Teledyne 3020T manual

i T race Oxyg en Analyzer Teledyne Analytical Instruments OPERA TING INSTR UCTIONS FOR Model 3020T T r ace Oxygen Analyz 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 WHICH[...]

ii Model 3020T 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 electroni[...]

iii T race Oxyg en 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 was sup[...]

iv Model 3020T 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 Desi[...]

v T race Oxyg en Analyzer Teledyne Analytical Instruments 3. 5 Gas Connections .......................................................... 3-12 3. 6 T esting the System ........................................................ 3-14 4 Operation 4.1 Introduction .................................................................... 4-1 4.2 Using the Cont[...]

vi Model 3020T Teledyne Analytical Instruments 5.3.4 Installing a New Micro-Fuel Cell .............................. 5-6 5.2.5 Cell W arr anty ........................................................... 5-6 5.4 Fuse Replacement ......................................................... 5-7 5.5 System Self Diagnostic T est ...........................[...]

1-1 T race Oxygen Anal yzer Introduction 1 Teledyne Analytical Instruments Introduction 1.1 Overview The Teledyne Analytical Instruments Model 3020T Trace Oxygen Analyzer is a versatile microprocessor-based instrument for detecting oxygen at the parts-per-million (ppm) level in a variety of gases. This manual covers the Model 3020T, trace oxygen, e[...]

1-2 1 Introduction Model 3020T Teledyne Analytical Instruments • Advanced Micro-Fuel Cell, redesigned for trace analysis, has an expected life of one year. • Versatile analysis over a wide range of applications. • Microprocessor based electronics: 8-bit CMOS microprocessor with 32 kB RAM and 128 kB ROM. • Three user definable output ranges [...]

1-3 T race Oxygen Anal yzer Introduction 1 Teledyne Analytical Instruments 1 . 5 Operator Interface All controls and displays on the standard 3020T are accessible from outside the housing. The instrument has two simple operator controls. A digital meter, an alphanumeric display, and a sample flowmeter give the operator constant feedback from the in[...]

1-4 1 Introduction Model 3020T Teledyne Analytical Instruments 1.5 .1 UP/DOWN Switch Functions: The UP/DOWN switch is used to select the function to be performed. Choose UP or DOWN to scroll through the following list of eleven functions: • Auto-Cal Set up an automatic calibration sequence. • PWD Install a password to protect your analyzer setu[...]

1-5 T race Oxygen Anal yzer Introduction 1 Teledyne Analytical Instruments 1.5.3 Displays Digital Meter Display: The meter display is a 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 acc[...]

1-6 1 Introduction Model 3020T Teledyne Analytical Instruments • Alarm Connections 2 concentration alarms and 1 system alarm. • RS-232 Port Serial digital concentration signal output and control input. • Remote Valves Used for controlling external solenoid valves, if desired. Figure 1-2: Electrical Connector Panel[...]

1-7 T race Oxygen Anal yzer Introduction 1 Teledyne Analytical Instruments • Remote Sensor Used for external sensor and thermocouple, if desired. • Remote Span/Zero Digital inputs allow external control of analyzer calibration. • Calibration Contact To notify external equipment that instrument is being calibrated and readings are not monitori[...]

1-8 1 Introduction Model 3020T Teledyne Analytical Instruments Optional: • Calibration Gas Ports Separate fittings for zero, span and sample gas input, plus internal valves for automatically switching the gases in sync with the 3020 electronics. Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. Th[...]

2-1 T race Oxyg en Anal yzer 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 analy[...]

2-2 2 Operational Theory Model 3020T 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 1¼ inches in diameter and 1¼ inches thick. It i[...]

2-3 T race Oxyg en Anal yzer Operational Theory 2 Teledyne Analytical Instruments At the top end of the cell is a diffusion membrane of Teflon, whose thickness is very accurately controlled. Beneath the diffusion membrane lies the oxygen sensing element—the cathode—with a surface area almost 4 cm 2 . The cathode has many perforations to ensure [...]

2-4 2 Operational Theory Model 3020T Teledyne Analytical Instruments The overall reaction for the fuel cell is the SUM of the half reactions above, or: 2Pb + O 2 → 2PbO (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 [...]

2-5 T race Oxyg en Anal yzer Operational Theory 2 Teledyne Analytical Instruments 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 gas panel inlets. Depending on the mode of operation either sample or calibration gas is delivered.[...]

2-6 2 Operational Theory Model 3020T Teledyne Analytical Instruments Figure 2-4 is the flow diagram for the sampling system. In the standard instrument, calibration gases (zero and span) can be connected directly to the Sample In port by teeing to the port with appropriate valves. The shaded portion of the diagram shows the components added when th[...]

2-7 T race Oxyg en Anal yzer Operational Theory 2 Teledyne Analytical Instruments Figure 2-5: Block Diagram of the Model 3020T Electronics[...]

2-8 2 Operational Theory Model 3020T 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 amplified in the second stage amplifier. The second stage amplifier also supplies temperature compensation for the oxygen sensor output. This amplifi[...]

T race Oxyg en Analyzer Installation 3 3-1 Teledyne Analytical Instruments Installation Installation of the Model 3020T 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[...]

3 Installation Model 3020T 3-2 Teledyne Analytical Instruments Figure 3-1: Front View of the Model 3020T (Simplified)[...]

T race Oxyg en Analyzer Installation 3 3-3 Teledyne Analytical Instruments Figure 3-2: Required Front Door Clearance 3 . 3 Electrical Connections Figure 3-3 shows the Model 3020T Electrical Connector Panel. There are terminal blocks for connecting power, communications, and both digital and analog concentration outputs. Figure 3-3: Electrical Conne[...]

3 Installation Model 3020T 3-4 Teledyne Analytical Instruments For safe connections, ensure that no uninsulated wire extends outside of the connectors they are attached to. Stripped wire ends must insert com- pletely into terminal blocks. No uninsulated wiring should be able to come in contact with fingers, tools or clothing during normal operation[...]

T race Oxyg en Analyzer Installation 3 3-5 Teledyne Analytical Instruments Figure 3-5: Analog Output Connections The outputs are: 0–1 V dc % of Range: Voltage rises linearly with increasing oxygen, from 0 V at 0 ppm to 1 V at full scale ppm. (Full scale = 100% of programmable range.) 0–1 V dc Range ID: 0.25 V = Low Range, 0.5 V = Medium Range, [...]

3 Installation Model 3020T 3-6 Teledyne Analytical Instruments Table 3-1: Analog Concentration Output—Example Voltage Signal Current Signal ppm O 2 Output (V dc) Output (mA dc) 0 0.0 4.0 10 0.1 5.6 20 0.2 7.2 30 0.3 8.8 40 0.4 10.4 50 0.5 12.0 60 0.6 13.6 70 0.7 15.2 80 0.8 16.8 90 0.9 18.4 100 1.0 20.0 To provide an indication of the range, a se[...]

T race Oxyg en Analyzer Installation 3 3-7 Teledyne Analytical Instruments Figure 3-6: Types of Relay Contacts 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). • Can be configured as failsafe or nonfailsafe. • Can be [...]

3 Installation Model 3020T 3-8 Teledyne Analytical Instruments ZERO: Floating input. 5 to 24 V input across the + and – terminals 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 close the exte[...]

T race Oxyg en Analyzer Installation 3 3-9 Teledyne Analytical Instruments Note: The remote probe connections (paragraph 3.3.9) provide 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 3020T automatically regul[...]

3 Installation Model 3020T 3-10 Teledyne Analytical Instruments • 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—are tripped (AL–x ON). Each status output is followed by a carriage return and line feed. Three input functions using R[...]

T race Oxyg en Analyzer Installation 3 3-11 Teledyne Analytical Instruments Figure 3-7: Remote Solenoid Return Connector Pinouts 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[...]

3 Installation Model 3020T 3-12 Teledyne Analytical Instruments When the micro-Fuel Cell needs to be installed or replaced, follow the procedures in chapter 5, Maintenance, for removing and installing cells. 3 . 5 Gas Connections Before using this instrument, it should be determined if the unit will be used for pressurized service or vacuum service[...]

T race Oxyg en Analyzer Installation 3 3-13 Teledyne Analytical Instruments Figure 3-9: Gas Connector Panel SAMPLE IN: In the standard model, gas connections are made at the SAMPLE IN and EXHAUST OUT connections. Calibration gases must be Tee'd into the Sample inlet with appropriate valves. The gas pressure in should be reasonably regulated. P[...]

3 Installation Model 3020T 3-14 Teledyne Analytical Instruments Note: If the unit is for vacuum service, see Sample In , above, for gas pressure/flow considerations. 3 . 6 T esting the System Before plugging the instrument into the power source: • Check the integrity and accuracy of the gas connections. Make sure there are no leaks. • Check the[...]

T race Oxygen Anal yzer 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: • Establish and start an automatic calibration cycle, if desired. (Electrically operated valves required.) • Define the three user selectable an[...]

4 Operation Model 3020T 4-2 Teledyne Analytical Instruments toward UP to move the VFD screen two selections upwards on the list of options (menu). The item that is between arrows on the screen is the item that is cur- rently selectable by choosing ENTER (turn-and-release toward ENTER with the ESCAPE/ENTER control). In these instructions, to ENTER m[...]

T race Oxygen Anal yzer Operation 4 4-3 Teledyne Analytical Instruments 2 PWD : Used to establish password protection or change the existing password. 3 LOGOUT : Logging out prevents unauthorized tampering with the analyzer settings. 4 VERSION : Displays Manufacturer, Model, and Software version of the instrument. 5 SELF-TEST : The instrument perfo[...]

4 Operation Model 3020T 4-4 Teledyne Analytical Instruments 9 RANGE : Used to set up three analysis ranges that can be switched automatically with auto-ranging or used as individual fixed ranges. 10 STANDBY : Remove power to outputs and displays, but maintain power to internal circuitry. Any function can be selected at any time. Just scroll through[...]

T race Oxygen Anal yzer Operation 4 4-5 Teledyne Analytical Instruments 4 .3 The A UT O-CAL Function 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. Note: If you require highly accurate AUTO-CAL timing, use exter[...]

4 Operation Model 3020T 4-6 Teledyne Analytical Instruments Once a unique password is assigned and activated, the operator MUST enter the UNIQUE password to gain access to any of the set-up functions (except to enter the password) . However, the instrument will continue to analyze sample gas and report on alarm conditions without entering the passw[...]

T race Oxygen Anal yzer Operation 4 4-7 Teledyne Analytical Instruments In a few seconds, if you do not ESCAPE, you will be given the oppor- tunity to change this password or keep it and go on. Change Password? <ENT>=Yes <ESC>=No ESCAPE to move on, or proceed as in Changing the Password , below. 4.4.2 Installing or Changing the Password[...]

4 Operation Model 3020T 4-8 Teledyne Analytical Instruments A A A A A Retype PWD To Verify Wait a moment for the entry ( <ENT> ) screen. You will be given clearance to proceed. A A A A A <ENT> TO Proceed ENTER the letters of your new password. Your password will be stored in the microprocessor and the system will immediately switch to t[...]

T race Oxygen Anal yzer Operation 4 4-9 Teledyne Analytical Instruments 4 . 7 The SELF-TEST Function The Model 3020T has a built-in self-testing diagnostic routine. Prepro- grammed signals are sent through the power supply, output board and sensor circuit. The return signal is analyzed, and at the end of the test the status of each function is disp[...]

4 Operation Model 3020T 4-10 Teledyne Analytical Instruments Although the instrument can be spanned using air, a span gas with a known oxygen concentration in the range of 70–90% of full scale of the range of interest is recommended. Since the oxygen concentration in air is 209,000 ppm, the cell can take a long time to recover if the instrument i[...]

T race Oxygen Anal yzer Operation 4 4-11 Teledyne Analytical Instruments 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 Slo[...]

4 Operation Model 3020T 4-12 Teledyne Analytical Instruments 4.8.1.3 Cell Failure Cell failure in the 3020T is usually associated with inability to zero the instrument down to a satisfactorily low ppm reading. When this occurs, the 3020T system alarm trips, and the VFD displays a failure message. #.# ppm Anlz CELL FAIL/ ZERO HIGH Before replacing t[...]

T race Oxygen Anal yzer Operation 4 4-13 Teledyne Analytical Instruments typing in the concentration of the span gas you are using, repeatedly select ENTER until the rightmost digit is reached, then, the next ENTER will exit the Span Val field. One more ENTER will enter the new span value, bring up the next screen, and start the span calibration. #[...]

4 Operation Model 3020T 4-14 Teledyne Analytical Instruments When the Span value displayed on the screen is sufficiently stable, ENTER it. (Generally, when the Span reading changes by 1 % or less of the full scale of the range being calibrated for a period of ten minutes it is suffi- ciently stable.) Once you ENTER it, the Span reading changes to t[...]

T race Oxygen Anal yzer Operation 4 4-15 Teledyne Analytical Instruments 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[...]

4 Operation Model 3020T 4-16 Teledyne Analytical Instruments –OR – Go to Ltch and then assert either DOWN two times or UP two times. (Toggle it to N N N N N and back to Y. Y. Y. Y. Y. ) 4.10 The RANGE Function The RANGE function allows the operator to program up to three concentration ranges to correlate with the DC analog outputs. If no ran[...]

T race Oxygen Anal yzer Operation 4 4-17 Teledyne Analytical Instruments Use the DOWN/UP control to enter the upper value of the range (all ranges begin at 0 ppm). Repeat for each range you want to set. ENTER to accept the values and return to the Analysis Mode . (See note below.) Note: The ranges must be increasing from low to high, for example, i[...]

4 Operation Model 3020T 4-18 Teledyne Analytical Instruments output continue to read the true value of the oxygen concen- tration regardless of the analog output range. 4.11 The CONTRAST Function If you cannot read anything on the display after first powering up: 1. Observe LED readout. a. If LED meter reads all eights and dots , go to step 3. b. I[...]

T race Oxygen Anal yzer Operation 4 4-19 Teledyne Analytical Instruments 4.13 The Analysis Mode This is the normal operating mode of the analyzer. In this mode the analyzer is monitoring the sample, measuring and displaying the amount of oxygen, and reporting alarm conditions. Normally, all of the functions automatically switch back to the Analysis[...]

4 Operation Model 3020T 4-20 Teledyne Analytical Instruments[...]

T race Oxygen Anal yzer 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 The Zero and Span Functions . WARNIN[...]

5 Maintenance Model 3020T 5-2 Teledyne Analytical Instruments Figure 5-1: Major Internal Components To swing open the cover panel, remove all screws. 5 . 3 Cell Replacement The 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[...]

T race Oxygen Anal yzer Maintenance 5 5-3 Teledyne Analytical Instruments 5.3.1 Storing and Handling Replacement Cells To have a replacement cell available when it is needed, it is recom- mended that one spare cell be purchased 9-10 months after commissioning the 3020T, or shortly before the end of the cell's one year warranty period. CAUTION:[...]

5 Maintenance Model 3020T 5-4 Teledyne Analytical Instruments Before replacing the cell: a. Check your span gas to make sure it is within specifications. b. Check for leaks downstream from the cell, where oxygen may be leaking into the system. If there are no leaks and the span gas is OK, replace the cell. 5.3 .3 Removing the Micro-Fuel Cell The Mi[...]

T race Oxygen Anal yzer Maintenance 5 5-5 Teledyne Analytical Instruments Figure 5-2: Exploded View of Cell Block and Micro-Fuel Cell Li ft Up G at e[...]

5 Maintenance Model 3020T 5-6 Teledyne Analytical Instruments 5.3.4 Installing a New Micro-Fuel Cell It is important to minimize the amount of time that 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 TAI O 2 sensor will recover to low O 2 measu[...]

T race Oxygen Anal yzer Maintenance 5 5-7 Teledyne Analytical Instruments 5.3.5 Cell Warranty The Class L-2C Micro-Fuel cell is used in the Model 3020T. This cell is a long life cell and is warranted for 1 year from the date of shipment. If any other cell is supplied with your instrument, check the front of this manual for any special information a[...]

5 Maintenance Model 3020T 5-8 Teledyne Analytical Instruments Figure 5-3: Removing Fuse Cap and Fuse from Holder 2. Replace fuse by reversing process in step 1. 5 . 5 System Self Diagnostic T est Use the DOWN/UP control to scroll through the MAIN MENU to SELF-TEST . The screen will follow the running of the diagnostic. RUNNING DIAGNOSTIC Testing Pr[...]

T race Oxygen Anal yzer Maintenance 5 5-9 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 Maintenance Model 3020T 5-10 Teledyne Analytical Instruments[...]

A-1 T race Oxyg en Analyzer Appendix Teledyne Analytical Instruments Appendix A-1 Specifications Packaging: Explosion-proof. Bulkhead mount. Sensor: L-2C trace analysis Micro-Fuel Cell. Cell Block: 316 stainless steel. Ranges: Three user definable ranges from 0–10 ppm to 0–250,000 ppm, plus air calibration range of 0- 250,000 ppm (25 %). Autora[...]

A-2 Appendix Model 3020T Teledyne Analytical Instruments Operating Temperature: 0-50 °C 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 achieved. Analog outputs: 0-1 V dc percent-of-range 0-1 V dc range ID. 4-20 mA dc pe[...]

A-3 T race Oxyg en Analyzer Appendix Teledyne Analytical Instruments A - 2 Recommended 2-Y ear Spare P ar ts List Qty Part Number Description 1 C62371B Display PCB 1 D65295A Customer Interface PCB 1 C62368-A Trace Preamplifier Board 1 C62365-A Main PCB 3 F1295 Fuse, 4A, 250V, 5x20 mm, T (Slow Blow) 1 O165 O-ring 1 C6689-L2C M icro-Fuel Cell A minim[...]

A-4 Appendix Model 3020T Teledyne Analytical Instruments A - 3 Drawing List D65908 Final Assembly Drawing D65909 Outline Drawing D65911 Wiring Diagram[...]

A-5 T race Oxyg en 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 3020T Teledyne Analytical Instruments The second function that the restriction device provides is a pressure drop. This device is selected to provide the only significant pressure drop in the sample path. RESTRICTOR KIT The current revision of the 3000 series analyzers are supplied with a kit containing two restrictors and a unio[...]

A-7 T race Oxyg en Analyzer Appendix 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. CALIBRATION GAS: 3000 series analyzer requirements for units wi[...]