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Teledyne 3000TA-XL-EU Oxygen Equipment User Manual

1. Needle Valve Flowmeter Figure 2 4 Piping Layout Figure 2 5 is the flow diagram for the sampling system In the standard instrument calibration gases can be connected directly to the Sample In port by teeing to the port with appropriate valves 2 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 Sample Under Pressure 2 20 psig Flow Control Flowmeter Needle Valve Exhaust Out Figure 2 5 Flow Diagram Sample Under Pressure Standard Model l 1 l Sample at 0 lt 2 psig Flow Control Needle Valve Flowmeter Vacuum Do not exceed 10 Hg Vacuum L Figure 2 5 1 Flow Diagram Sample at Zero Pressure Model 3000TA XL VS C Zero Inlet Sample Under Pressure 2 20 psig Flow Control Needle Span Inlet Valve Flowmeter Exhaust Out Figure 2 5 2 Flow Diagram Sample Under Pressure Model 3000TA XL CV Teledyne Analytical Instruments 2 7 2 Operational Theory Model 3000TA XL EU 2 4 Electronics and Signal Processing The Model 3000TA XL Trace Oxygen Analyzer uses an 8031 micro controller
2. 1 1 1 4 Model Designations ssseu 1 2 1 5 Front Panel Operator Interface 1 3 1 6 Rear Panel Equipment Interface 1 5 2 Operational Theory 2 1 cao uir e b inca Ub Ba c ED E EC PR E eR RR 2 1 2 2 Micro Fuel Cell 2 1 2 2 1 Principles of ODSFrallOfix sooo oto ioo p c pres 2 1 2 2 2 Anatomy of a Micro Fuel Cell 2 2 2 2 3 Electrochemical Reactions 2 3 2 2 4 The Effect of 2 4 2 2 5 Calibration Characteristics 2 4 23 Sampl System ainin 2 5 2 4 Electronics and Signal Processing 2 8 3 Installation 3 1 Unpacking the Analyzer ssseeeeeese 3 1 3 2 Mounting the Analyzer dra ddnde de conto 3 1 3 3 Rear Panel Connections 3 2 Gas COMMECIONS naniii 3 3 3 3 2 Electrical Connections 3 4 3 3 2 1 Primary Input 3 4 3 3 2 2 50 Pin Equipment Interface Connector 3 4 9 0 2 9 HO3292 POLL 3 9 3 4 Installing the Micro Fuel
3. A 3 A 3 Drawing ISH an A 4 4 19 Inch Relay Rack Panel Mount A 4 A 5 Application Notes on Pressures and Flow A 5 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix A 6 Material Safety Data A 8 A 7 Installing and Replacing Micro Fuel Cell A 12 W Teledyne Analytical Instruments vii Model 3000TA XL EU DANGER COMBUSTIBLE GAS USAGE WARNING This is a general purpose instrument designed for use in a nonhazardous 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 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 unau thorized 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 viii Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 Introduction 1 1 Overview The Teledyne Analytical Instruments Model 3000TA XL Trace Oxy
4. M IO H 100 Mode FX MED or M 10 H 100 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 concentra tion rises above the upper limit or default value as established by the operator for that particular range the output saturates at 1 V dc or 20 mA However the digital readout and the RS 232 output continue to read the true value of the oxygen concentration regardless of the analog output range 4 8 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 Ana lyze function Alternatively you can press the Analyze button at any time to return to analyzing your sample 4 9 Signal Output The standard Model 3000TA XL Trace Oxygen Analyzer is equipped with two 0 1 V dc analog output terminals accessible on the back panel one concentration and one range ID and two isolated 4 20 mA current outputs one concentration and one range ID See Rear Panel in Chapter 3 Installation for illustration The signal output for concentration is linear over the currently selected analysis range For example if the analyzer is set on range that was defined as 0 100 ppm O then the output would be Voltage Signal Current Signal ppm O Output V dc Output
5. Cell Output uA 125 50k 100 k 150 k 200 k Oxygen Concentration ppm Figure 2 3 Characteristic Input Output Curve for a Micro Fuel Cell 2 3 Sample System The sample system delivers gases to the Micro Fuel Cell sensor from the analyzer rear panel inlet Depending on the mode of operation either sample or calibration gas is delivered The Model 3000TA XL sample system is designed and fabricated to ensure that the oxygen concentration of the gas is not altered as it travels through the sample system The sample system for the standard instrument incorporates VCR tube fittings for sample inlet and 1 A 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 4 shows the piping layout and flow diagram for the standard model Teledyne Analytical Instruments 2 5 2 Operational Theory Model 3000TA XL EU SAMPLE IN TOP O RIGHT SIDE EM e P a Sample In TIE Out EE O
6. OPERATING INSTRUCTIONS FOR Model 3000TA XL EU Trace Oxygen Analyzer HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING SYSTEM PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND OR SERVICING BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR MANAGER P N M69603 11 24 04 ECO 03 0126 Teledyne Analytical Instruments Model 3000TA XL EU Copyright 1999 Teledyne Analytical Instruments All Rights Reserved No part of this manual may be reproduced transmitted tran scribed stored in a retrieval system or translated into any other language or computer language in whole or in part in any form or by any means whether it be electronic mechanical magnetic optical manual or otherwise without the prior written consent of Teledyne Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Warranty This equipment is sold subject to the mutual agreement that it is warranted by us free from defects of material and of construction and that our liability shall be limited to replacing or repairing at our factory without charge except for transportation or at customer plant at our option any material or
7. Three user definable output ranges from 0 1 ppm through 0 250 000 ppm allow best match to users process and equipment e Air calibration range for spanning at 20 9 209 000 ppm available Auto Ranging allows analyzer to automatically select the proper preset range for a given measurement Manual override allows the user to lock onto a specific range of interest e Two adjustable concentration alarms and a system failure alarm e Extensive self diagnostic testing at startup and on demand with continuous power supply monitoring Two way RFI protection e RS 232 serial digital port for use with a computer or other digital communication device e Four analog outputs two for measurement 0 1 V dc and Isolated 4 20 mA dc and two for range identification e Convenient and versatile steel flush panel or rack mountable case with slide out electronics drawer 1 4 Model Designations 3000TA XL Standard model for sample under pressure 3000TA XL VS Instrument configured for Vacuum Service 3000TA XL CV Instrument with calibration valves 1 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 1 5 Front Panel Operator Interface The standard 3000TA XL 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 viewin
8. are tripped AL x ON 3 10 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 3 4 Installing the Micro Fuel Cell The Micro Fuel Cell Model B 2CXL is not installed in the cell block when the instrument is shipped Install it before the analyzer is placed in service The Micro Fuel cell is located inside the stainless steel cell block behind the front panel see Figure 3 8 To install the cell 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 With one hand placed underneath the cell block ready to catch the Micro Fuel cell lift up on the stainless steel gate in front of the cell block This releases the cell and cell holder from the block The cell and holder will fall out in your hand CAUTION The cell is shipped separately inside two bags filled with oxygen free inert gas Extreme care must be taken to ensure that the cell is exposed to air for very minimum amount of time including during installation As an example an air exposure of 3 to 5 minutes may require 24 hours or longer before the cell recovers to less than 0 5 ppm on an oxygen free sample gas On the other hand if the air exposure is limited to less than 10 seconds the recovery time will be reduced to two hours or less 3 5 Testing the System Before plug
9. gen Analyzeris a versatile microprocessor based instrument for detecting oxygen at the parts per million ppm level in a variety of gases This manual covers the Model 3000TA XL General Purpose flush panel and or rack mount units only These units are for indoor use in a nonhazardous environ ment 1 2 Typical Applications A few typical applications of the Model 3000TA XL are 1 Monitoring inert gas blanketing Air separation and liquefaction Chemicalreaction monitoring Semiconductor manufacturing Petrochemical process control Quality assurance Gas analysis certification 3 Main Features of the Analyzer The Model 3000TA XL Trace Oxygen Analyzer is sophisticated yet simple to use The main features of the analyzer include A 2 line alphanumeric vacuum fluorescent display VFD screen driven by microprocessor electronics that continuously prompts and informs the operator High resolution accurate readings of oxygen content from low ppm levels through 25 Large bright meter readout Stainless steel cell block Teledyne Analytical Instruments 1 1 1 Introduction Model 3000TA XL EU e Advanced Micro Fuel Cell designed for trace analysis has a 0 1 ppm low range with less than a 0 2 ppm offset and six months warranty and an expected lifetime of one year e Versatile analysis over a wide range of applications e Microprocessor based electronics 8 bit CMOS microprocessor with 32 kB RAM and 128 kB ROM
10. setpoint Decide whether you want the alarms to be set as Teledyne Analytical Instruments 4 17 4 Operation Model 3000TA XL EU e Both high high and high high alarms or e high and one low alarm or Both low low and low low alarms 2 Are either or both of the alarms to be configured as failsafe In failsafe mode the alarm relay de energizes in an alarm condition For non failsafe operation the relay is energized in an alarm condition You can set either or both of the concentration alarms to operate in failsafe or non failsafe mode 3 Areeither of the alarms to be latching In latching mode once the alarm or alarms trigger they will remain in the alarm mode even if process conditions revert back to non alarm conditions This mode requires an alarm to be recognized before it can be reset In the non latching mode the alarm status will terminate when process conditions revert to non alarm conditions 4 Are either of the alarms to be defeated The defeat alarm mode is incorporated into the alarm circuit so that maintenance can be performed under conditions which would normally activate the alarms The defeat function can also be used to reset a latched alarm See procedures below If you are using password protection you will need to enter your password to access the alarm functions Follow the instructions in section 4 3 3 to enter your password Once you have clearance to proceed enter the
11. 3000TA XL Analyzer includes 1 Unpacking 2 Mounting 3 Gas connections 4 Electrical connections 5 Installing the Micro Fuel Cell 6 Testing the system 3 1 Unpacking the Analyzer The analyzer is shipped with all the materials you need to install and prepare the system for operation Carefully unpack the analyzer and inspect it for damage Immediately report any damage to the shipping agent 3 2 Mounting the Analyzer The Model 3000TA XL 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 XL standard front panel and mounting bezel There are four mounting holes one in each corner of the rigid frame Drawing number D 62928 at the back of this manual contains a panel cutout diagram On special order a 19 rack mounting panel can be provided For rack mounting one or two 3000XL series analyzers can be flush panel mounted on the rack panel See Appendix for dimensions of the mounting panel Teledyne Analytical Instruments 3 1 3 Installation Model 3000TA XL EU Latch Press SYSTEM 6 7 For Default Yalues Hinge Figure 3 1 Front Panel of the Model 3000TA XL 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 insid
12. 4 16 4 5 Switching of Sample Streams 4 16 4 5 1 Special notes on hydrogen gas stream 4 17 4 6 The Alarms Function 4 17 4 7 The Range 4 19 4 7 1 Setting the Analog Output Ranges 4 20 4 7 2 Fixed Range 4 20 4 8 The Analyze neea 4 21 Z9 Signal OU DUE eit no dua eds elect UM See Me 4 21 Maintenance 5 1 Routine Maintenance 5 1 5 2 Cell Replacement rre etr e eg a 5 1 5 2 1 Storing and Handling Replacement Cells 5 1 5 2 2 When to Replace a 5 2 5 2 3 Removing the Micro Fuel Cell 5 2 5 2 4 Installing a New Micro Fuel Cell 5 4 5 2 5 Cell Warranty en os EG eie tipi Ip Die tt 5 4 5 3 Fuse Replacements usi erre px eee 5 5 5 4 System Self Diagnostic 5 5 5 5 Major Internal 5 6 5 0 CORB alid 5 7 5 7 Troubleshooting htt indi da cepe ent 5 8 Appendix 1 Model 3000TA XL Specifications A 1 A 2 Recommended 2 Year Spare Parts List
13. Cell 3 11 3 5 Testing the SVSIOITTS acoso tin Loue e aai 3 11 4 Operation A 4 1 4 2 Using the Data Entry and Function Buttons 4 2 43 The System Function 4 3 4 3 1 Tracking the O Readings during CAI amp Alarm 4 4 4 3 2 Setting up an 4 5 4 3 3 Password Protection sis irren tees 4 6 4 3 3 1 Entering the Password 4 7 Teledyne Analytical Instruments V Model 3000TA XL EU vi 4 3 3 2 Installing or Changing the Password 4 8 4 3 4 uoti cinis enin 4 9 4 3 5 System Self Diagnostic Test 4 9 4 3 6 Version Screen s oii eoe ee rcp EE Ei Eius 4 10 4 4 Calibration of the 4 11 T4 zero Gal e D IEEE beo eno 4 11 4 4 1 1 Auto Mode Zeroing 4 12 4 4 1 2 Manual Mode Zeroing 4 12 Call Failure attente eed ioo 4 13 olde tbe DU 4 14 4 4 2 1 Auto Mode Spanning 4 14 4 4 2 2 Manual Mode Spanning 4 15 4 4 3 Span FallUeacndneci ice Servo eux Ob PDC Cim t Ped
14. 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 10 000 ppm and then switches to a continuous percent readout from 1 25 It is accurate across all analysis ranges without the discontinuity inherent in analog range switching Alphanumeric Interface Screen The VFD screen is an easy to use interface from operator to analyzer It displays values options and messages that give the operator immediate feedback NeedleValve To adjust flow of gas sample Flowmeter Monitors the flow of gas past the sensor Readout is 0 2 to 2 4 standard liters per minute SLPM of nitrogen Standby Button 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 Micro Fuel Cell the front panel swings open when the latch in the upper right corner of the panel is pressed 1 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Introduction 1 all the way in with a narrow gauge tool Accessing the main circuit board requires unfastening rear panel screws and sliding the unit out of the case 1 6 Rear Panel Equipment Interface The rear panel shown in F
15. Time 65 seconds at 25 C 77 F on 10 ppm range 100 seconds on 1 ppm range Ranges Three user definable ranges from 0 1 ppm to 0 250 000 ppm plus air calibration range of 0 250 000 ppm 25 96 Autoranging with range ID output Alarms system failure alarm contact to detect power failure or sensor zero failure Two adjustable concentration threshold alarm contacts with fully programmable setpoints Displays 2 line by 20 character screen and one 5 digit LED display Digital Interface Full duplex RS 232 communications port Teledyne Analytical Instruments A 1 Appendix Operating Temperature Power Accuracy Analog outputs Dimensions Model 3000TA XL EU Universal power supply 85 250 V ac at 47 63 Hz 5 35 C 2 of full scale at constant temperature 5 of full scale over operating temperature range except 0 10 ppm and 0 1 ppm analysis range once thermal equilibrium is reached 0 1 ppm on 0 1 ppm analysis range once thermal equalibrium 15 reached 0 1 V dc percent of range 0 1 V dc range ID 4 20 mA dc isolated percent of range 4 20 mA dc isolated range ID 19 cm high 24 9 cm wide 31 cm deep 6 96 in high 8 7 in wide 12 2 in deep Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix A 2 Recommended 2 Year Spare Parts List Part NuMBER DESCRIPTION 1 C65507A Back Panel Board 1 C62371 B Front Panel Board 1 C69
16. To remove an existing cell 5 2 W Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 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 With one hand placed underneath the cell block ready to catch the Micro Fuel cell lift up on the stainless steel gate in front of the cell block This releases the cell and cell holder from the block The cell and holder will fall out in your hand Needle Valve Cell Adaptor Figure 5 1 Removing the Micro Fuel Co ORing Coe Cell Holder 79 Teledyne Analytical Instruments 5 3 5 Maintenance Model 3000TA XL EU 5 2 4 Installing a New Micro Fuel Cell Before installing a new cell check the O ring in the base of the cell holder Replace if worn or damaged 1 Place the cell on the holder with the screen side facing down Note There is a small location hole drilled in the holder This hole mates with a guide pin on the bottom rear of the cell block The hole in the cell block holder must align with the guide pin on the cell block 2 With O ring in place align the guide pin with the hole on the cell holder Then with the holder lift cell into the cell block 3 Push the gate on the cell block down so that the slots on the side of the gate engage the l
17. Turn the analyzer off then turn back on again Press the System key when prompted by the analyzer Press System for default Values This will return the analyzer to its default settings in calibration and zero values If erratic behavior continues clean sensor contacts or replace the sensor Possible Cause Atmospheric Oxygen may be diffusing in through the vent and affecting the oxygen level which the sensor sees Solution Increase flow rate and or length or vent tubing in order to dilute or minimize the diffusion of oxygen from the vent back to the sensor Problem Inaccurate zero operation i e the user has zeroed the analyzer accidentally on gas much higher than one would normally use for a zero gas Solution Turn the analyzer off then back on again Press the System key when prompted by the analyzer Press System for default Values This will return the analyzer to its default settings in calibration and zero values Now proceed to carefully calibrate and zero the analyzer 5 8 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix Appendix A 1 Specifications Packaging General Purpose Flush panel mount Standard Relay rack mount Contains either one or two instruments in one 19 relay rack mountable plate Optional Sensor Teledyne B 2CXL trace analysis Micro Fuel Cell Cell Block 316 stainless steel SampleSystem All wetted parts of 316 stainless steel 90 Response
18. circuitry as long as the instrument is connected to the power source The red C switch on the front panel is for switching power on or off to the displays and out puts only The universal power supply requires a 85 250 V ac 47 63 Hz power source Fuse Installation The fuse block at the right of the power cord receptacle accepts US or European size fuses A 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 Replace ment in chapter 5 maintenance 3 3 2 2 50 PinEquipment 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 3 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 33 lt er tana arta cis UE o o o o o o o o o o o o o 18 50 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 V dc of Range 0 1 V dc Range ID 4 20 mA dc Range Voltage rises linearly with increasing oxygen from 0 V at 0 ppm to 1 V at full scale
19. construction in which defects become apparent within one year from the date of shipment except in cases where quotations or acknowledgements provide for a shorter period Components manufactured by others bear the warranty of their manufacturer This warranty does not cover defects caused by wear accident misuse neglect or repairs other than those performed by Teledyne or an autho rized service center We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage which may result from its use or misuse We reserve the right to employ any suitable material in the manufacture of our apparatus and to make any alterations in the dimensions shape or weight of any parts in so far as such alterations do not adversely affect our warranty Important Notice This instrument provides measurement readings to its user and serves as a tool by which valuable data can be gathered The information provided by the instrument may assist the user in eliminating potential hazards caused by his process however it is essential that all personnel involved in the use of the instrument or its interface with the process being measured be properly trained in the process itself as well as all instrumenta tion related to it The safety of personnel is ultimately the responsibility of those who control process conditions While this instrument may be able to provide ea
20. is to be performed automatically or manually Span Settling MAN lt ENT gt For Next Use the AV keys to toggle between AUTO and MAN span settling Stop when MAN appears blinking on the display Press Enter to move to the next screen Press Enterto move to the next screen Calib Holding time Cal hold 5 min This menue allows the operator to set the time the analyzer should be held in the AUTO span mode It does not 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 A lt UP gt to permit modification Mod of span value Use the arrow keys to enter the oxygen concentration of the span gas you are using 209000 00 if you are using air The lt gt arrows choose the digit and the AV arrows choose the value of the digit Press Enter to enter the span value into the system and begin the span calibration Once the span has begun the microprocessor samples the output at a predetermined rate It calculates the difference between successive samplings and displays this difference as a Slope on the screen It takes several 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 THHHE Span Slope HHHF 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
21. ppm Full scale 100 of programmable range 0 25 V Low Range 0 5 V Medium Range 0 75 V High Range 1 V Air Cal 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 4 20 mA dc Range ID 8 mA Low Range 12 mA Medium Range 16 mA High Range 20 mA Air Cal Range Table 3 1 Analog Output Connections Pin QN tA A Ut Function Range ID 4 20 mA floating Range ID 4 20 mA floating 96 Range 4 20 mA floating Range 4 20 mA floating Range ID 0 1 V dc 23 RangeID 0 1 V dc negative ground 24 Range 0 1 V dc 7 Range 0 1 V dc 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 concen tration is above threshold or low actuates when concentration is below threshold Teledyne Analytical Instruments 3 5 3 Insta lation Model 3000TA XL EU Can be configured as failsafe or nonfailsafe Can be configured as latching or nonlatching Can be co
22. rate trough the analyzer Any line attached to sample vent should be 1 4 or larger in diameter FLOW RATE RECOMMENDATIONS Ausable flow rate fora 3000XL series analyzer is one which can be measured on the flowmeter This is basically 0 5 2 0 SLPM The optimum flow rate is 1 SLPM mid scale Note response time is dependent on flow rate alow flow rate will result in slow response to O2 changes in the sample stream The span flow rate should be the approximately same as the sample flow rate CELL PRESSURE CONCERNS The sensors used in 3000XL series analyzers are optimized to function at atmospheric pressure At pressures other than atmospheric the diffusion rate of O2 willbe different than optimum value Higher pressures will produce faster O2 diffusion rates resulting in higher O2 reading and shorter cell life Tousea 3000XL series analyzer ata cell pressure other than atmospheric the analyzer must be calibrated with a known calibration gas at the new cell pressure to adjust for the different diffusion rate Cell pressures below 2 3 atmospheric are notrecommended because they tend to cause excessive internal expansion which may resultin seal failure For operation at cell pressures other than atmospheric care must be taken not to change the sample pressure rapidly or cell damage may occur For cell pressures above atmospheric caution must be exercised to avoid over pressuring the cell holder FLOW CONTROL VALVE All3000XL series analyze
23. 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 Teledyne Analytical Instruments 4 3 4 Operation Model 3000TA XL EU 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 e More Select and enter More to get a new screen with additional subfunctions listed Self Test The instrument performs a self diagnostic test to check the integrity of the power supply output boards and amplifiers e Version Displays Manufacturer Model and Software Version of instrument Show Negative The operator selects whether display can show ne
24. 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 password If you have decided not to employ password security use the default password TETAI This password will be displayed automatically by the microprocessor The operator just presses the Enter key to be allowed total access to the instrument s features NOTE If you use password security it is advisable to keep a copy of the password in a separate safe location 4 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 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 pass word for you Press System to enter the System mode TRAK HLD Auto Cal PSWD Logout More Use the lt gt arrow keys to scroll the blinking over to PSWD and press Enter to select the password function Either the default 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 or AAAAA Enter PWD The screen prompts you to enter the current password If you are not using passw
25. 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 3000TA implementation Table 3 6 Required RS 232 Options Parameter Setting Baud 2400 Byte 8 bits Parity none Stop Bits 1 Message Interval 2 secondsWhen CRC opens again zero and span are done and the sample is being analyzed Range ID Relays There are 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 2596 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 e concentration in ppm or percent e The range 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
26. 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 6 shows the location of the power supply and the main electronic PC boards The signal processing electronics including the microprocessor analog to digital and digital to analog converters are located on the motherboard at the bottom of the case The preamplifier board is mounted on top of the motherboard as shown in the figure These boards are accessible after re moving the back panel Figure 2 7 is a block diagram of the Analyzer electronics Universal Power Supply Front Panel Display Board Slide out Electronics Drawer Motherboard Preamplifier PCB Figure 2 6 Electronic Component Location Inside the Model S000TA XL 2 8 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 Current Second to Voltage Amplifier Amplifier A to D Converter Power m Supply Alarm 1 4 Alarm 2 L L System Micro Failure Processor Alarm Processing 0 1 V DtoA 4 20 mA Converter 0 1 V 4 20 mA 4 Figure 2 7 Block Diagram of the Model 3000TA XL Electronics In the presence of oxygen the cell generates a current A current to voltage amplifier converts this current to a voltage wh
27. 2 4 and the major electronic components locations are shown in Figure 2 5 in chapter 2 WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL The 3000TA XL contains the following major components e Analysis Section Micro Fuel Cell B 2CXL Stainless steel cell block Sample system 5 6 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 Power Supply e Microprocessor e Displays 5 digit LED meter 2 line 20 character alphanumeric VFD display e RS 232 Communications Port See the drawings in the Drawings section in back of this manual for details Figure 5 4 Rear Panel Screws To detach the rear panel remove only the eight screws marked with an X 5 6 Cleaning If instrument is unmounted at time of cleaning disconnect the instru ment 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 79 Teledyne Analytical Instruments 5 7 5 Maintenance Model 3000TA XL EU 5 7 Troubleshooting Problem Erratic readings of the Oxygen concentration as reported by the analyzer Possible Cause The analyzer may have been calibrated in an inaccurate fashion Solution
28. 367 Preamplifier Board Instruction 1 C73870 A Main Computer Board 1 F10 Fuse 2A 250V 3AG Slow Blow 2 1296 Fuse 2A 250V 5x20mm European Slow Blow 1 O165 O ring 1 A683 14 Back Panel Connector Kit 1 C6689 B2CXL Micro Fuel Cell do not store for more than 6 months 1 B66378 B2C adaptor for cell block A minimum charge is applicable to spare parts orders Note Orders for replacement parts should include the part number if available and the model and serial number of the instrument for which the parts are intended Orders should be sent to Teledyne Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Phone 626 934 1500 Fax 626 961 2538 TWX 910 584 1887 TDYANYL COID Web www teledyne ai com or your local representative Teledyne Analytical Instruments A 3 Appendix Model 3000TA XL EU A 3 Drawing List D 69604 Outline Drawing A 4 19 inch Relay Rack Panel Mount Figure A 1 Single and Dual 19 Rack Mounts dimensions in mm A 4 29 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix A 5 3000XL SERIES ANALYZERS APPLICATION NOTES ON PRESSURES AND FLOW RECOMMENDATIONS 3000 series analyzers require reasonably regulated sample pressures While the 3000 analyzers are not sensitive to variations of incoming pressure provided they are properly vented to atmospheric pressure The pressure must be maintained as to provide a useable flow
29. 4 7 The Range Function The Range function allows the operator to program up to three concen tration ranges to correlate with the DC analog outputs If no ranges are defined by the user the instrument defaults to Low 0 1 ppm Med 0 10 ppm High 0 100 ppm The Model 3000TA XL 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 Teledyne Analytical Instruments 4 19 4 Operation Model 3000TA XL EU concentration exceeds the upper limit of the range the DC output will saturate at 1 V dc 20 mA at the current output However the digital readout and the RS 232 output of the concentra tion are unaffected by the fixed range They continue to read accurately with full precision See Front Panel description in Chapter 1 The automatic air calibration range is always 0 25 and is not pro grammable 4 7 1 Setting the Analog Output
30. 8 34 35 Function Range 1 ID Contact Range 1 ID Contact Range 2 ID Contact Range 2 ID Contact Range 3 ID Contact Range 3 ID Contact Range 4 ID Contact Air Cal Range 4 ID Contact Air Cal 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 3000TA XL 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 SAMPLE return SAMPLE hot o NEL E Solenoid 2 hot ZERO hot j Solenoid 3 hot SPAN hot Matching Solenoid 1 hot EXHAUST hot Circuitry Solenoid 4 hot ZERO return SPAN return Solenoid 1 EXHAUST return Solenoid 4 return Necessary Solenoid 3 return If i Solenoid 2 return return Figure 3 5 Remote Probe Connections 3 8 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 The voltage from these outputs is nominally 0 V for the OFF and 15 V dc for the ON conditions The maximum combined current that can be pulled from these output lines is 100 mA If two lines are ON at the same time each must be limited to 50 mA etc If m
31. ALYZER USES ELECTRO LYTES WHICH CONTAIN TOXIC SUBSTANCES MAINLY LEAD AND POTASSIUM HYDROXIDE THAT CAN BE HARMFUL IF TOUCHED SWAL LOWED OR INHALED AVOID CONTACT WITH ANY FLUID OR POWDER IN OR AROUND THE UNIT WHAT MAY APPEAR TO BE PLAIN WATER COULD CONTAIN ONE OF THESE TOXIC SUBSTANCES IN CASE OF EYE CONTACT IMMEDIATELY FLUSH EYES WITH WATER FOR AT LEAST 15 MINUTES CALL PHYSICIAN SEE APPENDIX MATERIAL SAFETY DATA SHEET CAUTION Do not disturb the integrity of the cell package until the cell is to actually be used If the cell package is punctured and air is permitted to enter the cell will require an excessively long time to reach zero after installation 1 2 weeks 5 2 2 When to Replace a Cell Cell failure in the 3000TA XL is usually characterized by a significant increase in the zero offset of more than 1 0 ppm oxygen or the inability to calibrate the sensor When this occurs the 3000TA XL will still Zero but the system alarm trips and the LCD displays a failure message 1 14 Aniz 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 5 2 3 Removing the Micro Fuel Cell The Micro Fuel cell is located inside the stainless steel cell block behind the front panel see Figure 5 1
32. Alarm function Press the Alarm button on the 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 the lt gt arrow keys Then press Enter to move to the next screen AL 1 1000 ppm HI Dft N 5 Five parameters can be changed on this screen e Value of the alarm setpoint AL 1 ppm oxygen value can be set from 0 00 to 10 000 00 ppm e Out of range direction HI or LO 4 18 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 Defeated Dft Y N Yes No e Failsafe Fs Y N Yes No e Latching Ltch Y N Yes No define the setpoint use the lt gt arrow keys to move the blinking over to AL 1 Then use the AV arrow keys to change the number Holding down the key speeds up the incrementing or decrementing Remember the setpoint units are ppm O e To set other parameters use the lt gt arrow keys to move the blinking over to the desired parameter Then use the AV arrow keys to change the parameter e the parameters for alarm 1 have been set press Alarms again and repeat this procedure for alarm 2 AL 2 reset a latched alarm go to Dft and then press either A two times or V two times Toggle it to Y and then back to N OR Go to Ltch and then press either A two times or V two times Toggle it to N and back to Y
33. Ranges To set the ranges enter the range function mode by pressing the Hange button on the front panel Ei M 10 H 100 Mode AUTO Use the lt gt arrow keys to blink the range to be set low L medium M or high H Use the AV arrow keys to enter the upper value of the range all ranges begin at ppm Repeat for each range you want to set Press Enter to accept the values and return to Analyze mode See note below Note Theranges must be increasing from low to high for example if range 1 set as 0 100 ppm and range 2 is set as 0 1 000 ppm range cannot be set as 0 500 ppm since it is lower than range 2 Ranges alarms and spans are always set in ppm units over the entire 0 250 000 ppm range even though all concentration data outputs change from ppm units to percent when the concentration is above 10 000 ppm 4 7 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 Hange button on the front panel Use the arrow keys to move the blinking over AUTO Use the AV arrow keys to switch from AUTO to FX LO FX MED or FXHI to set the instrument on the desired fixed range low medium or high 4 20 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 M 10 H 100 Mode FX LO or
34. UTO appears blinking on the display Span Settling AUTO lt ENT gt For Next Press Enterto move to the next screen Calib Holding time Cal hold 5 min This menue allows the operator to set the time the analyzer should be held in the AUTO span mode after the readings of the analyzer settle Five minutes is the default but it could be adjusted anywhere from 1 to 60 min utes by using the UP or DOWN keys Press Enterto move to the next screen Span Val 000008 00 lt ENT gt Span lt UP gt Mod Use the AV arrow keys to enter the oxygen concentration mode Use the lt gt arrow keys to blink the digit you are going to modify Use the AV arrow keys again to change the value of the selected digit When you have finished typing in the concentration of the span gas you are using press Enterto begin the Span calibration dHHHE ppm Span Slope HHHF ppm s The beginning span value is shown in the upper left corner of the display As the span reading settles the screen displays and updates informa tion on Slope Spanning automatically ends when the span output corre 4 14 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 sponds within tolerance to the value of the span gas concentration Then the instrument automatically returns to the analyze mode 4 4 2 2 Manual Mode Spanning Press Span to start the Span function The screen that appears allows you to select whether the span calibration
35. at request Once a zero or span command is sent and acknowledged contact closes release it If the command is continued until after the zero or span is complete the calibration will repeat and the Cal Relay Contact CRC will close again Forexample 1 Test the CRC When the CRC is open Send a zero command until the CRC closes The CRC will quickly close 2 When the CRC closes remove the zero command 3 When CRC opens again send a span command until the CRC closes The CRC will quickly close 4 When the CRC closes remove the span command When CRC opens again zero and span are done and the sample is being analyzed Teledyne Analytical Instruments 3 7 3 Installation Model 3000TA XL EU 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 Internal valve option which includes additional zero and span gas inputs the 3000T 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 as signed 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 2596 Table 3 4 lists the pin connections Table 3 4 Range ID Relay Connections Pin 21 38 22 39 19 1
36. cell while in the instrument wear eye and hand protection Wipe down the area several times with a wet paper towel Use a fresh towel each time Contaminated paper towels are considered hazardous waste A 10 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix Section VIII Control Measures Eye Protection Chemical splash goggles Hand Protection Rubber gloves Other Protective Clothing Apron face shield Ventilation na Section IX Disposal Both lead and potassium hydroxide are considered poisonous substances and are regulated under TSCA and SARA Title III EPA Waste Number D008 California Waste Number 181 DOT Information RQ Hazardous Waste Solid N O S Lead Class 9 NA3077 PG III Follow all Federal State and Local regulations Section X References Material Safety Data Sheets from J T Baker Chemical Aldrich Malinckrodt ASARCO U S Department of Labor form OMB No 1218 0072 Title 8 California Code of Regulations TSCA SARA Title CFR 49 CFR 29 CFR 40 NOTE The above information is believed to be correct and is offered for your information consideration and investigation It should be used as a guide Teledyne Brown Engineering Analytical Instruments shall not be held liable for any damage resulting from handling or from contact with the above product Teledyne Analytical Instruments A 11 Appendix Model 3000TA XL EU A7 Installling and Replacing a new I
37. cking software version Logging out Zero Used to setup a zero calibration e 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 e Range Used to set up three analysis ranges that can be switched automatically with auto ranging or used as individual fixed ranges Any function can be selected at any time by pressing the appropriate button unless password restrictions apply The order as presented in this manual is appropriate for an initial setup Each of these functions is described in greater detail in the following procedures The VED screen text that accompanies each operation is repro duced at the appropriate point in the procedure in a Monospaced type style Pushbutton names are printed in Oblique type 4 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 Initiate Automatic Set Alarm Calibration Setpoints Define Analysis Confrigure Mode 9 of Alarm Set Password Operation Logout Show Negative Figure 4 1 Hierarchy of Functions and Subfunctions 4 3 The System Function The subfuctions of the System function are described below Specific procedures for their use follow the descriptions Auto Cal Used to define an automatic calibration
38. e signal O to 1 volt across the terminals allows Zero mode to terminate when done A synchronous signal must open and close the external zero valve appropriately See Remote Probe Connector The C option internal valves operate automatically Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 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 3000TA XL EU 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 th
39. e 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 3 3 Rear Panel Connections Figure 3 3 shows the Model 3000TA XL rear panel There are ports for gas inlet and outlet power communication and both digital and analog concentration output 3 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 Figure 3 3 Rear Panel of the Model 3000TA XL 3 3 1 Gas Connections NOTE Do not remove plastic caps on VCR fittings unless you are ready to make connections The unit is manufactured with sinch tube fittings and 6 mm adapters are supplied for metric system installations For a safe connection 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 A VCR fitting is pro vided for the inlet connection The inlet gas pressure should be reasonably regulated Pressures be tween 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 t
40. embrane Any oxygen in the sample gas is reduced on the surface of the cathode by the following HALF REACTION O 2H O 4e gt 4OH cathode Four electrons combine with one oxygen molecule in the presence of water from the electrolyte to produce four hydroxy ions When the oxygen is reduced at the cathode lead is simultaneously oxidized at the anode by the following HALF REACTION Pb 20H 2 Pb H O 2e anode Two electrons are transferred for each atom of lead that is oxidized Therefore it takes two of the above anode reactions to balance one cathode reaction and transfer four electrons The electrons released at the surface of the anode flow to the cathode surface when an external electrical path is provided The current is propor tional to the amount of oxygen reaching the cathode It is measured and used to determine the oxygen concentration in the gas mixture The overall reaction for the fuel cell is the SUM of the half reactions above or 2Pb O 2 2PbO Teledyne Analytical Instruments 2 3 2 Operational Theory Model 3000TA XL EU These reactions are specific to oxygen as long as no gaseous compo nents capable of oxidizing lead such as iodine bromine chlorine and fluorine are present in the sample In the absence of oxygen no current is generated 2 2 4 The Effect of Pressure In order to state the amount of oxygen present in the sample in parts per million or a percentage o
41. ents Address 16830 Chestnut Street City of Industry CA 91749 Phone 818 961 9221 Customer Service Extension 222 Environmental Health and Safety Extension 230 Date Prepared 04 26 95 Section II Hazardous Ingredients Composition Material or Component C A S Quantity OSHA PEL ACGIH TLV Lead Pb 7439 92 1 3 20 gms 0 05 mg m 0 15 mg m Potassium Hydroxide 1310 58 3 1 5 ml None 2 mg m Solution 1596 KOH Section Ill Physical Chemical Characteristics Material Appearance Boiling Specific Vapor Melting DensityEvap Solubility Odor Compo C Gravity Pres Point Rate in Water nent sure C 1744 11 34 na na Insoluble Solid silver Lead na 328 gray odorless 1320 2 04 na na Complete White or Potassium na 360 slightly Hydroxide yellow no odor A 8 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix Section IV Fire and Explosion Hazard Data Flash Point na Flammable Limits na LEL na UEL na Extinguishing Media Use extinguishing media appropriate to surrounding fire conditions No specific agents recommended Special Fire Fighting Wear NIOSH OSHA approved self contained breathing Equipment apparatus and protective clothing to prevent contact with skin and eyes Unusual Fire and Explosion Emits toxic fumes under fire conditions Hazards Section V Reactivity Data Stability Stable Incompatibilities Aluminum organic materials acid chlorides acid anhyd
42. f the gas mixture it is necessary that the sample diffuse into the cell under constant pressure If the total pressure increases the rate that oxygen reaches the cathode through the diffusing membrane will also increase The electron transfer and therefore the external current will increase even though the oxygen concen tration of the sample has not changed It is therefore important that the sample pressure at the fuel cell usually vent pressure remain relatively constant between calibrations 2 2 5 Calibration Characteristics Given that the total pressure of the sample gas on the surface of the Micro Fuel Cell input is constant a convenient characteristic of the cell is that the current produced in an external circuit is directly proportional to the rate at which oxygen molecules reach the cathode and this rate is directly proportional to the concentration of oxygen in the gaseous mixture In other words it has a linear characteristic curve as shown in Figure 2 3 Measuring circuits do not have to compensate for nonlinearities In addition since there is zero output in the absence of oxygen the characteristic curve has close to an absolute zero less than 0 2 ppm oxy gen Depending upon the application zeroing may still be used to compen sate for the combined zero offsets of the cell and the electronics 2 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 500 375 250
43. full scale of the range being calibrated for a period of ten minutes it is Teledyne Analytical Instruments 4 15 4 Operation Model 3000TA XL EU sufficiently stable Once Enteris pressed the Span reading changes to the correct value The instrument then automatically enters the Analyze func tion 4 4 3 Span Failure The analyzer checks the output of the cell at the end of the span If the raw output of the cell is less than 0 5 uA ppm the span will not be accepted The analyzer will return to the previous calibration values trigger the System Alarm and display in the VFD Span Failed This message will be shown for five seconds and the instrument shall return to the Analyze mode In the upper right hand corner of the VFD display FCAL will be shown This message flag will help the operator troubleshoot in case calibration was initiated remotely To reset the alarm and the flag message the unit must be turned off by cycling the standby key It will not reset if the next span cycle is correct A trace cell is unlikely to fail span As explained before when the sensor reaches the end of its useful life the zero offset begins to rise until the analyzer finds the zero unsatisfactory Nevertheless feeding the wrong span gas or electronics failure could set this feature off at the end of the span Consider this before replacing the cell 4 5 Switching of Sample Streams The Model 3000TA XL may be used to monit
44. g outputs and the range ID contacts start tracking again The concentration alarms freeze on their last state before entering calibration regardless of selecting HOLD or TRACK But when HOLD is selected the concentration alarms will remain frozen for the time displayed in the second line of the TRAK HLD menu after the analyzer returns to the Analyze mode The factory default is three minutes but the delay time is program mable To adjust to delay time use the Left or Right arrow keys When the time displayed on the second line blinks it can be adjusted by Pressing the Up or Down keys to increase or decrease its value The minimum delay is 1 minute the maximum is 30 This preference is stored in non volatile memory so that it is recovered if power is removed from the instrument 4 3 2 Setting up an Auto Cal When proper automatic valving is connected see chapter 3 installa tion the Analyzer can cycle itself through a sequence of steps that automati cally 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 3000TA XL is acurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 96 per day To setup an Auto Cal cycle CAUTION We do not recommend frequent Zero adjustments of the cell A newly installed cell may take 7 10 days of operation to reach a steady Zero typically less than 0 2 ppm If required t
45. g the sample flowmeter Function Keys Six touch sensitive membrane switches are used to change the specific function performed by the analyzer W Tel ledyne Analytical Instrument UR Digital Meter ANALYZE SYSTEM Alphanumeric Display Drm ALARMS Tm CN MET ESCAPE 3000TA XYGEN ware Sample System Flow Indicator Standby Switch Data Entry Buttons Function Buttons Figure 1 1 Model 3000TA XL Front Panel Analyze Perform analysis for oxygen content of a sample gas e System Performsystem related tasks described in detail in chapter 4 Operation Span Span calibrate the analyzer e Zero Zero calibrate the analyzer Teledyne Analytical Instruments 1 3 1 Introduction Model 3000TA XL EU e Alarms Setthealarm 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 e Left amp Right Arrows Select between functions currently displayed on the VFD screen Up amp Down Arrows Increment or decrement values of functions currently displayed Enter Moves display on to the next screen in a series If none remains returns to the Analyze screen Escape Moves VFD display back to the previous screen in a series If none remains returns to the Analyze screen Digital Meter Display The meter display is a
46. gative oxygen readings or not TRAKHLD The operator sets whether the instrument analog outputs track the concentration change during calibration and sets atime delay for the concentration alarms after calibration 4 3 1 Tracking the Oxygen Readings during Calibration and Alarm delay The user has the option of setting the preferenc as to whether the analog outputs track the display readings during calibration or not To set the prefer ence press the System key once and the first System menu will appear in the VFD display TRAK HLD Auto Cal PSWD Logout More TRAK HLD should be blinking To enter this system menu press the Enter key once Output Sttng TRACK Alarm Dly 10 min Or Output Sttng HOLD Alarm Dly 10 min 4 4 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 In the first line TRACK or HOLD should be blinking The operator can toggle between TRACK and HOLD with the Up or Down keys When TRACK is selected the analog outputs 0 1 VDC and 4 20 ma and the range ID contacts will track the instrument readings during calibration either zero or span TRACK is the factory default When HOLD is selected the analog outputs 0 1 VDC and 4 20 ma and the range ID contacts will freeze on their last state before entering one of the calibration modes When the instrument returns to the Analyze mode either by a successful or an aborted calibration there will be a three minute delay before the analo
47. ging the instrument into the power source e Check the integrity and accuracy of the gas connections Make sure there are no leaks e Check the integrity and accuracy of the electrical connections Make sure there are no exposed conductors e Check that inlet sample pressure is within the accepted range see section 3 3 1 Power up the system and test it by performing the following operation 1 Repeat the Self Diagnostic Test as described in chapter 4 section 4 3 5 29 Teledyne Analytical Instruments 3 11 3 Installation Model 3000TA XL EU Lift Up 6 Cell Block Micro Fuel Cell Figure 3 8 Removing the Micro Fuel Cell CO O Ring 2 Cell Holder 3 12 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 Operation 4 1 Introduction Once the analyzer has been installed it can be configured for your application To do this you will e Setsystem parameters e Establish a security password if desired requiring Operator to log in e Establish and start an automatic calibration cycle if desired e Calibrate the instrument e Define the three user selectable analysis ranges then choose autoranging or select a fixed range of analysis as required e Set alarm setpoints and modes of alarm operation latching failsafe etc Before you configure your 3000TA XL these default values are in effect Ranges LO ppm MED 10 ppm HI 100 ppm Auto Ranging ON Alarm Rela
48. han 2 psig vacuum service plumbing is recommended See next section Vacuum Service If greater sample flow is required for improved response time install a bypass in the sampling system upstream of the analyzer input VACUUM SERVICE If the sample pressure is at atmospheric or very low pressure the instrument must be ordered with the vacuum service option This will ensure that the flow control valve is located on the exhaust side of the Micro Fuel Cell Teledyne Analytical Instruments 3 3 3 Installation Model 3000TA XL EU 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 ifrequired 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
49. he instrument may be zeroed Teledyne Analytical Instruments 4 5 4 Operation Model 3000TA XL EU after this initial stabilizing period and may be checked again after a addi tional 7 10 day frequency of zero adjustment is at the discretion of the user once a month is suggested Choose System from the Function buttons The LCD will display five subfunctions TRAK HLD Auto Cal PSWD Logout More Use lt gt arrows to blink Auto Ca1 and press Enter new screen for Span Zero set appears Span OFF Nxt Od Oh Zero OFF Nxt Od Oh Press lt gt arrows to blink Span or Zero then press Enteragain You won t be able to set OFF to ON if a zero interval is entered A Span Every or Zero Every screen appears Span Every 0 d Start 0h fromnow Use AV arrows to set an interval value then use lt gt arrows to move to the start time value Use AV arrows to set a start time value To turn ON the Span and or Zero cycles to activate Auto Cal Press System again choose Aut o Ca 1 and press Enter again When the Span Zero values screen appears use the lt gt arrows to blink the Span or Zero OFF ON field Use AV arrows to set the OFF ON field to ON You can now turn these fields ON because there is a nonzero span interval defined 4 3 3 Password Protection If a password is assigned then setting the following system parameters can be done only after the password is entered span and zero settings alarm
50. he internal clock in the Model 3000TA XL is accurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 Operational Theory 2 1 Introduction The analyzer is composed of three subsystems 1 Micro Fuel Cell Sensor 2 SampleSystem 3 Electronic Signal Processing Display and Control The sample system is designed to accept the sample gas and transport it through the analyzer without contaminating or altering the sample prior to analysis The Micro Fuel Cell is an electrochemical galvanic device that translates the amount of oxygen present in the sample into an electrical current The electronic signal processing display and control subsystem simplifies operation of the analyzer and accurately processes the sampled data The microprocessor controls all signal processing input output and display functions for the analyzer 2 2 Micro Fuel Cell Sensor 2 2 1 Principles of Operation The oxygen sensor used in the Model 3000TA XL series is a Micro Fuel Cell Model B 2CXL designed and manufactured by Analytical Instru ments Itis a sealed plastic disposable electrochemical transducer The active components of the Micro Fuel Cell are a cathode an anode and the aqueous KOH electrolyte in which they are immersed The cell converts the energy from a chemical reaction into an electrical current in an external electrical circuit I
51. he recommended span gas concentration is between 7 0 to 9 0 ppm oxygen in nitrogen and will require calibration be performed in the 0 10 ppm analyzer range Air Calibration If desired a newly installed cell may be calibrated in air to 209 000 ppm However this practice is generally not recommended as the cell may take 24 hours or longer to recover to less than 0 2 ppm after being exposed to air for about 3 to 5 minutes 4 4 1 Zero Cal The B 2CXL cell has a zero offset of less than 0 2 ppm oxygen Nor mally the offset slowly decreases during the first 7 to 10 days of operation and is expected to reach a steady value after this time Generally the value of the zero offset is part of the oxygen reading of the sample gas as shown by the analyzer readout As an example a reading of 0 5 ppm oxygen may include 0 4 ppm oxygen in the sample gas and a 0 1 ppm zero offset The determination of the zero offset requires the use of oxygen free gas to the analyzer We recommend the use of nitrogen gas with a scrubber to assure oxygen levels below 0 02 ppm The user may decide to eliminate the zero offset for improved accu racy If so desired the analyzer is equipped to provide this function How ever we do not recommend carying out the cal zero during the first 10 days of the operation of the cell Teledyne Analytical Instruments 4 11 4 Operation Model 3000TA XL EU The Zero button on the front panel is used to enter the zero ca
52. ich is amplified in the second stage amplifier The second stage amplifier also supplies temperature compensation for the oxygen sensor output This amplifier circuit incorporates a thermistor Teledyne Analytical Instruments 2 9 2 Operational Theory Model 3000TA XL EU which is physically located in the cell block The thermistor is a temperature dependent resistor that changes the gain of the amplifier in proportion to the temperature changes in the block This change is inversely proportional to the change in the cell output The result is a signal that is temperature inde pendent within a specified tolerance The output from the second stage amplifier is sent to an 18 bit analog to digital converter controlled by the microprocessor The digital concentration signal along with input from the control panel is processed by the microprocessor and appropriate control signals are directed to the display alarms and communications port The same digital information is also sent to a 12 bit digital to analog converter that produces the 4 20 mA dc and the 0 1 V 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 2 10 Teledyne Analytical Instruments Trace Oxygen Analyzer Installation 3 Installation E s Installation of the Model
53. igure 1 2 contains the gas and electrical connectors for external inlets and outlets Some of those depicted are op tional and may not appear on your instrument The connectors are described briefly here and in detail in chapter 3 Installation e Teledyne Analytical Istrements AN CAUTION FS A o Hi Figure 1 2 Model 3000TA XL Rear Panel Power Connection Universal AC power source e Gas Inlet and Outlet inlet and one exhaust out Analog Outputs 0 1 V dc oxygen concentration plus 0 1 V dc range ID and isolated 4 20 mA dc oxygen concentration plus 4 20 mA dc range ID Alarm Connections 2concentration alarms and 1 system alarm Teledyne Analytical Instruments 1 5 1 Introduction Model 3000TA XL EU Note 1 6 e RS 232 Port Serial digital concentration signal output and control input Remote Probe Used in the 3000TA XL for controlling external solenoid valves only e RemoteSpan Zero Digital inputs allow external control of analyzer calibration e Calibration Contact To notify external equipment that instrument is being calibrated and readings are not monitoring sample e Range ID Contacts Four separate dedicated range relay contacts Low Medium High Cal e Network I O Serial digital communications for local network access For future expansion Not implemented at this printing If you require highly accurate Auto Cal timing use external Auto Cal control where possible T
54. libration function Zero calibration can be performed in either the automatic or manual mode In the automatic mode an internal algorithm compares consecutive readings from the sensor to determine when the output is within the accept able range for zero In the manual mode the operator determines when the reading is within the acceptable range for zero Make sure the zero gas is connected to the instrument If you get a CELL FAILURE message skip to section 4 4 1 3 4411 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 manu ally Use the AV arrow keys to toggle between AUTO and MAN zero settling Stop when AUTO appears blinking on the display Zero Settling AUTO lt ENT gt To Begin Press Enter to begin zeroing dHHHE PPM Zero Slope HHHE ppm s The beginning zero level is shown in the upper left corner of the dis play As the zero reading settles the screen displays and updates information on Slope unless the Slope starts within the acceptable zero range and does not need to settle further Then and whenever Slope is less than 0 08 for at least 3 minutes instead of Slope you will see a countdown 5 Left 4 Left and so fourth These are five steps in the zeroing process that the system must complete AFTER settling before it can go back to Analyze IHHHE PPM Zero 4 Left HAF ppm s The zeroing process will a
55. mA dc Teledyne Analytical Instruments 4 21 4 Operation Model 3000TA XL EU 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 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 relate the signal output to the actual concentration it is necessary to know what range the instrument is currently on especially when the analyzer is in the autoranging mode To provide an indication of the range a second pair of analog output terminals are used They generate a steady preset voltage or current when using the current outputs to represent a particular range The following table gives the range ID output for each analysis range Range Voltage V Current mA LO 0 25 8 MED 0 50 12 HI 0 75 16 CAL 0 25 1 00 20 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 in most cases quickly saturate the cell with oxygen which can then require a quite long purge down time for the sensor when then exposed to low oxygen concentrations In the event that flow is to be interrupted into the analyzer it is suggested that the user do one of the following 1 Bag the sensor in nitrogen during this time 2 Install a shut off valve on the vent port of the ana l
56. ndicated by acheck mark in the box Instrument Serial Number Options Included in the Instrument with the Above Serial Number 0 3000TA XL VS Instrument configured for Vacuum Service 3000TA XL CV Instrumentwithcalibration valves 0 19 Rack Mnt The 19 Relay Rack Mount units are available with either one or two 3000TA XL series analyzers installed inastandard 19 panel and ready to mount ina standard rack W Teledyne Analytical Instruments iii Model 3000TA XL EU Model 3000TA XL EU complies with all of the requirements of the Commonwealth of Europe CE for Radio Frequency Interfer ence Electromagnetic Interference RFI EMI and Low Voltage Directive LVD The following International Symbols are used throughout the Instruc tion Manual for your visual and immediate warnings and when you have to attend CAUTION while operating the instrument STAND BY Instrument is on Stand by but circuit is active PA GROUND Protective Earth S CAUTION The operator needs to refer to the manual for further information Failure to do so may compromise the safe operation of the equipment CAUTION Risk of Electric Shock gt gt iv Teledyne Analytical Instruments Trace Oxygen Analyzer Table of Contents 1 Introduction A ERE Ea 1 1 1 2 Typical Applications etre ea nen 1 1 1 8 Main Features of the
57. nfigured out defeated Threshold Alarm 2 Can be configured as high actuates when concen System Alarm tration is above threshold or low actuates when concentration is below threshold Can be configured as failsafe or nonfailsafe Can be configured as latching or nonlatching Can be configured out defeated Actuates when DC power supplied to circuits is unacceptable in one or more parameters Permanently configured as failsafe and latching Cannot be de feated Actuates if self test fails Reset by pressing button to remove power Then press QO again and any other button EXCEPT Systemto resume Further detail can be found in chapter 4 section 4 5 Pin 45 28 46 42 44 43 36 20 37 Table 3 2 Alarm Relay Contact Pins 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 O V off or 24 V dc on inputs for remote control of calibration See Remote Calibration Protocol below See Table 3 3 for pin connections Zero 3 6 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 th
58. nsta Trace Micro fuel Cell Read completely before beginning the procedure It is important to minimize the amount of time a Teledyne Trace Oxygen sensor is exposed to air during the installation process The quicker the sensor can be installed into the unit the faster your sensor will recover to low oxygen measurement levels Cell Block Lift up Gate to removed Cell Holder CAUTION Do not touch the sensing surface of the cell It is covered with a delicate Teflon membrane that can Micro uet Gel leak when punctured The sensor must be replaced if the membrane is damaged Protective Film Seal Cover Check O ring in the base of the cell holder Located this side before installing a new cell Replace it if worn or damaged O Ring Cell Holder A 12 Teledyne Analytical Instruments
59. ocating screws on the side of the block This forces the holder into position and forms a gas tight seal 5 2 5 Cell Warranty The Class B 2CXL Micro Fuel cell is used in the Model 3000TA XL This cell is warranted for 6 months from the date of shipment Note any Addenda attached to the front of this manual for special information applying to your instrument With regard to spare cells warranty period begins on the date of ship ment The customer should purchase only one spare cell per section 5 2 1 Do not attempt to stockpile spare cells The B 2CXL cell is not designed for applications where CO is a major component in the sample however concentrations of 1 000 ppm or less will not adversely effect the cell performance Consult TAI for the appropriate cell for measuring trace oxygen in the presence of CO If a cell was working satisfactorily but ceases to function before the watranty period expires the customer will receive credit toward the purchase of a new cell If you have a warranty claim you must return the cell in question to the factory for evaluation If it is determined that failure is due to faulty work manship or material the cell will be replaced at no cost to you Note Evidence of damage due to tampering or mishandling will render the cell warranty null and void 5 4 W Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 5 3 Fuse Replacement 1 Place small screwdriver in notch and p
60. or feel soapy or slippery to touch Other symptoms of exposure to lead include loss of sleep loss of appetite metallic taste and fatigue Lead is classified by the IARC as a class 2B carcinogen possibly carcinogenic to humans Where airborne lead exposures exceed the OSHA action level refer to OSHA Lead Standard 1910 1025 na Lead exposure may aggravate disease of the blood and blood forming organs hypertension kidneys nervous and possibly reproductive systems Those with preexist ing skin disorders or eye problems may be more suscep tible to the effects of the electrolyte In case of contact with the skin or eyes immediately flush with plenty of water for at least 15 minutes and remove all contaminated clothing Get medical attention immediately If ingested give large amounts of water and DO NOT INDUCE VOMITING Obtain medical attention immedi ately If inhaled remove to fresh air and obtain medical attention immediately Section VII Precautions for Safe Handling and Use NOTE The oxygen sensors are sealed and under normal circumstances the contents of the sensors do not present a health hazard The following information is given as a guide in the event that a cell leaks Protective measures during cell replacement Cleanup Procedures Before opening the bag containing the sensor cell check the sensor cell for leakage If the sensor cell leaks do not open the bag If there is liquid around the
61. or more than one type of sample gas such as nitrogen and helium or two streams of nitrogen contain ing low less than 1 ppm and high 5000 to 10 000 ppm concentrations of oxygen For these applications we recommend the following parameters and conditions be followed 1 While switching streams such as between nitrogen and helium both the gas streams must be made to flow continuosly even through only one stream is going through the analyzer at one time Failure to do so may result in spikes in output when the dead ended stream is switched in For more discussion of this read the Technical Bulletin TB00001 dated 3 98 This Bulletin is available upon request from TATAI 2 The analyzer is capable of handling the switching of streams without effecting the sensitivity of the cell This switching of streams between 4 16 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 nitrogen and helium will not require SPAN adjustment However care must be taken to keep sample flow rates in the desired levels as the flowmeter is calibrated for air and nitrogen streams only 3 The analyzer can withstand repeated switching of streams between low oxygen levels of less than 1 ppm and high oxygen levels of 5000 to 10 000 ppm Again care must be taken to ensure proper and continuous flows at all times 4 5 1 Special Notes on Hydrogen Gas Stream The standard oxygen cell Model B 2CXL though tested in nitrogen gas stream
62. ord letters and the AV arrow keys to change the letters to the new password The full set of 94 characters available for pass word use are shown in the table below Characters Available for Password Definition A B D E F G H I J K L M N 0 P Q R S T U V W X Y Z d f g h i j k 1 m n 0 q r 5 t u V w X y 2 kh ode E XI ni 0 1 2 4 5 6 8 9 lt gt When you have finished typing the new password press Enter verification screen appears The screen will prompt you to retype your password for verification AAAAA Retype PWD To Verify 4 8 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 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 allinstrument functions If all alarms are defeated the Analyze screen appears as 0 0 ppm Anlz Range 0 100 If an alarm is tripped the second line will change to show which alarm itis 0 0 ppm Anlz AL NOTE If youlog 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 pr
63. ord protection press Enter to accept TETAI as the default password If a password has been previously installed enter the password using the lt gt arrow keys to scroll back and forth between letters and the AV arrow keys to change the letters to the proper password Press Enter to enter the password If the password 15 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 Teledyne Analytical Instruments 4 7 4 Operation Model 3000TA XL EU 4 3 3 2 Installing or Changing the Password If you want to install a password or change an existing password proceed as above in Entering the Password When you are given the oppor tunity to change the password Change Password lt ENT gt Yes lt ESC gt No Press Enter to change the password either the default TETAI or the previously assigned password or press Escape to keep the existing pass word and move on If you chose Enter to change the password the password assignment screen appears TETAI lt ENT gt To Proceed or AAAAA lt ENT gt To Proceed Enter the password using the lt gt arrow keys to move back and forth between the existing passw
64. ore 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 voltage depending on the load impedance applied See Figure 3 6 LOAD june uos Figure 3 6 FET Series Resistance 3 3 23 RS 232 Port The digital signal output is a standard full duplex RS 232 serial com munications 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 e The concentration in ppm or percent e The range 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 AL x ON Each status output is followed by a carriage return and line feed Three input functions using RS 232 have been implemented to date They are described in Table 3 5 Teledyne Analytical Instruments 3 9 3 Installation Model 3000TA XL EU 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
65. ovides 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 the password is reentered To log out press the System button to enter the System function TRAK HLD Auto Cal PSWD Logout More Use the lt gt arrow keys to position the blinking over the Logout func tion and press Enterto Log out The screen will display the message ProtectedUnti Password Reentered 4 3 5 System Self Diagnostic Test The Model 3000TA XL 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 Teledyne Analytical Instruments 4 9 4 Operation Model 3000TA XL EU 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 will To initiate a self diagnostic test during operation Press the System button to start the System function TRAK HLD Auto Cal PSWD Logout More Use the lt gt arrow keys to blink More then press Enter Version Self Test Use the lt gt arrow keys again to move
66. rides magnesium copper Avoid contact with acids Hazardous Decomposition of wu E Byproducts Toxic fumes Hazardous Polymerization Will not occur Conditions to Avoid Section VI Health Hazard Data Routes of Entry Inhalation Highly unlikely Ingestion May be fatal if swallowed Skin The electrolyte potassium hydroxide is corrosive skin contact may cause irritation or chemical burns Eyes The electrolyte potassium hydroxide is corrosive eye contact may cause irritation or severe chemical burns Acute Effects The electrolyte is harmful if swallowed inhaled or adsorbed through the skin It is extremely destructive to tissue of the mucous membranes stomach mouth upper respiratory tract eyes and skin Chronic Effects Prolonged exposure with the electrolyte has a destructive effect on tissue Chronic exposure to lead may cause disease of the blood and blood forming organs kidneys and liver damage to the reproductive systems and decrease in fertility in men and women and damage to the fetus of a pregnant woman Chronic exposure from the lead contained in this product is extremely unlikely Teledyne Analytical Instruments A 9 Appendix Signs and Symptoms of Exposure Carcinogenicity OSHA NTP Medical Conditions Generally Aggravated by Exposure Emergency First Aid Procedures Model 3000TA XL EU Contact of electrolyte with skin or eyes will cause a burning sensation and
67. rly warning of imminent danger it has no control over process conditions and it can be misused In particular any alarm or control systems installed must be tested and understood both as to how they operate and as to how they can be defeated Any safeguards required such as locks labels or redun dancy must be provided by the user or specifically requested of Teledyne at the time the order is placed Therefore the purchaser must be aware of the hazardous process conditions The purchaser is responsible for the training of personnel for providing hazard warning methods and instrumentation per the appropriate standards and for ensuring that hazard warning devices and instrumentation are maintained and operated properly Teledyne Analytical Instruments the manufacturer of this instrument cannot accept responsibility for conditions beyond its knowledge and control No statement expressed or implied by this document or any information disseminated by the manufactur er or its agents is to be construed as a warranty of adequate safety control under the user s process conditions Teledyne Analytical Instruments Trace Oxygen Analyzer Specific Model Information The instrument for which this manual was supplied may incorporate one or more options not supplied in the standard instrument Commonly available options are listed below with check boxes Any that are incorporated in the instrument for which this manual is supplied are i
68. rolyte _ Cathode Anode Contact Plate Flexible Membrane Figure 2 2 Cross Section of a Micro Fuel Cell not to scale At the top end of the cell is a diffusion membrane of Teflon whose thickness is very accurately controlled Beneath the diffusion membrane lies 2 2 Teledyne Analytical Instruments Trace Oxygen Analyzer Operational Theory 2 the oxygen sensing element the cathode with a surface area almost 4 cm The cathode has many perforations to ensure sufficient wetting of the upper surface with electrolyte and it is plated with an inert metal The anode structure is below the cathode It is made of lead and has a proprietary design which is meant to maximize the amount of metal available for chemical reaction At the rear of the cell just below the anode structure is a flexible membrane designed to accommodate the internal volume changes that occur throughout the life of the cell This flexibility assures that the sensing mem brane remains in its proper position keeping the electrical output constant The entire space between the diffusion membrane above the cathode and the flexible rear membrane beneath the anode is filled with electrolyte Cathode and anode are submerged in this common pool They each have a conductor connecting them to one of the external contact rings on the contact plate which is on the bottom of the cell 2 2 3 Electrochemical Reactions The sample gas diffuses through the Teflon m
69. rs have a flow control device This device isa needle valve and serves two functions in the sample path The first function is to limit the flow rate of the sample through the analyzer The needle valve is chosen to operate over a specific range of pressures and provide a useable flow rate over thatrange The second function that the needle valve provides is a pressure drop This device is selected to provide the only significant pressure drop in the sample path Teledyne Analytical Instruments A 5 Appendix Model 3000TA XL EU BY PASS 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 A by pass provides a sample flow path around the analyzer of 2 18 SCFH typically CONVERSIONS 1 PSI 2 04 INCHES OF MERCURY in Hg 1 SCFH 0 476 SLPM NOTE The MSDS on this material is available upon request through the Teledyne Environmental Health and Safety Coordinator Contact at 626 934 1592 A 6 Teledyne Analytical Instruments Trace Oxygen Analyzer Appendix Teledyne Analytical Instruments A 7 Appendix Model 3000TA XL EU A 6 Material Safety Data Sheet Section Product Identification Product Name Micro Fuel Cells and Super Cells all classes except A 2C A 3 and A 5 Electrochemical Oxygen Sensors all classes except R 19 Mini Micro Fuel Cells all classes Manufacturer Teledyne Brown Engineering Analytical Instrum
70. ry cover off as shown in Figure 5 2 Fuse Block Housing E Notch Figure 5 2 Removing Fuse Block from Housing 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 Jumper Bar M 7 iE S ied Fuse Block e Z Fuse Cover QU iN Cover American Fuses European Fuses Figure 5 3 Installing Fuses Teledyne Analytical Instruments 5 5 5 Maintenance Model 3000TA XL EU 5 4 System Self Diagnostic Test 1 Press the System button to enter the system mode 2 Use the lt gt arrow keys to move to More and press Enter 3 Use the lt gt arrow keys to move to Self Test and press Enter The following failure codes apply Table 5 1 Self Test Failure Codes Power 0 OK 1 5 V Failure 2 15 V Failure 3 Both Failed Analog 0 OK 1 DAC A 0 1 V Concentration 2 DAC B 0 1 V Range ID 3 Both Failed Preamp 0 OK 1 Zero too high 2 Amplifier output doesn t match test input 3 Both Failed 5 5 Major Internal Components The Micro Fuel cell 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 illustrated in Figure
71. s is expected to perform well in hydrogen streams Hovewer for certain applications such as continuous monitoring of very low levels of oxygen in hydrogen the user may request cells that have been specifically tested in hydrogen streams Consult Teledyne for further details 4 6 The Alarms Function The Model 3000TA XL is equipped with 2 fully adjustable concentra tion alarms and a system failure alarm Each alarm has a relay with a set of form C contacts rated for 3 amperes resistive load at 250 V ac See Figure 3 5 in Chapter 3 Installation and or the Interconnection Diagram included at the back of this manual for relay terminal connections The system failure alarm has a fixed configuration 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 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
72. s to the Analyze mode 4 4 1 3 Cell Failure Cell failure in the 3000TA XL 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 3000TA XL system alarm trips and the LCD displays a failure message d ppm 12 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 Teledyne Analytical Instruments 4 13 4 Operation Model 3000TA XL EU 4 4 2 Span Cal The Span button on the front panel is used to span calibrate the ana lyzer Span calibration can be performed using the automatic mode where an internal algorithm compares consecutive readings from the sensor to determine when the output matches the span gas concentration Span cali bration can also be performed in manual mode where the operator deter mines when the span concentration reading is acceptable and manually exits the function 4 4 2 1 AutoModeSpanning Press Span to enter the span function The screen that appears allows you to select whether the span calibration is to be performed automatically or manually Use the AV arrow keys to toggle between AUTO and MAN span settling Stop when A
73. the blinking to the Self Test function The screen will follow the running of the diagnostic RUNNING DIAGNOSTIC Testing Preamp 83 During preamp testing there is a countdown in the lower right corner of the screen When the testing is complete the results are displayed Power OK Analog OK Preamp 3 The module is functioning properly if it is followed by OK A number indicates a problem in a specific area of the instrument Refer to Chapter 5 Maintenance and Troubleshooting for number code information The results screen alternates for a time with Press Any Key ToContinue 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 10 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 4 4 Calibration of the Analyzer The analyzer must be calibrated prior to its use For most applications where the desired range of measurement is 0 to 1 ppm we recommend the analyzer be calibrated using a span gas as detailed below Span Gas Calibration Before the cell is ready for calibration it must be purged with semple gas to low oxygen levels preferably below 0 2 ppm However if the oxygen contact of the sample gas is higher than 0 2 ppm a zero gas such as nitrogen with oxygen levels below 0 2 ppm may be required T
74. ts action is similar to that of a battery There is however an important difference in the operation of a battery as compared to the Micro Fuel Cell In the battery all reactants are stored within the cell whereas in the Micro Fuel Cell one of the reactants oxygen Teledyne Analytical Instruments 2 1 2 Operational Theory Model 3000TA XL EU comes from outside the device as a constituent of the sample gas being analyzed The Micro Fuel Cell is therefore a hybrid between a battery and a true fuel cell All of the reactants are stored externally in a true fuel cell 2 2 2 Anatomy of a Micro Fuel Cell The Micro Fuel Cell is a cylinder only 1 4 inches in diameter and 114 inches thick It is made of an extremely inert plastic which can be placed confidently in practically any environment or sample stream It is effectively sealed although one end is permeable to oxygen in the sample gas The other end of the cell is a contact plate consisting of two concentric foil rings The rings mate with spring loaded contacts in the sensor block assembly and provide the electrical connection to the rest of the analyzer Figure 2 1 illustrates the external features Top View Bottom View Concentric Sensing ZZ FoilContact Surface i lt gt Rings Figure 2 1 Micro Fuel Cell Refer to Figure 2 2 Cross Section of a Micro Fuel Cell which illus trates the following internal description Dress Ring Diffusion Membrane Elect
75. utomatically 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 AV keys to toggle between AUTO and MAN zero settling Stop when MAN appears blinking on the display 4 12 Teledyne Analytical Instruments Trace Oxygen Analyzer Operation 4 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 prede termined rate It calculates the differences between successive samplings and displays the rate of change as Slope a value in parts per million per second ppm s ppm Zero Slope HHHF ppm s NOTE It takes several seconds for the true Slope value to display Wait about 10 seconds Then wait until Slope is sufficiently close to zero before 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 return
76. ys Defeated 10 00 ppm HI Not failsafe Not latching Zero Auto every 0 days 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 Teledyne Analytical Instruments 4 1 4 Operation Model 3000TA XL EU 4 2 Using the Data Entry and Function Buttons Data Entry Buttons The lt gt arrow buttons select options from the menu currently being displayed on the screen The selected option blinks When the selected option includes a modifiable item the AV arrow buttons can be used to increment or decrement that modifiable item The Enter button is used to accept any new entries on the VFD screen The Escape button is used to abort any new entries on the VFD screen that are not yet accepted by use of the Enterbutton Figure 4 1 shows the hierarchy of functions available to the operator via the function buttons The six function buttons on the analyzer are e Analyze This 15 the normal operating mode The analyzer monitors the oxygen content of the sample displays the percent of oxygen and warns of any alarm conditions e System The system function consists of six subfunctions that regulate the internal operations ofthe analyzer e Auto Cal setup e Password assignment e Self Test initiation Che
77. yzer or somewhere within the users sample system 4 22 Teledyne Analytical Instruments Trace Oxygen Analyzer Maintenance 5 Maintenance 5 1 Routine Maintenance Aside from normal cleaning and checking for leaks at the gas connec tions routine maintenance is limited to replacing Micro Fuel cells and fuses and recalibration For recalibration see Section 4 4 Calibration WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL 5 2 Cell Replacement The B 2CXL Micro Fuel Cell is a sealed electrochemical 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 fuel cell should be dis carded according to local regulations This section describes fuel cell care as well as when and how to replace it 5 2 1 Storing and Handling Replacement Cells To have a replacement cell available when it is needed TAI recom mendis that one spare cell be purchased 9 10 months after commissioning the 3000TA XL or shortly before the end of the cell s one year warranty period CAUTION Do not stockpile cells The warranty period starts on the day of shipment The spare cell should be carefully stored in an area that is not subject to large variations in ambient temperature 75 F nominal or to rough handling Teledyne Analytical Instruments 5 1 5 Maintenance Model 3000TA XL EU WARNING THE SENSOR USED IN THE MODEL 3000TA XL TRACE OXYGEN AN

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