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Teledyne 3160 Operating Instructions Manual

Trace oxygen analyzer
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OPERATING INSTRUCTIONS FOR
Model 3160
Trace Oxygen Analyzer
DANGER
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 MAY PERSIST FOR A
TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.
ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING. BEFORE
CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/MANAGER.
P/N M52972
ECO# 99-0323
08/06/99
TELEDYNE ANALYTICAL INSTRUMENTS
i

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  • Page 1 OPERATING INSTRUCTIONS FOR Model 3160 Trace Oxygen Analyzer DANGER 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 MAY PERSIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.
  • Page 2 This warranty does not cover defects caused by wear, accident, misuse, neglect or repairs other than those performed by Teledyne or an authorized service center. We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage which may result from its use or misuse.
  • Page 3 TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 4: Table Of Contents

    4.1 Front Panel Controls ... 4-1 4.1.1 Spinning Wheel ... 4-2 4.1.2 Cell Output Factor ... 4-2 4.2 Modes of Operation ... 4-2 Cold Start-Up ... 4-5 TELEDYNE ANALYTICAL INSTRUMENTS T T T T T ab able of Contents le of Contents le of Contents...
  • Page 5 5.2 Troubleshooting ... 5-2 Appendix Specifications Sheet ... A-1 Recommended Spare Parts List ... A-2 Drawing List ... A-3 Material Safety Data Sheet ... A-4 Material Safety Data Sheet ... A-5 TELEDYNE ANALYTICAL INSTRUMENTS Monitoring and Control ... 4-21 ued) ued) ued) ued)
  • Page 6 TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 7: Introduction

    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 purity in high-grade gases. The 3160 computer uses an Intel kilobytes of random access memory (RAM) and 128 kilobytes of read-only memory (ROM).
  • Page 8 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction 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.

  • Page 9: Components

    Gas Inlet/Outlet Ports • Electrical Connections Options and Model Numbers The 3160 is available with the following standard options, which are designated by a descriptive suffix on the model number. Most of the options can be combined. Single fuel cell. •...

  • Page 10: Applications

    Semiconductor manufacturing. • Process monitoring of gaseous monomers—vinyl chloride, propylene, • butadiene, or ethylene. Gas purity certification. • • Glove box leak detection. • Natural gas treatment and transmission. • Inert gas welding of exotic metals. TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 11: Operational Theory

    The control module incorporates a microprocessor which allows the operation of the analyzer with a minimum of operator interaction. Figure 2-1 illustrates major components. TELEDYNE ANALYTICAL INSTRUMENTS Operational Theory 2 Operational Theory 2 Operational Theory 2...
  • Page 12 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory TELEDYNE ANALYTICAL INSTRUMENTS Figure 2-1. Major Components.

  • Page 13: Micro-Fuel Cell Sensor

    Depending on the mode of operation either a sample or zero gas is delivered. The Model 3160 sample system is designed and fabricated to ensure that the oxygen concentration of the gas is not altered as it travels through the sample system.
  • Page 14 In systems with a scrubber, oxygen-trapping media is used to remove any trace oxygen from the sample gas. This occurs automatically in the zero menu, where the pneumatic valves leading to the scrubber are triggered by a certain menu sequence. This process enables sample gas TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 15: Electronics And Signal Processing

    Figure 2-2: Model 3160 flow schematic. 2.1.3 Electronics and Signal Processing The Model 3160 analyzer has an embedded microcomputer, which controls all signal processing, input/output, and display functions for the analyzer. System power is supplied from a power supply module designed to be compatible with any interna- tional power source.
  • Page 16 The current injected is equal and opposite in polarity to the portion of the sensor current that needs offsetting. Digitization is provided by a 12-bit analog-to-digital converter, which digitizes the oxygen and temperature signals. TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 17: Range Identifier Table

    Table 2-1. Range Identifier Range Scale 1 PPM 10 PPM 100 PPM 1000 PPM Figure 2-3: Analog signal output offset TELEDYNE ANALYTICAL INSTRUMENTS Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Identifier Identifier...
  • Page 18 100V, 120V, 220V or 240V (50Hz or 60Hz). It also facilitates both North American and European fusing arrangements. Programming this mod- ule is described in the installation section of this manual. TELEDYNE ANALYTICAL INSTRUMENTS Programmable Options 1200 Baud 5, 6, 7, or 8 Bits...

  • Page 19: Installation

    N284 M52973 Front Panel The Model 3160 front and rear panels are illustrated in Figure 3–1 on the follow- ing page. The front panel contains the following displays and controls: 1. Main power switch. 2. Light Emitting Diode (LED) display: the O bold lettering.

  • Page 20: Rear Panel

    Rear Panel Figure 3–1 also shows the rear panel of the 3160. Located on the rear panel are the following electrical power and gas input ports, alarm relay outputs, and analog and...
  • Page 21 LIQUID CRYSTAL DISPLAY (LCD) COMPUTER MODULE KEYPAD SPAN GAS IN INSTRUMENT SAMPLE IN SAMPLE/SPAN VENT Figure 3–1: Analyzer front and rear panels. TELEDYNE ANALYTICAL INSTRUMENTS REMOVABLE TOP COVER DISPLAY FLOWMETER FLOW KNOB SENSOR ACCESS PANEL ANALOG RS-232 OUTPUT SERIAL PORT...

  • Page 22: Gas Line Connections

    ±2 psi of each other. A substantial difference in the span and sample gas pressures will cause a sudden change in gas flow rate. 3.4.4. Vent The vent transports the sample or span gas out of the system after exposure to the Micro-Fuel Cell sensor. TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 23: Micro-Fuel Cell Installation Or Replacement

    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 leaks or damage. See Figure 3-2. Figure 3-2: Sensor Installation. TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 24: Electrical Connections

    These five provide a set of Form C contacts for the user. The contacts are capable of switching up to 3 am- peres at 115 V ac into a resistive load. TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 25: Voltage Selection

    Figure 3-3: 3160 Rear Panel. 3.6.1 Voltage Selection Power cord must be disconnected before performing any voltage WARNING: selection! The voltage setting and fuses of the analyzer can be changed to international standards. To change the voltage setting or fuses: 1.

  • Page 26: Fuse Changing

    7. Replace the fuse block and the cover. Verify that the indicator pin is pointing to the correct voltage. 3.6.2 Fuse Changing NOTE: Spare fuses are located in a clip attached to the power supply enclosure inside of the analyzer. TELEDYNE ANALYTICAL INSTRUMENTS Figure 3–5: Voltage Selection...
  • Page 27 5. Slide the fuse block back on the Phillips screw and pedestal. 6. Tighten the Phillips screw and replace the cover. NOTE: The fuses that go into the housing first are the active set. TELEDYNE ANALYTICAL INSTRUMENTS Installation 3 Installation 3...

  • Page 28: Installation Checklist

    Checked for leaks from any of the rear panel connections? • Checked the sample and span gas pressures (5–10 psi)? • Checked the instrument air pressure (70–80 psi)? TELEDYNE ANALYTICAL INSTRUMENTS 3-10 Programmable Options 1200 Baud 5, 6, 7, or 8 Bits...

  • Page 29: Operations 4

    (SCFH). The flow set knob adjusts the flow rate of the gas during calibration and zeroing. In the panel below the LED screen is the LCD display. The five colored buttons below it are used to interface with the computer module in selecting modes, with the LCD TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4...

  • Page 30: Spinning Wheel

    The zeroing process automatically opens pneumatic valves on either side of the scrubber, and a gas with a high concentration of oxygen will react with the scrubber and necessitate replacement sooner. TELEDYNE ANALYTICAL INSTRUMENTS For the highest possible accuracy, the analyzer...
  • Page 31 AutoRanging mode, the range will step up at greater than 100% and step down at 80% of full scale of the current range. The analyzer is programmed to prevent oscillation between ranges during rapidly changing oxygen levels. TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4...
  • Page 32 System Statistics: Menu screens are available to view various system parameters, and for setting serial link operation parameters, including modem operation. TELEDYNE ANALYTICAL INSTRUMENTS trace level above or below a threshold. The fifth alarm may An internal clock provides the time and date...

  • Page 33: Cold Start-Up

    6. The main Analyze mode menu will appear, and the measured O level of the sample gas will display. The system should first be zeroed, then spanned, to obtain the most accurate O TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 measurements.

  • Page 34: Calibration Zeroing

    4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS Calibration Zeroing Calibration Zeroing Calibration Zeroing Calibration Zeroing Calibration Zeroing 1. At the main Analyze mode screen press ZERO. 2. Press ACK to acknowledge that a low O ready been connected to the sample port.
  • Page 35 (see step 7). You will then have to press ESC to abort, or ACK to retry. 10. If the zero is successful, the system will return to the main Analyzer mode menu. TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4 Operations 4...

  • Page 36: Calibration Using Span Gas

    4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS Calibration Using Span Gas Calibration Using Span Gas Calibration Using Span Gas Calibration Using Span Gas Calibration Using Span Gas 1. Enter the Calibration mode from the Analyze mode by pressing SPAN.
  • Page 37 ACK. 12. After step 11, the system will automatically span to the user-entered span value. TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4 Operations 4 Operations 4...
  • Page 38 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations TELEDYNE ANALYTICAL INSTRUMENTS 4-10 13. If the O 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.
  • Page 39 4. Press SENSR. (This option will not appear if only one sensor block is installed.) 5. Select sensor A or B. 6. The main Analyze mode menu will appear, and will indi- cate the chosen sensor. TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4 Operations 4 Operations 4...
  • Page 40 Press A or B for the sensor you are installing. 6. Install the sensor (either A or B from step 5) into the sensor block within two minutes, and press ACK. TELEDYNE ANALYTICAL INSTRUMENTS o Cells Onl o Cells Onl o Cells Only) y) y) y) y)
  • Page 41 The 10-minute flush may be restarted by pressing RE- SET, or aborted by pressing SKIP. 8. When sensor installation or alternate sensor test are complete, the system will return to the main Analyze mode menu. TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 level is displayed.

  • Page 42: Range Set-Up

    ACCPT. 4. If FIXED was chosen in step 2 and the range was speci- fied in step 3, the main Analyze mode screen will ap- pear, and will indicate the new manually set range. TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 43: Set-Up Alarms

    ACCPT, which will take you back to step 5. • LEVEL is the O threshold. • HIGH/LOW determines whether the alarm con- dition is above or below the alarm threshold. TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4 Operations 4 Operations 4 Operations 4 concentration for the alarm...
  • Page 44 5. When finished, press ACCPT. The next screen will ask you if there are more alarms to set. If not, pressing ESC three times will take you back to the Analyze mode main menu. TELEDYNE ANALYTICAL INSTRUMENTS or SYSTEM.

  • Page 45: Logger Set-Up

    After you are finished, press ACCPT, which will take you to step 4. The choices for the logger chart sampling mode (MODE =) are on the next page. TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4 Operations 4...
  • Page 46 Sample: The last sample measured in the time period between samples. Sample Sample Press EDIT in step 6 and then use the UP and DOWN keys to select the above choices for the logger chart mode. 4-18 TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 47: Set-Up Clock Functions

    ZERO: Sets the time for the next zero and the inter- val times for automatic zeroing. SPAN: Sets the time for the next span and interval times for automatic spanning. ALRMS: Displays alarm times and dates. TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4 Operations 4 Operations 4...
  • Page 48 12. If ALRMS was pressed in step 1, a menu displaying the most recent triggering time and date of each of the alarms will appear. From here, press ESC three times to return to the main menu screen. TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 49: Changing Passwords For Remote Monitoring And Control

    4. Press MORE. Press ESC to return to the Analyze mode 5. Press PASS1 to change the remote monitoring pass- 6. If you pressed PASS1 in step 5, the next screen will al- TELEDYNE ANALYTICAL INSTRUMENTS SETUP. and DOWN keys, and press ACCPT. You must enter the same authorization code set during the last COLD START.
  • Page 50 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. TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 51: System Statistics

    5. Status page three shows the time of the last zero, the time interval for scheduled zeroing (AutoZero), and whether or not scheduled zeroing is active. 6. Status page four shows the settings for the five pro- grammable alarms. TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4 Operations 4 Operations 4...
  • Page 52 Set-up sets up the modem for auto answer and other communication protocols. TELEDYNE ANALYTICAL INSTRUMENTS 300–2400 1–32000 sec.
  • Page 53 REV and FWD change the date by one page (or 64 points), while – and + go through the data one point at a time within a single page. Press ESC to return to status page ten. TELEDYNE ANALYTICAL INSTRUMENTS Operations 4 Operations 4 Operations 4...
  • Page 54 4 Operations 4 Operations 4 Operations 4 Operations 4 Operations 4-26 TELEDYNE ANALYTICAL INSTRUMENTS...

  • Page 55: Maintenance & Troubleshooting

    10 psig. Sample and span gas pressures should be within ±2 psig of each other. 5.1.1 Sensor Maintenance Sensor maintenance in the 3160 is limited to replacing the sensor(s) when replace- ment is indicated. Consult the troubleshooting section for symptoms that indicate that the sensor needs replacing.

  • Page 56: Troubleshooting

    No sample gas flow. No sample gas flow. No sample gas flow. No sample gas flow. No sample gas flow. TELEDYNE ANALYTICAL INSTRUMENTS leshooting leshooting leshooting leshooting Cause Cause Cause Cause Cause Faulty LCD or LED.
  • Page 57 Power Switch is ON (at "I" Power Switch is ON (at "I" position). position). position). position). position). TELEDYNE ANALYTICAL INSTRUMENTS Maintenance & T T T T T r r r r r oub Maintenance & Maintenance & Maintenance & Maintenance & Cause...
  • Page 58 5 Maintenance & T T T T T r r r r r oub 5 Maintenance & 5 Maintenance & 5 Maintenance & 5 Maintenance & oubleshooting TELEDYNE ANALYTICAL INSTRUMENTS leshooting leshooting leshooting leshooting...
  • Page 59 Alarms: Five user-programmable absolute-reading alarm setpoints, with Form C, SPDT relays (3A resistive). TELEDYNE ANALYTICAL INSTRUMENTS one 0–1 V dc non-isolated signal one 4–20 mA dc isolated signal one 0–1 V dc non-isolated signal one 4–20 mA dc isolated signal...

  • Page 60: Appendix

    Appendix Appendix Appendix Appendix Appendix Mounting and Enclosure: Relative Humidy: Power Requirements: TELEDYNE Analytical Instruments 16830 Chestnut Street City of Industry, CA 91749-1580 Phone (626) 934-1500, Fax (626) 961-2538 TWX (910) 584-1887 TDYANYL COID Web: www.teledyne-ai.com TELEDYNE ANALYTICAL INSTRUMENTS 19" relay rack, 20.3 cm (12.25 inches) high, for general purpose (nonhazardous) areas.

  • Page 61: Recommended Spare Parts List

    Fuse, 1.6A T Type (European) A.3 Drawing List D-56534 Outline Drawing C-64819 Interconnection Drawing NOTE: The MSDS on this material is available upon request through the Teledyne Environmental, Health and Safety Coordinator. Contact at (626) 934-1592 TELEDYNE ANALYTICAL INSTRUMENTS Description C6689B2 C6689B2C C6689A2 C6689A2C...
  • Page 62 Gravity Point (°C) or Compo- nent 11.34 1744 Lead 2.04 1320 Potassium Hydroxide TELEDYNE ANALYTICAL INSTRUMENTS Teledyne Analytical Instruments 16830 Chestnut Street, City of Industry, CA 91749 (818) 961-9221 Extension 222 2/12/96 C.A.S. # Quantity 7439-92-1 3–20 gms None 2 mg/m...
  • Page 63 Section VI – Health Hazard Data Routes of Entry: Skin: Eyes: Acute Effects: Chronic Effects: TELEDYNE ANALYTICAL INSTRUMENTS LEL: 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 contact with skin and eyes.
  • Page 64 Protective measures during cell replacement: Cleanup Procedures: 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.
  • Page 65 NOTE: The above information is believed to be correct and is offered for your information, consideration, and investigation. It should be used as a guide. Teledyne Analytical Instruments shall not be held liable for any damage resulting from handling or from contact with the above product.
  • Page 66 CAS Number: Melting Point/Range: Boiling Point/Range: Specific Gravity: Solubility in Water: Percent Volatiles by Volume: Appearance and Odor: TELEDYNE ANALYTICAL INSTRUMENTS Teledyne Analytical Instruments 16830 Chestnut Street, City of Industry, CA 91749 (818) 961-9221 08/08/91 (818) 961-9221 Lead (Pb), pure KOH 1310–58–3...
  • Page 67 Inhalation: Signs/symptoms of exposure: Medical conditions aggravated by exposure: Carcinogenity: Other health hazards: TELEDYNE ANALYTICAL INSTRUMENTS Ingestion, eye/skin contact .05 mg/cu.m. (Pb) 2 mg/cu.m. (KOH) The electrolyte could be harmful or fatal if swal- lowed. Oral LD50 (RAT) = 3650 mg/kg The electrolyte is corrosive;...
  • Page 68 The information is believed to be correct but does not purport to be all inclusive and shall be used only as a guide. Teledyne Analytical Instruments shall not be and shall be used only as a guide. Teledyne Analytical Instruments shall not be and shall be used only as a guide.

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