Instruction/ maintenance manual of the product 3000PA Teledyne
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i Percent Oxygen Analyzer Teledyne Analytical Instruments OPERA TING INSTR UCTIONS FOR Model 3000 PA P er cent Oxyg en Anal yzer P/N M64573 08/06/99 ECO:#99-0323 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.
ii Model 3000PA Teledyne Analytical Instruments Copyright © 1999 Teledyne Analytical Instruments All Rights Reserved. No part of this manual may be reproduced, transmitted, tran- scribed, stored in a.
iii Percent Oxygen Analyzer Teledyne Analytical Instruments Specific Model Information The instrument for which this manual was supplied may incorporate one or more options not included with the standard instrument. Commonly available options are listed below, with check boxes.
iv Model 3000PA Teledyne Analytical Instruments Table of Contents 1 Introduction 1.1 Overview ........................................................................ 1-1 1.2 T ypical Applications ......................................................
v Percent Oxygen Analyzer Teledyne Analytical Instruments 4.3.3.2 Installing or Changing the P a ss word ............. 4-7 4.3.4 Logout .................................................................... 4-8 4.3.5 System Self-Diagnostic T est .......
vi Model 3000PA Teledyne Analytical Instruments COMBUSTIBLE GAS USA G E W ARNING D ANGER This is a general purpose instrument designed for usage 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.
1-1 Percent Oxygen Analyzer Introduction 1 Teledyne Analytical Instruments Introduction 1.1 Overview The Teledyne Analytical Instruments Model 3000PA Percent Oxygen Analyzer is a versatile microprocessor- based instrument for detecting the percentage of oxygen in a variety of background gases.
1-2 1 Introduction Model 3000PA Teledyne Analytical Instruments • Advanced Micro-Fuel Cell, designed for percent oxygen analysis. Several options are available. • Versatile analysis over a wide range of applications. • Microprocessor based electronics: 8-bit CMOS microprocessor with 32 kB RAM and 128 kB ROM.
1-3 Percent Oxygen Analyzer Introduction 1 Teledyne Analytical Instruments All of the above options are available in combination. For example, the -C and -V options are combined as Model 3000PA-C-V.
1-4 1 Introduction Model 3000PA Teledyne Analytical Instruments Function Keys: Six touch-sensitive membrane switches are used to change the specific function performed by the analyzer: • Analyze Perform analysis for oxygen content of a sample gas. • System Perform system-related tasks (described in detail in chapter 4, Operation.
1-5 Percent Oxygen Analyzer Introduction 1 Teledyne Analytical Instruments Access Door: To provide access to the Micro-Fuel Cell, the front panel swings open when the latch in the upper right corner of the panel is pressed all the way in with a narrow gauge tool.
1-6 1 Introduction Model 3000PA Teledyne Analytical Instruments • Alarm Connections 2 concentration alarms and 1 system alarm. • RS-232 Port Serial digital concentration signal output and control input. • Remote Probe Used in the 3000PA for controlling external solenoid valves only.
2-1 Percent Oxygen Analyzer Operational Theory 2 Teledyne Analytical Instruments Operational Theory 2. 1 Introduction The analyzer is composed of three subsystems: 1.
2-2 2 Operational Theory Model 3000PA Teledyne Analytical Instruments 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 ¼ inches in diameter and 1 inch thick.
2-3 Percent Oxygen Analyzer Operational Theory 2 Teledyne Analytical Instruments the oxygen sensing element — the cathode — with a surface area almost 4 cm 2 . The cathode has many perforations to ensure sufficient wetting of the upper surface with electrolyte, and it is plated with an inert metal.
2-4 2 Operational Theory Model 3000PA Teledyne Analytical Instruments (These reactions will hold as long as no gaseous components capable of oxidizing lead — such as iodine, bromine, chlorine and fluorine — are present in the sample.
2-5 Percent Oxygen Analyzer Operational Theory 2 Teledyne Analytical Instruments Figure 2-3. Characteristic Input/Output Curve for a Micro-Fuel Cell 2.2.6 Micro-Fuel Cell “ Class ” TBE manufactures Micro-Fuel Cells with a variety of characteristics to give the best possible performance for any given sample conditions.
2-6 2 Operational Theory Model 3000PA Teledyne Analytical Instruments Nominal output in air is 0.19 mA, and 90 % response time is 45 s. Expected life in flue gas is 8 months. 2.2.6.3 Class B-1 Cell The class B-1 cell is for use in applications where it is exposed to less than 0.
2-7 Percent Oxygen Analyzer Operational Theory 2 Teledyne Analytical Instruments mizes residual gas pockets that can interfere with very low level oxygen analysis. The sample system for the standard instrument incorporates ¼ inch tube fittings for sample inlet and outlet connections at the rear panel.
2-8 2 Operational Theory Model 3000PA Teledyne Analytical Instruments Figure 2-5: Flow Diagram 2 . 4 Electronics and Signal Processing The Model 3000P Percent Oxygen Analyzer uses an 8031 microcon- troller with 32 kB of RAM and 128 kB of ROM to control all signal pro- cessing, input/output, and display functions for the analyzer.
2-9 Percent Oxygen Analyzer Operational Theory 2 Teledyne Analytical Instruments 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.
2-10 2 Operational Theory Model 3000PA Teledyne Analytical Instruments In the presence of oxygen the cell generates a current. A current to voltage amplifier converts this current to a voltage, and then the voltage is amplified in the second stage amplifier.
Percent Oxygen Analyzer Installation 3 3-1 Teledyne Analytical Instruments Installation Installation of the Model 3000PA Analyzer includes: 1. Unpacking 2. Mounting 3. Gas connections 4. Electrical connections 5. Installing the Micro-Fuel Cell 6. Testing the system.
3 Installation Model 3000PA 3-2 Teledyne Analytical Instruments Figure 3-1: Front Panel of the Model 3000PA All operator controls are mounted on the control panel, which is hinged on the left edge and doubles as the door that provides access to the sensor and cell block inside the instrument.
Percent Oxygen Analyzer Installation 3 3-3 Teledyne Analytical Instruments Figure 3-3: Rear Panel of the Model 3000PA 3.3.1 Gas Connections Before using this instrument, it should be determined if the unit will be used for pressurized service or vacuum service and low pressure applica- tions.
3 Installation Model 3000PA 3-4 Teledyne Analytical Instruments The unit is manufactured with 1 / 4 inch tube fittings. Six millimeter adapters are supplied for metric system installations. For a safe connection: 1. Insert the tube into the tube fitting, and finger-tighten the nut until the tubing cannot be rotated freely, by hand, in the fitting.
Percent Oxygen Analyzer Installation 3 3-5 Teledyne Analytical Instruments Primary Input Power: The power cord receptacle and fuse block are located in the same assembly.
3 Installation Model 3000PA 3-6 Teledyne Analytical Instruments Figure 3-4: Analog Output Connections Alarm Relays: The three alarm-circuit connectors are spring terminals for making connections to internal alarm relay contacts. Each provides a set of Form C contacts for each type of alarm.
Percent Oxygen Analyzer Installation 3 3-7 Teledyne Analytical Instruments Digital Remote Cal Inputs: Accept 0 V (off) or 24 V dc (on) inputs for remote control of calibration. (See Remote Calibration Protocol below.) Zero: Floating input. A 5 to 24 V pulse input across the + and – terminals puts the analyzer into the Zero mode.
3 Installation Model 3000PA 3-8 Teledyne Analytical Instruments Not e: The Remote Probe connector (paragraph 3.3.3) provides signals to ensure that the zero and span gas valves will be controlled synchronously.
Percent Oxygen Analyzer Installation 3 3-9 Teledyne Analytical Instruments st <enter> Toggling input. Stops/Starts any status message output from the RS-232, until st <enter> is sent again. The RS-232 protocol allows some flexibility in its implementation.
3 Installation Model 3000PA 3-10 Teledyne Analytical Instruments Figure 3-7: FET Series Resistance 3 . 4 Installing the Micro-Fuel Cell The Micro-Fuel Cell is not installed in the cell block when the instrument is shipped. It must be installed before the analyzer is placed in service.
Percent Oxygen Analyzer Operation 4 4-1 Teledyne Analytical Instruments Operation 4. 1 Introduction Once the analyzer has been installed, it can be configured for your application. To do this you will: • Set system parameters: • Establish a security password, if desired, requiring Operator to log in.
4 Operation Model 3000PA 4-2 Teledyne Analytical Instruments 4 . 2 Using the Data Entry and Function Buttons Data Entry Buttons: The < > arrow buttons select options from the menu currently displayed on the VFD screen. The selected option blinks.
Percent Oxygen Analyzer Operation 4 4-3 Teledyne Analytical Instruments Figure 4-1: Hierarchy of Functions and Subfunctions duced, at the appropriate point in the procedure, in a Monospaced type style. Pushbutton names are printed in Oblique type. 4 .
4 Operation Model 3000PA 4-4 Teledyne Analytical Instruments operation, such as setting the instrument span or zero setting, adjusting the alarm setpoints, or defining analysis ranges. After a password is assigned, the operator must log out to activate it.
Percent Oxygen Analyzer Operation 4 4-5 Teledyne Analytical Instruments 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 zero and span the instrument.
4 Operation Model 3000PA 4-6 Teledyne Analytical Instruments If you have decided not to employ password security, use the default password TBEAI . 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.
Percent Oxygen Analyzer Operation 4 4-7 Teledyne Analytical Instruments Change Password? <ENT>=Yes <ESC>=No Press Escape to move on, or proceed as in Changing the Password , below. 4.3.3.2 Installing or Changing the Password If you want to install a password, or change an existing password, proceed as above in Entering the Password .
4 Operation Model 3000PA 4-8 Teledyne Analytical Instruments A A A A A Retype PWD To Verify Wait a moment for the entry screen. You will be given clearance to proceed. A A A A A <ENT> TO Proceed Use the arrow keys to retype your password and press Enter when finished.
Percent Oxygen Analyzer Operation 4 4-9 Teledyne Analytical Instruments 4.3.5 System Self-Diagnostic Test The Model 3000PA has a built-in self-diagnostic testing routine. Pre- programmed signals are sent through the power supply, output board and sensor circuit.
4 Operation Model 3000PA 4-10 Teledyne Analytical Instruments 4 . 4 The Span Functions The analyzer is calibrated using span gas. NOTE: Zero is not necessary for Percent (%) level measurements. Additional information on Zero functions is provided in the Appendix A-6 of this manual.
Percent Oxygen Analyzer Operation 4 4-11 Teledyne Analytical Instruments Although the B-1 cell is standard in the 3000PA, check Specific Model Information in the Front Matter in this manual for the class of cell you purchased . Then check Cell Replacement in chapter 5 Maintenance , and do the prescribed calculations.
4 Operation Model 3000PA 4-12 Teledyne Analytical Instruments of the displayed value of the oxygen concentration (in ppm) for three min- utes. Then the instrument automatically returns to the analyze mode. 4.4.2.2 Manual Mode Spanning Press Span to start the Span function.
Percent Oxygen Analyzer Operation 4 4-13 Teledyne Analytical Instruments “ C" contacts rated for 3 amperes resistive load at 250 V ac. See Figure in Chapter 3, Installation and/or the Interconnection Diagram included at the back of this manual for relay terminal connections.
4 Operation Model 3000PA 4-14 Teledyne Analytical Instruments 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.
Percent Oxygen Analyzer Operation 4 4-15 Teledyne Analytical Instruments 4 . 6 The Range Function The Range function allows the operator to program up to three concen- tration ranges to correlate with the DC analog outputs. If no custom ranges are defined by the user, the instrument defaults to: Low = 0 – 1.
4 Operation Model 3000PA 4-16 Teledyne Analytical Instruments 4.6.2 Autoranging Analysis Set your analysis ranges as in 4.6.1, above. Leave Mode in Auto , or use the arrow buttons to change back to Auto .
Percent Oxygen Analyzer Operation 4 4-17 Teledyne Analytical Instruments Press Escape to re-enter the Analyze mode using the fixed range. NOTE: When performing analysis on a fixed range, if the oxygen.
4 Operation Model 3000PA 4-18 Teledyne Analytical Instruments The analog output signal has a voltage which depends on the oxygen concentration AND the currently activated analysis range.
Percent Oxygen Analyzer Maintenance 5 5-1 Teledyne Analytical Instruments 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.
5 Maintenance Model 3000P 5-2 Teledyne Analytical Instruments LEAD AND POTASSIUM HYDROXIDE, THAT CAN BE HARMFUL IF TOUCHED, SWALLOWED, OR IN- HALED. AVOID CONTACT WITH ANY FLUID OR POWDER IN OR AROUND THE UNIT. WHAT MAY APPEAR TO BE PLAIN WATER COULD CONTAIN THESE TOXIC SUBSTANCES.
Percent Oxygen Analyzer Maintenance 5 5-3 Teledyne Analytical Instruments 3. Divide the raw output reading by the percent oxygen concentration of your span gas. If the quotient is less than the Index value for the cell class you are using, replace the cell.
5 Maintenance Model 3000P 5-4 Teledyne Analytical Instruments Figure 5-1: Removing or Installing a Micro-Fuel Cell.
Percent Oxygen Analyzer Maintenance 5 5-5 Teledyne Analytical Instruments 5.2.4 Installing a New Micro-Fuel Cell CAUTION: Do not touch the sensing surface of the cell. It is covered with a delicate Teflon membrane that can leak if punctured. The sensor must be replaced if the membrane is damaged.
5 Maintenance Model 3000P 5-6 Teledyne Analytical Instruments 5.3 Fuse Replacement 1. Place small screwdriver in notch, and pry cover off, as shown in Figure 5-2. 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.
Percent Oxygen Analyzer Maintenance 5 5-7 Teledyne Analytical Instruments Table 5-1: Self Test Failure Codes Power 0O K 1 5 V Failure 2 15 V Failure 3 Both Failed Analog 0O K 1 DAC A (0 – 1 V Concentration) 2 DAC B (0 – 1 V Range ID) 3 Both Failed Preamp 0O K 1 Zero too high 2 Amplifier output doesn't match test input 3 Both Failed 5.
5 Maintenance Model 3000P 5-8 Teledyne Analytical Instruments 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.
Percent Oxygen Analyzer Maintenance 5 5-9 Teledyne Analytical Instruments 5.7 T roubleshooting Problem: Erratic readings of the Oxygen concentration as reported by the analyzer. Possible Cause: The analyzer may have been calibrated in an inaccurate fashion.
5 Maintenance Model 3000P 5-10 Teledyne Analytical Instruments.
A-1 Percent Oxygen Analyzer Appendix Teledyne Analytical Instruments Appendix A - 1 Model 3000P A Specifications Packaging: General Purpose • Flush panel mount (Standard ). • Rack mount — Relay rack mounted to contain either one or two instruments in one 19" relay rack mountable plate (Optional).
A-2 Appendix Model 3000PA Teledyne Analytical Instruments Accuracy: ±2% of full scale at constant temperature. ±5% of full scale over operating temperature range, on factory default analysis ranges, once thermal equilibrium has been reached.
A-3 Percent Oxygen Analyzer Appendix Teledyne Analytical Instruments A - 2 Recommended 2-Y ear Spare P ar ts List Qty Part Number Description 1 C62374 Back Panel Board 1 C62371-B Front Panel Board 1 C.
A-4 Appendix Model 3000PA Teledyne Analytical Instruments Figure A-1: Single and Dual 19" Rack Mounts A - 3 Drawing List D-64573 Final Assembly/Outline Drawing A - 4 19-inc h Relay Rack P anel Mo.
A-5 Percent Oxygen Analyzer Appendix Teledyne Analytical Instruments 3000 SERIES ANAL YZERS APPLICATION NOTES ON RESTRICTORS, PRESSURES, AND FLOW RECOMMENDATIONS 3000 series analyzers require reasonably regulated sample pressures.
A-6 Appendix Model 3000PA Teledyne Analytical Instruments RESTRICTOR KIT The current revision of the 3000 series analyzers are supplied with a kit containing two restrictors and a union which are user installed. These parts supplied to give the end user more flexibility when installing the analyzer.
A-7 Percent Oxygen Analyzer Appendix Teledyne Analytical Instruments customer must supply a control valves (or restrictors) for any SPAN or ZERO gas source which is attached to the Auto-Cal ports. The valve should be adjusted to the same flow rate as the sample gas .
A-8 Appendix Model 3000PA Teledyne Analytical Instruments A - 6 Zero Cal The Zero button on the front panel is used to enter the zero calibration function.
A-9 Percent Oxygen Analyzer Appendix Teledyne Analytical Instruments to toggle between AUTO and MAN zero settling. Stop when MAN appears, blinking, on the display. Zero: Settling: Man <ENT> To Begin Press Enter to begin the zero calibration. After a few seconds the first of five zeroing screens appears.
An important point after buying a device Teledyne 3000PA (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Teledyne 3000PA yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Teledyne 3000PA - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Teledyne 3000PA you will learn all the available features of the product, as well as information on its operation. The information that you get Teledyne 3000PA will certainly help you make a decision on the purchase.
If you already are a holder of Teledyne 3000PA, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Teledyne 3000PA.
However, one of the most important roles played by the user manual is to help in solving problems with Teledyne 3000PA. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Teledyne 3000PA along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
