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Teledyne 3010MB Oxygen Equipment User Manual
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1. PT Teledyne Analytical Instruments Part 3 3 3 Installation Model 3010MB Primary Input Power The universal power supply requires a 100 240V ac 50 60 Hz power source 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 100 240V 50 60Hz a Hot Ground Neutral Turn cw to hold ccw to loosen wire Insert wire here En o Figure 3 4 Primary Input Power Connections Fuse Installation The fuse holders accept 5 x 20 mm 1 0 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 Analog Outputs There are eight DC output signal connectors on the ANALOG OUTPUTS terminal block There are two connectors per output with the polarity noted See Figure 3 5 The outputs are 0 1 V de of Range Voltage rises linearly with increasing oxygen from OVat0 to 1 V at 100 Full scale 100 programmedrange 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 3 4 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit 4 20 mA dc Range M Option Current increases linearly wi
2. This equipment is sold subject to the mutual agreement that it is warranted by us free from defects of material and of construction and that our liability shall be limited to replacing or repairing at our factory without charge except for transportation or at customer plant at our 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 th
3. OPERATING INSTRUCTIONS Model 3010MB Percent Paramagnetic Oxygen Analyzer Bulkhead Mount Control Unit PN D 71385 Bulkhead Mount Analysis Unit PN D 71394 ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE SERVICING BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR MANAGER CC QU HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING SYSTEM PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND OR SERVICING BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR MANAGER P N xxxxxx 12 21 99 ECO 99 0000 Teledyne Analytical Instruments Model 3010MB Copyright O 1999 Teledyne Analytical Instruments All Rights Reserved No part of this manual may be reproduced transmitted transcribed stored in a retrieval system or translated into any other language or computer language in whole or in part in any form or by any means whether it be electronic mechanical magnetic optical manual or otherwise without the prior written consent of Teledyne Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Warranty
4. A 4 4 Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Appendix A 5 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 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 have trouble zeroing you may need to skip to section 4 8 1 3 Cell Failure 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 JHHHE Zero Slope HHHF ppm s 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 such as 1 Left O Left These are steps
5. recognized before it can be reset In the nonlatching mode the alarm status will terminate when process conditions revert to no 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 3 3 to enter your password Once you have clearance to proceed enter the Alarm function Press the A arm button on the front panel to enter the A arm function Make sure that AL 1 is blinking Teledyne Analytical Instruments Part i 4 17 4 Operation Model 3010MB AL 1 AL 2 Choose Alarm Set up alarm 1 by moving the blinking over to AL 1 using the lt gt arrow keys Then press Enterto move to the next screen AL 1 1000 ppm HI Dft N Fs N Ltch N Five parameters can be changed on this screen e Value of the alarm setpoint AL 1 ppm or oxygen e Out of range direction HI or LO e Defeated Dft Y N Yes No Failsafe Fs Y N Yes No e Latching Ltch Y N Yes No e To define the setpoint use the lt gt arrow keys to move the blinking over to AL 1 Then use the AV arrow keys to change the number Holding down the key speeds up the
6. 24 Water H O 0 02 Hydrogen bromide HBr 0 61 Xenon Xe 0 95 With gas mixtures the components are weighted according to their proporational volumes The cross interference with a gas mixture can be determined in advance if the concentration of the individual background gases is known 1 4 Example Cross sensitivity calculation for a gas mixture The gas to be measured consists of 10 CO 40 of N and 50 of Ar Co 0 27 x 10 0 027 Ar 0 22x50 0 11 TOTAL CROSS INTERFERENCE 0 137 Calculation of the zero value 0 0 Cross Interference Value Zero Point Value 0 0 137 0 137 0 Part Il 4 Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Maintenance 2 Maintenance 2 1 Routine Maintenance Aside from normal cleaning and checking for leaks at the gas connec tions routine maintenance is limited to replacing Paramagnetic Sensor and fuses and recalibration For recalibration see Section 4 4 The Zero and Span Functions WARNING SEE WARNINGS ON TITLE PAGE OF THIS MANUAL 2 2 Major Internal Components The 3010M contains the following major internal components e Paramagnetic Sensor 2 3 Sensor Replacement The Paramagnetic Sensor is maintenance free and has a long life Should the sensor fail contact the factory for service and replacement 2 4 Output Goes Negative If during operation of the instrument gas pressure exceeds 20 psig the output of the s
7. 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 6 1 Setting the Analog Output Ranges To set the ranges enter the range function mode by pressing the Range button on the front panel L HHHE M H4HFHF H 4HHHFHF Mode AUTO Use the lt gt arrow keys to blink the range to be set low L medium M or high H Use the AV arrow keys to enter the upper value of the range all ranges begin at 0 ppm Repeat for each range you want to set Press Enterto accept the values and return to Analyze mode See note below Note The ranges must be increasing from low to high for example if range 1 is set as 0 10 and range 2 is set as 0 100 range 3 cannot be set as 0 50 since it is lower than range 2 gt Teledyne Analytical Instruments Part I 4 19 4 Operation Model 3010MB 4 6 2 Fixed Range Analysis The autoranging mode of the instrument can be overridden forcing the analyzer DC outputs to stay
8. Slow Blow fuses The fuses are located inside the main housing on the Electrical Connector Panel as shown in Figure 5 3 To replace a fuse 1 Disconnect the Unit from its power source 2 Place a 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 cap and fuse as shown in Figure 5 1 Teledyne Analytical Instruments Part 5 1 5 Maintenance Model 3010MB Percent Paramagnetic Oxygen Analyzer 0 9A MAX USE 250 V 1 0 AT FUSE A A CAUTIO 1 RISK OF ELECTRIC 1 DO NOT OPEN NO USER SERVICEABLE PARTS INSIC SERVICE ONLY BY QUALIFIED PERSO a o Sa us a N Figure 5 1 Removing Fuse Block Cap and Fuse from Housing 2 Replace fuse by reversing process in step 1 5 2 System Self Diagnostic Test 1 Press the System button to enter the system mode 2 Use the lt gt arrow keys to move to More and press Enter 3 Use the lt gt arrow keys to move to Self Test and press Enter The following failure codes apply Table 5 1 Self Test Failure Codes Power 0 OK 1 5 V Failure 2 15 V Failures 3 Both Failed Analog 0 OK 1 DAC A 0 1 V Concentration 2 DAC B 0 1 V Range ID 3 Both Failed 5 2 Part Teledyne Analytical Instruments Part I Control Unit Maintenance 5 Preamp 0 OK 1 Zero too high 2 Amplifier output doesn t match test input 3 Both Failed 5 3 Major I
9. fully disconnect power from the instrument When chassis is exposed or when access door is open and power cable is connected use extra care to avoid contact with live electrical circuits Access Door For access to the electronics and interface panel the front panel swings open when the latch in the upper right corner of the panel is pressed all the way in with a narrow gauge tool Accessing the main circuit board and other electronics requires unfastening the rear panel screws and sliding the unit out of the case 1 3 Recognizing Difference Between LCD 8 VFD LCD has GREEN background with BLACK characters VFD has DARK background with GREEN characters In the case of VFD NO CONTRAST ADJUSTMENT IS NEEDED A Teledyne Analytical Instruments Part 1 3 1 Introduction Model 3010MB 1 4 Control Unit Interface Panel The Control Unit interface panel shown in Figure 1 2 contains the electrical terminal blocks for external inputs and outputs The input output functions are described briefly here and in detail in the Installation chapter of this manual AN Teledyne Analytical Instruments DIGITAL INPUL el al Dea 2 ue DEN Da S ne LAE Dea a BE SE AO DE o 2 Eg DE o pal lo 2 56 e CONTACT SO 00009000 SOs DO 11 DERE Geo FD SI alz a a4ls
10. in a single predetermined range To switch from autoranging to fixed range analysis enter the range function by pressing the Range button on the front panel Use the lt gt arrow keys to move the blinking over AUTO Use the AV arrow keys 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 LEE M H4HFHF H dHHHHF gt Mode FX LO or L HHHE M HHHF H dHHHHE Mode FX MED or L HHHE M H4HFHHF H dHHHHE Mode FX HI Press Escape to re enter the Analyze mode using the fixed range NOTE When performing analysis on a fixed range if the oxygen concentration rises above the upper limit or default value as established by the operator for that particular range the output saturates at 1 V dc or 20 mA However the digital readout and the RS 232 output continue to read the true value of the oxygen concentration regardless of the analog output range 4 7 The Analyze Function When the Analyze function is active the 3010MB is monitoring the sample gas currently flowing in the Analysis Unit cell block All undefeated alarms are ready to activate should their respective setpoints be crossed Press the Analyze button to put the analyzer in the Analyze mode Normally all of the functions automatically switch back to the Analyze function when they have completed their assigned operations Pressing the Escape button in many cases also switches the a
11. mixture of oxygen and nitrogen and the sample gas consists mainly of other gases with considerable magnetic susceptibility In this case the reading shows a measured value even if the sample gas contains no Oxygen It is actually displaying the cross sensitivity to another gas The following table shows the cross sensitivity of some gases when changing from pure nitrogen to 100 of one of the gases listed A Teledyne Analytical Instruments Part Il 1 3 1 Operational Theory Model 3010M Gas Cross Gas Cross Sensitivity Sensitivity in vol in vol Acetylene C H 0 24 Hydrogen chloride HCI 0 30 Allene C H 0 44 Hydrogen fluoride HF 0 10 Ammonia NH 0 26 Hydrogen iodide HI 1 10 Argon Ar 0 22 Hydrogen sulphide H S 0 39 Bromine Br 1 30 lodine 2 40 1 2 Butadiene C H 0 49 Isobutane C H 1 11 1 3 Butadiene C H 0 49 Isopantane C H 1 49 n ButaneC H 1 11 Krypton Kr 0 51 Butane C4H8 085 Laughing gas N O 0 20 cis 2 Butane C H 0 89 Methane CH 0 20 trans 2 Butane C H 0 92 Neon Ne 0 13 Carbon dioxide CO 0 27 NeopentaneC H 1 49 Carbon monoxide CO 0 06 Nitric acid HNO 0 43 Chlorine Cl 0 77 NitrogendioxideNO 28 00 Cyclo hexane C H 1 56 Nitrous oxide NO 40 00 Ethane C H 0 43 n OctaneC H 2 50 Ethylene C H 0 26 n PentaneC H 1 45 Helium He 0 30 Propane C H 0 86 n Heptane C H 2 10 Propylene C H 0 55 n Hexane C H 1 70 Vinyl chloride 0 63 Hydrogen H 0
12. move the blinking to the Self Test function 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 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 the initial System screen 4 3 6 Version Screen Move the lt gt arrow key to More and press Enter With Version blinking press Enter The screen displays the manufacturer model and software version information 4 3 7 Showing Negative Oxygen Readings For software version 1 4 4 or later the instrument only displays oxygen readings that are positive or zero The instrument can be reconfigured to show negative readings if sensor output drifts below zero This situation may arise after the instrument has been zeroed as time progresses the sensor may drift below the zero calibration setpoint To show negative oxygen readings on the display Press the System key 4 10 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit TRAK HLD Auto Cal PSWD Logout More Use the Righ
13. B is accurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day A Teledyne Analytical Instruments Part 1 5 1 Introduction Model 3010MB 1 6 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part Control Unit Operational Theory 2 1 Introduction The Model 3010MB Oxygen Analyzer Control Unit uses an 80C31 microcontroller with 32 kB of RAM and 128 kB of ROM to control all signal processing input output and display functions for the Model 3010MB analyzer The sample system and Paramagnetic sensor are covered in Part II Analysis Unit in this manual System power is supplied from a universal power supply module designed to be compatible with any international power source 2 2 Electronics and Signal Processing All of the Analyzer electronics are located on Printed Circuit Board PCB assemblies inside the Control Unit chassis The PCB locations are illustrated in section 5 Maintenance Refer to Figure 2 1 Block Diagram of the 3010MB CU Electronics In the presence of oxygen the sensor in the Analysis Unit generates a current A current to voltage amplifier in the Control Unit converts this current to a voltage The second stage amplifier amplifies the voltage The output from the second stage amplifier is sent to an 18 bit analog to digital converter con trolled by the microprocessor The digital concentration signal along with input from
14. Maintenance 2 1 2 2 Major Internal Components 2 1 2 3 Sensor Replacement oococcnocccccncccnnonocccccnnncnnnnnannncnnnnnnnns 2 1 2 4 Output Goes Negative ssssnneeseeennneeseerrrnesserrrrrneeee 2 1 ii Part Il 4 Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Operational Theory 1 Operational Theory 1 1 Introduction The analyzer is composed of three subsystems 1 Paramagnetic 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 Paramagnetic Sensor is an electromechanical device that translates the amount of oxygen present in the sample into an electrical signal 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 1 2 Precise Paramagnetic Sensor 1 2 1 Principles of Operation The heart of the 3010M is a paramagnetic type oxygen sensor that is maintanance free and has a long lifetime Oxygen has a very high magnetic sucseptibility compared to other gases and thus displays a particularly para magnetic behavior A small glass dumbbell filled with nitrogen and rotating on a taut platinum wire is suspended
15. N 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 Remote Probe Connector at end of section 3 3 With the C option the internal valves automati cally 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 Inputs to the Model 3010MB Analyzer the customer s controller must monitor the Cal Relay Contact 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 Ifthe 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 1 Test the 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 3 8 Part Teledyne Analytical I
16. Oxygen Analyzer Part l Control Unit CU Thermistor 1 Thermistor TARRA Sensor Signal 8 Block gis Sensor Signal 2 Sensor Return Sensor SURE Sensor Signal 1 Block Sensor Hot Sensor Signal 7 Figure 3 7 Remote Sensor Connector Pinouts 15V 15Vde Solenoid Valve 3 Sample In Sample return Solenoid Valve 4 15 Vdc sian a Solenoid Valve 9 E p Solenoid Valve 10 15 V de i i R Solenoid Valve 5 Zero In Zero return _ Solenoid Valve 6 2 15 V de Solenoid Valve n a Exhaust Exhaust return 7 Solenoid Valve n a Figure 3 8 Remote Solenoid Return Connector Pinouts The voltage from the solenoid outputs is nominally 0 V for the OFF and 15 V dc for the ON conditions The maximum combined 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 relays power amplifiers or other matching circuitry to provide the actual driving current Note that each individual line has a series FET with a nominal ON resistance of 5 ohms 9 ohms worst case This can limit the obtainable voltage depending on the load impedance applied See Figure 3 9 LOAD Figure 3 9 FET Series Resistance 47 Teledyne Analytical Instruments Part 3 11 3 Installation Model 3010MB 3 4 Test
17. Ranging ON Alarm Relays 1000 Defeated HI Not failsafe Not latching Span 000008 00 Auto every 0 days at 0 hours Zero Auto every 0 days at 0 hours If you choose not to use password protection the default password is automatically displayed on the password screen when you start up and you simply press Enter for access to all functions of the analyzer gt Teledyne Analytical Instruments Part 4 1 4 Operation Model 3010MB 4 2 Using the Data Entry and Function Buttons Data Entry Buttons The lt gt arrow buttons select options from the menu currently being displayed on the VFD screen The selected option blinks When the selected option includes a modifiable item the AV arrow buttons can be used to increment or decrement that modifiable item The Enter button is used to accept any new entries on the VFD screen The Escape button is used to abort any new entries on the VFD screen that are not yet accepted by use of the Enterbutton Figure 4 1 shows the hierarchy of functions available to the operator via the function buttons The six function buttons on the analyzer are e Analyze This is the normal operating mode The analyzer monitors the oxygen content of the sample displays the concentration of oxygen and warns of any alarm conditions e System The system function consists of six subfunctions that regulate the internal operations of the analyzer e Auto Cal setup e Password assignment e S
18. acking the Control Unit The analyzer is shipped with all the materials you need to install and prepare the system for operation Carefully unpack the Control Unit and inspect it for damage Immediately report any damage to the shipping agent 3 2 Mounting the Control Unit The Model 3010MB Control Unit is for indoor outdoor use in a general purpose area This Unit is NOT for any type of hazardous environments The standard model is designed for indoor outdoor mounting Figure 3 l is an illustration of a Model 3010MB standard Control Unit front panel and mounting brackets located two at the top and two at the bottom of the units frame 47 Teledyne Analytical Instruments Part 3 1 3 Installation Model 3010MB NPT Fitting supplied by customer AC POWER IN 50 60 HZ gt 3 4 NPT 100 240V ALARM ourrur 3 4 NPT DIGITAL INPUT SPAN ZERO CA CAL CONTACT RANGEL 4 n ID CONTACTS RS 23 NPT er CONDUCT M2 BEFORE CONDUCTING CONSULT WITH AUTHC SOLENOID RETUR ANALOG OUTPUTS REMOTE sensor f 1 NPT NET WORK Figure 3 1 Front Panel of the Model 3010MB Control Unit All operator controls are mounted on the inner control panel which is hinged on the left edge and doubles as a door to provide access to the inter nal components of the instrument The door will swing open when the button of the latch is pressed all the way in with a narrow gauge tool less than 0 18 inch wide such as a small hex wrench or screwdriver A
19. ally or manu ally Use the AV arrow keys to toggle between AUTO and MAN zero settling Stop when AUTO appears blinking on the display Zero Settling AUTO lt ENT gt To Begin Press Enter to begin zeroing HHH PPM Zero Slope HHHF ppm s 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 5 Left 4 Left and so fourth These are five steps in the zeroing process that the system must complete AFTER settling before it can go back to Analyze JHHHF PPM Zero 4 Left HHF ppm s The zeroing process will automatically conclude when the output is within the acceptable range for a good zero Then the analyzer automatically returns to the Analyze mode 4 12 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit 4 4 1 2 Manual Mode Zeroing Press Zero to enter the Zero function The screen that appears allows you to select between automatic or manual zero calibration Use the AV keys to toggle between AUTO and MAN zero settling Stop when MAN appears blinking on the display Zero Settling Man lt ENT gt To Begin Press Enter to begin the zero calibration After a fe
20. an lt UP gt Mod Use the AV arrow keys to enter the oxygen concentration mode Use the lt gt arrow keys to blink the digit you are going to modify Use the AV arrow keys again to change the value of the selected digit When you have finished typing in the concentration of the span gas you are using 209000 00 if you are using air press Enterto begin the Span calibration 4 14 Partl 4 Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit 1HHHE ppm Span Slope HHHF 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 4 2 2 Manual Mode Spanning Press Span 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 the AV keys to toggle between AUTO and MAN span settling Stop when MAN appears blinking on the display Press Enter to move to the next screen Press Enterto move to the next screen Calib Holding time Cal hold 5 min This menue allows the operator to set the time the analyzer should be held in the auto span mode It does not affect any
21. completes the information is stored in the microprocessor and the instrument automatically returns to the ANALYZE screen A 6 4 Teledyne Analytical Instruments
22. concen tration is above threshold or low actuates when concentration is below threshold e Can be configured as fail safe or non fail safe e Can be configured as latching or nonlatching e Can be configured out defeated Actuates when DC power supplied to circuits is unacceptable in one or more parameters Permanently configured as fail safe and latching Cannot be de feated Actuates if self test fails To reset a System Alarm during installation discon nect power to the instrument and then reconnect it Further detail can be found in chapter 4 section 4 5 Teledyne Analytical Instruments Part 3 7 3 Installation Model 3010MB 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 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 Remote Probe Connector at end of section 3 3 With the C option the internal valves automati cally operate synchronously Span Floating input 5 to 24 V input across the and terminals puts the analyzer into the SPA
23. e use of the instrument or its interface with the process being measured be properly trained in the process itself as well as all instrumen tation related to it The safety of personnel is ultimately the responsibility of those who control process conditions While this instrument may be able to provide early warning of imminent danger it has no control over process conditions and it can be misused In particular any alarm or control systems installed must be tested and understood both as to how they operate and as to how they can be defeated Any safeguards required such as locks labels or redundancy must be provided by the user or specifically requested of Teledyne at the time the order is placed Therefore the purchaser must be aware of the hazardous process conditions The purchaser is responsible for the training of personnel for providing hazard warning methods and instrumentation per the appropriate standards and for ensuring that hazard warning devices and instrumentation are maintained and operated properly Analytical Instruments the manufacturer of this instrument cannot accept responsibility for conditions beyond its knowledge and control No statement expressed or implied by this document or any information disseminated by the manufacturer or its agents is to be construed as a warranty of adequate safety control under the user s process conditions Teledyne Analytical Instruments Percent Paramagnetic Oxygen Anal
24. elf Testinitiation e Checking software version Logging out e Zero Used to set up a zero calibration e Span Used to set up a span calibration e Alarms Used to set the alarm setpoints and determine whether each alarm will be active or defeated HI or LO acting latching and or failsafe e Range Used to set up three analysis ranges that can be switched automatically with autoranging or used as individual fixed ranges Any function can be selected at any time by pressing the appropriate button unless password restrictions apply The order as presented in this manual is appropriate for an initial setup 4 2 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit SYSTE ANALYZE Perform Oxygen Analysis 0 the Sample TRAK HLD Set Instrument Span Perform Self Diagnostic Test ALARMS Set Instrument Zero Initiate Automatic Set Alarm Calibratio Setpoints Confrigure Mode of Alarm Set Password Operation Logout Show Negative Figure 4 1 Hierarchy of Functions and Subfunctions Each of these functions is described in greater detail in the following procedures The VFD screen text that accompanies each operation is repro duced at the appropriate point in the procedure ina Monospaced type style Pushbutton names are pr
25. ensor may reverse polarity readings on the display may go negative Ifthis happens Make sure analyzer is mounted in the upright position see chapter 3 Installation Turn power off by unplugging the instrument Turn gas pressure to less than 20 psig Turn power on again Return instrument to analyze mode 4 Teledyne Analytical Instruments Part II 2 1 2 Maintenance Model 3010M 2 2 Part Il T Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Appendix Appendix A 1 Specifications Packaging Sensor Ranges Sample System Alarms Diagnostics Response Time Displays Digital Interface Power Operating Temperature Accuracy 7 Teledyne Analytical Instruments Bulkhead mount Paramagnetic Sensor Three user definable ranges from 0 5 to 0 100 Autoranging with range ID output Positive pressure service Vacuum service optional Auto Cal Auto Zero Available with op tional electrically operated valves One system failure alarm contact to detect power failure Two adjustable concentration threshold alarms with fully programmable setpoints Start up or on demand self testing function 90 in 10 seconds or less 2 line by 20 alphanumeric VFD screen and one 5 digit LED display Full duplex RS 232 communications port Universal power supply 100 240 V ac at 50 or 60 Hz 70 Watts max 0 45 C 1 of full scale at constan
26. ent off By entering Logout you effectively log off the instrument leaving the system protected against use until the password is reentered To log out press the System button to enter the System function TRAK HLD Auto Cal PSWD Logout More Use the lt gt arrow keys to position the blinking over the Logout func tion and press Enterto Log out The screen will display the message Protected Until Password Reentered 4 3 5 System Self Diagnostic Test The Model 3010MB has a built in self diagnostic testing routine Pre programmed signals are sent through the power supply output board and sensor circuit The return signal 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 Note Remote Probe connector must be connected to the Analysis Unit or sensor circuit will not be properly checked The self diagnostics are run automatically by the analyzer whenever the instrument is turned on but the test can also be run by the operator at will To initiate a self diagnostic test during operation Teledyne Analytical Instruments Part 4 9 4 Operation Model 3010MB Press the System button to start the System function TRAK HLD Auto Cal PSWD Logout More Use the lt gt arrow keys to blink More then press Enter Version Self Test Use the lt gt arrow keys again to
27. enter the password using the lt gt arrow keys to scroll back and forth between letters and the AV arrow keys to change the letters to the proper password Press Enterto enter the password If the password is accepted the screen will indicate that the password restrictions have been removed and you have clearance to proceed PSWD Restrictions Removed In a few seconds you will be given the opportunity to change this password or keep it and go on Change Password lt ENT gt Yes lt ESC gt No Press Escape to move on or proceed as in Changing the Password below 4 3 3 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 When you are given the oppor tunity to change the password Change Password lt ENT gt Yes lt ESC gt No gt Teledyne Analytical Instruments Part 4 7 4 Operation Model 3010MB Press Enterto change the password either the default TETAI or the previously assigned password or press Escape to keep the existing pass word and move on If you chose Enterto change the password the password assignment screen appears TET AI lt ENT gt To Proceed or A A A A A lt ENT gt To Proceed Enter the password using the lt gt arrow keys to move back and forth between the existing password letters and the AV arrow keys to change the letters to the new password The full set of 94 characters a
28. er Alarms Setthe alarm setpoints and attributes e Range Setup the 3 user definable ranges for the instrument 1 2 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit Data Entry Keys Six touch sensitive membrane switches are used to input data to the instrument via the alphanumeric VFD display e Left amp Right Arrows Select between functions currently displayed on the VFD screen Up amp Down Arrows Increment or decrement values of functions currently displayed e Enter Moves VFD display on to the next screen in a series If none remains returns to the Analyze screen e Escape Moves VFD display back to the previous screen in a series If none remains returns to the Analyze screen Digital Meter Display The meter display is a LED device that produces large bright 7 segment numbers that are legible in any lighting It is accurate across all analysis ranges The MB model produce continuous readout from 0 1 through 0 100 Alphanumeric Interface Screen The backlit VFD screen is an easy to use interface between operator and analyzer It displays values options and messages that give the operator immediate feedback 1 0 Power Button The red O button switches the instrument power between ON and O a Keep Alive state In the O state the instrument s circuitry is operating but there are no displays or outputs CAUTION The power must be disconnected to
29. er the instrument can still be used for analysis or for initiating a self test without entering the password If you have decided not to employ password security use the default password TETAI This password will be displayed automatically by the microprocessor The operator just presses the Enter key to be allowed total access to the instrument s features NOTE If you use password security it is advisable to keep a copy of the password in a separate safe location 4 3 3 1 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 4 6 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit is in effect pressing the ENTER button will enter the default TETAI pass word for you Press System to enter the System mode TRAK HLD Auto Cal PSWD Logout More Use the lt gt arrow keys to scroll the blinking over to PSWD and press Enter to select the password function Either the default TBEAI password or AAAAA place holders for an existing password will appear on screen depending on whether or not a password has been previously installed TET AI Enter PWD Or A AAA A Enter PWD The screen prompts you to enter the current password If you are not using password protection press Enterto accept TETAI as the default password If a password has been previously installed
30. h or low alarms by the operator The alarm modes can be set as 4 16 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit latching or nonlatching and either failsafe or nonfailsafe 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 e 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 nonfailsafe operation the relay is energized in an alarm condition You can set either or both of the concentration alarms to operate in failsafe or nonfailsafe mode 3 Are either of the alarms 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 to no alarm conditions This mode requires an alarm to be
31. in an inhomogneous magnetic field This glass dumbbell is diamagnetic and tends to rotate out of the magnetic field The strength of the resulting torque determined by an susceptibility of the sample gas This torque is compensated for by a counter torque induced by an electrically charged platinum coil on the dumbbell The zero position of the dumbbell is controlled by means of an optical system consisting of a light source a mirror at the dumbbell axis and a pair of detectors The difference between the compensating currents required to bring the dumb 47 Teledyne Analytical Instruments Part Il 1 1 1 Operational Theory Model 3010M bell to the zero position in the presence of zero gas i e no O present or of sample gas is proportional to the partial pressure of oxygen in the sample gas The sensor enclosure is temperature controlled to 55 degrees centigrade to insure that the magnetic susceptibility of oxygen in the sample is not affected by the ambient temperature The measuring cell has a measuring volume of approximately 3 cm Sensor side view shown The Paramagnetic sensor enclosure holds not only the sensing elements butthe temperature controller electronics heating elements sensor electron ics and preamplifier The Electronics and heating elements require a separate power source from the rest of the 3020M capable of delivering 1 5 amps approximately at 24 volts dc The output of the senso
32. in the zeroing process that the system must complete AFTER settling before it can go back to ANALYZE 1HHHE Zero 1 Left HH ppm s The zeroing process will automatically conclude when the output is within the acceptable range for a good zero Then the analyzer automatically returns to the ANALYZE screen sx Teledyne Analytical Instruments A 5 Appendix Model 3010M 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 JHHHF Zero Slope HHHF ppm s NOTE lt 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
33. incrementing or decrementing Remember setpoint units are parts per million e To set the other parameters use the lt gt arrow keys to move the blinking over to the desired parameter Then use the AV arrow keys to change the parameter Once the parameters for alarm 1 have been set press Alarms again and repeat this procedure for alarm 2 AL 2 e Toreset a latched alarm go to Dft and then press either A two times or V two times Toggle it to Y and then back to N OR Go to Lich and then press either A two times or V two times Toggle it to N and back to Y 4 6 The Range Function The Range function allows the operator to program up to three concen tration ranges to correlate with the DC analog outputs If no ranges are defined by the user the instrument defaults to Range Limits Low 0 1 Med 0 5 High 0 10 4 18 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit The Model 3010MB 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 percent of range output and in the range
34. ing the System After The Control Unit and the Analysis Unit are both installed and interconnected and the system gas and electrical connections are complete the system is ready to test Before plugging either of the units into their respective power sources e Check the integrity and accuracy of the gas connections Make sure there are no leaks e Check the integrity and accuracy of all electrical connections Make sure there are no exposed conductors e Check that sample pressure is between 3 and 40 psig according to the requirements of your process 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 12 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit Operation 4 1 Introduction Once the analyzer has been installed configure it for your process To do this you can e Setsystem parameters e Specify a password if desired requiring operator to log in e Establish and start an automatic calibration cycle if desired e Calibrate the instrument e Define the three user selectable analysis ranges Then choose autoranging or select a fixed range of analysis as required e Set alarm setpoints and modes latching failsafe etc Before configuration these default values are in effect PARAMETER DEFAULT LO Range 100 MED Range 1000 HI Range 10 000 Auto
35. inted in Oblique type 4 3 The System Function The subfunctions of the System function are described below Specific procedures for their use follow the descriptions Auto Cal Used to define an automatic calibration sequence and or start an Auto Cal e PSWD Security can be established by choosing a 5 digit password PSWD from the standard ASCII character set See Installing or Changing a Password below for a table of ASCII characters available Once a unique password is assigned and gt Teledyne Analytical Instruments Part I 4 3 4 Operation Model 3010MB activated the operator MUST enter the UNIQUE password to gain access to set up functions which alter the instrument s operation such as setting the instrument span or zero setting adjusting the alarm setpoints or defining analysis ranges After a password is assigned the operator must log out to activate 1t Until then anyone can continue to operate the instrument without entering the new password Only one password can be defined Before a unique password is assigned the system assigns TETAI by default This allows access to anyone After a unique password is assigned to defeat the security the password must be changed back to TETAI e Logout Logging out prevents an unauthorized tampering with analyzer settings e More Select and enter More to get a new screen with additional subfunctions listed Self Test The instrument performs a self diagnostic tes
36. is status information in digital form updated every two seconds Status is reported in the following order 4 Teledyne Analytical Instruments Part 3 9 3 Installation Model 3010MB e The concentration in percent e The range is use HI lt MED lt LO e The span of the range 0 100 etc e Which alarm if any are disabled AL x DISABLED e Which alarms if any are tripped AL x ON Each status output is followed by a carriage return and line feed Three input functions using RS 232 have been implemented 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 3010MB Table 3 5 Required RS 232 Options Parameter Baud Byte Parity Stop Bits Message Interval Setting 2400 8 bits none 1 2 seconds Remote Sensor and Solenoid Valves The 3010MB is a single chassis instrument However the REMOTE SENSOR and SOLENOID RETURN connectors are provided for use with a remote sensor and or sampling system if desired See Figure 3 7 and 3 8 3 10 Part Teledyne Analytical Instruments Percent Paramagnetic
37. lelz a o DES DES DE 2 Da ray EL E s DER Dea Bas z o I Q Q El o 0 USE 250 V 1 0 Figure 1 2 Model 3010MB Rear Panel 1 4 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit Note e Power Connection e Analog Outputs Alarm Connections e RS 232 Port e Remote Probe e Remote Span Zero e Calibration Contact Range ID Contacts e Remote Probe Network I O AC power source 100 240VAC 50 60 Hz 0 1 V de concentration and 0 1 V de range ID Isolated 4 20 mA dc and 4 20 mA dc range ID 2 concentration alarms and 1 system alarm Serial digital concentration signal output and control input Provides all electrical interconnect to the Analysis Unit or Remote Probe Digital inputs allow external control of analyzer calibration To notify external equipment that instrument is being calibrated and readings are not monitoring sample Four separate dedicated range relay contacts Low Medium High Cal Interfaces with an Analysis Unit or Remote Probe external sensor sample system Serial digital communications for local network access For future expansion Not implemented at this printing If you require highly accurate Auto Cal timing use external Auto Cal control where possible The internal clock in the Model 3010M
38. llow 3 2 Part 47 Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit clearance for the door to open in a 90 degree arc of radius 11 75 inches See Figure 3 2 x x pE SL Le Figure 3 2 Required Front Door Clearance 3 3 Electrical Connections Figure 3 3 shows the Control Unit interface panel Connections for power communications and both digital and analog signal outputs are described in the following paragraphs Wire size and maximum length data appear in the Drawings at the back of this manual S 1 SO SOK NERE CO HE E oe DE reed SO 80006000 S00006000 SADO HE AEREAS CERRARSE ZEAE Fa 1 alala 4 s el7z 8 s i 2 100 240 V n SERE pra 50 60 Hz 900 SPO sooo ANA DEERE IN 6 HW oivor owor azmaor sonaor RANGE ID RaNGr RANGED RANGE Figure 3 3 Interface Panel of the Model 3010MB Control Unit For safe connections ensure that no uninsulated wire extends outside of the terminal blocks that are attached to Stripped wire ends must insert completely into terminal blocks No uninsulated wiring should be able to come in contact with fingers tools or clothing during normal operation
39. ls can be designed for a variety of hazardous environments Part II of this manual covers the 3010M Analysis Unit Typical Applications A few typical applications of the Model 3010MB are e Monitoring inert gas blanketing e Air separation and liquefaction e Chemical reaction monitoring e Semiconductor manufacturing e Petrochemical process control e Quality assurance e Gas analysis certification Teledyne Analytical Instruments V Model 3010MB vi Main Features of the Analyzer The Model 3010MB Percent Oxygen Analyzer is sophisticated yet simple to use The main features of the analyzer include A 2 line alphanumeric display screen driven by microprocessor electronics that continuously prompts and informs the operator High resolution accurate readings of oxygen content from low levels through 100 Large bright meter readout Stainless steel sample system Versatile analysis over a wide range of applications Microprocessor based electronics 8 bit CMOS microprocessor with 32 kB RAM and 128 kB ROM Three user definable output ranges from 0 5 through 0 100 allow best match to users process and equipment 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 de
40. mand with continuous power supply monitoring RS 232 serial digital port for use with a computer or other digital communication device Analog outputs for concentration and range identification 0 1 VDC standard and isolated 4 20 mADC Teledyne Analytical Instruments OPERATING INSTRUCTIONS Model 3010MB Oxygen Analyzer Part Control Unit NEMA 4 Bulkhead Mount Part Numbers D 71385 Teledyne Analytical Instruments Model 3010MB Percent Paramagnetic Oxygen Analyzer Table of Contents 1 Introduction 1 1 1 2 1 3 1 4 ONES Write tadas Control Unit Inner Control Panel eee eee eees Recognizing Difference Between LCD amp VFD Control Unit Interface Panel ro 2 Operational Theory 2 1 2 2 Introduction nnt rn rttr erreeeene Electronics and Signal Processing 3 Installation 3 1 3 2 3 3 Unpacking the Control UNit Mounting the Control Unit Electrical Connections lieti 3 4 Testing the System 4 Operation 4 1 Introdugtioni s i cana a ani 4 2 Using the Data Entry and Function Buttons 4 3 The System Function i 4 3 1 Tracking the O Readings during Calibration 4 3 2 Setting up an Auto Cal i 4 3 3 Password PIOLEGHON stlirrir ia 4 3 3 1 Entering the Password eeseeeeeeee
41. n Section 3 4 1 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 Analysis Unit SLPM flowmeter settles between 0 5 and 2 4 SLPM approximately 1 5 scfh PT Teledyne Analytical Instruments Part I 4 11 4 Operation Model 3010MB 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 sections 4 3 3 2 or 4 3 3 3 to enter your password Once you have gained clearance to proceed you can enter the Zero or Span function 4 4 1 Zero Cal The Zero button on the front panel is used to enter the zero calibration function Zero calibration can be performed in either the automatic or manual mode In the automatic mode an internal algorithm compares consecutive readings from the sensor to determine when the output is within the accept able 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 1s connected to the instrument If you get a CELL FAILURE message skip to section 4 4 1 3 4 4 1 1 Auto Mode Zeroing Press Zero to enter the zero function mode The screen allows you to select whether the zero calibration is to be performed automatic
42. nalyzer back to the Ana lyze function Alternatively you can press the Analyze button at any time to return to analyzing your sample 4 20 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit 4 8 Signal Output The standard Model 3010MB Percent Paramagnetic Oxygen Analyzer is equipped with two 0 1 V dc analog output terminals accessible on the interface panel one concentration and one range ID and two isolated 4 20 mA dc current outputs one concentration and one range ID See Rear Panel in chapter 3 Installation for illustration The signal output for concentration is linear over the currently selected analysis range For example if the analyzer is set on range that was defined as 0 10 O then the output would be Voltage Signal Current Signal ppm O Output V dc Output mA dc 0 0 0 4 0 1 0 1 5 6 2 0 2 F2 3 0 3 8 8 4 0 4 10 4 5 0 5 12 0 6 0 6 13 6 7 0 7 15 2 8 0 8 16 8 9 0 9 18 4 10 1 0 20 0 The analog output 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 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
43. nstruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit 4 When the CRC closes remove the span command When CRC opens again zero and span are done and the sample is being analyzed Note The Remote Probe connector paragraph 3 3 provides 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 3010MB automatically regulates the zero span and sample gas flow Range ID Relays Four dedicated RANGE ID CONTACT relays The first three ranges are assigned to relays in ascending order Low range is assigned 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 Network I 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 instrument 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 232 Pin 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 7 Request to Send CTS 8 Clear to Send RI 9 Ring Indicator The data sent
44. nternal Components The major components in the Control Unit are shown in Figure 5 3 Outer Door Inner Door Main PCB PreampPCB Display PCB Doors shown remove for clarity Electrical Connector Pane Box Subassembl Pad Gas Connector Panel not shown Figure 5 3 Control Unit Major Internal Components PT Teledyne Analytical Instruments Part 5 3 5 Maintenance Model 3010MB Percent Paramagnetic Oxygen Analyzer WARNING HAZARDOUS VOLTAGES EXIST ON CERTA1IN COMPONENTS INTERNALL Y WHICH MAY PERSIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED The 3010MB Control Units contain the following major components e Power Supply e Motherboard with Microprocessor RS 232 chip and Preamplifier PCB e Front Panel Display Board and Displays 5 digit LED meter 2 line 20 character alphanumeric VFD display See the drawings in the Drawings section in back of this manual for details 5 4 Part Teledyne Analytical Instruments OPERATING INSTRUCTIONS Model 3010M Oxygen Analyzer Part Il Analysis Unit Part Number D 71394 Teledyne Analytical Instruments Model 3010M Oxygen Analyzer Table of Contents 1 Operational Theory TED gt IMEOGUClONcasare ear 1 1 1 2 Precise Paramagnetic SenSsors eeren 1 1 1 2 1 Principles of Operation 1 1 1 3 Cross lntrface seria ti 1 3 2 Maintenance 2 1 Routine
45. ntroduction 1 1 Overview The Analytical Instruments Model 3010MB Analyzer Control Unit together with a 3010M Analysis Unit is a versatile microprocessor based instrument for detecting percent amounts of oxygen in a variety of gases Part I this part of this manual covers the Model 3010MB series Gen eral Purpose NEMA 4 Bulkhead mount Control Units The Analysis Unit is covered in Part II of this manual The Control Unit and Analysis Unit is for indoor outdoor use in a nonhazardous environment only 1 2 Control Unit Inner Control Panel The standard 3010MB Control Unit is housed in a rugged NEMA 4 metal case with all remote controls and displays accessible from the inner control panel See Figure 1 1 The inner control panel has a digital meter an alphanumeric display and thirteen buttons for operating the analyzer A Teledyne Analytical Instruments Part 1 1 1 Introduction Model 3010MB Outer Door Open Teledyne Analytical Instrument Viewing Window Outer Door Latch 3010MB Series Paramagnetic Oxygen Analyze Figure 1 1 Front of Unmounted Control Unit Function Keys Six touch sensitive membrane switches are used to change the specific function performed by the analyzer e Analyze Perform analysis for oxygen content of a sample gas e System Perform system related tasks described in detail in chapter 4 Operation e Span Span calibrate the analyzer e Zero Zero calibrate the analyz
46. r is roughly calibrated to be 0 to 1 volt DC for the the range of 0 to 100 02 The true calibration of the sensor is carried out by the microprocessor as described later in chap ter 4 The electrical interconnections to the sensor are done through a 15 pin D connector Some signals from the sensor are not connected They are only useful for troubleshooting by trained personnel as test points 1 2 Part Il 4 Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer rear view shown Pin out o I O LU R D 10 11 12 13 14 15 1 3 Operational Theory 1 Sensor 15Vdc test pin Not connected 15Vdc test pin Not connected Measuring ground Not used Preamplifier output 0 1 Vdc Not used 24 Vdc return power ground Collector of transistor switching heating element Not con nected Fault signal lt 0 Vde OK gt 4 6 Vdc Fault Not connected Not used Negative reference voltage Not connected Positive reference voltage Not connected Nominal temperature voltage signal Not connected Actual temperature voltage signal Not connected 24 Vdc power Cross Interference As mentioned previously the selectivity of the measuring system is based on the extraordinarily high magnetic susceptibility of Oxygen com pared to other gases In most cases the presence of other gases can be ig nored but significant errors can occur when the sensor is calibrated with a
47. range ID contacts will freeze on their last state before entering one of the calibration modes When the instrument returns to the Analyze mode either by a successful or an aborted calibration there will be a three minute delay before the analog outputs and the range ID contacts start tracking again The concentration alarms freeze on their last state before entering calibration regardless of selecting HOLD or TRACK But when HOLD is selected the concentration alarms will remain frozen for the time displayed in the second line of the TRAK HLD menu after the analyzer returns to the Analyze mode The factory default is three minutes but the delay time is program mable To adjust to delay time use the Left or Right arrow keys When the time displayed on the second line blinks it can be adjusted by Pressing the Up or Down keys to increase or decrease its value The minimum delay is 1 minute the maximum is 30 This preference is stored in non volatile memory so that it is recovered if power is removed from the instrument 4 3 2 Setting up an Auto Cal When the proper calibration gases are connected see chapter 3 instal lation the Analyzer can cycle itself through a sequence of steps that auto matically 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 3010MB is accurate to 2 3 Accordingly internally scheduled calibration
48. reset 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 3 6 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 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit 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 of alarm Each has both normally open and normally closed contact connections The contact connections are indicated by diagrams on the rear panel They are capable of switching up to 3 ampers at 250 V AC into a resistive load Figure 3 6 Normally closed Normally open Moving contact O TT 7 Norm e e a Movil S0 pu Figure 3 5 Types of Relay Contacts The connectors are Threshold Alarm 1 Threshold Alarm 2 System Alarm e Can be configured as high actuates when concentration is above threshold or low actuates when concentration is below thresh old e Can be configured as fail safe or non fail safe e Can be configured as latching or nonlatching e Can be configured out defeated e Can be configured as high actuates when
49. s can vary 2 3 per day To setup an Auto Cal cycle Choose System from the Function buttons The VFD will display five subfunctions Teledyne Analytical Instruments Part 4 5 4 Operation Model 3010MB TRAK HLD Auto Cal PSWD Logout More Use lt gt arrows to blink 4uto Ca 1 and press Enter A new screen for Span Zero set appears Span OFF Nxt Od Oh Zero OFF Nxt Od Oh Press lt gt arrows to blink Span or Zero then press Enter again You won t be able to set OFF to ON if a zero interval is entered A Span Every or Zero Every screen appears Span Every 0 d Start 0h from now Use AV arrows to set an interval value then use lt gt arrows to move to the start time value Use AV arrows to set a start time value To turn ON the Span and or Zero cycles to activate Auto Cal Press System again choose Aut o Ca 1 and press Enter again When the Span Zero values screen appears use the lt gt arrows to blink the Span or Zero OFF ON field Use AV arrows to set the OFF ON field to ON You can now turn these fields ON because there is a nonzero span interval defined 4 3 3 Password Protection If a password is assigned then setting the following system parameters can be done only after the password is entered span and zero settings alarm setpoints analysis range definitions switching between autoranging and manual override setting up an auto cal and assigning a new password Howev
50. seeesserenesee 4 3 3 2 Installing or Changing the Password 494 Lodo ansia e 4 3 5 System Self Diagnostic Test eene 4 3 6 Version Screen ili ii 4 3 7 Showing Negative Oxygen Readings 4 4 The Zero and Span Functions occccccccnnncnccccccncnnnnnnannncnos AO ZIO Call pioli ea ii Partl Teledyne Analytical Instruments Part I Control Unit 4 4 1 1 Auto Mode Zeroing 4 11 4 4 1 2 Manual Mode Zeroing 4 12 AAAS Cell Fallecidos 4 13 AAD Spadini elit 4 14 4 4 2 1 Auto Mode Spanning 4 14 4 4 2 2 Manual Mode Spanning ssesseeeeeeeeeeneeeeenne 4 16 443 Span Falle lira 4 16 4 5 The Alarms Function pisito 4 15 4 6 The Range Finclu 4 18 4 6 1 Setting the Analog Output Ranges 4 19 4 6 2 Fixed Range Analysis 4 20 4 7 The Analyze Function ascii ld 4 20 4 8 Signal QUT e ear aii 4 21 5 Maintenance 5 1 Fuse Replacement i 5 1 5 2 System Self Diagnostic TeSt eneee 5 2 5 3 Major Internal Component neeese 5 3 A Appendix Model 3010MB Specifications A 1 Teledyne Analytical Instruments Part iii Model 3010MB Percent Paramagnetic Oxygen Analyzer iv Pant Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit I
51. t l 4 13 4 Operation Model 3010MB c Check whether more time is needed for readings to drop to a satisfactory level This might happen when zero was started from very high PPM level If there are no leaks and the span gas is OK replace the cell as de scribed in Part II Analysis Units chapter 5 Maintenance 4 4 2 Span Cal The Span button on the front panel is used to span calibrate the ana lyzer 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 cali bration can also be performed in manual mode where the operator deter mines when the span concentration reading is acceptable and manually exits the function 4 4 2 1 Auto Mode Spanning Press Span to 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 AV arrow keys to toggle between AUTO and MAN span settling Stop when AUTO appears blinking on the display Span Settling AUTO lt ENT gt For Next Press Enter to move to the next screen Calib Holding time Cal hold 5 min This menue allows the operator to set the time the analyzer should be held in the auto span mode It does not affect anything in Manual Mode Just press Enter to continue Press Enter to move to the next screen Span Val 000008 00 lt ENT gt Sp
52. t or Left arrow keys and select More Press Enter Version Self Test Show_Negative N0 Use the Right or Left arrow keys and select Show_Negative NO Use the Up or Down key to toggle from NO to YES Press the Escape key twice to return to the analyze mode This preference is stored in non volatile memory so this configuration is remembered after a power shutdown If the instrument is cold started it will go back to default not showingg negative oxygen readings 4 4 The Zero and Span Functions Zeroing is not required in order to achieve the published accuracy specification of this unit Zeroing will eliminate offset error contributed by sensor electronics and internal and external sampling system and improve performance beyond published specification lim its The analyzer is calibrated using zero and span gases Any suitable oxygen free gas can be used for zero gas as long as it is known that it will not react adversely with the sample system Although the instrument can be spanned using air a 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 airis 20 9 209 000 ppm the cell can take longer to recover if the instrument is used for trace or less than 1 full scale oxygen analysis immediately following calibration in air Connect the calibration gases to the analyzer according to the instruc tions given i
53. t temperature 5 of full scale over operating temperature A 1 Appendix Model 3010M range on factory default analysis ranges once thermal equilibrium has been achieved Analog outputs 0 1 V dc percent of range 0 1 V dc range ID 4 20 MADC percent of range 4 20 mADC range ID Password Access Can be user configured for password protection A 2 4 Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Appendix A 2 Recommended 2 Year Spare Parts List Qrv PART NUMBER DESCRIPTION 1 C62371B Display PCB 1 D70046 Customer Interface PCB 1 C70043 Percent Preamplifier Board 1 C62365 A Main PCB 4 20 mA 4 F1295 Fuse 4A 250V 5x20 mm T Slow Blow 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 instrument 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 COID Web www teledyne ai com or your local representative A 3 Drawing List D 66826 Wiring Diagram C 71466 Interconnection Diagram 7 Teledyne Analytical Instruments Appendix Model 3010M NOTE The MSDS on this material is available upon request through the Teledyne Environmental Health and Safety Coordinator Contact at 626 934 1592
54. t to check the integrity of the power supply output boards and amplifiers e Version Displays Manufacturer Model and Software Version of instrument e Showing Negative The operator selects whether display can show negative readings or not TRAK HLD The operator sets whether the instrument analog outputs track the concentration change during calibration and sets a time delay for the concentration alarms after calibration 4 3 1 Tracking the Oxygen Readings during Calibration and Alarm delay The user has the option of setting the preferenc as to whether the analog outputs track the display readings during calibration or not To set the prefer ence press the System key once and the first System menu will appear in the VED display TRAK HLD Auto Cal PSWD Logout More TRAK HLD should be blinking To enter this system menu press the Enter key once Output Sttng TRACK Alarm Dly 10 min 4 4 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit Or Output Sttng HOLD Alarm Dly 10 min In the first line TRACK or HOLD should be blinking The operator can toggle between TRACK and HOLD with the Up or Down keys When TRACK is selected the analog outputs 0 1 VDC and 4 20 ma and the range ID contacts will track the instrument readings during calibration either zero or span TRACK is the factory default When HOLD is selected the analog outputs 0 1 VDC and 4 20 ma and the
55. th increas ing oxygen from 4 mA at 0 to 20 mA at full scale 100 Full scale 100 of programmed range 4 20 mA dc Range ID M Option 8 mA Low Range 12 mA Me dium Range 16 mA High Range 20 mA Air Cal Range ANALOG OUTPUTS Negative eae I SSS ground Turn cw to hold e e e 2 wo 0000 00 loosen wire Insert wire gt here O 1V O P 4 20MA O P RANGE RANGE ID Figure 3 5 Analog Output Connections Examples The analog output 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 1t is necessary to know what range the instrument is currently on especially when the analyzer is in the autoranging mode The signaloutput for concentration is linear over currently selected analysis range For example if the analyzer is set on a range that was defined as 10 O2 then the output would be as shown in Table 3 1 4 Teledyne Analytical Instruments Part 3 5 3 Installation Model 3010MB Table 3 1 Analog Concentration Output Examples Voltage Signal Current Signal 02 Output V dc Output MA dc 0 0 0 4 0 1 0 1 5 6 2 0 2 72 3 0 3 8 8 4 0 4 10 4 5 0 5 12 0 6 0 6 13 6 7 0 7 15 2 8 0 8 16 8 9 0 9 18 4 10 1 0 20 0 To provide an indication of the range a second pair of analog output terminals are used They generate a steady p
56. the control panel is processed by the microprocessor and appropriate control signals are directed to the display alarms and communications port as well as to the gas control valves in the Analysis Unit 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 concentra tion signal outputs and the analog range ID outputs The microprocessor monitors the power supply and activates the system failure alarm if a malfunction is detected Teledyne Analytical Instruments Part 2 1 2 Operational Theory Model 3010MB Current Second to Voltage Stage Amplifier Amplifier Sensor From Analysis Unit Pawn r u Auto dd Rang r m o de 1 System l ailure Alarm To Analysis Unit Process Control Valves Display az Self Test Signal Figure 2 1 Block Diagram of the 3010TB CU Electronics 2 2 Part a Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit Installation E Installation of Model 3010MB Analyzers includes 1 Unpacking mounting and interconnecting the Control Unit and the Analysis Unit 2 Making gas connections to the system 3 Making electrical connections to the system 4 Testing the system This chapter covers installation of the Control Unit Installation of the Analysis Unit is covered in Part II of this manual 3 1 Unp
57. the span will not be accepted The analyzer will return to the previous calibration values trigger the System Alarm and display in the VFD Span Failed This message will be shown for five seconds and the instrument shall return to the Analyze mode In the upper right hand corner of the VFD display FCAL will be shown This message flag will help the operator troubleshoot in case calibration was initiated remotely To reset the alarm and the flag message the unit must be turned off by cycling the standby key C It will not reset if the next span cycle is correct A trace cell is unlikely to fail span As explained before when the sensor reaches the end of its useful life the zero offset begins to rise until the analyzer finds the zero unsatisfactory Nevertheless feeding the wrong span gas or electronics failure could set this feature off at the end of the span Consider this before replacing the cell 4 5 The Alarms Function The Model 3010MB 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 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 hig
58. thing in the Manual Mode Just press Enter to continue Span Val 000008 00 lt ENT gt Span lt UP gt Mod Press A lt UP gt to permit modification Mod of span value Use the arrow keys to enter the oxygen concentration of the span gas you are using 209000 00 if you are using air The lt gt arrows choose the digit and the AV arrows choose the value of the digit Press Enter to enter the span value into the system and begin 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 gt Teledyne Analytical Instruments Part I 4 15 4 Operation Model 3010MB JHHHE Span Slope 4HHHF ppm s When the Span value displayed on the screen is sufficiently stable press Enter Generally when the Span reading changes by 1 or less of the full scale of the range being calibrated for a period of ten minutes it is sufficiently stable Once Enteris pressed the Span reading changes to the correct value The instrument then automatically enters the Analyze func tion 4 4 3 Span Failure The analyzer checks the output of the cell at the end of the span If the raw output of the cell is less than 0 5 uA ppm O
59. to represent a particular range The following table gives the range ID output for each analysis range Range Voltage V Current mA LO 0 25 8 MED 0 50 12 HI 0 75 16 CAL 0 25 1 00 20 gt Teledyne Analytical Instruments Part l 4 21 4 Operation Model 3010MB IMPORTANT In the event of loss of flow through the analyzer if the 4 22 Part 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 concen trations 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 Part I Control Unit Maintenance 5 Maintenance Aside from normal cleaning and checking for leaks at the gas connec tions routine maintenance is limited to replacing fuses and recalibration Checking for leaks and replacing fuses in the Analysis Unit are cov ered in Part II Chapter 5 For recalibration see Part I section 4 4 Calibra tion WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL gt gt 5 1 Fuse Replacement The 3010MB requires two 5 x 20 mm 1 0 A T type
60. vailable for pass word use are shown in the table below Characters Available for Password Definition A B C D E F G H I J K L M N 0 P Q R S T U V W X Z E Y J i _ a b C d e f g h 7 J k I m n 0 p q r S t u v W xX y Z gt i 4 amp di ae 0 1 2 3 4 5 6 7 8 9 lt gt When you have finished typing the new password press Enter A verification screen appears The screen will prompt you to retype your password for verification A AAA A Retype PWD To Verify Wait a moment The entry screen will give you clearance to proceed A A A A A lt ENT gt TO Proceed Use the arrow keys to retype your password and press Enter when finished Your password will be stored in the microprocessor and the system will immediately switch to the Analyze screen and you now have access to all instrument functions 4 8 Part Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Part l Control Unit If no alarms are tripped 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 AL 1 NOTE lf you previously logged off the system you will now be required to re enter the password to gain access to Span Zero Alarm and Range functions 4 3 4 Logout The Logout function provides a convenient means of leaving the analyzer in a password protected mode without having to shut the instrum
61. w 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 prede termined 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 1HHHE ppm Zero Slope HHHF ppm s NOTE lt takes several seconds for the true Slope value to display Wait about 10 seconds Then wait until Slope is sufficiently close to zero before pressing Enter to finish zeroing Slope is given in ppm s 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 press Enter In a few seconds the screen will update Once span settling completes the information is stored in the microprocessor and the instrument automatically returns to the Analyze mode 4 4 1 3 Cell Failure Cell failure in the 3010MB is usually associated with inability to zero the instrument down to a satisfactorily low ppm reading e g cell does not fail if it comes below SPPM When this occurs the 3010MB system alarm trips and the LCD displays a failure message 4 4 ppm Anlz CELL FAIL ZERO HIGH Before replacing the cell a Check your span gas to make sure it is within specifications b Check for leaks downstream from the cell where oxygen may be leaking into the system gt Teledyne Analytical Instruments Par
62. yzer Table of Contents Specific Model Information iv PROTA Gist sav sir nace ceecanedacac tanned users arr tete V Part Control Unit Model MB Part 1 1 Part Il Analysis Unit Model M Part Il 1 1 Appendices era A 1 Teledyne Analytical Instruments Model 3010MB Specific Model Information The instrument for which this manual was supplied may incorporate one or more options not supplied in the standard instrument Commonly available options are listed below with check boxes Any that are incorpo rated in the instrument for which this manual was supplied are indicated by a check mark in the box Instrument Serial Number iv Teledyne Analytical Instruments Percent Paramagnetic Oxygen Analyzer Preface Overview The Analytical Instruments Model 3010MB Percent Paramagnetic Oxygen Analyzer is a versatile microprocessor based instrument for detect ing parts per million ppm levels of oxygen in a variety of background gases It is a split architecture instrument This means that a general pur pose Control Unit designed for nonhazardous areas only remotely controls a specially designed Analysis Unit or remote probe Part I of this manual covers the Model 3010MB General Purpose NEMA 4 Bulkhead mount Control Unit only This Control Unit is for outdoor indoor use in a nonhazardous environment The Analysis Units or Remote Probes it contro
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