Teledyne 3000TB Instruction Manual
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Teledyne 3000TB Instruction Manual

Teledyne 3000TB Instruction Manual

Trace oxygen analyzer
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OPERATING INSTRUCTIONS FOR
Model 3000TB
Trace Oxygen Analyzer
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.
DANGER
Teledyne Analytical Instruments
Trace Oxygen Analyzer
P/N M66673
10/25/2011
i

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  • Page 1 Trace Oxygen Analyzer OPERATING INSTRUCTIONS FOR Model 3000TB 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 Any safeguards required such as locks, labels, or redun- dancy, must be provided by the user or specifically requested of Teledyne at the time the order is placed.
  • Page 3 Trace Oxygen Analyzer Model 3000TB complies with all of the requirements of the Commonwealth of Europe (CE) for Radio Frequency Interference, Electromagnetic Interference (RFI/EMI), and Low Voltage Directive (LVD). The following International Symbols are used throughout the In- struction Manual for your visual and immediate warnings and when...

  • Page 4: Table Of Contents

    Model 3000TB Table of Contents 1 Introduction 1.1 Overview ................ 1-1 1.2 Typical Applications ............1-1 1.3 Main Features of the Analyzer ........1-1 1.4 Model Designations ............1-2 1.5 Operator Interface ............1-3 1.5.1 Displays ..............1-6 1.5.2 Function Keys ............1-6 1.5.3 Data Entry Keys .............
  • Page 5 5.3 Cell Replacement ............5-2 5.2.1 Storing and Handling Replacement Cells ....5-3 5.2.2 When to Replace a Cell ........... 5-3 5.2.3 Removing the Micro-Fuel Cell ......... 5-4 5.2.4 Installing a New Micro-Fuel Cell ......5-6 5.2.5 Cell Warranty ............5-6 Teledyne Analytical Instruments...
  • Page 6 Model 3000TB 5.4 Fuse Replacement............5-7 5.5 System Self Diagnostic Test ........... 5-7 5.6 Troubleshooting ............. 5-9 Appendix A-1 Specifications ..............A-1 A-2 Recommended 2-Year Spare Parts List ......A-2 A-3 Drawing List ..............A-3 A-5 Application Notes on Restrictors, Pressure & Flow..A-4...
  • Page 7 Since the use of this instrument is beyond the control of Teledyne, no responsibility by Teledyne, its affiliates, and agents for damage or injury from misuse or neglect of this equipment is implied or assumed.
  • Page 8 Model 3000TB 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 supplied are indicated by a check mark in the box.

  • Page 9: Introduction

    The Teledyne Analytical Instruments Model 3000TB Trace Oxygen Analyzer is a versatile microprocessor-based instrument for detecting oxygen in a variety of gases. This manual covers the Model 3000TB, trace oxygen, bulkhead-mount, general purpose units only. These instruments are for use in nohazardous environments only.

  • Page 10: Model Designations

    In addition to all standard features, this model also has separate ports for zero and span gases, and built-in control valves. The internal valves are entirely under the control of the 3000TB electronics, to automatically switch between gases in synchronization with the analyzer’s operations Teledyne Analytical Instruments...

  • Page 11: Operator Interface

    Trace Oxygen Analyzer Introduction 1 Operator Interface Figure 1-1 is an illustration of the front of the Model 3000TB Oxygen Analyzer with the outer door open showing the control panel (which is also the inner door). All displays on the standard 3000TB are visible from outside the housing.
  • Page 12 1 Introduction Model 3000TB (Pressing the latch button will open the Inner Door) Figure 1-1: Model 3000TB—Outer Door Open—Showing Control Panel Teledyne Analytical Instruments...
  • Page 13 Trace Oxygen Analyzer Introduction 1 Figure 1-2: Model 3000TB—Inner Door Open—Showing Internal Components Teledyne Analytical Instruments...

  • Page 14: Displays

    1 Introduction Model 3000TB 1.5.1 Displays Digital Meter Display: The meter display is a LED device that produces large, bright, 7-segment numbers that are legible in any lighting environment. It produces a continuous readout from 0-9999 ppm and from 1- 25 %.

  • Page 15: I/O Power Button

    The connectors are described briefly here and in detail in the Installation chapter of this manual. CAUTION: The power cable must be disconnected to fully remove power from the instrument. Teledyne Analytical Instruments...
  • Page 16 1 Introduction Model 3000TB 3.0 A MAX Figure 1-3: Electrical Connector Panel Electrical Connections: The electrical connections on the electrical connector panel are described briefly here, and in more detail in chapter 3 Installation. • Power Connection 115 or 230 V dc, 50 or 60 Hz.

  • Page 17: Gas Connector Panel

    Those that are optional are shown shaded in the figure. The connectors are described briefly here and in detail in the Installation chapter of this manual. Note: For Additional information, please, see page 1-4 Figure 1-4: Model 3000TB Gas Connector Panel Teledyne Analytical Instruments...
  • Page 18 3000TB electronics. Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. The internal clock in the Model 3000TB is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. Teledyne Analytical Instruments...

  • Page 19: Operational Theory 2

    Micro-Fuel Cell Sensor 2.2.1 Principles of Operation The oxygen sensor used in the Model 3000TB series is a Micro-Fuel Cell designed and manufactured by Analytical Instruments. It is a sealed plastic disposable electrochemical transducer. The active components of the Micro-Fuel Cell are a cathode, an anode, and the 15% aqueous KOH electrolyte in which they are immersed.

  • Page 20: Anatomy Of A Micro-Fuel Cell

    2 Operational Theory Model 3000TB 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...

  • Page 21: Electrochemical Reactions

    The electrons released at the surface of the anode flow to the cathode surface when an external electrical path is provided. The current is propor- tional to the amount of oxygen reaching the cathode. It is measured and used to determine the oxygen concentration in the gas mixture. Teledyne Analytical Instruments...

  • Page 22: The Effect Of Pressure

    2 Operational Theory Model 3000TB The overall reaction for the fuel cell is the SUM of the half reactions above, or: → 2PbO 2Pb + O (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.)

  • Page 23: Sample System

    Depending on the mode of operation either sample or calibration gas is delivered. The Model 3000TB 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 24: Electronics And Signal Processing

    Sample In port by teeing to the port with appropriate valves. The shaded portion of the diagram shows the components added when the –C option is ordered. The valves, when supplied, are installed inside the 3000TB enclo- sure and are regulated by the instruments internal electronics.
  • Page 25 Trace Oxygen Analyzer Operational Theory 2 Figure 2-5: Block Diagram of the Model 3000TB Electronics Teledyne Analytical Instruments...
  • Page 26 2 Operational Theory Model 3000TB 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.

  • Page 27: Installation

    Immediately report any damage to the shipping agent. Mounting the Analyzer The Model 3000TB is designed for bulkhead mounting in nonhazard- ous environments. There are four mounting lugs—one in each corner of the enclosure. The outline drawing, at the back of this manual, gives the mount- ing hole size and spacing.
  • Page 28 3 Installation Model 3000TB Figure 3-1: Front View of the Model 3000TB (Simplified) Teledyne Analytical Instruments...

  • Page 29: Electrical Connections

    Trace Oxygen Analyzer Installation 3 Figure 3-2: Required Front Door Clearance Electrical Connections Figure 3-3 shows the Model 3000TB Electrical Connector Panel. There are terminal blocks for connecting power, communications, and both digital and analog concentration outputs. Figure 3-3: Electrical Connector Panel...

  • Page 30: Primary Input Power

    3 Installation Model 3000TB 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.
  • Page 31 The signal output for concentration is linear over the currently selected analysis range. For example, if the analyzer is set on a range that was defined as 0–100 ppm O , then the output would be as shown in Table 3-1. Teledyne Analytical Instruments...

  • Page 32: Alarm Relays

    3 Installation Model 3000TB Table 3-1: Analog Concentration Output—Example Voltage Signal Current Signal ppm O Output (V dc) Output (mA dc) 10.4 12.0 13.6 15.2 16.8 18.4 20.0 To provide an indication of the range, a second pair of analog output terminals are used.

  • Page 33: Digital Remote Cal Inputs

    Remote Zero and Span Inputs: The REMOTE SPAN and RE- MOTE ZERO inputs are on the DIGITAL INPUT terminal block. They accept 0 V (OFF) or 24 V dc (ON) for remote control of calibration. (See Remote Calibration Protocol below.) Teledyne Analytical Instruments...
  • Page 34 (See Remote Calibration Protocol below.) Remote Calibration Protocol: To properly time the Digital Remote Cal Inputs to the Model 3000TB Analyzer, the customer's controller must monitor the CAL CONTACT relay. When the contact is OPEN, the analyzer is analyzing, the Remote Cal Inputs are being polled, and a zero or span command can be sent.

  • Page 35: Range Di Relays

    If you have the –C Internal valve option—which includes additional zero and span gas inputs— the 3000TB automatically regulates the zero, span and sample gas flow. 3.3.6 Range ID Relays There are four dedicated RANGE ID CONTACT relays.

  • Page 36: Remote Sensor And Solenoid Valves

    Toggling input. Stops/Starts any status message output from the RS-232, until st<enter> is sent again. The RS-232 protocol allows some flexibility in its implementation. Table 3-5 lists certain RS-232 values that are required by the 3000TB implementation. Table 3-5: Required RS-232 Options...
  • Page 37 In addition, each individual line has a series FET with a nominal ON resistance of 5 ohms (9 ohms worst case). This could limit the obtainable voltage, depending on the load impedance applied. See Figure 3-9. Figure 3-9: FET Series Resistance 3-11 Teledyne Analytical Instruments...

  • Page 38: Installing The Micro-Fuel Cell

    3 Installation Model 3000TB Installing the Micro-Fuel Cell The Micro-Fuel Cell is not installed in the cell block when the instrument is shipped. It must be installed before the analyzer is placed in service. Once it is expended, or if the cell is exposed to air for too long, the Micro-Fuel Cell will need to be replaced.
  • Page 39 There are electrically operated valves inside for automatic switching between sample and calibration gases. These valves are com- pletely under control of the 3000TB Electronics. They can be externally controlled only indirectly through the Remote Cal Inputs, described below.

  • Page 40: Testing The System

    3 Installation Model 3000TB EXHAUST OUT: Exhaust connections must be consistent with the hazard level of the constituent gases. Check Local, State, and Federal laws, and ensure that the exhaust stream vents to an appropriately controlled area if required. Note: If the unit is for vacuum service, see Sample In, above, for gas pressure/flow considerations.

  • Page 41: Operation

    • Set alarm setpoints, and modes of alarm operation (latching, failsafe, etc). Before you configure your 3000TB these default values are in effect: Ranges: LO = 100 ppm, MED = 1000 ppm, HI = 10,000 ppm. Auto Ranging: ON Alarm Relays: Defeated, 1000 ppm, HI, Not failsafe, Not latching.

  • Page 42: Using The Data Entry And Function Buttons

    4 Operation Model 3000TB 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 Δ Δ Δ Δ Δ ∇ arrow buttons can be used to increment or decrement that modifiable item.

  • Page 43: The System Function

    Once a unique password is assigned and activated, the operator MUST enter the UNIQUE password to gain access to set-up functions which alter the instrument's operation, such as setting the instrument span or zero setting, adjusting the alarm setpoints, or defining analysis ranges. Teledyne Analytical Instruments...

  • Page 44: Tracking The O Readings During Calibration

    4 Operation Model 3000TB 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.

  • Page 45: Setting Up An Auto-Cal

    Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. The internal clock in the Model 3000TB is acurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. To setup an Auto–Cal cycle: Choose System from the Function buttons.

  • Page 46: Password Protection

    4 Operation Model 3000TB , and press Enter. A new screen for Use < > arrows to blink Auto—Cal Span/Zero set appears. Span OFF Nxt: 0d 0h Zero OFF Nxt: 0d 0h ), then press Enter again. (You Press < > arrows to blink...

  • Page 47: Installing Or Changing The Password

    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 Teledyne Analytical Instruments...
  • Page 48 4 Operation Model 3000TB Press Enter to change the password (either the default TETAI or the previously assigned password), or press Escape to keep the existing pass- word and move on. If you chose Enter to change the password, the password assignment screen appears.

  • Page 49: Logout

    Password Reentered 4.3.5 System Self-Diagnostic Test The Model 3000TB has a built-in self-diagnostic testing routine. Pre- programmed signals are sent through the power supply, output board and sensor circuit. The return signal is analyzed, and at the end of the test the status of each function is displayed on the screen, either as OK or as a number between 1 and 3.

  • Page 50: Version Screen

    4 Operation Model 3000TB The self diagnostics are run automatically by the analyzer whenever the instrument is turned on, but the test can also be run by the operator at will. To initiate a self diagnostic test during operation: Press the System button to start the System function.

  • Page 51: The Zero And Span Functions

    20.9% (209,000 ppm), the cell can take a long time to recover if the instrument is used for trace oxygen analysis immediately following calibration in air. Connect the calibration gases to the analyzer according to the instruc- tions given in Section 3.4.1, Gas Connections, observing all the prescribed precautions. Teledyne Analytical Instruments 4-11...

  • Page 52: Zero Cal

    4 Operation Model 3000TB Shut off the gas pressure before connecting it to the analyzer, and be sure to limit the pressure to 40 psig or less when turning it back on. Readjust the gas pressure into the analyzer until the flowrate (as read on the analyzer’s SLPM flowmeter) settles between 0.5 and 2.4 SLPM (ap-...

  • Page 53: Manual Mode Zeroing

    4.4.1.3 Cell Failure Cell failure in the 3000TB is usually associated with inability to zero the instrument down to a satisfactorily low ppm reading. When this occurs, the 3000TB system alarm trips, and the LCD displays a failure message.

  • Page 54: Span Cal

    4 Operation Model 3000TB CELL FAIL/ ZERO HIGH 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.

  • Page 55: Manual Mode Spanning

    (209000.00 if you are using air). The < > arrows choose the digit, and the Δ∇ arrows choose the value of the digit. Press Enter to enter the span value into the system and begin the span calibration. Teledyne Analytical Instruments 4-15...

  • Page 56: Span Failure

    Consider this before replacing the cell. The Alarms Function The Model 3000TB is equipped with 2 fully adjustable concentration alarms and a system failure alarm. Each alarm has a relay with a set of form “C" contacts rated for 3 amperes resistive load at 250 V ac. See Figure in...
  • Page 57 The defeat alarm mode is incorporated into the alarm circuit so that maintenance can be performed under conditions which would normally activate the alarms. The defeat function can also be used to reset a latched alarm. (See procedures, below.) Teledyne Analytical Instruments 4-17...
  • Page 58 4 Operation Model 3000TB If you are using password protection, you will need to enter your password to access the alarm functions. Follow the instructions in section 4.3.3 to enter your password. Once you have clearance to proceed, enter the Alarm function.

  • Page 59: The Range Function

    Med = 0–1,000 ppm High = 0–10,000 ppm. The Model 3000TB is set at the factory to default to autoranging. In this mode, the microprocessor automatically responds to concentration changes by switching ranges for optimum readout sensitivity. If the current range limits are exceeded, the instrument will automatically shift to the next higher range.

  • Page 60: Fixed Range Analysis

    4 Operation Model 3000TB Note: The ranges must be increasing from low to high, for example, if range 1 is set as 0–100 ppm and range 2 is set as 0–1,000 ppm, range 3 cannot be set as 0– 500 ppm since it is lower than range 2.

  • Page 61: The Analyze Function

    Bag the sensor in nitrogen during this time Install a shut off valve on the vent port of the ana- lyzer or somewhere within the users sample system. Teledyne Analytical Instruments 4-21...
  • Page 62 4 Operation Model 3000TB 4-22 Teledyne Analytical Instruments...

  • Page 63: Maintenance

    The major internal component locations are shown in Figure 5-1, the cell block is illustrated in Figure 5-2, and the fuse receptacle is shown in Figure 5-3. The 3000TB contains the following major internal components: • Micro-Fuel Cell (L-2C) •...

  • Page 64: Cell Replacement

    The Class L-2C Micro-Fuel Cell is used in the standard Model 3000TB. If any other cell is supplied with your instrument, check the front of this manual for any addenda applying to your special model.

  • Page 65: 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 3000TB, or shortly before the end of the cell's one year warranty period. CAUTION: Do not stockpile cells. The warranty period starts on the day of shipment.

  • Page 66: Removing The Micro-Fuel Cell

    5 Maintenance Model 3000TB 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. The only way to avoid all fail messages is to turn unit off and on.
  • Page 67 Maintenance 5 Lift Up Gate Cell Block Outer and inner doors removed for clarity Micro-Fuel Cell Cell Adaptor (For B-2 or A-2 series cell) O-Ring Cell Holder Figure 5-2: Exploded View of Cell Block and Micro-Fuel Cell Teledyne Analytical Instruments...

  • Page 68: Installing A New Micro-Fuel Cell

    Model 3000TB 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 sensor will recover to low O measurement levels.

  • Page 69: Cell Warranty

    Fuse Replacement The 3000TB requires two 5 x 20 mm, 4 A, T type (Slow Blow) fuses. The fuses are located inside the NEMA-4 housing on the Electrical Connec- tor Panel, as shown in Figure 5-2. To replace a fuse: 1.

  • Page 70: System Self Diagnostic Test

    5 Maintenance Model 3000TB 3.0 A MAX Figure 5-3: Removing Fuse Cap and Fuse from Holder 2. Replace fuse by reversing process in step 1. System Self Diagnostic Test 1. From System Mode, use arrow keys to move to More, and press Enter.

  • Page 71: Troubleshooting

    If erratic behavior continues replace the sensor. Possible Cause: Atmospheric Oxygen may be diffusing in through the vent and affecting the oxygen level which the sensor sees. Solution: Teledyne Analytical Instruments...
  • Page 72 5 Maintenance Model 3000TB Increase flow rate and/or length or vent tubing in order to dilute of minimize the diffusion of oxygen from the vent back to the sensor. Problem: Inaccurate zero operation (i.e. the user has zeroed the analyzer accidentally on gas much higher than one would normally use for a zero gas).

  • Page 73: Appendix A-1 Specifications

    Displays: 2 line by 20 alphanumeric, VFD screen, and one 5 digit LED display. Digital Interface: Full duplex RS-232 communications port. Power: 110 or 220 VAC at 50 or 60 Hz. Operating Temperature: 0-50 °C, XL option 5-35 °C Teledyne Analytical Instruments...

  • Page 74: Recommended 2-Year Spare Parts List

    Appendix Model 3000TB 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. XL-Option Accuracy: ±1 ppm on 0-10 ppm once thermal equilbrium is reached.

  • Page 75: Drawing List

    Web: www.teledyne-ai.com or your local representative. A-3 Drawing List D66674 Outline Drawing D66675 Wiring Diagram 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...
  • Page 76 Appendix Model 3000TB 3000 SERIES ANALYZERS 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 atmospheric pressure) The pressure must be maintained as to provide a useable flow rate trough the analyzer.
  • Page 77 ( off scale of flow-meter), pressure drops other than the restriction device could become significant , and result in pressurizing the cell. Example 2, A 3000TB is configured for vacuum service as follows. The un-marked restrictor is placed in the sample vent port. The down stream end of the restrictor is then connected to a vacuum pump and by-pass valve.
  • Page 78 Operation without a restrictor device is not recommend as mentioned above. A 3000TB without any flow restrictor device was tested on 11-19-97. This results in a flow rate of 2.4 SLPM @ 1 PSIG. This is a cv of 0.023 for the standard sample sys.

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