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Teledyne 3010TA Operating Instructions Manual

Trace oxygen analyzer
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OPERATING INSTRUCTIONS

Model 3010TA
Trace Oxygen Analyzer
Flush Mount Control Unit, PN D-64596A*
NEC Type Analysis Unit, PN D-65478*
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 PER-
SIST 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
Oxygen Analyzer
Oxygen Analyzer
Oxygen Analyzer
Oxygen Analyzer
Oxygen Analyzer
P/N M65693
11/22/99
ECO:#99-0459
i

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  • Page 1: Operating Instructions

    Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer OPERATING INSTRUCTIONS Model 3010TA Trace Oxygen Analyzer Flush Mount Control Unit, PN D-64596A* NEC Type Analysis Unit, PN D-65478* DANGER HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING SYSTEM.
  • Page 2 Any safeguards required such as locks, labels, or redundancy, must be provided by the user or specifically requested of Teledyne at the time the order is placed.
  • Page 3 Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Table of Contents Specific Model Information ........iv Preface ..............v Part I: Control Unit, Model TA....Part I: 1-1 Part II: Analysis Unit, Model T ....Part II: 1-1 Appendix ............

  • Page 4: Appendix

    Instrument Serial Number: __________________________ The instrument with the above serial number has the following Options: 3010TA-C Three gas inputs, for sample, zero and span gases, with three solenoid-actuated gas-flow control valves built in. Valves are automatically synchronized to the analyzer's electronic control sequences.

  • Page 5: Typical Applications

    Analysis Unit, or remote probe, that can operate in a hazardous area. Part I of this manual covers the Model 3010TA General Purpose flush- panel and/or rack-mount Control Unit only. This Control Unit is for indoor use in a nonhazardous environment.

  • Page 6: Main Features Of The Analyzer

    3010T_C means that the same unit is part of the 3010TAC and the 3010TBC models. 3010TA: NEC Type Trace Oxygen Analyzer with flush mount Control Unit. Consists of 3010TA Control Unit, PN D-64596A and a 3010T Analysis Unit, PN D-65478. 3010PA: NEC Type Percent Oxygen Analyzer with flush mount Control Unit.
  • Page 7 Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer • Stainless steel cell block is standard equipment. • Advance design Micro-Fuel Cell sensor, Specially designed model for trace analysis, has a one year warranty and an expected lifetime of two years. •...
  • Page 8 Model 3010 Model 3010 Model 3010 Model 3010 Model 3010 T T T T T A A A A A viii...
  • Page 9 Part I: Control Unit OPERATING INSTRUCTIONS 3010 TA Model Oxygen Analyzer Part I: Control Unit Flush Mount Part Numbers: D-64596A Part I: i...

  • Page 10: Table Of Contents

    Model 3010 Oxygen Analyzer Table of Contents 1 Introduction 1.1 Overview ................ 1-1 1.2 Control Unit Front Panel ..........1-1 1.3 Recognizing Difference Between LCD & VFD ....1-3 1.4 Control Unit Rear Panel ..........1-3 2 Operational Theory 2.1 Introduction ..............2-1 2.2 Electronics and Signal Processing ........
  • Page 11 Part I: Control Unit 4.4.1 Zero Cal ..............4-12 4.4.1.1 Auto Mode Zeroing ........4-12 4.4.1.2 Manual Mode Zeroing ........4-12 4.4.1.3 Cell Failure ............ 4-13 4.4.2 Span Cal ..............4-14 4.4.2.1 Auto Mode Spanning ........4-14 4.4.2.2 Manual Mode Spanning ......... 4-15 4.4.3 Span Failure ............
  • Page 12 Model 3010 Oxygen Analyzer iv: Part I...

  • Page 13: Introduction

    3010T Analysis Unit, is a versatile microprocessor-based instrument for detecting trace amounts of oxygen in a variety of gases. Part I, this part, of this manual covers the Model 3010TA series General Purpose flush-panel and/or rack-mount Control Units. (The Analysis Unit is covered in Part II of this manual.) The Control Unit is for indoor use in a...
  • Page 14 1 Introduction Model 3010 Door Latch Digital Meter Alphanumeric Display Standby Switch Data Entry Buttons F unction B uttons Figure 1-1: Front of Unmounted Control Unit Function Keys: Six touch-sensitive membrane switches are used to change the specific function performed by the analyzer: •...

  • Page 15: Recognizing Difference Between Lcd & Vfd

    Oxygen Analyzer Part I: Control Unit • Enter Moves VFD display on to the next screen in a series. If none remains, returns to the Analyze screen. • Escape Moves VFD display back to the previous screen in a series. If none remains, returns to the Analyze screen. Digital Meter Display: The meter display is a LED device that produces large, bright, 7-segment numbers that are legible in any lighting.
  • Page 16 1 Introduction Model 3010 Figure 1-2: Model 3010TA Rear Panel • Power Connection Universal AC power source. • Analog Outputs 0-1 V dc concentration and 0-1 V dc range ID. Isolated 4-20 mA dc and 4-20 mA dc range ID.
  • Page 17 Not implemented at this printing. Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. The internal clock in the Model 3010TA is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. Part I: 1-5...
  • Page 18 1 Introduction Model 3010 1-6: Part I...

  • Page 19: Operational Theory

    (PCB) assemblies inside the Control Unit chassis. The PCB locations are illustrated in section 5, Maintenance. Refer to Figure 2-1, Block Diagram of the 3010TA CU Electronics: In the presence of oxygen, the sensor (in the Analysis Unit) generates a current. A current to voltage amplifier (in the Control Unit) converts this current to a voltage.
  • Page 20 Operational Theory Model 3010 Figure 2-1: Block Diagram of the 3010TA CU Electronics 2-2: Part I...

  • Page 21: Temperature Control

    Oxygen Analyzer Part I: Control Unit The digital concentration signal—along with input from the control panel—is processed by the microprocessor, and appropriate control signals are directed to the display, alarms and communications port as well as to the gas control valves in the Analysis Unit. The same digital information is also sent to a 12 bit digital to analog converter that produces the 4-20 mA dc and the 0-1 V dc analog concentra- tion signal outputs, and the analog range ID outputs.
  • Page 22 Operational Theory Model 3010 2-4: Part I...

  • Page 23: Installation

    Immediately report any damage to the shipping agent. Mounting the Control Unit The Model 3010TA Control Unit is for indoor use in a general purpose area. It is NOT for hazardous environments of any type. The standard model is designed for flush panel mounting. Figure 3-1 is an illustration of a Model 3010 standard Control Unit front panel and mount- ing bezel.
  • Page 24 3 Installation Model 3010 Mounting Holes (4) Latch Hinge Figure 3-1: Front Panel of the Model 3010 Control Unit Figure 3-2: Single and Dual 19" Rack Mounts All operator controls are mounted on the control panel, which is hinged on the left edge and doubles as a door to provide access to the internal components of the instrument.

  • Page 25: Electrical Connections

    Oxygen Analyzer Part I: Control Unit open when the button in the center of the latch (upper right corner) is pressed all the way in with a narrow gauge tool (less than 0.18 inch wide), such as a small hex wrench or screwdriver Allow clearance for the door to open in a 90-degree arc of radius 7.125 inches.
  • Page 26 3 Installation Model 3010 Primary Input Power: The universal power supply requires a 85–250 V ac, 47-63 Hz power source. The power cord receptacle and fuse block are located in the same assembly. Insert the female plug end of the power cord into the power cord receptacle.
  • Page 27 Oxygen Analyzer Part I: Control Unit Alarm Relays: The three alarm-circuit connectors are spring terminals for making connections to internal alarm relay contacts. Each provides a set of Form C contacts for each type of alarm. Each has both normally open and normally closed contact connections.
  • Page 28 3 Installation Model 3010 Digital Remote Cal Inputs: Accept 0 V (off) or 24 V dc (on) inputs for remote control of calibration. (See Remote Calibration Protocol below.) Zero: Floating input. 5 to 24 V input across the + and – terminals puts the analyzer into the Zero mode.
  • Page 29 Oxygen Analyzer Part I: Control Unit When CRC opens again, zero and span are done, and the sample is being analyzed. Note: The Remote Probe connector (paragraph 3.3) provides signals to the Analysis Unit to ensure that the zero and span gas valves will be controlled synchronously.
  • Page 30 3 Installation Model 3010 The RS-232 protocol allows some flexibility in its implementation. Table 3-2 lists certain RS-232 values that are required by the 3010TA. Table 3-2: Required RS-232 Options Parameter Setting Baud 2400 Byte 8 bits Parity none Stop Bits...

  • Page 31: Testing The System

    Oxygen Analyzer Part I: Control Unit Figure 3-8: Remote Probe Connector Pinouts The voltage from the solenoid 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 must be limited to 50 mA, etc.) If more current and/or a different voltage is required, use relays, power amplifiers, or other matching circuitry to provide the actual driving current.
  • Page 32 3 Installation Model 3010 • Check the integrity and accuracy of the gas connections. Make sure there are no leaks. • Check the integrity and accuracy of all electrical connections. Make sure there are no exposed conductors • Check that sample pressure is between 3 and 40 psig, according to the requirements of your process.

  • Page 33: Operation

    Oxygen Analyzer Part I: Control Unit Operation Introduction Once the analyzer has been installed, configure it for your process. To do this you can: • Set system parameters— • Specify a password, if desired, requiring operator to log in. • Establish and start an automatic calibration cycle, if desired.
  • Page 34 4 Operation Model 3010 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 arrow buttons can be used to increment or decrement that modifiable item. The Enter button is used to accept any new entries on the VFD screen.

  • Page 35: The System Function

    Oxygen Analyzer Part I: Control Unit ANALYZE SYSTEM Perform Oxygen Analysis of SPAN the Sample TRAK/HLD ZERO Set Instrument Span ALARMS Perform Self-Diagnostic Test Set Instrument Zero RANG Initiate Set Alarm Automatic Setpoints Calibration Define Analysis Ranges Confrigure Mode of Alarm Set Password Operation Logout...

  • Page 36: Tracking The O Readings During Calibration

    4 Operation Model 3010 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 by default.

  • Page 37: 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 3010TA is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. To setup an cycle: Choose System from the Function buttons.

  • Page 38: Password Protection

    4 Operation Model 3010 , and press Enter . A new screen for Use < > arrows to blink set appears. ), then press Enter again. (You Press < > arrows to blink won’t be able to set if a zero interval is entered.) A ...

  • Page 39: Installing Or Changing The Password

    Oxygen Analyzer Part I: Control Unit Press System to enter the System mode. Use the < > arrow keys to scroll the blinking over to , and press Enter to select the password function. Either the default password or place holders for an existing password will appear on screen depending on whether or not a password has been previously installed.
  • Page 40 4 Operation Model 3010 Press Enter to change the password (either the default 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 41: Logout

    Enter to Log out. The screen will display the message: 4.3.5 System Self-Diagnostic Test The Model 3010TA 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...

  • Page 42: Version Screen

    4 Operation Model 3010 Press the System button to start the System function. , then press Enter . Use the < > arrow keys to blink Use the < > arrow keys again to move the blinking to the function. The screen will follow the running of the diagnostic. During preamp testing there is a countdown in the lower right corner of the screen.

  • Page 43: The Zero And Span Functions

    Oxygen Analyzer Part I: Control Unit - Use the Right or Left arrow keys and select More. Press Enter. - Use the Right or Left arrow keys and select “Show_Negative=NO”. - Use the Up or Down key to toggle from NO to YES. - Press the Escape key twice to return to the analyze mode.

  • Page 44: Zero Cal

    4 Operation Model 3010 If you are using password protection, you will need to enter your password to gain access to either of these functions. Follow the instructions in sections 4.3.3.2 or 4.3.3.3 to enter your password. Once you have gained clearance to proceed, you can enter the Zero or Span function.

  • Page 45: Manual Mode Zeroing

    4.4.1.3 Cell Failure Cell failure in the 3010TA is usually associated with inability to zero the instrument down to a satisfactorily low ppm reading. When this occurs, the 3010TA system alarm trips, and the LCD displays a failure message.

  • Page 46: Span Cal

    4 Operation Model 3010 4.4.2 Span Cal The Span button on the front panel is used to span calibrate the ana- lyzer. Span calibration can be performed using the automatic mode, where an internal algorithm compares consecutive readings from the sensor to determine when the output matches the span gas concentration.

  • Page 47: Manual Mode Spanning

    Oxygen Analyzer Part I: Control Unit sponds, within tolerance, to the value of the span gas concentration. Then the instrument automatically returns to the analyze mode. 4.4.2.2 Manual Mode Spanning Press Span to start the Span function. The screen that appears allows you to select whether the span calibration is to be performed automatically or manually.

  • Page 48: Span Failure

    Consider this before replacing the cell. The Alarms Function The Model 3010TA 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 chapter 3, Installation and/or the Interconnection Diagram included at the back of this manual for relay terminal connections.
  • Page 49 Oxygen Analyzer Part I: Control Unit Decide how your alarms should be configured. The choice will depend upon your process. Consider the following four points: 1. Which if any of the alarms are to be high alarms and which if any are to be low alarms? Setting an alarm as HIGH triggers the alarm when the oxygen concentration rises above the setpoint.

  • Page 50: The Range Function

    4 Operation Model 3010 Set up alarm 1 by moving the blinking over to using the < > arrow keys. Then press Enter to move to the next screen. Five parameters can be changed on this screen: • Value of the alarm setpoint, AL–1 #### (ppm or % oxygen) •...

  • Page 51: Setting The Analog Output Ranges

    Oxygen Analyzer Part I: Control Unit The Model 3010TA 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 52: The Analyze Function

    4 Operation Model 3010 To switch from autoranging to fixed range analysis, enter the range function by pressing the Range button on the front panel. Use the < > arrow keys to move the blinking over Use the arrow keys to switch from to set the instrument on the desired fixed range (low, medium, or high).

  • Page 53: Signal Output

    Part I: Control Unit Signal Output The standard Model 3010TA Trace Oxygen Analyzer is equipped with two 0-1 V dc analog output terminals accessible on the back panel (one concentration and one range ID) and two isolated 4-20 mA dc current outputs (one concentration and one range ID).
  • Page 54 4 Operation Model 3010 IMPORTANT: In the event of loss of flow through the analyzer, if the vent is vented to a location of high oxygen content, oxygen will back diffuse through the vent line and in most cases quickly saturate the cell with oxygen which can then require a quite a long purge down time for the sensor when then exposed to low oxygen concen- trations.

  • Page 55: Maintenance

    Part I: Control Unit Maintenance 5 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. Checking for leaks, replacing Micro-Fuel cells, and replacing fuses in the Analysis Unit are covered in Part II, Chapter 5.

  • Page 56: System Self Diagnostic Test

    5 Maintenance Model 3010 Oxygen Analyzer 3. Replace fuse as shown in Figure 5-2. 4. Reassemble Housing as shown in Figure 5-1. American Fuses European Fuses Figure 5-2: Installing Fuses System Self Diagnostic Test 1. Press the System button to enter the system mode. 2.

  • Page 57: Major Internal Components

    WARNING: HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED. The 3010TA Control Units contain the following major components: • Power Supply • Motherboard (with Microprocessor, RS-232 chip, and Preamplifier PCB) •...

  • Page 58: Cleaning

    5 Maintenance Model 3010 Oxygen Analyzer Figure 5-4: Rear-Panel Screws To detach the rear panel, remove only those four screws marked with an Cleaning If instrument is unmounted at time of cleaning, disconnect the instru- ment from the power source. Close and latch the front-panel access door. Clean outside surfaces with a soft cloth dampened slightly with plain clean water.

  • Page 59: Part Ii: Analysis Unit

    Part II: Analysis Unit Part II: Analysis Unit Part II: Analysis Unit Part II: Analysis Unit Part II: Analysis Unit OPERATING INSTRUCTIONS 3010TA Model Oxygen Analyzer Part II: Analysis Unit NEC Type Part Number D-65478 Part II: i...
  • Page 60 Model 3010T Model 3010T Model 3010T Thermal Conductivity Anal Thermal Conductivity Anal Thermal Conductivity Analyz Thermal Conductivity Anal yz yz yz yzer er er er er Model 3010T Model 3010T Thermal Conductivity Anal Table of Contents 1 Introduction 1.1 Overview ................ 1-1 1.2 Gas Connector Panel.............
  • Page 61 Part II: Analysis Unit Part II: Analysis Unit Part II: Analysis Unit Part II: Analysis Unit Part II: Analysis Unit 5 Maintenance 5.1 Routine Maintenance ............. 5-1 5.2 Major Components ............5-1 5.2 Cell Replacement ............5-2 5.2.1 Storing and Handling Replacement Cells ....5-2 5.2.2 When to Replace a Cell ..........
  • Page 62 Model 3010T Model 3010T Model 3010T Thermal Conductivity Anal Thermal Conductivity Anal Thermal Conductivity Analyz Thermal Conductivity Anal yz yz yz yzer er er er er Model 3010T Model 3010T Thermal Conductivity Anal iv: Part II...

  • Page 63: Introduction

    Oxygen Analyzer Part II: Analysis Unit Introduction Overview The Analytical Instruments Model 3010T Analysis Unit is a versatile remotely controlled instrument for detecting trace amounts of oxygen (0-10 ppm to 0-250 ppm) in a variety of background gases. Details are recorded in Specifications in the Appendix to this manual.

  • Page 64: Electrical Connector Panel

    1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction Model 3010 Figure 1-1: Cutaway View of 3010T Analysis Unit CAUTION: Depending on the user’s process, the EXHAUST gas may contain toxic components. In such cases, the exhaust MUST vent to a suitably contained area.
  • Page 65 Oxygen Analyzer Part II: Analysis Unit Figure 1-2: Electrical Connector/Control Panel • Power In Power input terminals for electric heater. Requires 110 or 220 V ac, depending on position of the Voltage Selector switch. Use 50/60 Hz. CAUTION: Check the position of the Voltage Selector switch BEFORE applying power to the Power Input termi- nals.
  • Page 66 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction Model 3010 1-4: Part II...

  • Page 67: Operational Theory

    Oxygen Analyzers Part II: Analysis Units Operational Theory Introduction The Analysis Unit is composed of two subsystems: the Micro-Fuel Cell sensor and the sample system. The Micro-Fuel Cell is an electrochemical galvanic device that trans- lates the amount of oxygen present in the sample into an electrical current. The sample system is designed to accept the sample and calibration gasses, select between them (in response to Control Unit signals), and transport the gas through the analyzer—without contaminating or altering its composition...

  • Page 68: Anatomy Of A Micro-Fuel Cell

    2 Operational Theory Model 3010 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 A Micro-Fuel Cell (MFC) is a cylinder only 1¼ inches in diameter and 1¼...

  • Page 69: Electrochemical Reactions

    Oxygen Analyzers Part II: Analysis Units 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 The cathode has many perforations to ensure sufficient wetting of the upper surface with electrolyte, and it is plated with an inert metal.

  • Page 70: The Effect Of Pressure

    2 Operational Theory Model 3010 The overall reaction for the fuel cell is the SUM of the half reactions above, or: 2Pb + O 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 the fuel cell is limited by (1) the amount of oxygen in the cell at the time and (2) the amount of stored anode material.

  • Page 71: Micro-Fuel Cell "Class

    Oxygen Analyzers Part II: Analysis Units Figure 2-3. Characteristic Input/Output Curve for a Micro-Fuel Cell 2.2.6 Micro-Fuel Cell “Class” Analytical Instruments manufactures Micro-Fuel Cells with a variety of characteristics to give the best possible performance for any given applica- tion. Each unique cell type is given an alphanumeric designation consistent with its application.

  • Page 72: Sample System

    2 Operational Theory Model 3010 Sample System The sample system delivers gases to the Micro-Fuel Cell sensor from the Analysis Unit Gas Control Panel inlets. Depending on the mode of operation either sample or calibration gas is delivered. Figure 2-4 is a typical flow diagram for the sampling system. The flame arrestors and valves (shaded) are optional.

  • Page 73: Installation

    Oxygen Analyzer Part II: Analysis Unit Installation Installation of the Model 3010 Analyzer includes: 1. Unpacking, mounting, and interconnecting the Control Unit and the Analysis Unit 2. Making gas connections to the system 3. Making electrical connections to the system 4.

  • Page 74: Gas Connector Panel Connections

    3 Installation Model 3010 Figure 3-1 is a view with the cover removed showing the external Gas Connector Panel and the internal Electrical Connector Panel. Figure 3-1: View of Analysis Unit Showing Connector Panels Gas Connector Panel Connections Before using this instrument, it should be determined if the unit will be used for pressurized service or vacuum service and low pressure applica- tions.
  • Page 75 Oxygen Analyzer Part II: Analysis Unit For pressurized service, use the restrictor without the blue dot and union from the restrictor kit and attach it to the Sample In port. The small circular orifice should face away from the back of the unit (against the direction of gas flow).

  • Page 76: Electrical Connector Panel

    3 Installation Model 3010 2. Hold the fitting body steady with a backup wrench, and with another wrench rotate the nut another 1 turns. The gas pressure should be reasonably regulated. Pressures between 3 and 40 psig are acceptable as long as the pressure, once established, will keep the flowmeter reading in an acceptable range (0.1 to 2.4 SLPM).
  • Page 77 Oxygen Analyzer Part II: Analysis Unit Figure 3-3: Electrical Connector/Control Panel; For safe connections, ensure that uninsulated tips of the wires do not extend beyond the terminal block screws to which they are attached. Voltage Selector Switch: Set the Voltage Selector switch to the source voltage (110 or 220 V ac) that will be used to power the Analysis Unit internal heater.
  • Page 78 3 Installation Model 3010 Figure 3-4: Control Unit (CU) to Analysis Unit (AU) Connector Cable If you use your own gas control valves, use the interconnect diagram in Figure 3-5 for the valves. The sensor and thermistor remain connected as in Figure 3-4, above.

  • Page 79: Installing The Micro-Fuel Cell

    Oxygen Analyzer Part II: Analysis Unit Figure 3-6: FET Series Resistance 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 during initial installation. Once it is expended, the Micro-Fuel Cell will need to be replaced. The cell could also require replacement if the cell is exposed to air for too long, or if the instrument has been idle for too long.
  • Page 80 3 Installation Model 3010 3-8: Part II...

  • Page 81: Operation

    Oxygen Analyzer Part II: Analysis Unit Operation Introduction All operation (except observing the flowmeter), including testing, and configuring the analyzer to your process/application, is performed from the Control Unit and is described in Part I, Chapter 4 Operation, of this manual.

  • Page 82: System Self Diagnostic Test

    4 Operation Model 3010T 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 is used for trace oxygen analysis immediately following calibration in air.

  • Page 83: Cell Failure Checks

    Oxygen Analyzer Part II: Analysis Unit Table 4-1: Self Test Failure Codes Power 5 V Failure 15 V Failure Both Failed Analog DAC A (0–1 V Concentration) DAC B (0–1 V Range ID) Both Failed Preamp Zero too high Amplifier output doesn't match test input Both Failed The results screen alternates for a time with: Then the analyzer returns to the initial System screen.
  • Page 84 4 Operation Model 3010T 4-4: Part II...

  • Page 85: Maintenance

    Oxygen Analyzer Part II: Analysis Unit Maintenance 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. Self-diagnostic testing of the system and fuse replacement in the Con- trol Unit are covered in Part I, chapter 5 of this manual.

  • Page 86: Cell Replacement

    Maintenance Model 3010 Figure 5-1: Major Components 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. The spent fuel cell should be discarded accord- ing to local regulations.

  • Page 87: When To Replace A Cell

    Oxygen Analyzer Part II: Analysis Unit The spare cell should be carefully stored in an area that is not subject to large variations in ambient temperature (75 °F nominal) or to rough handling. WARNING: THE SENSORS USED IN THE MODELS 3010 OXY- GEN ANALYZERS USE ELECTROLYTES WHICH CONTAIN TOXIC SUBSTANCES, MAINLY LEAD AND POTASSIUM HYDROXIDE, THAT CAN BE...

  • Page 88: Removing The Micro-Fuel Cell

    Maintenance Model 3010 5.2.3 Removing the Micro-Fuel Cell WARNING: DO NOT TOUCH THE SENSING SURFACE OF THE CELL. IT IS COVERED WITH A DELICATE TEFLON MEMBRANE THAT CAN LEAK CAUSTIC AND COR- ROSIVE CHEMICALS WHEN PUNCTURED. The Micro-Fuel cell is located inside the housing in a stainless steel cell block.

  • Page 89: Installing A New Micro-Fuel Cell

    The cell and holder will fall out in your hand. 5.2.4 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...

  • Page 90: Cell Warranty

    Maintenance Model 3010 Step 9. Push the gate on the cell block down so that the slots on the side of the gate engage the locating screws on the side of the block. This forces the holder into position and forms a gas- tight seal.

  • Page 91: System Self Diagnostic Test

    Oxygen Analyzer Part II: Analysis Unit 1. Disconnect the Unit from its power source. 2. Place a small screwdriver in the notch in the fuse holder cap, push in, and rotate 1/4 turn. The cap will pop out a few millimeters.
  • Page 92 Maintenance Model 3010 5-8: Part II...
  • Page 93 Oxygen Analyzer Appendix OPERATING INSTRUCTIONS 3010 TA Models Oxygen Analyzers Appendix Flush Mount Control Unit, PN CU64596A NEC Type Analysis Unit, PN AU65478...
  • Page 94 Appendix Model 3010 Contents A-1 Model 3010TA Specifications ........A-3 A-2 Recommended 2-Year Spare Parts List ......A-5 A-3 Drawing List ..............A-6 A-4 Application Notes on Restrictors, Pressures, & Flow ..A-7 A-5 Material Safety Data Sheet ..........A-10...
  • Page 95 Oxygen Analyzer Appendix Appendix A-1 Models 3010 Specifications Packaging: General Purpose Control Unit • Flush panel mount (Standard). • Rack mount — Relay rack mounted to contain either one or two instruments in one 19" relay rack mountable plate (Optional). Packaging: Explosion Proof Analysis Unit NEMA 4 Instrument Enclosure.
  • Page 96 Appendix Model 3010 Diagnostics: Start-up or on-demand, comprehensive, self testing function initiated by keyboard or remote command. Displays: 2 line by 20 alphanumeric, VFD screen, and one 5 digit LED display. Flowmeter on Analysis Unit. Digital Interface: Full duplex RS-232 communications port. Power: General Purpose Control Unit Universal power supply 85-250 V ac, 47-63 Hz.
  • Page 97 (if available) and the model and serial number of the instru- ment 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...
  • Page 98 D-64596A: Final Assembly/Outline Drawing, Control Unit, Trace Oxygen D-65478: Final Assembly/Outline Drawing, Analysis Unit, Trace Oxygen D-64950: 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...
  • Page 99 Oxygen Analyzer Appendix 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 100 ( off scale of flow-meter), pressure drops other than the restriction device could become significant , and result in pressurizing the cell. Example 2, A 3010TA 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 101 Operation without a restrictor device is not recommend as mentioned above. A 3010TA 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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