Teledyne 3000PA manuel d'utilisation

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. HAZARDOUS VOLTAGES EXIST [...]

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 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 electron[...]

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. Any that are incorporated in the instrument for which this manual is su[...]

iv Model 3000PA Teledyne Analytical Instruments Table of Contents 1 Introduction 1.1 Overview ........................................................................ 1-1 1.2 T ypical Applications ....................................................... 1-1 1.3 Main Features of the Analyzer ....................................... 1-1 1.4 Model Desig[...]

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 .................................. 4-9 4.3.6 V ersion Screen .............................................[...]

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. The customer should ens[...]

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. This manual covers the Model 3000PA General Purpose flu[...]

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. • Three user definable output ra[...]

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. Figure 1-1: Model 3000PA Front Panel 1 . 5 Front P anel (Operator Interface) The standard 3000PA is housed in a rugged metal case with all controls and[...]

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. ). • Span Sp[...]

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. Accessing the main circuit board requires unfastening the rear panel screws and slidin[...]

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. • Remote Span/Zero Digital inputs allow external control o[...]

2-1 Percent Oxygen Analyzer Operational Theory 2 Teledyne Analytical Instruments Operational Theory 2. 1 Introduction The analyzer is composed of three subsystems: 1. Micro-Fuel Cell Sensor 2. Sample System 3. Electronic Signal Processing, Display and Control The sample system is designed to accept the sample gas and transport it through the analyz[...]

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. It is [...]

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. The anode structure is below the cathode. It i[...]

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.) The output of the fuel cell is limited by (1) the amount of oxygen in the cell at the time and (2) the amount o[...]

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. A few typical Micro-Fuel C[...]

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 0.1 % of carbon dioxide, and where fast response is important. Nominal ou[...]

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. For metric system installations, 6 mm adapters[...]

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. System power is su[...]

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. The preamplifier board is mounted on top of the motherboard as shown in the figure. These board[...]

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. The second stage amplifier also supplies temperature compensation for the oxygen sensor out[...]

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 . 1 Unpacking the Analyzer The analyzer is shipped with all the materials you nee[...]

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. The door is spring loaded and will swing open when the b[...]

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. Inspect the restrictor kit that came with the unit. The [...]

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. Insert the female plug end of the power cord into the power cord receptacle. CAUTION: Power is applied to the instrument's circuitry as long as the instrument is connected to[...]

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. Each has both normally open and normally closed contact co[...]

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. Either side may b[...]

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. If you have the – C Internal valve option — which includes additional zero and span gas inputs — the 3000P automatically regulates th[...]

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. Table 3-2 lists certain RS-232 values that are required by the 3000PA implementat[...]

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. Once it is expended, or if the cell is exposed to air for too lo[...]

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. • Establish and start an automatic calibra[...]

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. When the selected option includes a modifiable item, the ∆ ∆ ∆ ∆ ∆∇ arrow buttons can[...]

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 . 3 The System Function The subfuctions of the System function are described below. Specific procedu[...]

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. Until then, anyone can continue to operate the instrument without entering the new password. [...]

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. No t e: If you require highly accurate Auto-Cal timing, use ext[...]

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. NOTE: If you use password securit[...]

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 . Wh[...]

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. Your password will be stored in the microprocessor and the system will imme[...]

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. The return signal is analyzed, and at the end of the test the status of each function i[...]

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. Although the instrument can be spanned using air, a span gas with a[...]

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. If a weak cell is indicated, re[...]

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. The screen that appears allows you to select whether the span calibration is[...]

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. The system failure alarm has a fixed configuration described in cha[...]

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. Follow the instructions in section 4.3.3 to enter your password. Once you have clearance to pr[...]

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 – 1.00 % Med = 0 – 5.00 % High = 0 – 10[...]

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 . When operating in autoranging, if the oxygen concentration in your sample goes ABOVE your HIGHEST range setting, the analyzer will go into the sp[...]

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 concentration rises above the upper limit (or default value) as established by the operator for that particular range, the output saturates at 1 V dc[...]

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. 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 [...]

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. For recalibration, see Section 4.4 Calibration . WARNING: SEE WARNINGS ON[...]

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. IN CASE OF EYE CONTACT, IMMEDIATELY FLUSH EYES WITH WA- TER FOR AT [...]

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. Table 5-1: Cell Indices Cell Class Index A-3 1.818 A-5 1.818 B-1 4.545 B-3 3.716 B-5 1.244 B[...]

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. 1. Place the Cell in the Probe with the sensing surf[...]

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. 3. R[...]

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 Maj[...]

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. Close and latch the front-panel access door. Clean outside surfaces with [...]

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. Solution: Turn the analyzer off, then back on again. Press the System key when prompted by t[...]

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). Sensor: Class B-1 Micro-Fuel Cell (standa[...]

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. Analog outputs: 0-1 V dc percent-of-range (Standard) 0-1 V dc range ID (Standard) 4-20 mA dc — isolated [...]

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 C62368-B Percent Preamplifier Board 1* C62365-C Main Computer Board (std) 1* C62365-A Main Computer Board (4-20 mA) 3 F 9 Fuse, 1 A, 250 V, 3 AG, Slow [...]

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 Mount[...]

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. While the 3000 analyzers are not sensitive to variations of incoming pressure (provided they are properly vented to atm[...]

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. The restrictor kit is suitable for high and low p[...]

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 . When restrictors are used, the gas pressure must be adjusted to achieve the proper[...]

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. 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 [...]

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. The number in the upper left hand corne[...]