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Teledyne 3000ZA Oxygen Equipment User Manual

1. Show Negative Zero Used to set up a zero calibration Span Used to set up a span calibration 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 Range Used to set up three analysis ranges that can be switched automatically with auto ranging or used as individual fixed ranges 4 Teledyne Analytical Instruments 29 Operation 3000ZA ANALYZE SYSTEM Perform Oxygen Analysis 0 the Sample SPAN TRAK HLD ZERO Set Instrument Perform ALARM S sell Diegnesile Set Instrument Initiate Automatic Alarm Calibration etpoints Define Analysis Ranges Confrigure Mode of Alarm Set Password Operation Logout Show Negative Figure 4 1 Hierarchy of Available Functions 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 Each of these functions is described in greater detail in the following procedures The VFD screen text that accompanies each operation is reproduced at the appropriate point in the procedure in a Ariel Narrow Bold type style Pushbutton names are printed in Oblique type 4 Teledyne Analytical Instruments 30 Trace Oxygen Analyzer Operation www ssrsssFwwsmsrrCtw rss smsscaksrsOc lt acs 4 3 The System
2. a b d e f g h i 1 m n o p q r S t u w x y 7 amp 0 1 2 3 4 5 6 7 8 9 lt gt 9 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 AAAAA Retype PWD To Verify Wait a moment for the entry screen You will be given clearance to proceed AAAAA 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 If all alarms are defeated the Analyze screen appears as 0 0 ppm Aniz Range 0 100 4 Teledyne Analytical Instruments 36 Trace Oxygen Analyzer Operation www ssrsssFwwsmsrrCtw rss smsscaksrsOc lt acs If an alarm 15 tripped the second line will change to show which alarm it is 0 0 ppm Aniz AL 1 Note If you log off the system using the logout function in the system menu 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 instrument off By entering Logout you effectively log off the instrument leaving the system protected against use until
3. Note that response time is dependent on flow rate a low flow rate will result in slow response to changes in the sample stream The span flow rate should be the approximately same as the sample flow rate RESTRICTION DEVICES For proper operation all 3000 series analyzers require a flow restriction device This device is typically a restrictor or a valve The restriction device serves two functions in the sample path 1 Itis used to limit the flow rate of the sample through the analyzer A restrictor is chosen to operate over a range of pressures and provide a useable flow rate over that range 2 The restriction device provides 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 are supplied to give the end user more flexibility when installing the analyzer The restrictor kit is suitable for high and low 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix s usOV R a essen ts positive pressure applications as well as vacuum service applications see manual for installation Instructions The standard restrictor BLUE DOT is recommended for pressures between 5 and 50 PSIG For positive low pressure application 5 psig or less the unmarked restrictor is better suited For unpress
4. OPERATING INSTRUCTIONS FOR MODEL 3000ZA Trace Oxygen Analyzer i I gt A 8 HH IH 5 UU il CH P N M75739 4 10 04 DANGER Toxic gases and or flammable liquids may be present in this monitoring system Personal protective equipment may be required when servicing this instrument Hazardous voltages exist on certain components internally which may persist for a time even after the power is turned off and disconnected Only authorized personnel should conduct maintenance and or servicing Before conducting any maintenance or servicing consult with authorized supervisor manager 4 Teledyne Analytical Instruments 3000ZA Copyright 2003 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 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 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
5. 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 4 1 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure A 1 Model 3000ZA Front Panel Model 3000ZA Rear Panel Model 3000ZA Sample System Flow Diagram with Options Component Location Electronic Block Diagram Front Panel Required Front Door Clearance Rear Panel Equipment Interface Connector Pin Arrangement Remote Probe Connections FET Series Resistance Hierarchy of Available Functions Replacing the ZrO2 Sensor Removing Fuse Block from Housing Installing Fuses Rear Panel Removal Single and Dual 19 Rack Mounts 4 Teledyne Analytical Instruments xi 3000ZA List of Tables Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table 3 5 Table 3 6 Table 4 1 Table 4 2 Table 5 1 Table 5 2 Analog Output Connections Alarm Relay Contact Pins Remote Calibration Connections Range ID Relay Connections Commands via RS 232 Input Required RS 232 Options Output Signals Range ID Output Voltage Self test Failure Codes Troubleshooting 4 Teledyne Analytical Instruments 20 21 22 23 25 25 49 50 54 56 xii Trace Oxygen Analyzer Introduction ws iu Introduction 1 1 Overview The Teledyne Analytical Instruments Model 3000ZA 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
6. Baud 2400 Byte 8 bits 4 Teledyne Analytical Instruments 25 Installation 3000ZA suc c T _ _ Parity none Stop Bits 1 Message Interval 2 seconds When CRC opens again zero and span are done and the sample is being analyzed Range ID Relays There are three dedicated Range ID relay contacts 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 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 options to 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 It requires a standard 9 pin D connector The data is status information in digital form updated every two seconds Status is reported in the following order The concentration in ppm or percent Therange in use HI MED LO The 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 ON 3 4 Installing the Zirconium Oxide Sensor The ZrO sensor may not installed in the cell block when the instrument is shipped It must be installed before the analyzer is placed in service When the ZrO sensor needs to be installed or replaced follow
7. blink the range to be set low L medium M or high H Use the __ 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 Enter to 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 ppm and range 2 is set as 0 100 ppm range 3 cannot be set as 0 50 ppm since it is lower than range 2 4 6 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 pressing the Range button on the front panel Use the arrow keys to move the blinking over AUTO Use the arrow keys to switch from AUTO to FX MED or FXIHI to set the instrument on the desired fixed range low medium or high L 10 M 100 H 250 Mode FX LO L 10 M 100 H 250 Mode FX MED L 10 M 100 H 250 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 4 Teledyne Analytical Instruments 48 Trace Oxygen Analyzer Operation as established by the operator for that particular range the output saturates at 1 VDC or 20 mA However the
8. 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 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 analyzer back to the Analyze function Alternatively you can press the Analyze button at any time to return to analyzing your sample 4 8 Signal Output The standard Model 3000ZA Trace Oxygen Analyzer is equipped with two 0 1 VDC analog output terminals accessible on the back 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 connection details 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 0 100 ppm then the output would be Table 4 1 Output Signals Voltage Signal Current Signal ppm O gt Output VDC Output mA DC 0 0 0 4 0 10 0 1 5 6 20 0 2 7 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 4 Teledyne Analytical Instruments 49 Operation 3000ZA 80 0 8 16 8 90 0 9 18 4 100 1 0 20 0 The analog output signal has a voltage which depends on the oxygen concentration AND the currently activated analysis range To relat
9. gases require conditioning prior to entering the sensor e Flammable gases such as methane alcohol and carbon monoxide may cause a measurement error They must be filtered from the sample gas before entering the cell Gases containing halogen atoms F Cl Br etc such as Freon must be filtered before entering the cell The sensor will be damaged by the decomposition of Freon Gases containing SOx H2S silicone vapor and adhesives must not enter the sensor These components adversely affect the performance of the sensor e Dust and oil should be filtered from the sample gas Water vapor in contact with the sensor will damage the sensor Use a moisture trap or filter to remove any water vapor in the sample 2 5 Electronics and Signal Processing The Model 3000ZA Trace Oxygen Analyzer uses an 8031 microcontroller 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 supplied from a universal power supply module designed to be compatible with any international power source Figure 2 3 shows the location of the power supply and the main electronic PC boards 4 Teledyne Analytical Instruments 10 Trace Oxygen Analyzer Operational Theory Gw vOO 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
10. is mounted on top of the motherboard as shown in the figure These boards are accessible after removing the back panel Figure 2 4 is a block diagram of the analyzer electronics 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 output from the second stage amplifier is sent to an 18 bit analog to digital converter controlled by the microprocessor The high operating temperature of the ZrO sensor is required for proper operation of the sensor The amplifier PCB contains a circuit that drives the heater embedded in the sensor The voltage across the heater rises slowly to avoid damaging the heater sensor assembly After a few minutes the sensor will be at the proper operating temperature 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 and the 0 1 VDC analog concentration signal outputs and the analog range 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 4 Teledyne Analytical Instruments 11 Operational Theory 3000ZA Universal Power
11. logging out 28 logout 36 LOGOUT 30 low alarm See alarm concentration low pressure applications 15 manual override 2 manuals additional vi measurement error 9 membrane switches See keys meter 3 4 microcontroller 9 microprocessor 7 10 55 Index model designation 2 model information 111 MORE 30 motherboard 10 mounting holes 13 network I O 6 22 25 non failsafe 44 non latching 45 normally closed 19 normally open 19 operating temperature 58 operating the analyzer 27 operator controls 14 operator interface 3 options rack mountable iii vacuum service 111 output range 2 output saturation 46 output signal 48 oxygen concentration mode 42 oxygen reduction 7 panel mount 2 password 30 33 available characters 35 changing 34 new 33 password assignment 28 password protection 27 PC board location 10 percent of range output 18 pin configuration 18 polarity 18 power cord receptacle 17 power supply 55 signal monitoring 10 universal 9 17 57 power supply monitoring 2 preamplifier board 10 preference setting 31 pressure drop 62 pressure regulation 16 pressure sensitivity 6 pressures other than atmospheric 6 PSWD 30 rack mount 2 13 60 RAM 2 9 range range function 46 range ID 10 49 4 Teledyne Analytical Instruments Index relay connections 22 relay contacts 22 range ID contact 6 range ID relay contacts 25 range identification 2 RANGE k
12. off as shown in Figure 5 2 Fuse Block Cover Housing Figure 5 2 Removing Fuse Block from Housing 4 Teledyne Analytical Instruments 53 Maintenance 3000ZA k a sr r T 2 To change between American and European fuses remove the single retaining screw flip Fuse Block over 180 degrees and replace screw 3 Replace fuse as shown in Figure 5 3 4 Reassemble Housing as shown in Figure 5 2 Fuses Fuse Block Cover Jumper Bar E GUT Bar American Fuses European Fuses Figure 5 3 Installing Fuses 5 4 System Self Diagnostic Test 1 Press the System button to enter the system mode 2 Usethe arrow keys to move to More and press Enter 3 Usethe arrow keys to move to Self Test and press Enter The following failure codes apply Table 5 1 Self Test Failure Codes Power OK 5 V Failure 15 V Failure Both Failed Q N Analog OK DAC A 0 1 V Concentration DAC B 0 1 V Range ID Both Failed Q N Oo 4 Teledyne Analytical Instruments 54 Trace Oxygen Analyzer Maintenance GwacFFwsswWIssrewsrrrws Orr C Preamp OK Zero too high Amplifier output doesn t match test input Both Failed Q N 5 5 Major Internal Components The zirconium sensor is accessed by unlatching and swinging open the front panel as described earlier Other internal components are accessed by removing the rear panel and sliding out the entire chassis See Figure 5 4 below The gas piping is il
13. that the principles of operation of this equipment is well understood by the user Misuse of this product in any manner tampering with its components or unauthorized substitution of any component may adversely affect the safety of this instrument Since the use of this instrument is beyond the control of Teledyne no responsibility by Teledyne its affiliates and agents for damage or injury from misuse or neglect of this equipment is implied or assumed 4 Teledyne Analytical Instruments vii 3000ZA Table of Contents Safety Messages LLL LU 1 1 Overview 1 2 Typical Applications 1 3 Main Features of the Analyzer 1 4 Model Designations 1 5 Front Panel Operator Interface 1 6 Rear Panel Equipment Interface Operational Theory 2 1 Introduction 2 2 Sensor 2 2 1 Principles of Operation 2 3 Sample System 2 4 Zirconium Oxide Sensor Application Notes 2 5 Electronics and Signal Processing Installation eere eren 3 1 Unpacking the Analyzer 3 2 Mounting the Analyzer 3 3 Rear Panel Connections 3 3 1 Gas Connections 3 3 2 Electrical Connections 3 3 2 1 Primary Input Power 3 3 2 2 50 Pin Equipment Interface Connector 3 3 2 3 RS 232 Port 3 4 Installing the Zirconium Oxide Sensor 3 5 Testing the System 4 Teledyne Analytical Instruments viii Trace Oxygen Analyzer u eae eee eee eee eee eee 28 4 1 Introducti
14. the procedures in Section 5 2 3 5 Testing the System Before plugging the instrument into the power source 4 Teledyne Analytical Instruments 26 Trace Oxygen Analyzer Installation Gr n a Check the integrity and accuracy of the gas connections Make sure there are no leaks Check the integrity and accuracy of the electrical connections Make sure there are no exposed conductors Check that inlet sample pressure is within the accepted range see Section 3 3 1 Power up the system and test it by repeating the Self Diagnostic Test as described in Chapter 4 Section 4 3 5 4 Teledyne Analytical Instruments 27 Operation 3000ZA as sIrn Fr T Operation 4 1 Introduction Once the analyzer has been installed it can be configured for your application To do this you will Set system parameters e Establish a security password if desired requiring Operator to log in Establish and start an automatic calibration cycle if desired e Calibrate the instrument Define the three user selectable analysis ranges then choose autoranging or select a fixed range of analysis as required Set alarm setpoints and modes of alarm operation latching failsafe etc Before you configure your 3000ZA these default values are in effect Ranges LO 10 ppm MED 100 ppm HI 250 ppm Auto Ranging ON Alarm Relays Defeated 10 00 ppm HI Not failsafe Not latching Zero Auto every 0 days
15. 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 __ arrow keys to position the blinking over the Logout function and press Enter to Log out The screen will display the message Protected Until Password Reentered 4 3 5 System Self Diagnostic Test The Model 3000ZA 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 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 any time To initiate a self diagnostic test during operation Press the System button to start the System function 4 Teledyne Analytical Instruments 37 Operation 3000ZA an HH TRAKIHLD Auto Cal PSWD Logout More Use the arrow keys to blink More then press Enter Version Self Test Use __ arrow keys again to 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 compl
16. voltage depending on the load impedance applied See Figure 3 6 Figure 3 6 FET Series Resistance 4 Teledyne Analytical Instruments 24 Trace Oxygen Analyzer Installation Gw lt sFKCsr iwF WwrsHmwCwvsat a a 3 3 23 RS 232 PORT The digital signal output is a standard full duplex RS 232 serial communications port used to connect the analyzer to a computer terminal or other digital device It requires a standard 9 pin D connector The output data is status information in digital form updated every two seconds Status is reported in the following order The concentration in ppm or percent Therange in use HI MED LO The span of the range 0 100 ppm etc Which alarms if any are disabled AL x DISABLED e Which alarms if any are tripped 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 5 Table 3 5 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 6 lists certain RS 232 values that are required by the 3000ZA implementation Table 3 6 Required RS 232 Options Parameter Setting
17. 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 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 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 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 automatically or manually Use the X 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 99 PPM Zero Slope The beginning zero level is shown in the upper left corner of the display 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 sett
18. 68729 Restrictor kit 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 Web www teledyne ai com or your local representative 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix A 3 Drawing List D 75739 Final Assembly D 75738 Outline Drawing A 4 19 inch Relay Rack Panel Mount Figure A 1 Single and Dual 19 Rack Mounts dimensions in mm 4 Teledyne Analytical Instruments 3000ZA A 5 Application Notes 3000 SERIES ANALYZERS APPLICATION NOTES ON RESTRICTORS PRESSURES AND FLOW RECOMMENDATIONS The 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 to provide a useable flow rate through the analyzer Any line attached to sample vent should be 1 4 or larger in diameter FLOW RATE RECOMMENDATIONS A usable flow rate for a 3000 series analyzer is one which can be measured on the flowmeter This is basically 0 2 2 4 SLPM The optimum flow rate is 1 SLPM mid scale
19. ART NUMBERS Restrictor kit A68729 Union SS U11 LP Restrictor R2323 low pressure vac service Std Restrictor R2324 Blue dot Nut N73 Ferrule F73 Ferrule F74 Both ferrules are required CONVERSIONS 1 PSI 2 04 inches of mercury in Hg 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix s r e ss esee 1SCFH 0 476 SLPM 4 Teledyne Analytical Instruments Index Index AC power connection 6 accuracy 58 address 59 alarm 57 concentration 2 6 44 configuration 44 freeze 31 relay contact pins 20 relays 19 setpoint 45 system failure 2 6 10 20 44 threshold 1 19 threshold 2 19 ALARMS key 28 alphanumeric display 3 amplifier PCB 10 analog output 2 6 10 18 48 58 freeze 31 analog output connections 19 analog to digital converter 10 analyze function 48 ANALYZE key 28 analyzer components 54 analyzer functions 4 anode 7 application notes 61 applications 1 auto ranging 2 AUTO span time interval 42 AUTOCAL 30 auto cal setting up 32 auto cal setup 28 automatic calibration 30 32 autoranging 46 47 back diffusion 49 block diagram 10 by pass 63 bypass line 17 by pass valve 62 calibration automatic zero 39 connections 21 manual zero 40 3000ZA remote cal protocol 21 remote control 20 span 21 zero 20 calibration contact 6 21 calibration input 20 calibration port 6 15 cathode 7 caution sign v CE mark 1 cell bloc
20. BLE PARTS INSIDE SERVICE ONLY BY QUALIFIED 85 250Vac 47 63Hz 0 9 AMAX USE 250V 1 0 T FUSE ZERO IN SAMPLE IN SPAN IN PAN SEE MANUAL FOR INTERCONNECTION DETAIL e CN o ms Jo Figure 3 3 Rear Panel of the Model 3000ZA with Span and Zero Ports 3 3 1 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 applications The kit included with the instrument contains two restrictors and a union for 1 4 diameter tubing Notice that there are two 1 3 4 long 1 4 diameter restrictors There is an open end and a closed end with a small circular orifice The restrictor without the blue sticker is for low pressure applications and vacuum service For high 4 Teledyne Analytical Instruments 16 Trace Oxygen Analyzer Installation OOO pressure applications 5 50 psig use the restrictor that has a blue sticker on the body Pressurized service Connect the restrictor with the blue dot to the Sample In port The small circular orifice should face AWAY from the back of the unit against the direction of gas flow Note Remove the blue sticker from the restrictor before using Low pressure applications Connect the restrictor without the blue sticker in the same manner less than 5 psig Vacuum Service For applications involving pressure less than 5 10 in Hg connect the restrictor without the bl
21. Function The sub fuctions 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 PSWD Security can be established by choosing a 5 digit password PSWD from the standard ASCII character set See Installing or Changing the Password below for a table of ASCII characters available Once a unique password is assigned and 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 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 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 Logout Logging out prevents unauthorized tampering with analyzer settings More Select and enter More to get a new screen with additional sub functions listed Self Test The instrument performs a self diagnostic test to check the integrity of the power supply output boards and amplifiers Version Displays Manufacturer Model and So
22. Slope is sufficiently close to zero before pressing 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 press Enter In a few seconds the screen will update Once zero settling is completed 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 3000ZA is usually associated with inability to zero the instrument down to a satisfactorily low ppm reading When this occurs the instrument will still Zero but the 3000ZA system alarm trips and the LCD displays a failure message ppm Aniz 4 Teledyne Analytical Instruments 41 Operation 3000ZA CELL FAIL ZERO HIGH Before replacing the cell a Check your span gas to make sure it is within specifications b Check for leaks up stream from the cell where oxygen may be leaking into the system If there are no leaks and the span gas is within specification replace the cell as described in chapter 5 Maintenance 4 4 2 Span Cal The Span button on the front panel 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 w
23. Supply Front Panel Display Board ea as lt Slide out Electronics Drawer Motherboard Preamplifier PCB 4 Teledyne Analytical Instruments 12 Trace Oxygen Analyzer Operational Theory Gw C_w s rrsnror n w Current Second to Voltage stage Amplifier Amplifier Ato D Converter Heater Driver Circuit Processor Displays Bias Voltage Processing Self Test DtoA Converter Figure 2 4 Electronic Block Diagram 4 Teledyne Analytical Instruments 13 Installation 3000ZA su CC te _ _ Installation Installation of the Model 3000ZA Analyzer includes 1 Unpacking Mounting Gas connections 2 3 4 Electrical connections 5 Installing the sensor 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 3000ZA is for indoor use in a general purpose area It is NOT for hazardous environments of any type The standard model is designed for flush panel mounting Figure 3 1 is an illustration of the 3000TA standard front panel the 3000ZA is similar and mounting bezel There are four mounting holes one in each corner of the rigid frame Drawings at the back of this manual illustrate the dimensions and mounting h
24. URCE THE RED AN SWITCH ON THE FRONT PANEL IS FOR SWITCHING POWER ON OR OFF TO THE DISPLAYS AND OUTPUTS ONLY The universal power supply requires a n 85 250 VAC 47 63 Hz power source 4 Teledyne Analytical Instruments 18 Trace Oxygen Analyzer Installation Gw lt sFKCsr iwF WwrsHmwCwvsat a a Fuse Installation The fuse block at the right of the power cord receptacle accepts US or European size fuses jumper replaces the fuse in whichever fuse receptacle is not used Fuses are not Installed at the factory Be sure to Install the proper fuse as part of Installation See Fuse Replacement Chapter 5 Maintenance 3 3 2 2 50 PIN EQUIPMENT INTERFACE CONNECTOR Figure 3 4 shows the pin layout of the Equipment Interface Connector The arrangement is shown as seen when the viewer faces the rear panel of the analyzer The pin numbers for each input output function are given where each function is described in the paragraphs below 33 060909 o O18 a 99 9909 9909 9 9 9 9 Figure 3 4 Equipment Interface Connector Pin Arrangement Analog Outputs There are four DC output signal pins two pins per output For polarity see Table 3 1 The outputs are 0 1 VDC of Range Voltage rises linearly with increasing oxygen from 0 V at 0 ppm to 1 V at full scale ppm Full scale 10096 of programmable range 0 1 VDC Range ID 0 25 V Low Range 0 5 V Medium Range 0 75 V High R
25. UTION Risk of Electrical Shock gt P 4 Teledyne Analytical Instruments iv Trace Oxygen Analyzer Safety Messages Your safety and the safety of others is very important We have provided many important safety messages in this manual Please read these messages carefully A safety message alerts you to potential hazards that could hurt you or others Each safety message is associated with a safety alert symbol These symbols are found in the manual and inside the instrument The definition of these symbols is described below D P P P Symbol GENERAL WARNINGICAUTION Refer to the instructions for details on the specific danger These cautions warn of specific procedures which if not followed could cause bodily Injury and or damage the instrument CAUTION HoT SURFACE WARNING This warning is specific to heated components within the instrument Failure to heed the warning could result in serious burns to skin and underlying tissue WARNING ELECTRICAL SHOCK HAZARD Dangerous voltages appear within this instrument This warning is specific to an electrical hazard existing at or nearby the component or procedure under discussion Failure to heed this warning could result in injury and or death from electrocution Technician Symbol All operations marked with this symbol are to be performed by qualified maintenance personnel only NOTE Additional information and comments regarding a specific component or procedure ar
26. ange 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 100 of programmable range optional 4 20 mA DC Range ID 8 mA Low Range 12 mA Medium Range 16 mA High Range 4 Teledyne Analytical Instruments 19 Installation 3000ZA Table 3 1 Analog Output Connections Pin Function 3 Range ID 4 20 mA floating 4 Range ID 4 20 mA floating 5 ppm Range 4 20 mA floating optional 6 ppm Range 4 20 mA floating optional 8 Range ID 0 1 VDC 23 Range ID 0 1 V dc negative ground 24 ppm Range 0 1 VDC 7 ppm Range 0 1 VDC negative ground Alarm Relays The nine alarm circuit connector pins connect to the Internal alarm relay contacts Each set of three pins provides one set of Form C relay contacts Each relay has both normally open and normally closed contact connections The contact connections are shown in Table 3 2 They are capable of switching up to 3 amperes at 250 V ac into a resistive load The connectors are Threshold Alarm 1 Can be configured as high actuates when concentration is above threshold or low actuates when concentration is below threshold Can be configured as failsafe or non failsafe Can be configured as latching or non latching Can be configured out defeated Threshold Alarm 2 Can be configured as high actuates when concentration is above threshold
27. at 0 hours Span Auto at 000 008 00 ppm 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 4 Teledyne Analytical Instruments 28 Trace Oxygen Analyzer Operation 4 2 Using the Data Entry Function Buttons Data Entry Buttons The _ 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 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 Enter button 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 percent of oxygen and warns of any alarm conditions System The system function consists of seven sub functions that regulate the internal operations of the analyzer Track or hold values during calibration Auto Cal setup Password assignment Self test initiation Checking software version Logging out
28. ata The microprocessor controls all signal processing input output and display functions for the analyzer 2 2 ZrO Sensor 2 2 1 Principles of Operation Teledyne s zirconium oxide sensor is a miniature solid state sensor It uses a stabilized zirconia disc as an electrolyte with a sensing electrode the cathode and a counter electrode the anode on each side of the disc The zirconia is heated to a temperature of about 500 C via a built in heater By applying a suitable reference voltage approximately 0 75 volt across the cathode and anode the heated zirconia acts as an electrolyte which is capable of moving oxygen ions within its crystalline structure This allows for the reduction of oxygen molecules reaching the cathode and the generation of a current equivalent to the parts per million oxygen in the sample gas This sensor has been modified to sense low levels of oxygen less than 1 ppm and generate a current proportional to the concentration The sensor is designed for long term stability and an operating life of 5 years 4 Teledyne Analytical Instruments 8 Trace Oxygen Analyzer Operational Theory Gwsssrc_ca s 2 3 Sample System The sample system delivers gases to the ZrO sensor from the analyzer rear panel inlet Depending on the mode of operation either sample or calibration gas is delivered The Model 3000ZA sample system 15 designed and fabricated to ensure that the oxygen concentration of the gas 15 not altered a
29. covers the Model 3000ZA General Purpose flush panel and or rack mount units with CE mark These units are for indoor use in a non hazardous environment 1 2 Typical Applications A few typical applications of the Model 3000ZA are Monitoring inert gas blanketing Air separation and liquefaction Chemical reaction monitoring Semiconductor manufacturing Petrochemical process control Quality assurance e Gas analysis certification 1 3 Main Features of the Analyzer The Model 3000ZA Trace 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 e High resolution accurate readings of oxygen content for low ppm levels Large bright meter readout Zirconium oxide sensor designed for trace analysis It has a 0 10 ppm low range with less than a 0 2 ppm 4 Teledyne Analytical Instruments 1 Introduction 3000ZA offset and six months warranty and an expected lifetime of more than three years 0 1 ppm range 15 possible too No reference gas required 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 1 ppm through 0 250 ppm allow best match to users process and equipment Auto ranging allows analyzer to automatica
30. 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 authorized service center We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage which may result from its use or misuse We reserve the right to employ any suitable material in the manufacture of our apparatus and to make any alterations in the dimensions shape or weight of any parts in so far as such alterations do not adversely affect our warranty Important Notice This instrument provides measurement readings to its user and serves as a tool by which valuable data can be gathered The information provided by the instrument may assist the user in eliminating potential hazards caused by his process however it is essential that all personnel involved in the use of the instrument or its interface with the process being measured be properly trained in the process itself as well as all instrumentation related to it The safety of personnel is ultimately the responsibility of those who control process conditions While
31. e 2 ID Contact 19 Range 3 ID Contact 18 Range 3 ID Contact 34 Spare Contact 35 Spare Contact 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 for future options to the instrument Pins 13 and 29 Remote Valve Connections The 3000ZA is a single chassis instrument which has no Remote Valve Unit Instead the Remote Valve connections are used as a method for directly controlling external sample zero span gas valves See Figure 3 5 4 Teledyne Analytical Instruments 23 Installation Matching Circuitry If Necessary Figure 3 5 Remote Probe Connections Solenoid 2 3000ZA Solenoid 2 hot Solenoid 1 hot hot Solenoid 3 hot hot Solenoid 4 hot return Solenoid 3 return Solenoid 1 return Solenoid 4 return The voltage from these outputs is nominally 0 V for the OFF and 15 VDC 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 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 can limit the obtainable
32. e highlighted in the form of a note 4 Teledyne Analytical Instruments 3000ZA CAUTION THE ANALYZER SHOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL IF YOU USE THE ANALYZER IN A MANNER OTHER THAN THAT FOR WHICH IT WAS INTENDED UNPREDICTABLE BEHAVIOR COULD RESULT POSSIBLY ACCOMPANIED WITH HAZARDOUS CONSEQUENCES This manual provides information designed to guide you through the installation calibration and operation of your new analyzer Please read this manual and keep it available Occasionally some instruments are customized for a particular application or features and or options added per customer requests Please check the front of this manual for any additional information in the form of an Addendum which discusses specific information procedures cautions and warnings that may be peculiar to your instrument Manuals do get lost Additional manuals can be obtained from Teledyne at the address given in the Appendix Some of our manuals are available in electronic form via the internet Please visit our website at www teledyne ai com 4 Teledyne Analytical Instruments vi Trace Oxygen Analyzer WARNING This is a general purpose instrument designed for use in a non hazardous area It is the customer s responsibility to ensure safety especially when combustible gases are being analyzed since the potential of gas leaks always exist The customer should ensure
33. e next screen in a series or returns to the Analyze screen if none remain Escape Backs display to the previous screen in a series or returns to the Analyze screen if none remain Digital Meter Display The meter display is a Light Emitting Diode LED device that produces large bright 7 segment numbers that are legible in any lighting It produces a continuous readout from 0 250 ppm 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 4 Teledyne Analytical Instruments 4 Trace Oxygen Analyzer Introduction Standby Button O The Standby turns off the display and outputs but circuitry is still operating CAUTION THE POWER CABLE MUST BE UNPLUGGED TO 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 ZrO sensor 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 requires unfastening rear panel screws and slid
34. e not monitoring sample Range ID Contacts Four separate dedicated range relay contacts Low Medium High Cal Network I O Serial digital communications for local network access For future expansion Not currently implemented Optional Calibration Gas Ports Separate fittings for zero span and sample gas input internal valves for automatic gas switching Current Signal Output Additional isolated 4 20 mA DC plus optional 4 20 mA DC range ID Note If you require highly accurate Auto Cal timing use external Auto Cal control where possible The internal clock in the Model 3000ZA is accurate to 2 3 Accordingly internally 4 Teledyne Analytical Instruments 6 Trace Oxygen Analyzer Introduction scheduled calibrations vary 2 3 day 4 Teledyne Analytical Instruments 7 Operational Theory 3000ZA Operational Theory 2 1 Introduction The analyzer is composed of three subsystems 1 Zirconium Oxide ZrO2 Sensor 2 Sample System 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 ZrO sensor is a 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 d
35. e the signal output to the actual concentration it is necessary to know what range the instrument 15 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 to represent a particular range The following table gives the range ID output for each analysis range Table 4 2 Range ID Output Voltage Range Voltage V Current mA LO 0 25 8 MED 0 50 12 HI 0 75 16 IMPORTANT In 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 enter the cell This can saturate the cell with oxygen and require a long purge down time before the sensor can recover However the ZrO2 sensor recovers faster than the microfuel oxygen sensor In the event that flow 15 to be interrupted into the analyzer it is suggested that the user do one of the following 1 Bag sensor in nitrogen during this time 2 Install a shut off valve on the vent port of the analyzer or somewhere within the users sample system 4 Teledyne Analytical Instruments 50 Trace Oxygen Analyzer Operation w sssrrsss ss F lt wss lt WwW sss TsFwFF s lt msm lt smA 4 Teledyne Analytical Instruments 51 Maintenance 3000ZA k a sr r T Maintenance 5 1 Routine Maintenance Aside fro
36. ed in non volatile memory so the configuration is remembered after a power shutdown If the instrument is cold started it will go back to the default case where negative oxygen readings are not shown 4 4 The Zero and Span Functions Zeroing is not required in order to achieve the published accuracy specification of this unit however zeroing will eliminate offset error contributed by the sensor electronics and the internal and external sampling systems It will improve performance beyond published specification limits 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 to be oxygen free and does not react adversely with the sample system A span gas with a known oxygen concentration in the range of 70 100 of full scale of the range of interest is recommended In the 0 10 ppm range 8 ppm span gas would be best suited Connect the calibration gases to the analyzer according to the instructions given in Section 3 3 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 analyzer s SLPM flowmeter settles between 0 1 and 2 4 SLPM approximately 0 2 5 SCFH 4 Teledyne Analytical Instruments 39 3000ZA If
37. eral seconds for the first Slope value to display Slope indicates the rate of change of the Span reading It is a sensitive indicator of stability HHH Span Slope 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 Enter is pressed the Span reading changes to the correct value The instrument then automatically enters the Analyze function 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 too low 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 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 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 unsatisfacto
38. ero mode to terminate when done A synchronous signal must open and close the external zero valve appropriately See Remote Probe Connector The C option internal valves operate automatically 4 Teledyne Analytical Instruments 21 Installation 3000ZA su CC te _ _ Span Floating input 5 to 24 V input across the and pins 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 external span valve appropriately See Figure 3 5 Remote Probe Connector The C option internal valves operate automatically Cal Contact This relay contact is closed while analyzer is spanning and or zeroing See Remote Calibration Protocol below Table 3 3 Remote Calibration Connections Pin Function 9 Remote Zero 11 Remote Zero 10 Remote Span 12 Remote Span 40 Cal Contact 41 Cal Contact Remote Calibration Protocol To properly time the Digital Remote Cal Inputs to the Model 3000ZA 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 ac
39. ers to the proper password Press Enter to 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 opportunity to change the password Change Password lt ENT gt Yes lt ESC gt No Press Enter to change the password either the default TETAI or the previously assigned password or press Escape to keep the existing password and move on If you chose Enter to change the password the password assignment screen appears TETAI lt ENT gt To Proceed AAAAA lt ENT gt To Proceed 4 Teledyne Analytical Instruments 35 Operation 3000ZA an HH Enter the password using the __ arrow keys to move back and forth between the existing password letters and _ arrow keys to change the letters to the new password The full set of 94 characters available for password use are shown in the table below Characters Avallable for Password Definition A B D E F G H I J K L M N O P Q R S T U V W X Y Z
40. ete 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 and Troubleshooting 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 __ 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 Teledyne Analytical Instruments 38 Trace Oxygen Analyzer Operation TRAKIHLD Auto Cal PSWD Logout More Use the arrow keys to blink More then press Enter Version Self Test Show_Negative NO Use the __ arrow keys and select Show Negative NO Use the __ arrow keys to toggle from NO to YES Press the Escape key twice to return to the analyze mode This preference is stor
41. ey 28 readout 4 rear panel 5 15 rear panel removal 54 recovery 49 remote calibration connections See calibration remote probe 6 remote probe connections 23 remote valve 22 reset latched alarm 45 response time 17 57 61 restrictor 15 See flow restriction device restrictor kit 62 ROM 2 9 routine maintenance 51 RS 232 2 25 RS 232 commands 24 RS 232 port 6 24 55 57 safety information v sample in 16 sample system 7 8 55 second stage amplifier 10 self diagnostic test initiating 36 self diagnostic test initiation 28 self diagnostic test 2 26 36 53 SELF TEST 30 sensor zirconium oxide sensor 57 sensor operating temperature 10 sensor removal 51 serial number 111 serial port 2 setpoint See alarm setpoint setpoint units 45 setting ranges 46 show negative 28 SHOW NEGATIVE 30 3000ZA signal processing 9 slope 39 40 42 43 software version 28 solenoid valve 6 span calibration See calibration span span failure 43 span flow rate 6 span gas concentration 38 SPAN key 28 span settling 41 spare parts 59 specifications 57 stability indicator 43 standby button 5 subsystems 7 symbols iv system alarm 40 system function 30 SYSTEM key 28 Teledyne address 59 testing the system 25 tracking oxygen readings 31 TRAK HLD 30 troubleshooting 55 unpacking the analyzer 13 unpressurized sample 62 vacuum fluorescent display 1 4 vacuum p
42. ftware Version of instrument Show Negative The operator selects whether display can show negative oxygen 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 Teledyne Analytical Instruments 31 Operation 3000ZA 4 3 1 Tracking the Oxygen Readings during Calibration and Alarm delay The user has the option of setting the preference as to whether the analog outputs track the display readings during calibration or not To set the preference press the System key once and the first System menu will appear in the VFD display TRAKIHLD Auto Cal PSWD Logout More TRAKIHLD should be blinking To enter this system menu press the Enter key once Output Sttng TRACK Alarm Dly 10 min 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 span TRACK is the factory default When HOLD is selected the analog outputs 0 1 VDC and 4 20 ma and the 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 abo
43. he front panel to enter the Alarm function Make sure that AL 1 is blinking AL 1 AL 2 Choose Alarm Set up alarm 1 by moving the blinking over to AL 1 using _ arrow keys Then press Enter to move to the next screen AL 1 10 ppm HI Dft N Fs N Ltch N Five parameters can be changed on this screen Value of the alarm setpoint AL 1 ppm oxygen value can be set from 0 to 10 000 00 ppm although the sensor output is good only to 250 ppm Out of range direction HI or LO Defeated Dft Y N Yes No Failsafe Fs YIN Yes No Latching Ltch Y N Yes No To define the setpoint use the arrow keys to move the blinking over to AL 1 Then use the arrow keys to change the number Holding down the key speeds up the incrementing or decrementing Remember the setpoint units are ppm O 4 Teledyne Analytical Instruments 46 Trace Oxygen Analyzer Operation To set the other parameters use arrow keys to move the blinking over to the desired parameter Then use the __ 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 To reset a latched alarm go to Dft and then press either two times or two times Toggle it to Y and then back to N Go to Ltch and then press either two times two times Toggle it to N and back to Y 4 6 The Range Function The Range function allows the operat
44. hen 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 __ 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 menu allows the operator to set the time the analyzer should be held in the AUTO span mode after the readings of the analyzer settle Five minutes is the default but it could be adjusted anywhere from 1 to 60 minutes by using the _ keys Press Enter to move to the next screen Span Val 000008 00 lt ENT gt Span lt UP gt Mod 4 Teledyne Analytical Instruments 42 Trace Oxygen Analyzer Operation OOOO Use the arrow keys to enter the oxygen concentration mode Use the __ arrow keys to blink the digit you are going to modify Use the __ 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 press Enter to begin the Span calibration THHH ppm Span Slope The beginning span value is shown in the upper left corner of the display As the span reading settles the screen displays and updates information on Slope Spanning a
45. hoose System from the Function buttons The LCD will display five sub functions TRAK HLD Auto Cal PSWD Logout More Use __ arrows to blink Auto Cal and press Enter A new screen for Span Zero set appears Span OFF Nxt 0d 0h Zero OFF Nxt 0d 0h Press __ 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 0 h from now Use arrows to set an interval value then use __ arrows to move to the start time value Use arrows to set a start time value To turn ON the Span and or Zero cycles to activate Auto Cal Press System again choose Auto Cal and press Enter again When the Span Zero values screen appears use arrows to blink the Span or 4 Teledyne Analytical Instruments 33 Operation 3000ZA Zero OFF ON field Use __ 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 However the instrument can still be used for analysis or for initiating a self test without entering the passwo
46. ing the unit out of the case 1 6 Rear Panel Equipment Interface The rear panel shown in Figure 1 2 contains the gas and electrical connectors for external inlets and outlets Some of those depicted are optional and may not appear on your instrument The connectors are described briefly here and in detail in Chapter 3 nstallation Teledyne Analytical Instruments RS 232 o Jo Seo NO USER SERVICEABLE PARTS INSIDE SERVICE ONLY BY QUALIFIED 85 250Vac 47 63Hz C 0 9 AMAX 45 USE 250V 1 0A T FUSE p a p ZEROIN SAMPLEIN SPANIN A SEE MANUAL FOR INTERCONNECTION DETAIL gt Figure 1 2 Model 3000ZA Rear Panel 4 Teledyne Analytical Instruments 5 Introduction 3000ZA Power Connection Universal AC power source Gas Inlet and Outlet One inlet must be externally valved and one exhaust out Three inlets when option C is ordered 9 Pin RS 232 Port Serial digital concentration signal output and control input 50 Pin Equipment Interface Port Analog Outputs 0 1 VDC oxygen concentration plus 0 1 V dc range ID Alarm Connections 2 concentration alarms and 1 system alarm Remote Valve Used in the 3000ZA for controlling external solenoid valves only Remote Span Zero Digital inputs allow external control of analyzer calibration Calibration Contact To notify external equipment that instrument is being calibrated and readings ar
47. 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 BY PASS 4 Teledyne Analytical Instruments Appendix 3000ZA kawa V To improve the system response a by pass can be added to increase the sample flow rate to the analyzer by a factor of ten by pass provides a sample flow path around the analyzer of 2 18 SCFH typically CALIBRATION GAS 3000 series analyzer requirements for units with Auto Cal options are as follows The customer must supply control valves or restrictors for any SPAN or ZERO gas source which is 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 gas 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 A 3000TA without any flow restrictor device was tested on 11 19 97 This results ina flow rate of 2 4 SLPM 1 PSIG This is a cv of 0 023 for the standard sample system REFERENCE FLOW 1 XLS amp FLOW 2 XLS for information on flow rates at various pressures TAI P
48. k 51 55 57 cell failure 40 cell life 6 cleaning 55 contact rating 19 44 control panel 14 copyright 11 counter electrode 7 current output 18 current to voltage amplifier 10 data entry buttons 28 data entry keys 4 default 32 default ranges 46 default values 27 defeat alarm 45 delay 31 diffusion rate 61 digital input See input digital meter See meter digital signal output See RS 232 digital to analog converter 10 dimensions 58 display 57 door 5 door clearance 14 door latch 14 drawings 60 dual rack mounting 60 electrical connections 17 ENTER key 4 28 equipment interface connector 18 ESCAPE key 4 28 4 Teledyne Analytical Instruments Trace Oxygen Analyzer exhaust out 16 17 external control 6 external valves 22 failsafe 44 failure codes 53 features 1 FET 23 fixed range 46 47 flow range 16 flow rate 61 flow restriction devic 62 flowmeter 8 16 flowmeter window 3 flush panel mount 13 form C contacts 44 form C relay contacts 19 front panel 3 14 function hierarchy 29 fuse 53 fuse block 17 fuse block cover 52 fuse installation 18 fuse replacement 52 gas conditioning 9 gas connections 6 general purpose instrument 13 halogens 9 heater 7 high alarm See alarm concentration improve performance 38 incrementing display 45 input 6 installation 13 jumper 18 keys 4 latching 44 LED display 55 linear output 48
49. knowledged 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 For example 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 4 Teledyne Analytical Instruments 22 Trace Oxygen Analyzer Installation 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 Note The Remote Valve connections described below 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 3000ZA automatically regulates the zero span and sample gas flow Range ID Relays Four dedicated Range ID relay contacts 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 The fourth range is reserved for the Air Cal Range 25 Table 3 4 lists the pin connections Table 3 4 Range ID Relay Connections Pin Function 21 Range 1 ID Contact 38 Range 1 ID Contact 22 Range 2 ID Contact 39 Rang
50. le 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 H PPM Zero 4 Left ppm s 4 Teledyne Analytical Instruments 40 Trace Oxygen Analyzer Operation www ssrsssFwwsmsrrCtw rss smsscaksrsOc lt acs 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 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 __ 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 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 predetermined 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 THHH ppm Zero Slope Note It takes several seconds for the true Slope value to display Wait about 10 seconds Then wait until
51. lly 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 CE compliance RS 232 serial digital port for use with a computer or other digital communication device Four analog outputs two for measurement 0 1 VDC and Isolated 4 20 mA DC and two for range identification Convenient and versatile steel flush panel or rack mountable case with slide out electronics drawer 1 4 Model Designations 3000ZA Standard model for sample under pressure 3000ZA C In addition to all the 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 3000ZA electronics to automatically switch between gases in synchronization with the analyxer s operation 4 Teledyne Analytical Instruments 2 Trace Oxygen Analyzer Introduction 3000ZA M This model has current output signals 4 20 mA for ppm range and range ID in addition to voltage outputs 3000ZA V Gas flow through the cell block in this model is driven by vacuum downstream from the cell block instead of upstream pressure The Internal restrictor 15 located downstream from the cell block to support this configuration All othe
52. lustrated in Figures 2 1 and Figure 2 2 and the major electronic components locations are shown in Figure 2 3 in Chapter 2 WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL Figure 5 4 Rear Panel Removal Remove only those screws marked with an X The 3000ZA contains the following major components 4 Teledyne Analytical Instruments 55 Maintenance 3000ZA k a sr r T Analysis Section Zirconium oxide sensor Cellblock Sample system Power Supply Microprocessor Displays 5 digit LED meter 2 line 20 character alphanumeric VFD display RS 232 Communications Port See the drawings in the Drawings section in back of this manual for details 5 6 Cleaning If instrument is unmounted at time of cleaning disconnect the instrument from the power source Close and latch the front panel access door Clean outside surfaces with a soft cloth dampened slightly with plain clean water Do not use any harsh solvents such as paint thinner or benzene For panel mounted instruments clean the front panel as prescribed in the above paragraph DO NOT wipe front panel while the instrument is controlling your process 5 7 Troubleshooting Table 5 2 Troubleshooting Problem Possible Cause Solution Erratic readings of the Analyzer may have 1 Turn analyzer off oxygen concentration been calibrated in an then back on again as reported by the inaccurate fashion Press System key analyzer when
53. m normal cleaning and checking for leaks at the gas connections routine maintenance is limited to replacing the sensor and fuses and recalibration For recalibration see Section 4 4 Calibration WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL 5 2 Cell Replacement The ZrO sensor is a sealed transducer with no electrolyte to change or electrodes to clean When the cell reaches the end of its useful life it is replaced The spent sensor should be discarded according to local regulations 5 2 1 Removing the Sensor The ZrO sensor is located inside the nylon cell block behind the front panel To remove an existing cell refer to Figure 5 1 1 Remove power to the instrument by unplugging the power cord at the power source 2 Open the front panel door by pressing the release button on the top right corner of the door all the way in with a narrow gauge tool 3 Unscrew the collar on the top assembly of the cell block from the bottom section of the cell block assembly The sensor is attached to pin sockets on the bottom assembly 4 Teledyne Analytical Instruments 52 Trace Oxygen Analyzer Maintenance Gw csrsraeCcWN sII 4 Remove the old sensor and install a new sensor by matching the ortentation notch on the sensor to the silkscreen on the sensor holder Cell Block Assembly ZrO Sensor Figure 5 1 Replacing the ZrO Sensor 5 3 Fuse Replacement 1 Place small screwdriver in notch and pry cover
54. nt the alarms to be set as e Both high high and high high alarms or One high and one low alarm or Both low low and low low alarms 4 Are either or both of the alarms to be configured as failsafe 5 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 6 Are either of the alarms to be latching 7 In latching mode once the alarm or alarms trigger they will remain in the alarm mode even if process conditions revert 4 Teledyne Analytical Instruments 45 Operation 3000ZA back 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 8 Are either of the alarms to be defeated 9 The defeat alarm mode is incorporated into the alarm circuit so that maintenance can be performed under conditions which would normally activate the alarms 10 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 Alarm button on t
55. ole spacing for this unit On special order a 19 rack mounting panel can be provided For rack mounting one or two 3000 series analyzers can be flush panel mounted on the rack panel See Appendix for dimensions of the mounting panel 4 Teledyne Analytical Instruments 14 Trace Oxygen Analyzer Installation Gs FVOt m ai HINININIE Press SYSTEM 1 For Default Values 1 Figure 3 1 Front Panel of the Model 3000TA Model 3000ZA similar All operator controls except the flow control needle valve are mounted on the control panel which is hinged on the left edge and doubles as the door that provides access to the sensor and cell block inside the instrument The door latch is spring loaded and will swing open when the button in the center of the latch upper right corner is pressed all the way in with a narrow gauge tool less than 0 18 inch wide Allow clearance for the door to open in a 90 degree arc of radius 7 125 inches See Figure 3 2 Figure 3 2 Required Front Door Clearance 4 Teledyne Analytical Instruments 15 Installation 3000ZA asas 3 3 Rear Panel Connections Figure 3 3 shows the Model 3000ZA rear panel There are ports for gas power and equipment interface The Zero In and Span In ports are not included on the standard model but are available as options A 4 Teledyne Analytical Instruments RS 232 0 Jo CAUTION Mer BEC BIC oer DO NOT OPEN NO USER SERVICEA
56. on 28 4 2 Using the Data Entry and Function Buttons 29 4 3 The System Function 31 4 3 1 Tracking the Oxygen Readings during Calibration 32 4 3 2 Setting up an Auto Cal 33 4 3 3 Password Protection 34 4 3 3 1 Entering the Password 34 4 3 3 2 Installing or Changing the Password 35 4 3 4 Logout 37 4 3 5 System Self Diagnostic Test 37 4 3 6 Version Screen 38 4 3 7 Showing Negative Oxygen Readings 38 4 4 The Zero and Span Functions 39 4 4 1 Zero Cal 40 4 4 1 1 Auto Mode Zeroing 40 4 4 1 2 Manual Mode Zeroing 41 4 4 1 3 Cell Failure 41 4 4 2 Span Cal 42 4 4 2 1 Auto Mode Spanning 42 4 4 2 2 Manual Mode Spanning 43 4 4 3 Span Failure 44 4 5 The Alarms Function 45 4 6 The Range Function 47 4 6 1 Setting the Analog Output Ranges 47 4 6 2 Fixed Range Analysis 48 4 7 The Analyze Function 49 4 8 Signal Output 49 Maintenance EM 52 5 1 Routine Maintenance 52 5 2 Cell Replacement 52 5 2 1 Removing the Sensor 52 4 Teledyne Analytical Instruments ix 3000ZA 5 3 Fuse Replacement 5 4 System Self Diagnostic Test 5 5 Major Internal Components 5 6 Cleaning 5 7 Troubleshooting App endiX u e A 1 Specifications A 2 Recommended 2 Year Spare Parts List A 3 Drawing List A 4 19 inch Relay Rack Panel Mount A 5 Application Notes 4 Teledyne Analytical Instruments 53 54 55 56 56 58 60 61 61 62 Trace Oxygen Analyzer List of Figures Figure 1 1 Figure 1 2 Figure 2
57. or low actuates when concentration is below threshold Can be configured as failsafe or non failsafe Can be configured as latching or non latching Can be configured out defeated System Alarm 4 Teledyne Analytical Instruments 20 Trace Oxygen Analyzer Installation Actuates when DC power supplied to circuits is unacceptable in one or more parameters Permanently configured as failsafe and latching Cannot be defeated Actuates if self test fails Reset by pressing button to remove power Then press again and any other button EXCEPT System to resume Further detail can be found in Chapter 4 Section 4 5 Table 3 2 Alarm Relay Contact Pins Pin 45 28 46 42 44 43 36 20 37 Contact Threshold Alarm 1 normally closed contact Threshold Alarm 1 moving contact Threshold Alarm 1 normally open contact Threshold Alarm 2 normally closed contact Threshold Alarm 2 moving contact Threshold Alarm 2 normally open contact System Alarm normally closed contact System Alarm moving contact System Alarm normally open contact Digital Remote Cal Inputs Accept 0 V off or 24 VDC on inputs for remote control of calibration See Remote Calibration Protocol below See Table 3 3 for pin connections Zero Floating input 5 to 24 V input across the and pins 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 Z
58. or 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 10 ppm Med 0 100 ppm High 0 250 ppm The Model 3000ZA 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 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 VDC 20 mA at the current output However the digital readout and the RS 232 output of the concentration are unaffected by the fixed range They continue to read accurately with full precision See Front Panel description in Chapter 1 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 4 Teledyne Analytical Instruments 47 Operation 3000ZA L 10 M 100 H 250 Mode AUTO Use the __ arrow keys to
59. ppm O2 0 1 ppm analysis possible Option b 0 10 to 0 1000 ppm O2 Autoranging with range ID output One system failure alarm contact to detect power failure or sensor zero failure Two adjustable concentration threshold alarm contacts with fully programmable setpoints 2 line by 20 character VFD screen and one 5 digit LED display Full duplex RS 232 communications port 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Power Operating Temperature Accuracy Analog outputs Dimensions Appendix Universal power supply 85 250 V ac at 47 63 Hz 5 35 C 2 of full scale at constant temperature at ca obrated ramge 5 of full scale over operating temperature range except 0 1 ppm analysis range once thermal equilibrium is reached 0 2 ppm on 0 1 ppm analysis range once thermal equilibrium is reached 0 1 VDC percent of range 0 1 VDC range ID 4 20 mA DC isolated percent of range 4 20 mA DC isolated range ID optional 19 cm high 24 9 cm wide 31 cm deep 6 96 in high 8 7 in wide 12 2 in deep 4 Teledyne Analytical Instruments Appendix 3000ZA kawa V A 2 Recommended 2 Year Spare Parts List Qty Part Number Description 1 C65507A Back Panel Board 1 C62371 A Front Panel Board 1 75734 Trace Preamplifier Board 1 C73870 A Main Computer Board 1 F10 Fuse 2A 250V 3AG Slow Blow 2 F1296 Fuse 2A 250V 5x20mm Slow Blow 1 A68314 Back Panel Connector Kit 1 A
60. prompted by analyzer Press System for Default Values This will return the default settings to the 4 Teledyne Analytical Instruments 56 Trace Oxygen Analyzer Maintenance analyzer 2 If erratic behavior continues replace sensor Atmospheric oxygen diffusing through vent and altering the oxygen level the sensor sees Increase flow rate and or length of vent tubing to dilute or minimize oxygen diffusion from vent to sensor Inaccurate zero operation i e user has zeroed the instrument using a gas concen tration much higher than normal for a zero gas Turn analyzer off then back on again Press System key when prompted by analyzer Press System for Default Values This will return the analyzer to default calibration and zero settings Now proceed to carefully calibrate and zero the analyzer 4 Teledyne Analytical Instruments 57 Appendix Appendix A 1 Specifications Packaging Sensor Cell Block Sample System 90 Response Time Ranges Alarms Displays Digital Interface 3000ZA General Purpose Flush panel mount Standard Relay rack mount Contains either one or two instruments in one 19 relay rack mountable plate Optional Zirconium oxide sensor Nylon wetted parts of 316 stainless steel 65 seconds at 25 C 77 F on 10 ppm range 100 seconds on 1 ppm range Option a 0 10 to 0 200
61. put 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 ZERO IN and SPAN IN Optional These are additional ports for inputting span and zero gas There are electrically operated valves inside for automatic switching between calibration and sample gases These valves are completely under control of the 3000ZA electronics They can be externally controlled only indirectly through the remote cal inputs as described below Pressure flow and safety considerations are the same as prescribed for the SAMPLE IN inlet above 3 3 2 Electrical Connections For safe connections no uninsulated wiring should be able to come in contact with fingers tools or clothing during normal operation CAUTION USE SHIELDED CABLES ALSO USE PLUGS THAT PROVIDE EXCELLENT EMI RFI PROTECTION THE PLUG CASE MUST BE CONNECTED TO THE CABLE SHIELD AND IT MUST BE TIGHTLY FASTENED TO THE ANALYZER WITH ITS FASTENING SCREWS ULTIMATELY IT IS THE INSTALLER WHO ENSURES THAT THE CONNECTIONS PROVIDE ADEQUATE EMI RFI SIELDING 3 3 2 1 Primary Input Power The power cord receptacle and fuse block are located in the same assembly Insert the power cord into the power cord receptacle CAUTION POWER IS APPLIED TO THE INSTRUMENT S CIRCUITRY AS LONG AS THE INSTRUMENT IS CONNECTED TO THE POWER SO
62. r standard features are present in this model 1 5 Front Panel Operator Interface The standard 3000ZA is housed in a rugged metal case with all controls and displays accessible from the front panel See Figure 1 1 The front panel has thirteen buttons for operating the analyzer a digital meter an alphanumeric display and a window for viewing the sample flowmeter Door Latcr igital Meter A Enter Alphanumeric Display Sample System Flow Indicator Data Entry Function Buttons Buttons Standby Switch Figure 1 1 Model 3000ZA Front Panel Teledyne Analytical Instruments 3 Introduction 3000ZA Function Keys Six touch sensitive membrane switches are used to change the specific function performed by the analyzer Analyze Perform analysis for oxygen content of a sample gas System Perform system related tasks described in detail in chapter 4 Operation Span Span calibrate the analyzer Zero Zero calibrate the analyzer Alarms Setthe alarm setpoints and attributes Range Setup the 3 user definable ranges for the instrument Data Entry Keys Six touch sensitive membrane switches are used to input data to the instrument via the alphanumeric VFD display 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 Enter Advances VFD display to th
63. rd 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 is in effect pressing the Enter button will enter the default TETAI password for you Press System to enter the System mode TRAK HLD Auto Cal PSWD Logout More Use the __ arrow keys to scroll the blinking over to PSWD and press Enter to select the password function Either the default TETAI password or AAAAA place holders for an existing password will appear on screen depending on whether or not a password has been previously installed TETAI Enter PWD AAAAA Enter PWD 4 Teledyne Analytical Instruments 34 Trace Oxygen Analyzer Operation ww swmwKCs u srssswxww wm svai The screen prompts you to enter the current password If you are not using password protection press Enter to accept TETAI as the default password If a password has been previously installed enter the password using the arrow keys to scroll back and forth between letters and the arrow keys to change the lett
64. rted 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 4 Teledyne Analytical Instruments 32 Trace Oxygen Analyzer Operation www ssrsssFwwsmsrrCtw rss smsscaksrsOc lt acs The factory default is three minutes but the delay time 15 programmable 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 proper automatic valving is connected see Chapter 3 Installation the Analyzer can cycle itself through a sequence of steps that automatically calibrates the instrument Note If you require highly accurate Auto Cal timing use external Auto Cal control where possible The internal clock in the Model 3000ZA is acurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day To setup an Auto Cal cycle C
65. ry 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 Teledyne Analytical Instruments 44 Trace Oxygen Analyzer Operation 4 5 Alarms Function The Model 3000ZA 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 VAC See Table 3 2 in Chapter 3 nstallation and or the Interconnection Diagram included at the back of this manual for relay terminal connections The system failure alarm has a fixed configuration as 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 2 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 3 Decide whether you wa
66. s it travels through the sample system The sample system for the standard instrument incorporates compression tube fittings for sample inlet and 1 4 outlet tube connections at the rear panel The sample or calibration gas that flows through the system is monitored by a flowmeter downstream from the cell Figure 2 1 shows the piping layout for the standard model Figure 2 2 shows the flow diagram for sampling systems used for the three configurations offered as options for this instrument In the standard instrument calibration gases can be connected directly to the Sample In port by teeing to the port with appropriate valves Side View Top View Flow meter Cell Block Exhaust Sample In Figure 2 1 Model 3000ZA Sample System 4 Teledyne Analytical Instruments 9 Operational Theory 3000ZA Span In a Components in the shaded area are in the C option internal control valves only and are not shown in the piping Zero In diagram above Sample In gt Solenoid Valves In vacuum service restrictor should be In normal service the Flowmeter placed here restrictor should be g placed here Exhaust Out 75 Restrictor _ Figure 2 2 Flow Diagram with Options 2 4 Zirconium Oxide Sensor Application Notes The following sample
67. this instrument may be able to provide early warning of imminent danger it has no control over process conditions and it can be misused In particular any alarm or control systems installed must be tested and understood both as to how they operate and as to how they can be defeated Any safeguards required such as locks labels or redundancy must be provided by the user or specifically requested of Teledyne at the time the order is placed Therefore the purchaser must be aware of the hazardous process conditions The purchaser is responsible for the training of personnel for providing hazard warning methods and instrumentation per the appropriate standards and for ensuring that hazard warning devices and instrumentation are maintained and operated properly Teledyne Analytical Instruments the manufacturer of this instrument cannot accept responsibility for conditions beyond its knowledge and control No statement expressed or implied by this document or any information disseminated by the manufacturer or its agents is to be construed as a warranty of adequate safety control under the user s process conditions 4 Teledyne Analytical Instruments ii Trace Oxygen Analyzer Specific Model Information The instrument for which this manual was supplied may incorporate one or more options not supplied in the standard instrument Commonly available options are listed below with check boxes Any that are incorporated in the instrument for
68. ue sticker to the Exhaust Out port The small circular orifice should face TOWARD the back of the unit against the direction of gas flow CAUTION OPERATING THE UNIT WITHOUT RESTRICTORS CAN CAUSE DAMAGE TO THE SENSOR The unit is manufactured with 1 4 tube fittings and includes 6 mm adapters for metric system installations For a safe connection 1 Insert the tube into the fitting and finger tighten the nut until the tubing cannot be rotated freely by hand in the fitting This may require an additional 1 8 turn beyond finger tight 2 Hold the fitting body steady with a backup wrench using another wrench rotate the nut another 1 1 4 turns 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 inlet gas pressure should be reasonably regulated Pressures between 2 and 50 psig are acceptable as long as the pressure once established will keep the front panel flowmeter reading in an acceptable range 0 5 to 2 0 SLPM For non pressurized sample or very low pressure less than 2 psig vacuum service plumbing is recommended Exact figures will depend on your process 4 Teledyne Analytical Instruments 17 Installation 3000ZA suu sv VW If greater sample flow is required for improved response time install a bypass in the sampling system upstream of the analyzer in
69. ump 62 vacuum service 15 62 VCR fittings 8 vent 6 version 37 VERSION 30 VFD display 55 voltage output 18 warning sign warranty 11 water vapor 9 web address 59 website address vi zero calibration See calibration zero ZERO key 28 zero settling 39 40 zirconium oxide sensor 5 7 54 55 57 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Index 4 Teledyne Analytical Instruments
70. urized sample applications the marked restrictor should be used and configured for vacuum service Note For extremely low positive pressure applications 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 particles 005 dia or larger A sample filter must be included in the sample line prior to the restrictor A 60 micron filter is recommended 3000TA EXAMPLES Example 1 With a incoming pressure of 10 psig the std restrictor blue dot will provide a flow rate of 0 76 SLPM Upstream 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 drops 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 result in pressurizing the cell Example 2 A 3000TA is configured for vacuum service as follows The unmarked restrictor is placed in the sample vent port The down stream end of the restrictor
71. utomatically ends when the span output corresponds 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 __ 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 Enter to move to the next screen Calib Holding time Cal hold 5 min This menu allows the operator to set the time the analyzer should be held in the AUTO span mode It does not have any effect in the MANual mode Just press Enter key to continue Span Val 000008 00 lt ENT gt Span lt UP gt Mod Press UP to permit modification Mod of span value Use the arrow keys to enter the oxygen concentration of the span gas you are using The arrows choose the digit and the arrows choose the value of the digit 4 Teledyne Analytical Instruments 43 Operation 3000ZA 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 a Slope on the screen It takes sev
72. which this manual is supplied are indicated by a check mark in the box Instrument Serial Number Options Included in the Instrument with the Above Serial Number H H 3000ZA C 3000ZA Rack Mnt In addition to all the 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 3000ZA electronics to automatically switch between gases in synchronization with the analyxer s operation The 19 Relay Rack Mount units are available with either one or two 3000 series analyzers installed in a standard 19 panel and ready to mount in a standard rack 4 Teledyne Analytical Instruments 3000ZA Important Notice Model 3000ZA complies with all of the requirements of the Commonwealth of Europe for Radio Frequency Interference Electromagnetic Interference RFI EMI and Low Voltage Directive LVD The following International Symbols are used throughout the Instruction Manual These symbols are visual indicators of important and immediate warnings and when you must exercise CAUTION while operating the instrument See also the Safety Information on the next 3 amp ga 6 STAND BY Instrument is on Stand by but circuit is active GROUND Protective Earth CAUTION The operator needs to refer to the manual for further information Failure to do so may compromise the safe operation of the equipment CA

Teledyne 3000ZA Oxygen Equipment User Manual

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