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Teledyne 3000ZA-3X Operating Instructions Manual

Trace oxygen analyzer
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Trace Oxygen Analyzer
OPERATING INSTRUCTIONS FOR
MODEL 3000ZA-3X
Trace Oxygen Analyzer
P/N M77579
11/29/11
DANGER
Toxic gases and or flammable liquids may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
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.
Teledyne Analytical Instruments
i

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  • Page 1 Trace Oxygen Analyzer OPERATING INSTRUCTIONS FOR MODEL 3000ZA-3X Trace Oxygen Analyzer P/N M77579 11/29/11 DANGER Toxic gases and or flammable liquids may be present in this monitoring system. Personal protective equipment may be required when servicing this instrument. Hazardous voltages exist on certain components internally which may persist for a time even after the power is turned off and disconnected.
  • Page 2 Teledyne Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-1580.
  • Page 3  3000ZA-Rack Mnt: The 19" Relay Rack Mount units are available with either one or two 3000 series analyzers installed in a standard 19" panel and ready to mount in a standard rack. Teledyne Analytical Instruments...
  • Page 4 STAND-BY: Instrument is on Stand-by, but circuit is active GROUND: Protective Earth CAUTION: The operator needs to refer to the manual for further information. Failure to do so may compromise the safe operation of the equipment. CAUTION: Risk of Electrical Shock Teledyne Analytical Instruments...

  • Page 5: Safety Messages

    Technician Symbol: All operations marked with this symbol are to be performed by qualified maintenance personnel only. NOTE: Additional information and comments regarding a specific component or procedure are highlighted in the form Symbol of a note. Teledyne Analytical Instruments...
  • Page 6 Manuals do get lost. Additional manuals can be obtained from Teledyne Analytical Instruments at the address given in the Appendix. Some of our manuals are available in electronic form via the internet. Please visit our website at: www.teledyne-ai.com.
  • Page 7 Since the use of this instrument is beyond the control of Teledyne Analytical Instruments, no responsibility by Teledyne Analytical Instruments, its affiliates, and agents for damage or injury from misuse or neglect of this equipment is implied or assumed.

  • Page 8: Table Of Contents

      3.3 Rear Panel Connections   3.3.1 Gas Connections   3.3.2 Electrical Connections   3.3.2.1 Primary Input Power   3.3.2.2 50-Pin Equipment Interface Connector   3.3.2.3 RS-232 Port   3.4 Installing the Zirconium Oxide Sensors   Teledyne Analytical Instruments viii...
  • Page 9   4.4.2 Span Value   4.4.3 Span Timer   4.4.4 Span Finish   4.4.5 Span Begin   4.5 Zero Menu   4.5.1 Zero Finish   4.5.2 Zero Value   4.5.3 Zero Begin   4.5.4 Zero Timer   Teledyne Analytical Instruments...
  • Page 10 5.5 Major Internal Components   5.6 Cleaning   5.7 Troubleshooting   Appendix ............... 53   A-1 Specifications   A-2 Recommended 2-Year Spare Parts List   A-3 Drawing List   A-4 19-inch Relay Rack Panel Mount   A.5 Application Notes   Teledyne Analytical Instruments...
  • Page 11 Figure 4-1: Hierarchy of Available Functions Figure 5-1: Sensor Block with Middle Sensor Installed Figure 5-2: Removing Fuse Block from Housing Figure 5-3: Installing Fuses Figure 5-4: Rear Panel Removal Figure A-1: Single and Dual 19" Rack Mounts Teledyne Analytical Instruments...
  • Page 12 Table 3-1: Analog Output Connections Table 3-2: Alarm Relay Contact Pins Table 3-3: Remote Calibration Connections Table 3-4: Range ID Relay Connections Table 3-5: Commands via RS-232 Input Table 3-6: Required RS-232 Options Table 5-1: Self-Test Result Display Table 5-2: Troubleshooting Teledyne Analytical Instruments...

  • Page 13: Introduction

    Introduction Introduction 1.1 Overview The Teledyne Analytical Instruments Model 3000ZA 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 3000ZA General Purpose flush- panel and/or rack-mount units with CE mark.

  • Page 14: Model Designations

    3000ZA-C: In addition to all the 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 3000ZA electronics to automatically Teledyne Analytical Instruments...

  • Page 15: Front Panel (Operator Interface)

    See Figure 1-1. The front panel has thirteen buttons for operating the analyzer, a digital meter, an alphanumeric display, and a window for viewing the sample flowmeter. Figure 1-1: Model 3000ZA Front Panel Teledyne Analytical Instruments...
  • Page 16 The VFD screen is an easy-to-use interface from operator to analyzer. It displays values, options, and messages that give the operator immediate feedback. Flowmeter: Monitors the flow of gas past the sensor. Readout is 0.2 to 2.4 standard liters per minute (SLPM). Teledyne Analytical Instruments...

  • Page 17: Rear Panel (Equipment Interface)

    Some of those depicted are optional and may not appear on your instrument. The connectors are described briefly here and in detail in Chapter 3 Installation. Figure 1-2: Model 3000ZA Rear Panel Teledyne Analytical Instruments...
  • Page 18 DC plus 4–20 mA DC range ID. Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. The internal clock in the Model 3000ZA is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. Teledyne Analytical Instruments...

  • Page 19: Operational Theory

    2.2 ZrO Sensor 2.2.1 Principles of Operation Teledyne’s zirconium oxide sensor is a miniature solid state sensor. It uses a stabilized zirconia disc as an electrolyte with a sensing electrode (the cathode) and a counter electrode (the anode) on each side of the disc.

  • Page 20: Sample System

    In the standard instrument, calibration gases can be connected directly to the Sample In port by teeing to the port with appropriate valves. Figure 2-1: Model 3000ZA-3X Sample System Teledyne Analytical Instruments...

  • Page 21: Zirconium Oxide Sensor Application Notes

    2.5 Electronics and Signal Processing The Model 3000ZA Trace Oxygen Analyzer uses an 8031 microcontroller with 32 kB of RAM and 128 kB of ROM to control all signal processing, input/output, and display functions for the analyzer. Teledyne Analytical Instruments...
  • Page 22 4-20 mA dc and the 0-1 VDC analog concentration signal outputs, and the analog range ID outputs. Signals from the power supply are also monitored, and through the microprocessor, the system failure alarm is activated if a malfunction is detected. Teledyne Analytical Instruments...

  • Page 23: Figure 2-3: Component Location

    Trace Oxygen Analyzer Operational Theory Figure 2-3: Component Location Teledyne Analytical Instruments...

  • Page 24: Figure 2-4: Electronic Block Diagram

    Operational Theory 3000ZA-3X Figure 2-4: Electronic Block Diagram Teledyne Analytical Instruments...

  • Page 25: Unpacking The Analyzer

    On special order, a 19" rack-mounting panel can be provided. For rack mounting, one or two 3000 series analyzers can be flush-panel mounted on the rack panel. See Appendix for dimensions of the mounting panel. Teledyne Analytical Instruments...

  • Page 26: Figure 3-1: Front Panel Of The Model 3000Ta

    (less than 0.18 inch wide). Allow clearance for the door to open in a 90-degree arc of radius 7.125 inches. See Figure 3-2. Figure 3-2: Required Front Door Clearance Teledyne Analytical Instruments...

  • Page 27: Rear Panel Connections

    The kit included with the instrument contains two restrictors and a union for 1/4” diameter tubing. Notice that there are two 1-3/4” long, 1/4” diameter restrictors. There is an open end and a Teledyne Analytical Instruments...
  • Page 28 The inlet gas pressure should be reasonably regulated. Pressures between 2 and 50 psig are acceptable as long as the pressure, once established, will keep the front panel flowmeter reading in an acceptable range (0.5 to 2.0 SLPM). For non-pressurized sample or very low Teledyne Analytical Instruments...

  • Page 29: Electrical Connections

    ULTIMATELY, IT IS THE INSTALLER WHO ENSURES THAT THE CONNECTIONS PROVIDE ADEQUATE EMI/RFI SIELDING. 3.3.2.1 P RIMARY NPUT OWER The power cord receptacle and fuse block are located in the same assembly. Insert the power cord into the power cord receptacle. Teledyne Analytical Instruments...

  • Page 30: 50-Pin Equipment Interface Connector

    0 V at 0 ppm to 1 V at full scale ppm. (Full scale = 100% of programmable range.) 0–1 VDC Range ID: 0.20 V = Low Range, 0.5 V =  Medium Range, 0.80 V = High Range. Teledyne Analytical Instruments...

  • Page 31: Table 3-1: Analog Output Connections

    Can be configured as high (actuates when concentration  is above threshold), or low (actuates when concentration is below threshold). Can be configured as failsafe or non-failsafe.  Can be configured as latching or non-latching.  Can be configured out (defeated).  Teledyne Analytical Instruments...

  • Page 32: Table 3-2: Alarm Relay Contact Pins

    System Alarm, moving contact System Alarm, normally open contact Digital Remote Cal Inputs: Accept 0 V (off) or 24 VDC (on) inputs for remote control of calibration. (See Remote Calibration Protocol below.) See Table 3-3 for pin connections. Teledyne Analytical Instruments...

  • Page 33: Table 3-3: Remote Calibration Connections

    Cal Inputs are being polled, and a zero or span command can be sent. When the contact is CLOSED, the analyzer is already calibrating. It will ignore your request to calibrate, and it will not remember that request. Teledyne Analytical Instruments...

  • Page 34: Table 3-4: Range Id Relay Connections

    High range is assigned to Range 3 ID. Table 3-4 lists the pin connections. Table 3-4: Range ID Relay Connections Function Range 1 ID Contact Range 1 ID Contact Range 2 ID Contact Range 2 ID Contact Range 3 ID Contact Range 3 ID Contact Spare Contact Spare Contact Teledyne Analytical Instruments...

  • Page 35: Figure 3-5: Remote Probe Connections

    In addition, each individual line has a series FET with a nominal ON resistance of 5 ohms (9 ohms worst case). This can limit the obtainable voltage, depending on the load impedance applied. See Figure 3-6. Teledyne Analytical Instruments...

  • Page 36: Rs-232 Port

    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 RS-232 have been implemented to date. They are described in Table 3-5. Teledyne Analytical Instruments...

  • Page 37: Table 3-5: Commands Via Rs-232 Input

    RS-232 Port: The digital signal output is a standard RS-232 serial communications port used to connect the analyzer to a computer, terminal, or other digital device. It requires a standard 9-pin D connector. Teledyne Analytical Instruments...

  • Page 38: Installing The Zirconium Oxide Sensors

    If they are not installed, the sensors will be packaged with their Teledyne Analytical Instruments part number marked on the bag. When the ZrO sensor needs to be installed or replaced, follow the procedures in Section 5.2.

  • Page 39: Operation

    Low sensor= 80 ppm. Span Timer 7 min. Password: If you choose not to use password protection, the default password is automatically displayed on the password screen when you start up and you have access to all functions of the analyzer. Teledyne Analytical Instruments...

  • Page 40: Using The Data Entry And Function Buttons

    ENTER key), the alterations are lost. Navigation and Data Entry is possible using the UP and DOWN KEYS, the ENTER key, the ESCAPE key and the 7 special function keys (ANALYZE, SYSTEM, SPAN, ZERO, ALARMS, RANGE, and Teledyne Analytical Instruments...

  • Page 41: Arrow Keys

    (discarding the displayed/modified value). 3. In sequential operations such as the Password Entry Routine the ESCAPE key restores the original value of the parameter and backs up to the previous letter or operation in the sequence. Teledyne Analytical Instruments...

  • Page 42: Special Function Keys

    If in Range 3 the message "R3: 0-nnnn.nn ppm". or, if range is in percent, "Rx: 0-nnn.nn %". 4.3.2 System Menu The SYSTEM screen can be accessed by pressing the SYSTEM key and it has the following functions: Teledyne Analytical Instruments...

  • Page 43: Figure 4-1: Hierarchy Of Available Functions

    Trace Oxygen Analyzer Operation ----------------------- PASSWORD LOGOUT MODEL SELF TEST FILTER ANALOG-OUT ADJUST AUTO-CALIBRATION CHANGE STREAM ----------------------- Figure 4-1: Hierarchy of Available Functions Teledyne Analytical Instruments...

  • Page 44: Password Routine

    -> Change Password ----------------------- Pressing ESCAPE causes a return to the Analyze Mode. Pressing ENTER proceeds as follows. ----------------------- Enter New Password 'T' 'A' 'I' ----------------------- Old password is supplied as starting letters. Enter password. ----------------------- Reenter New Password Teledyne Analytical Instruments...

  • Page 45: Logout Routine

    Password Changed! ----------------------- The password is replaced by the entered password. 4.3.4 Logout Routine ----------------------- Restrict Access? ENTER-YES ESCAPE-NO ----------------------- Pressing ENTER causes access to most menus to now be restricted. 4.3.5 Model Routine ----------------------- 3000 ZO-x3 Analyzer Teledyne Analytical Instruments...

  • Page 46: Self-Test Routine

    Then pressing UP or DOWN selects a number ranging from 1 to 10. Lower filter values cause the analyzer to converge on new inputs more quickly, but also allow more noise in the sample. 4.3.8 Analog-Out Adjust Routine ----------------------- 4-20mA Offset: 0 Teledyne Analytical Instruments...
  • Page 47 Then pressing UP or DOWN toggles the value. When TRUE, the analog output cannot put less than 4mA out of the analog output (during ANALYZE MODE). When FALSE, the output may be lower than 4mA by approximately 10%. Teledyne Analytical Instruments...

  • Page 48: Auto-Calibration Timer

    Analyze, Zero or Span. This will allow the user to check the analyzer response to cal gas without entering calibration mode. 4.4 Span Menu The SYSTEM screen is as follows: ----------------------- Span Sensor: Low Span 200 ppm Span Timer: 7 min. Span AUTO Finish Span Begin ----------------------- Teledyne Analytical Instruments...

  • Page 49: Span Sensor

    Pressing UP or DOWN adjusts the number. 4.4.3 Span Timer ----------------------- ->Span Timer: 7 min. ----------------------- This function sets the hold time in span mode before the analyzer actually performs the span. Adjust to give enough time to purge with span gas. Teledyne Analytical Instruments...

  • Page 50: Span Finish

    Begin Span? ENTER-YES ESCAPE-NO ----------------------- Pressing ENTER causes the screen to prompt to begin the span routine (as displayed above). Pressing ENTER again causes the analyzer to commence the span routine, and begin analyzing in SPAN MODE. Teledyne Analytical Instruments...

  • Page 51: Zero Menu

    AUTO. 4.5.2 Zero Value ----------------------- ->Zero 0.00 ppm ----------------------- Pressing ENTER causes the number after 'Zero' to start flashing. The number has a range of 0 ppm to 100 ppm and should be set equal to Teledyne Analytical Instruments...

  • Page 52: Zero Begin

    MODE. 4.5.4 Zero Timer ----------------------- ->Zero Timer: 7 min. ----------------------- This function sets the hold time in zero mode before the analyzer actually performs the zero adjustment. Give enough time to purge the analyzer with zero gas. Teledyne Analytical Instruments...

  • Page 53: Alarms Menu

    Then pressing UP or DOWN toggles between the 2 words. Defeating an alarm causes the alarm to return to a non-alarming condition and prevents further tripping of the alarm. 4.6.2 Alarm Polarity ----------------------- ->AL-1 HIGH ----------------------- Teledyne Analytical Instruments...

  • Page 54: Alarm Failsafe

    4.6.5 Alarm Setpoint ----------------------- ->AL-1 80.00 ppm ----------------------- Pressing ENTER causes the setpoint concentration to start flashing. Then pressing UP or DOWN adjusts the setpoint up or down respectively. Setpoints may range from 0.00 ppm to 100.00 %. Teledyne Analytical Instruments...

  • Page 55: Range Menu

    When Dgtl (Digital), the analyzer will select the range according to the signals on the remote digital cal contacts on the rear panel (and therefore disabling their original intent of being used aa remote calibration initiation inputs). Teledyne Analytical Instruments...

  • Page 56: Manual Range Select

    R1, R2, and R3. They may be set to a value in the range of 1.00 ppm to 100% with the stipulation that the each range must have a setpoint equal to or greater than the setpoint of the range below it plus 1ppm. Teledyne Analytical Instruments...

  • Page 57: Maintenance

    CONNECTED TO THE POWER SOURCE. THE RED SWITCH ON THE FRONT PANEL IS FOR SWITCHING POWER ON OR OFF TO THE DISPLAYS AND OUTPUTS ONLY. 1. Remove power to the instrument by unplugging the power cord at the power source. Teledyne Analytical Instruments...
  • Page 58 On the center P/N S1492 (0 – 2 % range ) On the right side P/N S1442 (0 – 95 % range ) CAUTION: MAKE SURE OF THE CORRECT POSITION OF EACH SENSOR. DO NOT PLACE A SENSOR IN THE WRONG SOCKET OR THE ANALYZER WILL FAIL! Teledyne Analytical Instruments...

  • Page 59: Fuse Replacement

    Trace Oxygen Analyzer Maintenance Figure 5-1: Sensor Block with Middle Sensor Installed 5.3 Fuse Replacement 1. Place small screwdriver in notch, and pry cover off, as shown in Figure 5-2. Figure 5-2: Removing Fuse Block from Housing Teledyne Analytical Instruments...

  • Page 60: System Self Diagnostic Test

    “Pre L - Test : GOOD” ( Tests offset of low range amplifier ) “Pre M - Test : GOOD” ( Tests offset of medium range amplifier) “Pre H - Test : GOOD” ( Tests offset of high range amplifier ) Teledyne Analytical Instruments...

  • Page 61: Major Internal Components

    SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL. Figure 5-4: Rear Panel Removal (Remove only those screws marked with an X) The 3000ZA contains the following major components: Analysis Section  Zirconium oxide sensors  Cell block  Teledyne Analytical Instruments...

  • Page 62: Cleaning

    Analyzer may have Recalibrate analyzer, oxygen concentration been calibrated in an making sure the as reported by the inaccurate fashion. proper gas is fed, the analyzer proper sensor is selected, and the proper value of span gas is input. Teledyne Analytical Instruments...
  • Page 63 Press the ENTER to confirm returning the analyzer to factor defaults. Re-span each of the sensors without doing the zero. If the analyzer seems to be working Ok, up to this point, retry to zero. Teledyne Analytical Instruments...
  • Page 64 Maintenance 3000ZA-3X Teledyne Analytical Instruments...

  • Page 65: Appendix

    Two adjustable concentration threshold alarm contacts with fully programmable setpoints. Displays: 2-line by 20-character, VFD screen, and one 5 digit LED display. Digital Interface: Full duplex RS-232 communications port. Power: Universal power supply 85-250 VAC, at 47-63 Hz. Teledyne Analytical Instruments...
  • Page 66 Analog outputs: 0-1 VDC percent-of-range, 0-1 VDC range ID. 4-20 mA DC (isolated) percent-of-range, 4-20 mA DC (isolated) range ID. Dimensions: 19 cm high, 24.9 cm wide, 31 cm deep (6.96 in high, 8.7 in wide, 12.2 in deep). Teledyne Analytical Instruments...

  • Page 67: Recommended 2-Year Spare Parts List

    (if available) and the model and serial number of the instrument for which the parts are intended. Orders should be sent to: TELEDYNE Analytical Instruments 16830 Chestnut Street City of Industry, CA 91749-1580 Phone (626) 934-1500, Fax (626) 961-2538 Web: www.teledyne-ai.com...

  • Page 68: Drawing List

    Maintenance 3000ZA-3X A-3 Drawing List D-77579 Final Assembly D-75738 Outline Drawing A-4 19-inch Relay Rack Panel Mount Figure A-1: Single and Dual 19" Rack Mounts (dimensions in mm) Teledyne Analytical Instruments...

  • Page 69: Application Notes

    (percent analyzers will require some type of cell retainer to prevent the cell from being pushed out by the pressure). For operation at pressures below atmospheric pressure a suffix C (clamped) cell is required. Teledyne Analytical Instruments...
  • Page 70 Example 1: With an incoming pressure of 10 psig the standard restrictor (blue dot) will provide a flow rate of 0.76 SLPM. Upstream of the restrictor the sample line pressure will be 10 psig, while down stream Teledyne Analytical Instruments...
  • Page 71 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 system. REFERENCE: FLOW_1.XLS & FLOW_2.XLS for information on flow rates at various pressures. Teledyne Analytical Instruments...
  • Page 72 Restrictor kit: A68729 Union (SS) LP Restrictor R2323 (low pressure / vac. service) Std. Restrictor R2324 Blue dot Ferrule Ferrule Both ferrules are required CONVERSIONS: 1 PSI 2.04 inches of mercury (in. Hg.) 1 SCFH = 0.476 SLPM Teledyne Analytical Instruments...

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