Teledyne 3020T Operating Instructions Manual
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Teledyne 3020T Operating Instructions Manual

Teledyne 3020T Operating Instructions Manual

Trace oxygen analyzer
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Trace Oxygen Analyzer
OPERATING INSTRUCTIONS FOR
Model 3020T
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 PER-
P/N M65908
SIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.
11/22/99
ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING.
ECO # 99-0459
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 3020T 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 PER- P/N M65908 SIST 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 19" panel and ready to mount in a standard rack. See Appendix for details. Cell Class* ____________________ (L-2C standard). Enter Class Designation * See Part II, Chapter 2 and/or any addendum that may be attached to this manual for cell specifications. Teledyne Analytical Instruments Trace Oxygen Analyzer...

  • Page 4: Table Of Contents

    Model 3020T 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 UP/DOWN Switch ... 1-4 1.5.2 ESCAPE/ENTER Switch ... 1-4 1.5.3 Displays ...
  • Page 5 5.2 Major Internal Components ... 5-1 5.3 Cell Replacement ... 5-2 5.3.1 Storing and Handling Replacement Cells ... 5-3 5.3.2 When to Replace a Cell ... 5-3 5.3.3 Removing the Micro-Fuel Cell ... 5-4 Teledyne Analytical Instruments Trace Oxygen Analyzer...
  • Page 6 Model 3020T 5.3.4 Installing a New Micro-Fuel Cell ... 5-6 5.2.5 Cell Warranty ... 5-6 5.4 Fuse Replacement... 5-7 5.5 System Self Diagnostic Test ... 5-7 Appendix A-1 Specifications ... A-1 A-2 Recommended 2-Year Spare Parts List ... A-3 A-3 Drawing List ... A-4 A-4 Application Notes on Restrictors, Pressures &...

  • Page 7: Introduction

    Quality assurance • Gas analysis certification. Main Features of the Analyzer The Model 3020T Trace Oxygen Analyzer is sophisticated yet simple to use. The main features of the analyzer include: • A 2-line alphanumeric display screen, driven by microprocessor electronics, that continuously prompts and informs the operator.

  • Page 8: 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 3020T electronics, to automatically switch between gases in synchronization with the analyzer’s operations 3020T-F: Flame arrestors for Groups C and D installed.

  • Page 9: Operator Interface

    Trace Oxygen Analyzer Introduction 1 Operator Interface All controls and displays on the standard 3020T are accessible from outside the housing. The instrument has two simple operator controls. A digital meter, an alphanumeric display, and a sample flowmeter give the operator constant feedback from the instrument.

  • Page 10: Up/Down Switch

    If none remains, returns to the Analyze screen. With a Value Selected: Enters the value into the analyzer as data. AdvancesVFD to next operation. (See Chapter 4 for details.) Teledyne Analytical Instruments Model 3020T Contrast Function is DISABLED (Refer to Section 1.6)

  • Page 11: Displays

    Power Connection • Analog Outputs 115 or 230 V dc, 50 or 60 Hz. 0-1 V dc concentration plus 0-1 V dc range ID, and isolated 4-20 mA dc plus 4-20 mA dc range ID. Teledyne Analytical Instruments Introduction 1...
  • Page 12 • Alarm Connections • RS-232 Port • Remote Valves Figure 1-2: Electrical Connector Panel Teledyne Analytical Instruments 2 concentration alarms and 1 system alarm. Serial digital concentration signal output and control input. Used for controlling external solenoid valves, if desired.

  • Page 13: 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. Figure 1-3: Model 3020T Gas Connector Panel • Gas Inlet and Outlet Used for external sensor and thermocouple, if desired.

  • Page 14: Introduction

    Calibration Gas Ports Separate fittings for zero, span and Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. The internal clock in the Model 3020T is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. Teledyne Analytical Instruments...

  • Page 15: Operational Theory

    Micro-Fuel Cell Sensor 2.2.1 Principles of Operation The oxygen sensor used in the Model 3020T 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 16: Anatomy Of A Micro-Fuel Cell

    Figure 2-1: Micro-Fuel Cell Refer to Figure 2-2, Cross Section of a Micro-Fuel Cell, which illus- trates the following internal description. Figure 2-2. Cross Section of a Micro-Fuel Cell (not to scale) Teledyne Analytical Instruments Model 3020T...

  • Page 17: Electrochemical Reactions

    Operational Theory 2 O + 4e – – – – – – – – – – – – – – – O + 2e – – – – – Teledyne Analytical Instruments (cathode) (anode)

  • Page 18: The Effect Of Pressure

    (within ± 1 ppm oxygen). In practical application, zeroing may still used to compensate for the combined zero offsets of the cell and the electronics. (The electronics is zeroed auto- matically when the instrument power is turned on.) Teledyne Analytical Instruments Model 3020T...

  • Page 19: Sample System

    Depending on the mode of operation either sample or calibration gas is delivered. The Model 3020T 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 20: Electronics And Signal Processing

    –C and/or F options are ordered. The valves, when supplied, are installed inside the 3020T enclosure and are regulated by the instruments internal electronics. The flame arrestors, when supplied, are installed in the Gas Connector Panel.
  • Page 21 Trace Oxygen Analyzer Operational Theory 2 Figure 2-5: Block Diagram of the Model 3020T Electronics Teledyne Analytical Instruments...

  • Page 22: Temperature Control

    2.5 Temperature Control For accurate analysis this instrument is temperature controlled not to fall beneath a certain temperature. This temperature is 22 the sensor from freezing in cold environments. Teledyne Analytical Instruments Model 3020T F. This is to prevent...

  • Page 23: Installation

    Immediately report any damage to the shipping agent. Mounting the Analyzer The Model 3020T is designed for bulkhead mounting in hazardous environments. There are four mounting lugs—one in each corner of the enclosure, as shown in Figure 3-1. The outline drawing, at the back of this manual, gives the mounting hole size and spacing.
  • Page 24 3 Installation Model 3020T Figure 3-1: Front View of the Model 3020T (Simplified) Teledyne Analytical Instruments...

  • Page 25: Electrical Connections

    Trace Oxygen Analyzer Installation 3 Figure 3-2: Required Front Door Clearance Electrical Connections Figure 3-3 shows the Model 3020T 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 26: Primary Input Power

    (See Fuse Replacement in chapter 5, maintenance.) 3.3.3 Analog Outputs There are eight DC output signal connectors on the ANALOG OUT- PUTS connector block. There are two connectors per output with the polar- ity noted. See Figure 3-5. Teledyne Analytical Instruments Model 3020T...
  • Page 27 0.75 V = High Range, 1 V = Air Cal Range. from 4 mA at 0 ppm to 20 mA at full scale ppm. (Full scale = 100% of programmable range.) mA = High Range, 20 mA = Air Cal Range. Teledyne Analytical Instruments Installation 3...

  • Page 28: Alarm Relays

    Each has both normally open and normally closed contact connections. The contact connections are indicated by diagrams on the connector panel. They are capable of switching up to 3 amperes at 250 V ac into a resistive load. See Figure 3-6. Teledyne Analytical Instruments Current Signal Output (mA dc) 10.4 12.0...

  • Page 29: Digital Remote Cal Inputs

    Permanently configured as failsafe and latching. Cannot be de- feated. Actuates if self test fails. To reset a System Alarm during installation, discon- nect power to the instrument and then reconnect it. Teledyne Analytical Instruments Installation 3...
  • Page 30 (See Remote Calibration Protocol below.) Remote Calibration Protocol: To properly time the Digital Remote Cal Inputs to the Model 3020T 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 31: Rs-232 Port

    If you have the –C Internal valve option—which includes additional zero and span gas inputs— the 3020T automatically regulates the zero, span and sample gas flow. 3.3.6 Range ID Relays There are four dedicated RANGE ID CONTACT relays.

  • Page 32: 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 3020T imple- mentation. Table 3-5: Required RS-232 Options...

  • Page 33: Installing The Micro-Fuel Cell

    Once it is expended, or if the cell is exposed to air for too long, the Micro-Fuel Cell will need to be replaced. The cell could also require replace- ment if the instrument has been idle for too long. Figure 3-8: FET Series Resistance Teledyne Analytical Instruments Installation 3 3-11...

  • Page 34: Gas Connections

    (This may require an additional 2. Hold the fitting body steady with a backup wrench, and with another wrench rotate the nut another 1 Teledyne Analytical Instruments 3-12 inch tube fittings only. Adapters must turn beyond finger-tight.) turns.
  • Page 35 There are electrically operated valves inside for automatic switching between sample and calibration gases. These valves are com- pletely under control of the 3020T Electronics. They can be externally controlled only indirectly through the Remote Cal Inputs, described below.

  • Page 36: Testing The System

    Connector Panel is in the appropriate position for your power source. Power up the system, and test it by performing the following operations: 1. Repeat the Self-Diagnostic Test as described in chapter 4, section 4.3.5. Teledyne Analytical Instruments 3-14 Model 3020T...

  • Page 37: Operation

    • Establish a security password, if desired, requiring Operator to log in. Before you configure your 3020T 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 38: Mode/Function Selection

    The MAIN MENU consists of 11 functions you can use to customize the operations of the analyzer. Figure 4-1 shows the functions available with the Model 3020T. They are listed here with brief descriptions: 1 AUTO-CAL: Used to define and/or start an automatic calibration sequence.
  • Page 39 8 ALARMS: Used to set the alarm setpoints and determine whether each alarm will be active or defeated, HI or LO acting, latching or not, and failsafe or not. Contrast Function is DISABLED Figure 4-1: Modes and Functions Teledyne Analytical Instruments Operation 4 (Refer to Section 1.6)

  • Page 40: Data Entry

    If you do not wish to continue a function, you can abort the session with a turn-and-release toward ESCAPE. Escaping a function takes the analyzer back to the previous screen, or to the ANALYZE Function, depend- ing on the function escaped. Teledyne Analytical Instruments type style. Model 3020T...

  • Page 41: The Auto-Cal Function

    Note: If you require highly accurate AUTO-CAL timing, use external AUTO-CAL control where possible. The internal clock in the Model 3020T is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. To setup an AUTO-CAL cycle: Scroll to AUTO-CAL, and ENTER.

  • Page 42: Entering The Password

    The last ENTER enters the password. If the password is accepted, the screen will indicate that the password restrictions have been removed and you have clearance to proceed. Teledyne Analytical Instruments place-holder password for an existing as the default password.

  • Page 43: Installing Or Changing The Password

    94 characters available for password use are shown in the table below. Characters Available for Password Definition: When you have finished typing the new password, the last ENTER enters it. A verification screen appears. The screen will prompt you to retype your password for verification. Teledyne Analytical Instruments Operation 4...

  • Page 44: The Logout Function

    ENTER to log out. The screen will display the message: The VERSION Screen Scroll through the MAIN MENU to VERSION, and ENTER. The screen displays the manufacturer, model, and software version information. Teledyne Analytical Instruments ) screen. You will be given SPAN, ZERO, ALARM, Model 3020T...

  • Page 45: The Self Test Function

    Trace Oxygen Analyzer The SELF-TEST Function The Model 3020T has a built-in self-testing diagnostic routine. Prepro- grammed 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 3.

  • Page 46: Zero Cal

    Use the DOWN/UP control to toggle between zero settling. Stop when ENTER to begin zeroing. 4-10 Teledyne Analytical Instruments message skip to section 4.8.1.3. appears on the display. Model 3020T...

  • Page 47: Manual Mode Zeroing

    Stop when a value in parts per million per second is less than 0.05 ppm/s is close enough to zero, ENTER it. In a Teledyne Analytical Instruments Operation 4 , and so fourth. appears on value to display.

  • Page 48: Cell Failure

    4 Operation 4.8.1.3 Cell Failure Cell failure in the 3020T is usually associated with inability to zero the instrument down to a satisfactorily low ppm reading. When this occurs, the 3020T system alarm trips, and the VFD displays a failure message.

  • Page 49: Manual Mode Spanning

    Slope on the screen. It takes several seconds for the first Slope value to display. Slope indicates rate of change of the Span reading. It is a sensitive indicator of stability. Manual Mode Spanning ) of span value. Teledyne Analytical Instruments Operation 4 span settling. Stop 4-13...

  • Page 50: The Alarms Function

    The instrument then automatically enters the ANALYZE function. The ALARMS Function The Model 3020T 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 51 ALARM function again, and repeat this procedure for next alarm. • To reset a latched alarm, go to two times or UP two times. (Toggle it to and then back to and then assert either DOWN Teledyne Analytical Instruments Operation 4 4-15...

  • Page 52: The Range Function

    Med = 0–1,000 ppm High = 0–10,000 ppm. The Model 3020T 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 53: Fixed Range Analysis

    1 V dc (or 20 mA). However, the digital readout and the RS-232 between the arrows. Teledyne Analytical Instruments Operation 4 to either or one...

  • Page 54: The Contrast Function

    Setup Mode, or it will reset to factory defaults. Use this function whenever you want to power down without loosing all of the configuration you programmed into your instrument in the Setup Mode. 4-18 Teledyne Analytical Instruments Model 3020T...

  • Page 55: The Analysis Mode

    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 Operation 4 4-19...
  • Page 56 4 Operation Model 3020T 4-20 Teledyne Analytical Instruments...

  • Page 57: Maintenance

    The major internal component locations are shown in Figure 3-1, the cell block is illustrated in Figure 3-2, and the fuse receptacle is shown in Figure 3-3 The 3020T contains the following major internal components: • Micro-Fuel Cell (L-2C) •...

  • Page 58: Cell Replacement

    The Class L-2C Micro-Fuel Cell is used in the standard Model 3020T. If any other cell is supplied with your instrument, check the front of this manual for any addenda applying to your special model.

  • Page 59: 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 3020T, 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 60: Removing The Micro-Fuel Cell

    Micro-Fuel Cell. 4. Lift up on the stainless steel gate in front of the cell block. This releases the cell and cell holder from the block. The cell and holder will fall out in your hand. Teledyne Analytical Instruments Model 3020T...
  • Page 61 Trace Oxygen Analyzer Maintenance 5 Lift Up G ate Figure 5-2: Exploded View of Cell Block and Micro-Fuel Cell Teledyne Analytical Instruments...

  • Page 62: Installing A New Micro-Fuel Cell

    5 Maintenance 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 to low O measurement.

  • Page 63: Cell Warranty

    Fuse Replacement The 3020T requires two 5 x 20 mm, 4 A, T type (Slow Blow) fuses. The fuses are located inside the explosion proof housing on the Electrical Connector Panel, as shown in Figure 5-2. To replace a fuse: 1.

  • Page 64: System Self Diagnostic Test

    The module is functioning properly if it is followed by indicates a problem in a specific area of the instrument. Refer to Table 5-1 for number-code information. The results screen alternates for a time with: The following failure codes apply: Teledyne Analytical Instruments Model 3020T . A number...
  • Page 65 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 Teledyne Analytical Instruments Maintenance 5...
  • Page 66 5 Maintenance Model 3020T 5-10 Teledyne Analytical Instruments...

  • Page 67: Appendix A-1 Specifications

    Displays: 2 line by 20 alphanumeric, VFD screen, and Digital Interface: Full duplex RS-232 communications port. Power: Universal power supply 115 or 230 V ac, at Teledyne Analytical Instruments 0–250,000 ppm, plus air calibration range of 0- 250,000 ppm (25 %).
  • Page 68 Appendix Model 3020T Operating Temperature: 0-50 °C 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. Analog outputs: 0-1 V dc percent-of-range 0-1 V dc range ID.

  • Page 69: Recommended 2-Year Spare Parts List

    (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 70: Drawing List

    Appendix A-3 Drawing List D65908 Final Assembly Drawing D65909 Outline Drawing D65911 Wiring Diagram Teledyne Analytical Instruments Model 3020T...
  • Page 71 The first function is to limit the flow rate of the sample through the analyzer. A restrictor is chosen to operate over a range of pressures and provide a useable flow rate over that range. 3000 SERIES ANALYZERS Teledyne Analytical Instruments Appendix...
  • Page 72 ( off scale of flow-meter), pressure drops other than the restriction device could become significant , and result in pressurizing the cell. Example 2, A 3020T 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 73 Operation without a restrictor device is not recommend as mentioned above. A 3020T 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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