Teledyne 3160 manual

i TELEDYNE ANALYTICAL INSTRUMENTS OPERA TING INSTR UCTIONS FOR Model 3160 T race Oxyg en Anal yz er P/N M52972 ECO# 99-0323 08/06/99 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 INTERNA[...]

ii TELEDYNE ANALYTICAL INSTRUMENTS Copyright © 1999 Teledyne Analytical Instruments All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any other language or computer language in whole or in part, in any form or by any means, whether it be electronic, mechanical,[...]

iii TELEDYNE ANALYTICAL INSTRUMENTS[...]

iv TELEDYNE ANALYTICAL INSTRUMENTS T T T T T ab ab ab ab ab le of Contents le of Contents le of Contents le of Contents le of Contents 1 Introduction 1.1 Features ....................................................................................... 1- 1 1.1.1 Fixed Features .............................................................. 1- 1 1.1.2[...]

v TELEDYNE ANALYTICAL INSTRUMENTS T T T T T ab ab ab ab ab le of Contents (contin le of Contents (contin le of Contents (contin le of Contents (contin le of Contents (contin ued) ued) ued) ued) ued) Calibration Zeroing ........................................................... 4- 6 Calibration Using Span Gas .......................................[...]

vi TELEDYNE ANALYTICAL INSTRUMENTS[...]

1-1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 TELEDYNE ANALYTICAL INSTRUMENTS Introduction 1.1 Features 1.1.1 Fixed Features The Model 3160 is a microprocessor-based trace oxygen monitoring system that provides on-line monitoring of trace oxygen at parts-per-million (PPM) levels and can directly measure the level of[...]

1-2 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction TELEDYNE ANALYTICAL INSTRUMENTS The 3160 features six full-scale linear ranges of analysis: • 0–1 PPM • 0–10 PPM • 0–100 PPM • 0–1000 PPM • 0–1% • 0–25% An AutoRanging feature automatically selects the range that is appropriate for a given reading[...]

1-3 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 TELEDYNE ANALYTICAL INSTRUMENTS 1.2 Components The analyzer is designed to mount in a standard 19-inch rack. All of the opera- tional controls are easily accessed through the front panel. The analyzer contains each of the following: • Analysis Section • Single or Dua[...]

1-4 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction TELEDYNE ANALYTICAL INSTRUMENTS 1.4 Applications The analyzer is an invaluable tool in the following applications and industries: • Inert and gaseous hydrocarbon stream monitoring. • Measuring the purity of various gases in air separation plants. • Prevention of ox[...]

Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 2-1 TELEDYNE ANALYTICAL INSTRUMENTS Operational Theory 2.1 Principles of Operation The sub-systems that make up the analyzer are: 1. Micro-Fuel Cell Sensor 2. Sample System 3. Electronic Signal Processing The Micro-Fuel Cell sensor is an electro[...]

2-2 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory TELEDYNE ANALYTICAL INSTRUMENTS Figure 2-1. Major Components. O I[...]

Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 2-3 TELEDYNE ANALYTICAL INSTRUMENTS 2.1.1 Micro-Fuel Cell Sensor The Micro-Fuel Cell is a sealed plastic disposable oxygen transducer that mea- sures 1 ¼ inches in diameter and is ¾ inch thick. Inside of the cell are a cathode and anode immers[...]

2-4 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory TELEDYNE ANALYTICAL INSTRUMENTS • Electropolished 316L-type stainless steel components. To eliminate oxygen absorption and desorption from the internal wetted surfaces of the sample system components, the sample system is fabricated from e[...]

Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 2-5 TELEDYNE ANALYTICAL INSTRUMENTS to be used to zero the analyzer, eliminating the need to switch external tanks. • Overall Design. The design of the sample system minimizes the volume of dead space, which can retain residual gas from anothe[...]

2-6 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory TELEDYNE ANALYTICAL INSTRUMENTS Electronics in the analyzer are grouped according to function: 1. Analog in 2. Analog out 3. Digital circuit 4. Power supply Analog signal processing is accomplished in two plug-in circuit cards operating unde[...]

Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 2-7 TELEDYNE ANALYTICAL INSTRUMENTS The analog output printed circuit board (PCB) generates the two 0 – 1 volt and the two 4 – 20 mA analog signal outputs available on the rear panel of the analyzer. These signals, generated in digital forma[...]

2-8 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory TELEDYNE ANALYTICAL INSTRUMENTS The digital printed circuit board (PCB) is a general purpose microcomputer used to control all functions of the analyzer. The analog input PCB and the analog output PCB plug directly into connectors located on[...]

Installation 3 Installation 3 Installation 3 Installation 3 Installation 3 3-1 TELEDYNE ANALYTICAL INSTRUMENTS Installation Installation of the analyzer includes: 1. Unpacking the system. 2. Recognizing the necessary precautions when installing the system. 3. Hooking up the sample/span gas and air supply to appropriate connections. 4. Installing th[...]

3-2 3 Installation 3 Installation 3 Installation 3 Installation 3 Installation TELEDYNE ANALYTICAL INSTRUMENTS 3. Parts Per Million (PPM) and Percent Oxygen indicators: the PPM light will light while the instrument is measuring O 2 in units of PPM. The percent light will light while the instrument is measuring O 2 concentration in percent. 4. Flow [...]

Installation 3 Installation 3 Installation 3 Installation 3 Installation 3 3-3 TELEDYNE ANALYTICAL INSTRUMENTS Figure 3–1: Analyzer front and rear panels. LED DIS P LA Y PPM INDICA T O R PER CENT INDICA T O R LIQUI D CRYST AL DIS P LA Y (LCD) POWER SWI TCH COMPUTER MODULE KEY P AD FLOW SET KNOB FLOW METER SEN SO R ACCESS PA N E L REMO V ABLE TOP [...]

3-4 3 Installation 3 Installation 3 Installation 3 Installation 3 Installation TELEDYNE ANALYTICAL INSTRUMENTS 3.4 Gas Line Connections All of the gas lines to the system hook up at the back of the unit (see Figure 3 – 1). All of the fittings on the removable back panel are ¼ " male VCR type fittings, with the exception of the compressed ai[...]

Installation 3 Installation 3 Installation 3 Installation 3 Installation 3 3-5 TELEDYNE ANALYTICAL INSTRUMENTS Figure 3-2: Sensor Installation. 3.5 Micro-Fuel Cell Sensor Installation or Replacement The 3160 comes with the Micro-Fuel Cell(s) already installed. When installing or replacing the cells, remember to inspect the replacement sensor for le[...]

3-6 3 Installation 3 Installation 3 Installation 3 Installation 3 Installation TELEDYNE ANALYTICAL INSTRUMENTS 1. The sensor compartment is located in the lower right-hand corner of the analyzer front panel. To remove the sensor compartment panel, loosen the thumbscrews located left and right center of the panel. 2. Make sure that sample gas is flo[...]

Installation 3 Installation 3 Installation 3 Installation 3 Installation 3 3-7 TELEDYNE ANALYTICAL INSTRUMENTS Figure 3-3: 3160 Rear Panel. 3.6.1 Voltage Selection WARNING: Power cord must be disconnected before performing any voltage selection! The voltage setting and fuses of the analyzer can be changed to international standards. To change the v[...]

3-8 3 Installation 3 Installation 3 Installation 3 Installation 3 Installation TELEDYNE ANALYTICAL INSTRUMENTS Figure 3-4: Removing the Voltage Card 4. Turn the card so that the desired voltage can be read at the bottom. 5. Slide the indicator pin around the card so that it is pointing up when the voltage is read at the bottom (see Figure 3 – 5).[...]

Installation 3 Installation 3 Installation 3 Installation 3 Installation 3 3-9 TELEDYNE ANALYTICAL INSTRUMENTS WARNING: Power cord must be disconnected before performing any voltage selection! To change from North American to European fuses, perform the following: 1. Use a small blade screwdriver to open the cover. 2. Loosen the Phillips screw two [...]

3-10 3 Installation 3 Installation 3 Installation 3 Installation 3 Installation TELEDYNE ANALYTICAL INSTRUMENTS 3.6.3 RS-232 Serial Digital Port The RS-232 port is configured as data terminal equipment (DTE) and uses a 9-pin D connector wired as follows: 1. No connection 2. Transmit Data 3. Receive Data 4. N/C 5. Ground 6. N/C 7. RTC 8. CTS 9. N/C [...]

Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 4-1 TELEDYNE ANALYTICAL INSTRUMENTS Operations 4.1 Front Panel Controls The front panel of the analyzer, shown in Figure 4-1, contains indicators and displays through which the computer module can be accessed. The upper left-hand side of the panel has an LED screen that displays the o[...]

4-2 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS displaying the function of each button directly above it. The LCD screen displays the current mode and any warning messages, instructions and button functions. 4.1.1 Spinning Wheel A “ spinning wheel ” appears in the upper left-hand corner of th[...]

Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 4-3 TELEDYNE ANALYTICAL INSTRUMENTS When waiting for manual sensor settling during calibration zeroing, wait until the oxygen concentration has reached its lowest value and has remained so for 10 – 15 minutes. It is important to make sure that the sensor is reading the lowest possib[...]

4-4 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS Set-Up Alarms: Each of five alarms provided may be programmed to actuate at any O 2 trace level above or below a threshold. The fifth alarm may also be programmed as a system alarm to monitor several system-level condi- tions. The system alarm can b[...]

4-5 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 TELEDYNE ANALYTICAL INSTRUMENTS 1. A cold start will automatically occur the first time you start the analyzer. In any other situation, you can cold start by turning the analyzer off and holding down the red key below the LCD screen while you turn the power back on. Continue to ho[...]

4-6 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS 1. At the main Analyze mode screen press ZERO. 2. Press ACK to acknowledge that a low O 2 gas has al- ready been connected to the sample port. The sample gas O 2 level should be close to zero to preserve the life of the scrubber (if one is installed[...]

4-7 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 TELEDYNE ANALYTICAL INSTRUMENTS 7. If the O 2 cell current is too large to be zeroed, an error message will appear. Press ACK to retry or ESC to abort the zeroing process. 8. If AUTO was chosen in step 4, wait for the O 2 level to settle before the system zeros. This may take from[...]

4-8 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS 1. Enter the Calibration mode from the Analyze mode by pressing SPAN. 2. Press ACK if zeroing has already been done. Make sure to zero before calibrating to ensure correct O 2 readings. 3. If the span gas tank is not connected to the span port, conn[...]

4-9 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 TELEDYNE ANALYTICAL INSTRUMENTS 7. If AUTO was chosen in step 6, wait for the O 2 level to settle before the system spans. This may take from fif- teen (15) to thirty (30) minutes or longer, depending on the sample gas oxygen level. Go to step 11 if MAN was chosen in step 6. 8. If[...]

4-10 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS 13. If the O 2 cell current is too strong or too weak to span, an error message will appear. This will not occur if the user-entered span gas concentration is correct. Press ACK to retry, or ESC to abort the span. 14. If the span is successful, the[...]

4-11 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 TELEDYNE ANALYTICAL INSTRUMENTS 1. Enter set-up from the Analyze mode main menu by pressing SETUP. If only one cell block is installed, the TEST and INSTL options on the next screen are omitted. 2. Press SET to change the active sensor. 3. Enter your authorization code by using t[...]

4-12 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS 1. Enter set-up from the Analyze mode by pressing SETUP. If only one cell is installed, the TEST and INSTL op- tions on the next screen are omitted. 2. Press TEST to test the alternate sensor or INSTL to in- stall a new sensor. 3. If TEST was chose[...]

4-13 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 TELEDYNE ANALYTICAL INSTRUMENTS 7. After pressing ACK in step 6, the new sensor is flushed for 10 minutes while the measured O 2 level is displayed. The 10-minute flush may be restarted by pressing RE- SET, or aborted by pressing SKIP. 8. When sensor installation or alternate sen[...]

4-14 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS 1. Enter Range Set-Up mode from the Analyze mode by pressing RANGE. 2. Press AUTO for AutoRanging, or FIXED to manually fix the O 2 measurement range. In AutoRange mode, the range will be automatically determined so that the O 2 measurements are wi[...]

4-15 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 TELEDYNE ANALYTICAL INSTRUMENTS 1. Enter set-up from the Analyze mode by pressing SETUP. 2. Press SET to set the alarms. 3. Enter the authorization code by using the SELEC, UP and DOWN keys, and press ACCPT. If this is a COLD START, the code you enter will be the code set for eve[...]

4-16 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS • LATCHING actuates the alarm above a certain setpoint even if the level falls back below the setpoint. • RELAY indicates the relay (on the rear panel) actuated by the alarm, which is changeable. • FAILSAFE=YES enables the relay which actu- a[...]

4-17 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 TELEDYNE ANALYTICAL INSTRUMENTS 1. Enter set-up from the Analyze mode by pressing SETUP. 2. Press SET to set up the logger. 3. Enter the authorization code by using the SELEC, UP and DOWN keys. Then press ACCPT. 4. Press LOG for the logger functions. Press ESC to return to the An[...]

4-18 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS Note: Note: Note: Note: Note: The above screens use T to indicate two values: seconds and minutes. The first value is The above screens use T to indicate two values: seconds and minutes. The first value is The above screens use T to indicate two va[...]

4-19 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 TELEDYNE ANALYTICAL INSTRUMENTS 1. Enter set-up from the Analyze mode by pressing SETUP. 2. Press SET to set the clock functions. (If only one cell block is installed, TEST and INSTL will be omitted.) 3. Enter the authorization code by using the SELEC, UP and DOWN keys, and press[...]

4-20 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS 7. If SET was pressed in step 1, the menu for setting the time and date will appear. Use the SELEC, UP and DOWN keys to set the time and date, and then press ACCPT. 8. If ZERO was pressed in step 1, the menu for setting AutoZeroing ON/OFF, time/dat[...]

4-21 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 TELEDYNE ANALYTICAL INSTRUMENTS 1. Enter set-up from the Analyze mode by pressing SETUP. 2. Press SET to set the password(s). 3. Enter your authorization code by using the SELEC, UP and DOWN keys, and press ACCPT. You must enter the same authorization code set during the last COL[...]

4-22 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS 7. If you pressed PASS2 in step 5, the next screen will al- low you to change the remote control password. Use SELEC, UP and DOWN to choose the new password, and press ACCPT, which will take you to step 4.[...]

4-23 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 TELEDYNE ANALYTICAL INSTRUMENTS 1. Enter set-up from the Analyze mode by pressing SETUP. ESC in any status page will take you to the last set-up screen and eventually the main analyze mode. PREV steps you back one status page. NEXT moves forward one status page. 2. Press STAT for[...]

4-24 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS 7. Status page five shows the time and date of the last time the alarm was triggered for each of the five program- mable alarms. 8. Status page six shows the set-up for the serial port, and allows you to reconfigure the serial port. Press EDIT to b[...]

4-25 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 TELEDYNE ANALYTICAL INSTRUMENTS 12. After checking for the modem, pressing ESC returns you to status page seven in step 10. If INIT was pressed in status page 7 and then SETUP pressed in step 11, pressing ACK will return you to this screen. Press ESC to return to status page seve[...]

4-26 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS[...]

5-1 Maintenance & Maintenance & Maintenance & Maintenance & Maintenance & T T T T T r r r r r oub oub oub oub oub leshooting 5 leshooting 5 leshooting 5 leshooting 5 leshooting 5 TELEDYNE ANALYTICAL INSTRUMENTS Maintenance & T r oub leshooting 5.1 Routine Maintenance 1. Calibrate the analyzer at least once each week during t[...]

5-2 5 Maintenance & 5 Maintenance & 5 Maintenance & 5 Maintenance & 5 Maintenance & T T T T T r r r r r oub oub oub oub oub leshooting leshooting leshooting leshooting leshooting TELEDYNE ANALYTICAL INSTRUMENTS Analyzers equipped with a scrubber should only be used with inert gases and saturat- ed hydrocarbons. 5.2 T roub leshoo[...]

5-3 Maintenance & Maintenance & Maintenance & Maintenance & Maintenance & T T T T T r r r r r oub oub oub oub oub leshooting 5 leshooting 5 leshooting 5 leshooting 5 leshooting 5 TELEDYNE ANALYTICAL INSTRUMENTS Symptom Symptom Symptom Symptom Symptom Cause Cause Cause Cause Cause Correction Correction Correction Correction Corre[...]

5-4 5 Maintenance & 5 Maintenance & 5 Maintenance & 5 Maintenance & 5 Maintenance & T T T T T r r r r r oub oub oub oub oub leshooting leshooting leshooting leshooting leshooting TELEDYNE ANALYTICAL INSTRUMENTS[...]

A-1 Appendix Appendix Appendix Appendix Appendix TELEDYNE ANALYTICAL INSTRUMENTS Appendix A.1 Specifications (Subject to change without notice.) Ranges: (Six ranges with AutoRanging on all ranges) 1: 0 – 1 part per million (ppm) O 2 2: 0 – 10 ppm O 2 3: 0 – 100 ppm O 2 4: 0 – 1000 ppm O 2 5: 0 – 1% O 2 6: 0 – 25 % O 2 Accuracy: ±2% of [...]

A-2 Appendix Appendix Appendix Appendix Appendix TELEDYNE ANALYTICAL INSTRUMENTS Mounting and Enclosure : 19" relay rack, 20.3 cm (12.25 inches) high, for general purpose (nonhazardous) areas. (Class I, Division II, hazardous area models available on special order.) Sensor: Class B-2, B2C, A2, or A2C, Micro-Fuel Cells. Altitude: 1,609 m Relati[...]

A-3 Appendix Appendix Appendix Appendix Appendix TELEDYNE ANALYTICAL INSTRUMENTS A .2 Recommended Spare P ar ts List Description P/ N Micro-Fuel Cell sensor C6689B2 C6689B2C C6689A2 C6689A2C O-ring O165 Suction purifier P670 Solenoid valve V462 Pneumatic valve upper body B435 Hose fitting tee T978 Fuse, 3A T Type F68 Fuse, 1.6A T Type (European) F7[...]

A-4 Appendix Appendix Appendix Appendix Appendix TELEDYNE ANALYTICAL INSTRUMENTS A .4 Material Safety Data Sheet I Product Name: Micro-Fuel Cells and Super Cells, all classes except A-2C, A-3, and A-5. Electrochemical Oxygen Sensors, all classes except R-19. Mini-Micro-Fuel Cells, all classes. Manufacturer: Teledyne Analytical Instruments Address: [...]

A-5 Appendix Appendix Appendix Appendix Appendix TELEDYNE ANALYTICAL INSTRUMENTS Flash Point: na Flammable Limits: na LEL: na UEL: na Extinguishing Media: Use extinguishing media appropriate to surrounding fire conditions. No specific agents recommended. Wear NIOSH/OSHA approved self-contained breathing apparatus and protective clothing to prevent [...]

A-6 Appendix Appendix Appendix Appendix Appendix TELEDYNE ANALYTICAL INSTRUMENTS Contact of electrolyte with skin or eyes will cause a burning sensation and/or feel soapy or slippery to touch. Other symptoms of exposure to lead include loss of sleep, loss of appetite, metallic taste and fatigue. Carcinogenicity: Lead is classified by the IARC as a [...]

A-7 Appendix Appendix Appendix Appendix Appendix TELEDYNE ANALYTICAL INSTRUMENTS Section VIII – Control Measures Eye Protection: Chemical splash goggles Hand Protection: Rubber gloves Other Protective Clothing: Apron, face shield Ventilation: na Section IX – Disposal Both lead and potassium hydroxide are considered poisonous substances and are [...]

A-8 Appendix Appendix Appendix Appendix Appendix TELEDYNE ANALYTICAL INSTRUMENTS A .5 Material Safety Data Sheet II Section I – Product Identification Product Name: Micro-Fuel Cells Mini-Micro-Fuel Cells, all classes Super Cells, all classes except T – 5F Oxygen Sensors, all classes. Manufacturer: Teledyne Analytical Instruments Address: 16830 [...]

A-9 Appendix Appendix Appendix Appendix Appendix TELEDYNE ANALYTICAL INSTRUMENTS Section III – Ph ysical Hazards Potential for fire and explosion: The electrolyte in the Micro – Fuel Cells is not flam- mable. There are no fire or explosion hazards associated with Micro – Fuel Cells. Potential for reactivity: The sensors are stable under norma[...]

A-10 Appendix Appendix Appendix Appendix Appendix TELEDYNE ANALYTICAL INSTRUMENTS Section V – Emergency and First Aid Procedures Eye Contact: Flush eyes with water for at least 15 minutes and get immediate medical attention. Skin Contact: Wash affected area with plenty of water and remove contaminated clothing. If burning persists, seek medical a[...]