Teledyne P/NM70946 manual

i Trace Oxygen Analyzer Teledyne Analytical Instruments OPERA TING INSTR UCTIONS FOR Model Ultra T race 3000 Oxyg en Anal yz er 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 W[...]

ii Model Ultr a T ace 3000 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 [...]

iii Trace Oxygen Analyzer Teledyne Analytical Instruments 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 suppli[...]

iv Model Ultr a T ace 3000 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 [...]

v Trace Oxygen Analyzer Teledyne Analytical Instruments 4.3.3.2 Installing or Changing the P a ss word ............. 4-8 4.3.4 Logout .................................................................... 4-9 4.3.5 System Self-Diagnostic T est .................................. 4-9 4.3.6 V ersion Screen ...............................................[...]

vi Model Ultr a T ace 3000 Teledyne Analytical Instruments COMBUSTIBLE GAS USA GE W ARNING D ANGER 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 sh[...]

1-1 Ultra Trace Oxygen Analyzer Introduction 1 Teledyne Analytical Instruments Introduction 1.1 Overview The Teledyne Analytical Instruments Model 3000 Ultra Trace Oxygen Analyzer is a versatile microprocessor-based instrument for detecting oxygen at the parts-per-billion (ppb) level in a variety of gases. This manual covers the Model Ultra Trace 3[...]

1-2 1 Introduction Model Ultra Trace 3000 Teledyne Analytical Instruments • Advanced Micro-Fuel Cell, designed for trace analysis, has a 0- 250 ppb low range with less than a 100 ppb offset and six months warranty and an expected lifetime of one year. • Versatile analysis over a wide range of applications. • Microprocessor based electronics: [...]

1-3 Ultra Trace Oxygen Analyzer Introduction 1 Teledyne Analytical Instruments 1 . 5 Front P anel (Operator Interface) The standard Ultra Trace 3000 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 alp[...]

1-4 1 Introduction Model Ultra Trace 3000 Teledyne Analytical Instruments • Alarms Set the alarm setpoints and attributes. • Range Set up the 3 user definable ranges for the instrument. Data Entry Keys: Six touch-sensitive membrane switches are used to input data to the instrument via the alphanumeric VFD display: • Left & Right Arrows Se[...]

1-5 Ultra Trace Oxygen Analyzer Introduction 1 Teledyne Analytical Instruments 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 Figure 1-2, contains the gas and electrical connectors f[...]

1-6 1 Introduction Model Ultra Trace 3000 Teledyne Analytical Instruments • RS-232 Port Serial digital concentration signal output and control input. • Remote Probe Used in the Ultra Trace3000 for controlling external solenoid valves only. • Remote Span/Zero Digital inputs allow external control of analyzer calibration. • Calibration Contac[...]

2-1 Ultra Trace 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 an[...]

2-2 2 Operational Theory Model Ultra Trace 3000 Teledyne Analytical Instruments 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 Mi[...]

2-3 Ultra Trace 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. [...]

2-4 2 Operational Theory Model Ultra Trace 3000 Teledyne Analytical Instruments (These reactions are specific to oxygen as long as no gaseous components 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[...]

2-5 Ultra Trace Oxygen Analyzer Operational Theory 2 Teledyne Analytical Instruments temperature minimizes the cell offset (typically less than 75 PPB). A second benefit of the TEC system is that by regulating the cell temperature the analyzer becomes tolerant of thermal transients. The TEC module is a solid-state semiconductor heat – pump. Passi[...]

2-6 2 Operational Theory Model Ultra Trace 3000 Teledyne Analytical Instruments 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 Ultra Trace 3000 sample system is designed and fabricated t[...]

2-7 Ultra Trace Oxygen Analyzer Operational Theory 2 Teledyne Analytical Instruments Figure 2-5: Flow Diagram-Sample Under Pressure -Standard Model Ultra Trace 3000 Figure 2-5-1: Flow Diagram-Sample at Zero Pressure -Model Ultra Trace 3000-V -Do not exceed 10" Hg Vacuum-[...]

2-8 2 Operational Theory Model Ultra Trace 3000 Teledyne Analytical Instruments 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 . 4 Electronics and Signal Processing The Model Ultra Trace 3000 Oxygen[...]

2-9 Ultra Trace Oxygen Analyzer Operational Theory 2 Teledyne Analytical Instruments Figure 2-7: Block Diagram of the Model Ultra Trace 3000 Electronics Po w e r Su pp ly A to D Con ver t er Curre nt to V olt age Am pl ifi er Se cond St age Am pl ifi er System Fa i l u r e Alarm Di sp l ays Mi c r o- Pr oces sor Pr oces sin g Au to Range 0- 1 V 4- [...]

2-10 2 Operational Theory Model Ultra Trace 3000 Teledyne Analytical Instruments In the presence of oxygen the cell generates a current. A current to voltage amplifier converts this current to a voltage, which is further amplified in the second stage amplifier. The output from the second stage amplifier is sent to an 18 bit analog to digital conver[...]

Ultra Trace Oxygen Analyzer Installation 3 3-1 Teledyne Analytical Instruments Installation Installation of the Model Ultra Trace 3000 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 Although the analyzer is shipped complet[...]

3 Installation Model Ultra Trace 3000 3-2 Teledyne Analytical Instruments Figure 3-1: Front Panel of the Model Ultra Trace 3000 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 s[...]

Ultra Trace Oxygen Analyzer Installation 3 3-3 Teledyne Analytical Instruments 3 . 3 Rear P anel Connections Figure 3-3 shows the Model Ultra Trace 3000 rear panel. There are ports for gas inlet and outlet, power, communication, and both digital and analog concentration output. Figure 3-3: Rear Panel of the Model Ultra Trace 3000 3.3.1 Gas Connecti[...]

3 Installation Model Ultra Trace 3000 3-4 Teledyne Analytical Instruments 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.[...]

Ultra Trace Oxygen Analyzer Installation 3 3-5 Teledyne Analytical Instruments 3.3.2.2 50-Pin Equipment Interface Connector Figure 3-4 shows the pin layout of the Equipment Interface connector. The arrangement is shown as seen when the viewer faces the rear panel of the analyzer. The pin numbers for each input/output function are given where each f[...]

3 Installation Model Ultra Trace 3000 3-6 Teledyne Analytical Instruments 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 lo[...]

Ultra Trace Oxygen Analyzer Installation 3 3-7 Teledyne Analytical Instruments Zero: Floating input. 5 to 24 V input across the + and – pins puts the analyzer into the Zero mode. Either side may be grounded at the source of the signal. 0 to 1 volt across the terminals allows Zero mode to terminate when done. A synchronous signal must open and clo[...]

3 Installation Model Ultra Trace 3000 3-8 Teledyne Analytical Instruments 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 clos[...]

Ultra Trace Oxygen Analyzer Installation 3 3-9 Teledyne Analytical Instruments Figure 3-5: Remote Probe Connections 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 limi[...]

3 Installation Model Ultra Trace 3000 3-10 Teledyne Analytical Instruments 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 fron[...]

Ultra Trace Oxygen Analyzer Installation 3 3-11 Teledyne Analytical Instruments Figure 3-8: Installing the Micro-Fuel Cell COLLAR CELL BLOCK SENSOR O-RING CELL HOLDER[...]

3 Installation Model Ultra Trace 3000 3-12 Teledyne Analytical Instruments IMPORTANT: ` I n 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 [...]

Ultra Trace 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 cal[...]

4 Operation Model Ultra Trace 3000 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 being displayed on the VFD screen. The selected option blinks. When the selected option includes a modifiable item, the ∆ ∆ ∆ ∆ ∆∇ a[...]

Ultra Trace Oxygen Analyzer Operation 4 4-3 Teledyne Analytical Instruments 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 sequence and/or start an Auto-Cal. • PSWD : Security can be established [...]

4 Operation Model Ultra Trace 3000 4-4 Teledyne Analytical Instruments 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[...]

Ultra Trace Oxygen Analyzer Operation 4 4-5 Teledyne Analytical Instruments 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 (ei[...]

4 Operation Model Ultra Trace 3000 4-6 Teledyne Analytical Instruments 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?[...]

Ultra Trace Oxygen Analyzer Operation 4 4-7 Teledyne Analytical Instruments 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[...]

4 Operation Model Ultra Trace 3000 4-8 Teledyne Analytical Instruments 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? <ENT>=Yes <ESC>=No Press Enter to [...]

Ultra Trace Oxygen Analyzer Operation 4 4-9 Teledyne Analytical Instruments 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 immediately switch t[...]

4 Operation Model Ultra Trace 3000 4-10 Teledyne Analytical Instruments status of each function is displayed on the screen, either as OK or as a num- ber 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 a[...]

Ultra Trace Oxygen Analyzer Operation 4 4-11 Teledyne Analytical Instruments 4.3.7 Filter Function The response time on the most sensitive range (ppb range) is user definable from approximately 1-60 minutes. The adjustable filter allows the user to tune the response of the analyzer to best balance sensor noise and response time requirements. The fa[...]

4 Operation Model Ultra Trace 3000 4-12 Teledyne Analytical Instruments 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 requ[...]

Ultra Trace Oxygen Analyzer Operation 4 4-13 Teledyne Analytical Instruments #### PPM Zero 4 Left=### ppm/s The zeroing process will automatically conclude when the output is within the acceptable range for a good zero. Then the analyzer automatically returns to the Analyze mode. Because the reading of the slope is not very sensitive, it is recom- [...]

4 Operation Model Ultra Trace 3000 4-14 Teledyne Analytical Instruments instrument returns back to analyzer mode without taking the zero calibration. The Ultra Trace 3000 system alarm trips, and the LCD displays a failure message. #.# ppm Anlz CELL FAIL/ ZERO HIGH Before replacing the cell: a. Check your span gas to make sure it is within specifica[...]

Ultra Trace Oxygen Analyzer Operation 4 4-15 Teledyne Analytical Instruments This menu allows the operator to set the time the analyzer should be held in the AUTO span mode, after the readings of the analyzer settle. Five minutes is the default, but it could be adjusted anywhere from 1 to 60 min- utes by using the UP or DOWN keys. Press Enter to mo[...]

4 Operation Model Ultra Trace 3000 4-16 Teledyne Analytical Instruments Span Val: 008.00ppm <ENT>Span <UP>Mod # Press ∆ ( <UP> ) to permit modification ( Mod # ) of span value. Use the arrow keys to enter the oxygen concentration of the span gas you are using (999.99 is maximum value of span gas). The < > arrows choose the[...]

Ultra Trace Oxygen Analyzer Operation 4 4-17 Teledyne Analytical Instruments 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 Ultra Trace 3000 may be used to monitor more than one type of sample gas, such as nitrogen and helium, or two [...]

4 Operation Model Ultra Trace 3000 4-18 Teledyne Analytical Instruments 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 a[...]

Ultra Trace Oxygen Analyzer Operation 4 4-19 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 [...]

4 Operation Model Ultra Trace 3000 4-20 Teledyne Analytical Instruments Alarm Hysterisis: There is alarm hysterisis to prevent chatter of the alarm contacts. It is set to 0.2 ppm for alarms set above 1 ppm, and 10 ppb for alarms set below 1 ppm. 4 . 7 The Range Function The Range function allows the operator to program up to three concen- tration r[...]

Ultra Trace Oxygen Analyzer Operation 4 4-21 Teledyne Analytical Instruments Use the ∆∇ arrow keys to enter the upper value of the range (all ranges begin at 0). Repeat for each range you want to set. Press Enter to accept the values and return to Analyze mode. (See note below.) Note: The ranges must be increasing from low to high, for example,[...]

4 Operation Model Ultra Trace 3000 4-22 Teledyne Analytical Instruments 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[...]

Ultra Trace Oxygen Analyzer Operation 4 4-23 Teledyne Analytical Instruments 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 rang[...]

4 Operation Model Ultra Trace 3000 4-24 Teledyne Analytical Instruments[...]

Ultra Trace 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 WARNI[...]

5 Maintenance Model Ultra Trace 3000 5-2 Teledyne Analytical Instruments WARNING: THE SENSOR USED IN THE MODEL 3000 TRACE OXYGEN ANALYZER USES ELECTROLYTES WHICH CONTAIN TOXIC SUBSTANCES, MAINLY LEAD AND POTASSIUM HYDROXIDE, THAT CAN BE HARMFUL IF TOUCHED, SWALLOWED, OR INHALED. AVOID CONTACT WITH ANY FLUID OR POWDER IN OR AROUND THE UNIT. WHAT MAY[...]

Ultra Trace Oxygen Analyzer Maintenance 5 5-3 Teledyne Analytical Instruments 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). To remove an existing cell: 1. Remove power to the instrument by unplugging the power cord at the power source. 2. Open the fro[...]

5 Maintenance Model Ultra Trace 3000 5-4 Teledyne Analytical Instruments 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. Verify that the 0-ring is properly located. 2. Place the cell on cell holder with the screen side facing down. 3. Place the cell[...]

Ultra Trace Oxygen Analyzer Maintenance 5 5-5 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 r[...]

5 Maintenance Model Ultra Trace 3000 5-6 Teledyne Analytical Instruments 5 . 4 System Self Diagnostic T est 1. Press the System button to enter the system mode. 2. Use the < > arrow keys to move to More, and press Enter . 3. Use the < > arrow keys to move to Self-Test, and press Enter . The following failure codes apply: Table 5-1: Self[...]

Ultra Trace Oxygen Analyzer Maintenance 5 5-7 Teledyne Analytical Instruments • TEC cooler assembly • Power Supplys • Microprocessor • Displays 5 digit LED meter 2 line, 20 character, alphanumeric, VFD display • RS-232 Communications Port. • TEC temperature controller PCB See the drawings in the Drawings section in back of this manual f[...]

5 Maintenance Model Ultra Trace 3000 5-8 Teledyne Analytical Instruments 5.7 T r oubleshooting 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 turn back on again. Press the System key when prompt[...]

A-1 Ultra Trace Oxygen Analyzer Appendix Teledyne Analytical Instruments Appendix A - 1 Specifications Packaging: General Purpose • Flush panel mount (Standard ). • Relay rack mount. Contains one instrumentsin one 19" relay rack mountable plate (Optional). Sensor: Teledyne B-2CXL trace analysis Micro-Fuel Cell. Cell Block: 316 stainless st[...]

A-2 Appendix Model Ultra Trace 3000 Teledyne Analytical Instruments Power: Universal power supply 85-250 V ac, at 47-63 Hz. Operating Temperature: 5-40 ° C Accuracy: ±2% of full scale for all ranges except 0-250 ppb range, at constant temperature. For 0-250 ppb range accuracy is as follows: ±5 ppb at constant temperature. ±10 ppb over temperatu[...]

A-3 Ultra Trace Oxygen Analyzer Appendix Teledyne Analytical Instruments A - 2 Recommended 2-Y ear Spare Parts List Q TY .P ART N UMBER D ESCRIPTION 1 CP2037 TEC Cooler 1 C65507 Back Panel Board 1 C62371-B Front Panel Board 1 C71410 Preamplifier Board (Instruction) 1 C70941 TEC Controller PCB 1 C62365-A Main Computer Board 3 F 9 Fuse, 1A, 250V 3AG [...]

A-4 Appendix Model Ultra Trace 3000 Teledyne Analytical Instruments A - 3 Drawing List B-71228 Piping Diagram A - 4 19-inch Rela y Rack P anel Mount Figure A-1: Single 19" Rack Mounts (dimensions in mm) 5.75 8.72[...]

A-5 Ultra Trace Oxygen Analyzer Appendix Teledyne Analytical Instruments Ultra T race 3000 SERIES ANAL YZERS 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 [...]

A-6 Appendix Model Ultra Trace 3000 Teledyne Analytical Instruments 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[...]