED TO A FULLY REMOVE POWER FROM THE INSTRUMENT Subfunctions Once a Function is entered the UP DOWN switch is used to select between any subfunctions displayed on the VED screen Parameter values When modifiable values are displayed on the VED the UP DOWN switch can be used to increment or decrement the values 1 5 2 ESCAPE ENTER Switch Data Entry The ESCAPE ENTER switch is used to input data from the alphanumeric screen into the instrument e Escape Moves VFD display back to the previous screen in a series If none remains returns to the Analyze screen e Enter With a Subfunction Selected Moves VED display on to the next screen in a series If none remains returns to the Analyze screen With a Value Selected Enters the value into the analyzer as data AdvancesVFD to next operation See Chapter 4 for details 1 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 1 5 3 Displays Digital Meter Display The meter display is a LED device that produces
37. en the output is within the acceptable range for a good zero Then the analyzer automatically returns to the ANALYZEscreen 4 8 1 2 Manual Mode Zeroing ENTER the ZERO function The screen that appears allows you to select between automatic or manual zero calibration Use DOWN UP to toggle between AUTO and MAN zero settling Stop when MAN appears on the display Zero Settling Man lt ENT gt To Begin ENTER to begin the zero calibration After a few seconds the first of five zeroing screens appears The number in the upper left hand corner is the first stage zero offset The microprocessor samples the output at a predeter mined rate It calculates the differences between successive samplings and displays the rate of change as Slope a value in parts per million per second ppm s THHHE ppm X Zero Slope iHHHE ppm s NOTE It takes several seconds for the true Slope value to display Wait about 10 seconds Then wait until Slope is sufficiently close to zero before using ENTER to finish zeroing Generally you have a good zero when Slope is less than 0 05 ppm s for about 30 seconds When Slope is close enough to zero ENTER it In a few seconds the screen will update Once zero settling completes the information is stored in the microprocessor and the instrument automatically returns tothe ANALYZE screen Teledyne Analytical Instruments 4 11 4 Operation Model 3020 4 8 1 3 Cell Failure Cell failure in the 3020T
38. ersatile analysis over a wide range of applications Microprocessor based electronics 8 bit CMOS microprocessor with 32 KB RAM and 128 Three user definable output ranges from 0 10 ppm through 0 250 000 ppm allow best match to users process and equipment Air calibration range for convenient spanning at 20 9 Auto Ranging allows analyzer to automatically select the proper preset range for a given measurement Manual override allows the user to lock onto a specific range of interest Two adjustable concentration alarms and a system failure alarm Extensive self diagnostic testing at startup and on demand with continuous power supply monitoring RS 232 serial digital port for use with a computer or other digital communication device Four analog outputs two for measurement 0 1 V dc and Isolated 4 20 mA dc and two for range identification 4 Model Designations Standard model In addition to all standard features this model also has separate ports for zero and span gases and built in control valves The internal valves are entirely under the control of the 3020 electronics to automatically switch between gases in synchronization with the analyzer s operations Flame arrestors for Groups and D installed Flame arrestors for Groups and D amp C option installed Flame arrestors for Group B hydrogen installed Flame arrestors for Group B amp C option installed All of the above op
39. fier Amplifier EOS ru EES Range ram Sach r System Failure Alarm Self Test Signal Figure 2 5 Block Diagram of the Model 3020T Electronics Teledyne Analytical Instruments 2 7 2 Operational Theory Model 3020T In the presence of oxygen the cell generates a current current to voltage amplifier converts this current to a voltage which is amplified in the second stage amplifier The second stage amplifier also supplies temperature compensation for the oxygen sensor output This amplifier circuit incorporates a thermistor which 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 same temperature changes The result is a signal that is temperature independent The output from the second stage amplifier is sent to an 18 bit analog to digital converter controlled by the microprocessor The digital concentration signal along with input from the control panel is processed by the microprocessor and appropriate control signals are directed to the display alarms and communications port The same digital information is also sent to a 12 bit digital to analog converter that produces the 4 20 mA dc and the 0 1 V dc analog concentration signal outputs and the analog rang
40. he entry lt ENT gt screen You will be given clearance to proceed AAAAA lt ENT gt TO Proceed ENTER the letters of your new password Your password will be stored in the microprocessor and the system will immediately switch to the ANA LYZE screen and you now have access to all instrument functions If all alarms are defeated the ANALYZE screen appears as 0 0 ppm Anlz Range 0 100 If an alarm is tripped the second line will change to show which alarm itis 0 0 ppm Anlz 1 1 NOTE If you log off the system using the LOGOUT function in the MAIN MENU you will now be required to re enter the pass word to gain access to SPAN ZERO ALARM and RANGE functions 4 5 The LOGOUT Function By entering LOGOUT you effectively log off the instrument leaving the system protected against tampering until the password 15 reentered To log out scroll to place the LOGOUT function between the arrows and ENTER to log out The screen will display the message Protected Until Password Reentered 4 6 The VERSION Screen Scroll through the MAIN MENU to VERSION and ENTER The screen displays the manufacturer model and software version information 4 8 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 4 7 The SELF TEST Function The Model 3020T has a built in self testing diagnostic routine Prepro grammed signals are sent through the power supply output board and sensor circuit The return sign
41. he number Holding the control on the DOWN or UP position while the number changes speeds up the incrementing or decrementing Remember the setpoint units are always ppm O e To set the other parameters use ENTER to blink the desired parameter Then use DOWN UP to change the parameter Once the parameters for the alarm have been set ENTER the ALARM function again and repeat this procedure for next alarm e Toreseta latched alarm go to and then assert either DOWN two times or UP two times Toggle it to Y and then back to Teledyne Analytical Instruments 4 15 4 Operation Model 3020 OR Go to Ltch and then assert either DOWN two times or UP two times Toggle it to N and back to Y 4 10 The RANGE Function The RANGE function allows the operator to program up to three concentration ranges to correlate with the DC analog outputs If no ranges are defined by the user the instrument defaults to Low 0 100 ppm Med 0 1 000 ppm High 0 10 000 ppm The Model 3020T is set at the factory to default to autoranging In this mode the microprocessor automatically responds to concentration changes by switching ranges for optimum readout sensitivity If the current range limits are exceeded the instrument will automatically shift to the next higher range If the concentration falls to below 85 of full scale of the next lower range the instrument will switch to that range A corresponding shift in the DC
42. icated RANGE ID CONTACT relays The first three ranges are assigned to relays in ascending order Low range is as signed to RANGE 1 ID Medium range is assigned to RANGE 2 ID and High range is assigned to RANGE 3 ID RANGE 4 ID is reserved for the Air Cal Range 25 3 3 7 Networkl O A serial digital input output for local network protocol At this printing this port is not yet functional It is to be used in future versions of the instru ment 3 3 8 RS 232 Port The digital signal output is a standard RS 232 serial communications port used to connect the analyzer to a computer terminal or other digital device The pinouts are listed in Table 3 3 Table 3 3 RS 232 Signals RS 232 Sig RS 232Pin Purpose DCD 1 Data Carrier Detect RD 2 Received Data TD 3 Transmitted Data DTR 4 Data Terminal Ready COM 5 Common DSR 6 Data Set Ready RTS J Request to Send CTS 8 Clear to Send RI 9 Ring Indicator The data sent is status information in digital form updated every two seconds Status is reported in the following order The concentration in ppm or percent Teledyne Analytical Instruments 3 9 3 Installation Model 3020 e The range in use HI MED LO span of the range 0 100 ppm etc Which alarms if any are disabled AL x DISABLED Which alarms if any are tripped AL x Each status output is followed by a carriage return and line feed Three input functions using RS 232 have been i
43. inside the explosion proof housing on the Electrical Connector Panel as shown in Figure 5 2 To replace a fuse 1 Disconnect the Unit from its power source 2 Placea small screwdriver in the notch in the fuse holder cap push in and rotate 1 4 turn The cap will pop out a few millimeters Pull out the fuse holder cap and fuse as shown in Figure 5 3 Teledyne Analytical Instruments 5 5 Maintenance Model 3020 3 0 A MAX USE 250 V 1 0 ATFUSE e D CAUTION a USER SERVICEABLE PARTS INSIDI SERVICE ONLY BY QUALIFIED PERSON VOLTAGE SELECTOR D Figure 5 3 Removing Fuse Cap and Fuse from Holder 2 Replace fuse by reversing process step 1 5 5 System Self Diagnostic Test Use the DOWN UP control to scroll through the MAIN MENU to SELF TEST The screen will follow the running of the diagnostic RUNNING DIAGNOSTIC Testing Preamp 83 During preamp testing there is a countdown in the lower right corner of the screen When the testing is complete the results are displayed Power OK Analog OK Preamp 3 The module is functioning properly if it is followed by OK A number indicates a problem in a specific area of the instrument Refer to Table 5 1 for number code information The results screen alternates for a time with Press Any Key To Continue The following failure codes apply 5 8 Teledyne Analytical Instruments Trace Oxygen Analyze
44. is usually associated with inability to zero the instrument down to a satisfactorily low ppm reading When this occurs the 3020T system alarm trips and the VFD displays a failure message AA ppm 12 CELL FAIL ZERO HIGH Before replacing the cell a Check for leaks downstream from the cell where oxygen may be leaking into the system b Check your span gas to make sure it is within specifications If there are no leaks and the span gas is OK replace the cell as described in chapter 5 Maintenance d Aftercorrecting the condition reset the Cell Fail Alarm by taking the analyzer into and then back out of STANDBY 4 8 2 Span Cal SPAN is used to span calibrate the analyzer Span calibration can be performed using the automatic mode where an internal algorithm compares consecutive readings from the sensor to determine when the output matches the span gas concentration Span calibration can also be performed in manual mode where the operator determines when the span concentration reading is acceptable and manually exits the function 4 8 21 Auto Mode Spanning Scroll to SPAN and ENTER the SPAN function The screen that appears allows you to select whether the span calibration is to be performed automatically or manually Use the DOWN UP control to toggle between AUTO and MAN span settling Stop when AUTO appears on the display Span Settling AUTO lt ENT gt For Next Use ENTER to move to the next screen Span Val 20900
45. l one of the reactants oxygen comes from outside the device as a constituent of the sample gas being Teledyne Analytical Instruments 2 1 2 Operational Theory Model 3020T analyzed Micro Fuel Cell is therefore hybrid between a battery and a true fuel cell of the reactants stored externally in a true fuel cell 2 2 2 Anatomy ofa Micro Fuel Cell The Micro Fuel Cell is a cylinder only 1 inches in diameter and 114 inches thick It is made of an extremely inert plastic which can be placed confidently in practically any environment or sample stream It is effectively 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 View Bottom View Concentric 22 FoilContact lt gt Rings Sensing Surface 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 Electrolyte _ Cathode Anode Contact Plate Flexible Membrane Figure 2 2 Cross Section of a Micro Fuel Cell not to scale 2 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 At the to
46. l can be found in chapter 4 section 4 5 3 3 5 Digital Remote Cal Inputs Remote Zero and Span Inputs The REMOTE SPAN and RE MOTE ZERO inputs are on the DIGITAL INPUT terminal block They accept 0 V OFF or 24 V dc ON for remote control of calibration See Remote Calibration Protocol below Teledyne Analytical Instruments 3 7 3 Installation Model 3020T ZERO Floating input 5 to 24 V input across the and terminals puts the analyzer into the Zero mode Either side may be grounded at the source of the signal 0 to 1 volt across the terminals allows Zero mode to terminate when done A synchronous signal must open and close the external zero valve appropriately See 3 3 9 Remote Sensor and Solenoid Valves With the option the internal valves automatically operate synchronously SPAN Floating input 5 to 24 V input across the and terminals puts the analyzer into the Span mode Either side may be grounded at the source of the signal 0 to 1 volt across the terminals allows Span mode to terminate when done A synchronous signal must open and close the external span valve appropriately See 3 3 9 Remote Sensor and Solenoid Valves With the option the internal valves automatically operate synchronously Cal Contact This relay contact is closed while analyzer is spanning and or zeroing See Remote Calibration Protocol below Remote Calibration Protocol To properly time the Digital Remote Cal
47. large bright 7 segment numbers that are legible in any lighting It produces a continuous readout from 0 10 000 ppm and then switches to a continuous percent readout from 1 25 It is accurate across all analysis ranges without the discontinuity inherent in analog range switching Alphanumeric Interface Screen The VFD screen is an easy to use interface from operator to analyzer It displays values options and messages that give the operator immediate feedback Flowmeter Monitors the flow of gas past the sensor Readout is 0 2 to 2 4 standard liters per minute 51 1 6 Recognizing Difference Between LCD amp VFD LCD has GREEN background with BLACK characters VFD has DARK background with GREEN characters In the case of NO CONTRAST ADJUSTMENT IS NEEDED 1 7 Equipment Interface 1 7 1 Electrical Connector Panel The electrical connector panel shown in Figure 1 2 contains the electrical connections for external inlets and outlets The connectors are described briefly here and in detail in the Installation chapter of this manual CAUTION The power cable must be disconnected to fully remove power from the instrument Access To access the electrical connector panel or the sensor block the control panel doubles as a door that can be unbolted and swung open Electrical Connections The electrical connections on the electrical connector panel are described briefly here and in more detail in chapter 3 Installation
48. lytical Instruments A 1 Model 3020 Operating Temperature 0 50 C A 2 Analog outputs Password Access Accuracy 2 of full scale at constant temperature 5 of full scale over operating temperature range on factory default analysis ranges once thermal equilibrium has been achieved 0 1 V dc percent of range 0 1 V dc range ID 4 20 mA dc percent of range 4 20 mA dc range ID Can be user configured for password protection Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix A 2 Recommended 2 Year Spare Parts List Qty Part Number Description 1 C62371B Display PCB 1 D65295A Customer Interface PCB 1 62368 Trace Preamplifier Board 1 62365 Main 3 F1295 Fuse 4A 250 5x20 mm Slow Blow 1 O165 O ring 1 C6689 L2C Micro FuelCell A minimum charge is applicable to spare parts orders Note Orders for replacement parts should include the part number if available and the model and serial number of the instru ment for which the parts are intended Orders should be sent to Teledyne Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Phone 626 934 1500 Fax 626 961 2538 TWX 910 584 1887 TDYANYL Web www teledyne ai com or your local representative Teledyne Analytical Instruments A 3 Appendix Model 3020T A 3 Drawing List D65908 Final Assembly Drawing 065909 Outline Drawing D6
49. mplemented to date They are described in Table 3 4 Table 3 4 Commands via RS 232 Input Command Description as lt enter gt Immediately starts an autospan az lt enter gt Immediately starts an autozero st lt enter gt Toggling input Stops Starts any status message output from the RS 232 until st lt enter gt is sent again The RS 232 protocol allows some flexibility in its implementation Table 3 5 lists certain RS 232 values that are required by the 3020T imple mentation Table 3 5 Required RS 232 Options Parameter Setting Baud 2400 Byte 8 bits Parity none Stop Bits 1 MessageInterval 2 seconds 3 3 9 Remote Sensor and Solenoid Valves The 3020T is a single chassis instrument which has its own sensor and in the C option its own gas control solenoid valves The REMOTE SEN SOR connector is not used and the SOLENOID RETURN connectors are used without the option to synchronize external gas control valves if desired See Figure 3 7 3 10 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 15 V dc E E E 15 V dc MEN 15 V de 5 Matching Circuitry SAMPLE return If SPAN return Necessary Re iari ss dritter E Figure 3 7 Remote Solenoid Return Connector Pinouts The voltage from these outputs is nominally 0 V for the OFF and 15 V dc for the ON conditions The maximum combined
50. must be changed back to TETAI NOTE If you use password security it is advisable to keep a copy of the password in a separate safe location 4 4 4 Entering the Password To install a new password or change a previously installed password you must key in and ENTER the old password first If the default password is in effect issuing the ENTER command will enter the default TETAI pass word for you Scroll to PWD and ENTER to select the password function Either the TETAI default password or AAAAA place holder password for an existing password will appear on screen depending on whether or not a password has been previously installed TETAI Enter PWD or Enter PWD The screen prompts you to enter the current password If you are not using password protection ENTER to accept TETAI as the default password If a password has been previously installed enter the password using EN TER to scroll through the letters and the DOWN UP keys to change the letters to the proper password The last ENTER enters the password If the password is accepted the screen will indicate that the password restrictions have been removed and you have clearance to proceed PWD Restrictions Removed 4 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 In a few seconds if you do not ESCAPE you will be given the oppor tunity to change this password or keep it and go on Change Password lt ENT gt Yes l
51. n membrane that can leak when punctured The sensor must be replaced if the membrane is damaged Place the cell on the holder with the screen side facing down There mates is a small location hole drilled in the holder This hole with a guide pin on the bottom rear of the cell block The hole in the cell block holder must align with the guide pin on the cell block Step 1 Remove power from instrument Step 2 Remove the old sensor if installed from the analyzer Step 3 Purge the analyzer at approximately 1 SCFH flow rate with Step 4 Step 5 Step 6 Step 7 N or applicable sample gas with the sensor holder re moved Remove sensor from double bag storage Remove sensor shorting button Place sensor on sensor holder so that the gold contact plate of the sensor is facing up towards the sky Install sensor and sensor holder into cell block Step 8 With O ring in place align the guide pin with the hole on the Step 9 cell holder Then with the holder lift cell into the cell block Push the gate on the cell block down so that the slots on the side of the gate engage the locating screws on the side of the block This forces the holder into position and forms a gas tight seal Step 10 Purge system with sample or zero gas Step 11 Power up If steps 4 through 10 are accomplished quickly elapsed time less than 15 seconds recovery to less than 1ppm level should occur in less than 8 hours
52. of span value Use ESCAPE ENTER to choose the digit and use DOWN UP to choose the value of the digit When you have finished typing in the concentration of the span gas you are using repeatedly select ENTER until the rightmost digitis reached then the next ENTER will exit the Span Val field One more ENTER will enter the new span value bring up the next screen and start the span calibration Once the span has begun the microprocessor samples the output at a predetermined rate It calculates the difference between successive samplings and displays this difference as Slope on the screen It takes several seconds for the first Slope value to display Slope indicates rate of change of the Span reading It is a sensitive indicator of stability THHHE Span Slope iHHHE ppm s Teledyne Analytical Instruments 4 13 4 Operation Model 3020 When the Span value displayed on the screen is sufficiently stable ENTER it Generally when the Span reading changes by or less of the full scale of the range being calibrated for a period of ten minutes it is suffi ciently stable Once you ENTER it the Span reading changes to the correct value The instrument then automatically enters the ANALYZE function 4 9 The ALARMS Function The Model 3020T is equipped with 2 fully adjustable concentration alarms and a system failure alarm Each alarm has a relay with a set of form C contacts rated for 3 amperes resistive load at 250 V ac
53. onents All internal components are accessed by unbolting and swinging open the front cover as described earlier The major internal component locations are shown in Figure 3 1 the cell block is illustrated in Figure 3 2 and the fuse receptacle is shown in Figure 3 3 The 3020T contains the following major internal components e Micro Fuel Cell L 2C e Stainless steel cell block e Customer Interface PCB Power Supply on bottom surface e Preamp PCB Contains Microprocessor Front Panel PCB Contains Displays 5 digit LED meter 2 line 20 character alphanumeric VFD display e Solenoid Operated Gas Control Valves option only See the drawings in the Drawings section in back of this manual for details Teledyne Analytical Instruments 5 1 5 Maintenance Model 3020 Display Preamp SEKR Teledyne Analytical Er H KKH EE ET e Door Subassembly Cross Section Box Subassembly Gas Connector Panel not shown Customer Interface Panel Electrical Connector Panel Gas Control Valves CV Option Only Figure 5 1 Major Internal Components To swing open the cover panel remove all screws 5 3 Cell Replacement The Micro Fuel Cell is a sealed electrochemical transducer with no electrolyte to change or electrodes to clean When the cell reaches
54. ops in the sample path are insignificant at these flow rates This insures that the cell operates at atmospheric pressure At very high flow rates off scale of flow meter pressure drops other than the restriction device could become significant and resultin pressurizing the cell Example 2 3020T is configured for vacuum service as follows un marked restrictor is placed in the sample vent port The down stream end of the restrictor is then connected to a vacuum pump and by pass valve The by pass valve is adjusted to provide a flow rate of 1 SLPM The sample pressure between the pump and the restrictor will be approximately 7 inches of mercury while the pressure in the balance of the sample system including the cell will be approximately at atmospheric pressure provided the sample flow into the analyzer is not blocked A 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix BY PASS Toimprove the system response a by pass can be added to increase the sample flow rate to the analyzer by a factor often A by pass provides a sample flow path around the analyzer of 2 18 typically CALIBRATION GAS 3000 series analyzer requirements for units with Auto Cal options The customer must supply acontrol valves orrestrictors forany SPAN or ZERO gas source whichis attached to the Auto Cal ports The valve should be adjusted to the same flow rate as the sample gas When restrictors are used the g
55. p end of the cell is a diffusion membrane of Teflon whose thickness 15 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 available 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 sensing mem brane 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 electrolyte 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 2H 0 4e gt 40H cathode Four electrons combine with one oxygen molecule in the presence of water f
56. r Maintenance 5 Table 5 1 Self Test Failure Codes Power 0 OK 1 5 V Failure 2 15 V Failure 3 Both Failed Analog 0 OK 1 DAC A 0 1 V Concentration 2 DAC B 0 1 V Range ID 3 Both Failed Preamp 0 OK 1 Zero too high 2 Amplifier output doesn t match test input 3 Both Failed Teledyne Analytical Instruments 5 9 5 Maintenance Model 3020 5 10 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix Appendix A 1 Specifications Packaging Explosion proof Bulkhead mount Sensor L 2C trace analysis Micro Fuel Cell Cell Block 316 stainless steel Ranges Three user definable ranges from 0 10 ppm to 0 250 000 ppm plus air calibration range of 0 250 000 ppm 25 Autoranging with range ID output Sample System Flow indicator visible from front of unit Positive pressure service Vacuum service optional Auto Cal Auto Zero Available with op tional electrically operated valves Alarms system failure alarm contact to detect power failure Two adjustable concentration threshold alarms with fully programmable setpoints Diagnostics Start up or on demand comprehensive self testing function initiated by keyboard or remote command Displays 2 line by 20 alphanumeric VFD screen and one 5 digit LED display Digital Interface Full duplex RS 232 communications port Power Universal power supply 115 or 230 V ac at 50 or 60 Hz Teledyne Ana
57. r 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 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 instrumenta tion related to it The safety of personnel is ultimately the responsibility of those who control process conditions While thi
58. rational Theory 2 1 Introduction The analyzer 18 composed of three subsystems 1 Micro Fuel Cell Sensor 2 SampleSystem 3 Electronic Signal Processing Display and Control The sample system is designed to accept the sample gas and transport it through the analyzer without contaminating or altering the sample prior to analysis The Micro Fuel Cell is an electrochemical galvanic device that translates the amount of oxygen present in the sample into an electrical current The electronic signal processing display and control subsystem simplifies operation of the analyzer and accurately processes the sampled data The microprocessor controls all signal processing input output and display functions for the analyzer 2 2 Micro Fuel Cell Sensor 2 2 1 Principles of Operation The oxygen sensor used in the Model 3020T series is a Micro Fuel Cell designed and manufactured by Analytical Instruments It is a sealed plastic disposable electrochemical transducer The active components of the Micro Fuel Cell are a cathode an anode and the 15 aqueous KOH electrolyte in which they are immersed The cell converts the energy from a chemical reaction into an electrical 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 Cel
59. re d here Figure 3 4 Primary Input Power Connections 3 3 2 Fuse Installation The fuse holders accept 5 x 20 mm 1 6 A T type slow blow fuses Fuses are not installed at the factory Be sure to install the proper fuse as part of installation See Fuse Replacement in chapter 5 maintenance 3 3 3 Analog Outputs There are eight DC output signal connectors on the ANALOG OUT PUTS connector block There are two connectors per output with the polar ity noted See Figure 3 5 3 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 ANALOG OUTPUTS Negative min SSS ground Turn cw to hold ews loosen wire EIL O 1V OyP O 1V OyP 4 20mA 4 4 2 RANGE ID RANGE ID Yo Figure 3 5 Analog Output Connections The outputs are 0 1 V of Range Voltage rises linearly with increasing oxygen from 0 V at 0 ppm to 1 V at full scale ppm Full scale 10046 of programmable range 0 1 V dc Range ID 0 25 V Low Range 0 5 V Medium Range 0 75 V High Range 1 V Air Cal Range 4 20 mA dc Range Current increases linearly with increasing oxygen from 4 mA at 0 ppm to 20 mA at full scale ppm Full scale 2 10046 of programmable range 4 20 mA dc Range ID 8 mA Low Range 12 mA Medium Range 16 mA High Range 20 mA Air Cal Range Examples The analog outpu
60. rom the electrolyte to produce four hydroxy ions When the oxygen is reduced at the cathode lead is simultaneously oxidized at the anode by the following HALF REACTION Pb 20H 2 Pb 2e anode 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 propor tional to the amount of oxygen reaching the cathode It is measured and used to determine the oxygen concentration in the gas mixture Teledyne Analytical Instruments 2 3 2 Operational Theory Model 3020T The overall reaction for the fuel cell is the SUM of the half reactions above or 2Pb 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 no current is generated 2 2 4 The Effect of Pressure In order to state the amount of oxygen present in the sample in parts per million or a percentage of the gas mixture it is necessary that the sample diffuse into the cell under constant pressure If th
61. s 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 redun dancy 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 manufactur er or its agents is to be construed as a warranty of adequate safety control under the user s process conditions Teledyne Analytical Instruments Trace Oxygen Analyzer Specific Model Information The instrument for which this manual was supplied may incorporate or more options not supplied in the standard instrument Commonly available options are listed below with check boxes Any that are incorporated in the instrumen
62. s on Restrictors Pressures amp Flow A 4 A 5 Material Safety Data Sheet vi 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 Introduction 1 1 Overview The Teledyne Analytical Instruments Model 3020T Trace Oxygen Analyzer is a versatile microprocessor based instrument for detecting oxygen at the parts per million ppm level in a variety of gases This manual covers the Model 3020T trace oxygen explosion proof bulkhead mount units only 1 2 Typical Applications A few typical applications of the Model 3020T are Monitoring inert gas blanketing e Air separation and liquefaction e Chemical reaction monitoring e Semiconductor manufacturing e Petrochemical process control Quality assurance e Gasanalysis certification 1 3 Main Features of the Analyzer The Model 3020T Trace Oxygen Analyzer is sophisticated yet simple to use The main features of the analyzer include A2 line alphanumeric display screen driven by microprocessor electronics that continuously prompts and informs the operator e High resolution accurate readings of oxygen content from low ppm levels through 25 Large bright meter readout e Stainless steel cell block Teledyne Analytical Instruments 1 1 1 Introduction Model 3020 3020 3020 3020 3020T G 3020T H 3020 Advanced Micro Fuel Cell redesigned for trace analysis has expected life of one year V
63. s to be latching In latching mode once the alarm or alarms trigger they will remain in the alarm mode even if process conditions revert back 4 14 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 to non alarm conditions This mode requires an alarm to be recognized before it can be reset In the non latching mode the alarm status will terminate when process conditions revert to non alarm conditions 4 Are either of the alarms to be defeated The defeat alarm mode is incorporated into the alarm circuit so that maintenance can be performed under conditions which would normally activate the alarms The defeat function can also be used to reset a latched alarm See procedures below If you are using password protection you will need to enter your password to access the alarm functions Follow the instructions in section 4 4 to enter your password Once you have clearance to proceed ENTER the ALARM function AL 1 1 2 Choose Alarm Use the DOWN UP control to blink your choice of alarm AL 1 or AL 2 Then ENTER to move to the next screen AL 1 1000 ppm Dft N Fs N Ltch N Five parameters can be changed on this screen e Value of the alarm setpoint AL 1 ppm oxygen e Out of range direction HI or LO Defeated Yes No Dft Y N Failsafe Yes No Fs Y N e Latching Yes No Ltch Y N e define the setpoint use ENTER to blink AL 1 Then use the DOWN UP control to change t
64. se DOWN UP to set a start time value and ENTER To turn ON the Span and or Zero cycles to activate AUTO CAL Scroll to Auto Ca 7 and ENTER it again Span OFF Nxt Od Oh Zero OFF Nxt Od Oh When the Span Zero values screen appears use the scroll DOWN to blink the OF F ON field of the SPAN or ZERO function Use DOWN UP to set the OF F ON field to ON You can now turn these fields ON because there is anonzero span interval defined 4 4 The PWD Password Function Security can be established by choosing a 5 digit password from the standard ASCII character set If you decide NOT to employ password security use the default password TETAI This password will be displayed automatically by the microprocessor The operator just ENTERS it to be allowed total access to the instrument s features Teledyne Analytical Instruments 4 5 4 Operation Model 3020 Once a unique password is assigned and activated the operator MUST enter the UNIQUE password to gain access to any of the set up functions except to enter the password However the instrument will continue to analyze sample gas and report on alarm conditions without entering the password Only one password can be defined e After a password is assigned the operator must log out to activate it Until then anyone can continue to operate the instrument without entering the new password e To defeat the security after a unique password is activated the password
65. t ESC gt No ESCAPE to move on or proceed as in Changing the Password below 4 4 2 Installing or Changing the Password If you want to install a password or change an existing password Proceed as above in Entering the Password until you are given the opportu nity to change the password Change Password lt ENT gt Yes lt 5 gt ENTER to change the password to change either the default TETAI or the previously assigned password or ESCAPE to keep the existing pass word and move on If you choose ENTER to change the password the password assign ment screen appears TETAI lt ENT gt To Proceed or lt gt Enter the password using ENTER to scroll through the existing pass word letters and DOWN UP to change the letters to the new password The full set of 94 characters available for password use shown the table below Characters Available for Password Definition D F G H J K L M N 0 P Q R 5 U W X Y Z in Y 4 a b f g h 1 J k m n 0 4 r t u W X y 7 E Ji D 4 0 4 2 3 4 5 6 7 8 9 lt gt When you have finished typing the new password the last ENTER enters it A verification screen appears The screen will prompt you to retype your password Analytical Instruments 4 7 4 Operation Model 3020 Retype PWD To Verify Wait a moment for t
66. t for which this manual was supplied are indicated by acheck markin the box Instrument Serial Number The instrument with the above serial number has the following Options LI 3020T C 3020 D 3020T G 3020 1 3020T I L Cell Class Three gas inputs for sample zero and span gases with three solenoid actuated gas flow control valves built in Valves are automatically synchronized to the analyzer s electronic control sequences Built in flame arresters for Groups C and D service Built in flame arresters for Groups C and D service plus gas control valves as in C option above Built in flame arresters for Group B hydrogen service Built in flame arresters for Group B hydrogen service plus gas control valves as in C option above L 19 Rack Mount The 19 Relay Rack Mount units are available with either one or two series 3000 analyzer Control Units installed in a standard 19 panel and ready to mount in a standard rack See Appendix for details L 2C standard Enter Class Designation See Part II Chapter 2 and or any addendum that may be attached to this manual for cell specifications 9 Teledyne Analytical Instruments Model 3020 1 Table of Contents Introduction HOV 1 1 1 2 Typical Applications 1 1 1 3 Main Features of the Analyzer
67. t signal has a voltage which depends on the oxygen concentration AND the currently activated analysis range To relate the signal output to the actual concentration it is necessary to know what range the instrument is currently on especially when the analyzer is in the autoranging mode The signal output for concentration is linear over the currently selected analysis range For example if the analyzer is set on a range that was defined as 0 100 ppm O then the output would be as shown in Table 3 1 Teledyne Analytical Instruments 3 5 3 Installation Model 3020T Table 3 1 Analog Concentration Output Example Voltage Signal Current Signal ppm O Output V dc Output mA dc 0 0 0 4 0 10 0 1 5 6 20 0 2 2 2 30 0 3 8 8 40 0 4 10 4 50 0 5 12 0 60 0 6 13 6 70 0 7 15 2 80 0 8 16 8 90 0 9 18 4 100 1 0 20 0 To provide an indication of the range a second pair of analog output terminals are used They generate a steady preset voltage or current when using the current outputs to represent a particular range Table 3 2 gives the range ID output for each analysis range Table 3 2 Analog Range ID Output Example Range Voltage V Current mA LO 0 25 8 MED 0 50 12 HI 0 75 16 CAL 0 25 1 00 20 3 3 4 Alarm Relays There are three alarm circuit connectors on the alarm relays block under RELAY OUTPUTS for making connections to internal alarm relay contacts Each provides a set of Form C contacts for each type
68. the end of its useful life itis replaced The spent fuel cell should be discarded in accor dance with to all applicable safety and environmental regulations This section describes fuel cell care as well as when and how to replace it The Class L 2C Micro Fuel Cell is used in the standard Model 3020T If any other cell is supplied with your instrument check the front of this manual for any addenda applying to your special model 5 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 5 3 1 Storing and Handling Replacement Cells To have a replacement cell available when it is needed it is recom mended that one spare cell be purchased 9 10 months after commissioning the 3020T or shortly before the end of the cell s one year warranty period CAUTION Do not stockpile cells The warranty period starts on the day of shipment The spare cell should be carefully stored in an area that is not subject to large variations in ambient temperature 75 F nominal or to rough handling WARNING THE SENSOR USED IN THE MODEL 3020T TRACE OXYGEN ANALYZER USES ELECTROLYTES WHICH CONTAIN TOXIC SUBSTANCES MAINLY LEAD AND POTASSIUM HYDROXIDE THAT CAN BE 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
69. tions are available in combination 1 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 1 5 Operator Interface controls displays on the standard 3020T are accessible from outside the housing The instrument has two simple operator controls digital meter an alphanumeric display and a sample flowmeter give the operator constant feedback from the instrument See Figure 1 1 controls are described briefly here and in greater detail in chapter 4 Through Side Port ALARM OUTPUTS HHHHH r DIGITAL METER CONCENTRATION VFD SCREEN DIGTAL oe SPAN ZE CAL SONTAG RANGE ID CONTACTS RS 232 J AC POWER 2 Through Side Port Soro Through Side Port 115 230 V DOWN UP SOLENOID RETURN CONTROL ANALOG OUTPUTS REMOTE SENSOR NET WORK Through Side Port ESCAPE ENTER CONTROL 1 FLOWMETER SAMPLE IN mm SPAN IN ZERO IN EXHAUST OUT Figure 1 1 Model 3020T Controls Indicators and Connectors Se Teledyne Analytical Instruments 1 3 1 Introduction Model 3020 1 5 1 UP DOWN Switch Functions The UP DOWN switch is used to select the function to be performed Choose UP or DOWN to scroll through the following list of eleven functions e Auto Cal Setup an automatic calibration sequence e PWD Install a password to protect your analyzer setup e Logout Locks Setup Mode e Version Displays model and version of analyzer S
70. truments internal electronics The flame arrestors when supplied are installed in the Gas Connector Panel Span In gt gt lt Components in the s E v the C option intern only and are not sho Zero In gt gt lt 1 diagram abov Sample In gt gt lt E CH oeno alves In vacuum service the SC restrictor should b In normal service the placed here restrictor should b CN placed here LD Exhaust DA Restrictor Figure 2 4 Flow Diagram 2 4 Electronics and Signal Processing The Model 3020T Trace Oxygen Analyzer uses an 8031 microcontrol ler with 32 kB of RAM and 128 kB of ROM to control all signal processing input output and display functions for the analyzer System power is sup plied from a universal power supply module designed to be compatible with most international power sources See chapter 5 Maintenance for the location of the power supply and the main electronic PC boards The signal processing electronics including the microprocessor analog to digital and digital to analog converters are located on the motherboard at the bottom of the case The preamplifier board is mounted on top of the motherboard as shown in the figure These boards are accessible after re moving the access panel Figure 2 5 is a block diagram of the Analyzer electronics 2 6 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 Current Second to Voltage Ampli
71. tubing Notice that the two 1 3 4 long 1 4 diameter tubing are restrictors It has an open end and a closed end with a small circular orifice The restrictor without the blue sticker is for ow pressure and vacuum service For high pressure 2 to 50 psig applica tions use the restrictor that has a blue sticker on the body For pressurized service use the restrictor without the blue dot and union from the restrictor kit and attach it to the Sample In port The small circular orifice should face away from the back of the unit against the direction of gas flow Use the restrictor without the blue dot sticker in the same manner for low pressure applications less than 5 psig For vacuum service 5 10 in Hg use the restrictor without the blue dot sticker and union but attach it to the Exhaust Out port The small circular orifice should face toward the back of the unit against the direction of gas flow Remove the blue sticker from the restrictor before using WARNING Operating the unit without restrictors can cause damage to t the micro fuel cell Figure 3 9 is an illustration of the Gas Connector Panel Optional gas connections are shown in a shaded block The unit is manufactured with 4inch tube fittings only Adapters must be used for metric tubing At least 6 mm is recommended For safe connection 1 Insert the tube into the tube fitting and finger tighten the nut until the tubing cannot be rotated freely by h
72. u into the next field to continue programming If the screen is completed ENTER takes you to the next screen in the process or if the process is completed ENTER takes you back to the ANALYZE screen 4 2 2 2 ESCAPE If you do not wish to continue a function you can abort the session with a turn and release toward ESCAPE Escaping a function takes the analyzer back to the previous screen or to the ANALYZE Function depend ing on the function escaped 4 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 4 3 The AUTO CAL Function When proper automatic valving 1s connected see chapter 3 installa tion the Analyzer can cycle itself through a sequence of steps that automati cally zero and span the instrument Note If you require highly accurate AUTO CAL timing use external AUTO CAL control where possible The internal clock in the Model 3020T is accurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day To setup an AUTO CAL cycle Scroll to AUTO CAL and ENTER A new screen for Span Zero set appears Span OFF Nxt Od Oh Zero OFF Nxt Od Oh If SPAN or ZERO is not between the arrows scroll with DOWN UP control to SPAN or ZERO then ENTER You won t be able to set OFF to ON if a zero interval is entered Span Every or Zero Every screen appears Span Every 0 Start 0 h from now Use DOWN UP control to set an interval value and ENTER Then u
73. y external equipment that instrument is being calibrated and readings are not monitoring sample e Range ID Contacts Four separate dedicated range relay contacts Low Medium High Cal e Network I O Serial digital communications for local network access For future expansion Notimplemented at this printing 1 7 2 Gas Connector Panel The gas connector panel shown in Figure 1 3 contains the gas con nections for external inlets and outlets Those that are optional are shown shaded in the figure The connectors are described briefly here and in detail in the nstallation chapter of this manual FLOV 1 4 TUBE CONN SAMPLE IN 1 4 TUBE CONN SPAN IN 1 4 TUBE CONN ZERO IN EXHAUST 1 4 TUBE CONN Figure 1 3 Model 3020T Gas Connector Panel e Gas Inlet and Outlet One inlet must be externally valved and one exhaust out Teledyne Analytical Instruments 1 7 1 Introduction Model 3020 Optional e Calibration Gas Ports Separate fittings for zero span and sample gas input plus internal valves for automatically switching the gases in sync with the 3020 electronics Note If you require highly accurate Auto Cal timing use external Auto Cal control where possible The internal clock in the Model 3020T is accurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day 1 8 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 Ope

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