Teledyne 3000ZA Operating Instructions Manual
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Teledyne 3000ZA Operating Instructions Manual

Teledyne 3000ZA Operating Instructions Manual

Trace oxygen analyzer
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Trace Oxygen Analyzer
OPERATING INSTRUCTIONS FOR
MODEL 3000ZA
Trace Oxygen Analyzer
P/N M75739
4/10/04
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 Trace Oxygen Analyzer P/N M75739 4/10/04 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 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  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.
  • Page 4 3000ZA Important Notice Model 3000ZA 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 Instruction Manual. These symbols are visual indicators of important and immediate warnings and when you must exercise CAUTION while operating the instrument.

  • 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 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, 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: Table Of Contents

    3.2 Mounting the Analyzer 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 Sensor 3.5 Testing the System Teledyne Analytical Instruments viii...
  • Page 9 4.5 The Alarms Function 4.6 The Range Function 4.6.1 Setting the Analog Output Ranges 4.6.2 Fixed Range Analysis 4.7 The Analyze Function 4.8 Signal Output Maintenance..............52 5.1 Routine Maintenance 5.2 Cell Replacement 5.2.1 Removing the Sensor Teledyne Analytical Instruments...
  • Page 10 5.4 System Self Diagnostic Test 5.5 Major Internal Components 5.6 Cleaning 5.7 Troubleshooting Appendix ................58 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 Index ................66 Teledyne Analytical Instruments...
  • Page 11 Trace Oxygen Analyzer List of Figures Figure 1-1: Model 3000ZA Front Panel Figure 1-2: Model 3000ZA Rear Panel Figure 2-1: Model 3000ZA Sample System Figure 2-2: Flow Diagram with Options Figure 2-3: Component Location Figure 2-4: Electronic Block Diagram Figure 3-1: Front Panel...
  • Page 12 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 4-1: Output Signals Table 4-2: Range ID Output Voltage Table 5-1: Self-test Failure Codes Table 5-2: Troubleshooting Teledyne Analytical Instruments...

  • Page 13: Overview

    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. These units are for indoor use in a non-hazardous environment.

  • Page 14: Model Designations

    1.4 Model Designations 3000ZA: Standard model for sample under pressure 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...

  • Page 15: Front Panel (Operator Interface)

    1.5 Front Panel (Operator Interface) The standard 3000ZA is housed in a rugged metal case with all controls and displays accessible from the front panel. 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.
  • 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 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 optional 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 Teledyne Analytical Instruments...
  • Page 19 Trace Oxygen Analyzer Introduction scheduled calibrations can vary 2-3 % per day. Teledyne Analytical Instruments...

  • Page 20: 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 21: Sample System

    Depending on the mode of operation either sample or calibration gas is delivered. The Model 3000ZA 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 22: 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.
  • Page 23 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 24: Figure 2-3: Component Location

    Operational Theory 3000ZA Figure 2-3: Component Location Teledyne Analytical Instruments...

  • Page 25: Figure 2-4: Electronic Block Diagram

    Trace Oxygen Analyzer Operational Theory Figure 2-4: Electronic Block Diagram Teledyne Analytical Instruments...

  • Page 26: Installation

    Immediately report any damage to the shipping agent. 3.2 Mounting the Analyzer The Model 3000ZA 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 the 3000TA standard front panel (the 3000ZA is similar) and mounting bezel.

  • Page 27: Figure 3-1: Front Panel

    Trace Oxygen Analyzer Installation Figure 3-1: Front Panel of the Model 3000TA (Model 3000ZA similar) All operator controls, except the flow control needle valve, are mounted on the control panel, which is hinged on the left edge and doubles as the door that provides access to the sensor and cell block inside the instrument.

  • Page 28: Rear Panel Connections

    The Zero In and Span In ports are not included on the standard model but are available as options. Figure 3-3: Rear Panel of the Model 3000ZA with Span and Zero Ports 3.3.1 Gas Connections...
  • Page 29 (0.5 to 2.0 SLPM). For non-pressurized sample or very low pressure, (less than 2 psig) vacuum service plumbing is recommended. Exact figures will depend on your process. Teledyne Analytical Instruments...

  • Page 30: Electrical Connections

    These valves are completely under control of the 3000ZA electronics. They can be externally controlled only indirectly through the remote cal inputs as described below. Pressure, flow, and safety considerations are the same as prescribed for the SAMPLE IN inlet above.

  • Page 31: 50-Pin Equipment Interface Connector

    20 mA at full scale ppm. (Full scale = 100% of programmable range) (optional) 4–20 mA DC Range ID: 8 mA = Low Range • 12 mA = Medium Range 16 mA = High Range Teledyne Analytical Instruments...

  • Page 32: 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). • System Alarm: Teledyne Analytical Instruments...

  • Page 33: Table 3-2: Alarm Relay Contact Pins

    0 to 1 volt across the terminals allows Zero mode to terminate when done. A synchronous signal must open and close the external zero valve appropriately. See Remote Probe Connector. (The –C option internal valves operate automatically.) Teledyne Analytical Instruments...

  • Page 34: Table 3-3: Remote Calibration Connections

    Cal Contact Cal Contact Remote Calibration Protocol: To properly time the Digital Remote Cal Inputs to the Model 3000ZA Analyzer, the customer's controller must monitor the Cal Relay Contact. 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: Table 3-4: Range Id Relay Connections

    At this printing, this port is not yet functional. It is to be used for future options to the instrument. Pins 13 (+) and 29 (–). Remote Valve Connections: The 3000ZA is a single-chassis instrument, which has no Remote Valve Unit. Instead, the Remote Valve connections are used as a method for directly controlling external sample/zero/span gas valves.

  • Page 36: 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. Figure 3-6: FET Series Resistance Teledyne Analytical Instruments...

  • Page 37: Rs-232 Port

    RS-232, until st<enter> is sent again. The RS-232 protocol allows some flexibility in its implementation. Table 3-6 lists certain RS-232 values that are required by the 3000ZA implementation. Table 3-6: Required RS-232 Options Parameter Setting...

  • Page 38: Installing The Zirconium Oxide Sensor

    It must be installed before the analyzer is placed in service. When the ZrO sensor needs to be installed or replaced, follow the procedures in Section 5.2. 3.5 Testing the System Before plugging the instrument into the power source: Teledyne Analytical Instruments...
  • Page 39 Make sure there are no exposed conductors. Check that inlet sample pressure is within the accepted range • (see Section 3.3.1). Power up the system, and test it by repeating the Self- • Diagnostic Test as described in Chapter 4, Section 4.3.5. Teledyne Analytical Instruments...

  • Page 40: Operation

    Set alarm setpoints, and modes of alarm operation (latching, • failsafe, etc). Before you configure your 3000ZA, these default values are in effect: Ranges: LO = 10 ppm, MED = 100 ppm, HI = 250 ppm.

  • Page 41: Using The Data Entry And Function Buttons

    HI or LO acting, latching, and/or failsafe. Range. Used to set up three analysis ranges that can be • switched automatically with auto-ranging or used as individual fixed ranges. Teledyne Analytical Instruments...

  • Page 42: Figure 4-1: Hierarchy Of Available Functions

    Each of these functions is described in greater detail in the following procedures. The VFD screen text that accompanies each operation is reproduced, at the appropriate point in the procedure, in a type style. Pushbutton names are printed in Oblique Ariel Narrow Bold type. Teledyne Analytical Instruments...

  • Page 43: The System Function

    Show Negative: The operator selects whether display can • show negative oxygen readings or not. TRAK/HLD: The operator sets whether the instrument • analog outputs track the concentration change during calibration and sets a time delay for the concentration alarms after calibration Teledyne Analytical Instruments...

  • Page 44: Tracking The Oxygen Readings During Calibration

    . But, when HOLD TRACK HOLD selected the concentration alarms will remain frozen for the time displayed in the second line of the menu after the analyzer TRAK/HLD returns to the Analyze mode. Teledyne Analytical Instruments...

  • 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 3000ZA 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

    AAAAA place holders for an existing password will appear on screen depending on whether or not a password has been previously installed. T E T A I Enter PWD —or— A A A A A Enter PWD Teledyne Analytical Instruments...

  • Page 47: Installing Or Changing The Password

    Escape to keep the existing password and move on. If you chose Enter to change the password, the password assignment screen appears. T E T A I <ENT> To Proceed —or— A A A A A <ENT> To Proceed Teledyne Analytical Instruments...
  • Page 48 Your password will be stored in the microprocessor and the system will immediately switch to the Analyze screen, and you now have access to all instrument functions. If all alarms are defeated, the Analyze screen appears as: ppm Anlz Range: 0 — 100 Teledyne Analytical Instruments...

  • Page 49: Logout

    Password Reentered 4.3.5 System Self-Diagnostic Test The Model 3000ZA 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

    This situation may arise after the instrument has been zeroed. As time progresses, the sensor may drift below the zero calibration setpoint. To show negative oxygen readings on the display: Press the System key Teledyne Analytical Instruments...

  • Page 51: The Zero And Span Functions

    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 0.1 and 2.4 SLPM (approximately 0.2 - 5 SCFH). Teledyne Analytical Instruments...

  • Page 52: Zero Cal

    Slope you will see a countdown: 5 Left, 4 Left, and so fourth. These are five steps in the zeroing process that the system must complete, AFTER settling, before it can go back to Analyze. #### PPM Zero 4 Left=### ppm/s Teledyne Analytical Instruments...

  • Page 53: Manual Mode Zeroing

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

  • Page 54: Span Cal

    AUTO Five minutes is the default, but it could be adjusted anywhere from 1 to 60 minutes by using the __ keys. Press Enter to move to the next screen. Span Val: 000008.00 <ENT>Span <UP>Mod # Teledyne Analytical Instruments...

  • Page 55: Manual Mode Spanning

    ) of span value. Mod # Use the arrow keys to enter the oxygen concentration of the span gas you are using. The __ arrows choose the digit, and the __ arrows choose the value of the digit. Teledyne Analytical Instruments...

  • Page 56: Span Failure

    Nevertheless, feeding the wrong span gas or electronics failure could set this feature off at the end of the span. Consider this before replacing the cell. Teledyne Analytical Instruments...

  • Page 57: The Alarms Function

    Operation 4.5 The Alarms Function The Model 3000ZA 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 VAC.
  • Page 58 To define the setpoint, use the __ arrow keys to move the blinking over to . Then use the __ arrow keys to change the number. AL–1 #### Holding down the key speeds up the incrementing or decrementing. (Remember, the setpoint units are ppm O Teledyne Analytical Instruments...

  • Page 59: The Range Function

    Low = 0–10 ppm Med = 0–100 ppm High = 0–250 ppm. The Model 3000ZA 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.

  • Page 60: Fixed Range Analysis

    —or— L—10 M—10 0 H—250 Mode—FX/HI Press Escape to re-enter the Analyze mode using the fixed range. Note: When performing analysis on a fixed range, if the oxygen concentration rises above the upper limit (or default value) Teledyne Analytical Instruments...

  • Page 61: The Analyze Function

    4.8 Signal Output The standard Model 3000ZA Trace Oxygen Analyzer is equipped with two 0–1 VDC 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 62: Table 4-2: Range Id Output Voltage

    1. Bag the sensor in nitrogen during this time 2. Install a shut off valve on the vent port of the analyzer or somewhere within the users sample system. Teledyne Analytical Instruments...
  • Page 63 Trace Oxygen Analyzer Operation Teledyne Analytical Instruments...

  • Page 64: Maintenance

    3. Unscrew the collar on the top assembly of the cell block from the bottom section of the cell block assembly. The sensor is attached to pin sockets on the bottom assembly. Teledyne Analytical Instruments...

  • Page 65: Fuse Replacement

    Figure 5-1: Replacing the ZrO Sensor 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 66: System Self Diagnostic Test

    3. Use the __ arrow keys to move to Self-Test, and press Enter. The following failure codes apply: Table 5-1: 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 Teledyne Analytical Instruments...

  • Page 67: Major Internal Components

    Figure 2-2 and the major electronic components locations are shown in Figure 2-3, in Chapter 2. WARNING: 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: Teledyne Analytical Instruments...

  • Page 68: Cleaning

    Press System key as reported by the inaccurate fashion. analyzer when prompted by analyzer “Press System for Default Values”. This will return the default settings to the analyzer. Teledyne Analytical Instruments...
  • Page 69 “Press System for Default than normal for a zero Values”. This will gas). return the analyzer to default calibration and zero settings. Now proceed to carefully calibrate and zero the analyzer. Teledyne Analytical Instruments...

  • Page 70: Appendix

    Alarms: One system-failure alarm contact to detect power failure or sensor-zero failure. 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. Teledyne Analytical Instruments...
  • Page 71 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 (optional). 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 72: 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 73: Drawing List

    Trace Oxygen Analyzer Appendix A-3 Drawing List D-75739 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 74: Application Notes

    The current revision of the 3000 series analyzers are supplied with a kit containing two restrictors and a union which are user installed. These parts are supplied to give the end user more flexibility when installing the analyzer. The restrictor kit is suitable for high and low Teledyne Analytical Instruments...
  • Page 75 The sample pressure between the pump and the restrictor will be approximately -7 inches of mercury, while the pressure in the balance of the sample system including the cell will be approximately at atmospheric pressure (provided the sample flow into the analyzer is not blocked). BY-PASS: Teledyne Analytical Instruments...
  • Page 76 TAI PART NUMBERS 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.) Teledyne Analytical Instruments...
  • Page 77 Trace Oxygen Analyzer Appendix 1 SCFH = 0.476 SLPM Teledyne Analytical Instruments...

  • Page 78: Index

    14 bypass line, 17 drawings, 60 by-pass valve, 62 dual rack mounting, 60 calibration electrical connections, 17 automatic-zero, 39 ENTER key, 4, 28 connections, 21 equipment interface connector, 18 manual-zero, 40 ESCAPE key, 4, 28 Teledyne Analytical Instruments...
  • Page 79 PSWD, 30 measurement error, 9 rack mount, 2, 13, 60 membrane switches. See keys RAM, 2, 9 meter, 3, 4 range, 1 microcontroller, 9 range function, 46 microprocessor, 7, 10, 55 range ID, 10, 49 Teledyne Analytical Instruments...
  • Page 80 40 restrictor, 15. See flow restriction system function, 30 device SYSTEM key, 28 restrictor kit, 62 Teledyne address, 59 ROM, 2, 9 testing the system, 25 routine maintenance, 51 tracking oxygen readings, 31 RS-232, 2, 25 TRAK/HLD, 30...
  • Page 81 Trace Oxygen Analyzer Index Teledyne Analytical Instruments...

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