Teledyne 3010PA Operating Instructions Manual
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Teledyne 3010PA Operating Instructions Manual

Teledyne 3010PA Operating Instructions Manual

Percent oxygen analyzer
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OPERATING INSTRUCTIONS

Model 3010PA
Percent Oxygen Analyzer
Flush Mount Control Unit, PN D-64596B*
NEC Type Analysis Unit, PN D-65479*
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 M66106
08/06/99
ECO # 99-0323
i

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  • Page 1: Operating Instructions

    Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer OPERATING INSTRUCTIONS Model 3010PA Percent Oxygen Analyzer Flush Mount Control Unit, PN D-64596B* NEC Type Analysis Unit, PN D-65479* 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 PA ....Part I: 1-1 Part II: Analysis Unit, Model P ....Part II: 1-1 Appendix ............

  • Page 4: Appendix

    Instrument Serial Number: __________________________ The instrument with the above serial number has the following Options: o 3010PA-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 3010PA 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

    D-66192A, and a 3010T_C Analysis Unit, PN D-66193. 3010PAC: CENELEC type Percent Oxygen Analyzer with flush mount Control Unit. Consists of 3010PA Control Unit, PN D-66192 B or C, and a 3010P_C Analysis Unit, PN D-66191. 3010TBC: CENELEC type Trace Oxygen Analyzer with bulkhead mount Control Unit.
  • Page 7 Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer Oxygen Analyzer • Optional stainless steel cell block available. • Advance design Micro-Fuel Cell sensor with a one year warranty and an expected lifetime of two years. • Versatile analysis over a wide range of applications. •...
  • Page 8 Model 3010 Model 3010 Model 3010 Model 3010 Model 3010PA 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 Instruc-...
  • Page 9 Part I: Control Unit OPERATING INSTRUCTIONS Models 3010PA Oxygen Analyzer Part I: Control Unit Flush Mount Part Number: D-64596B 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 The Span Functions............4-10 4.4.1 Cell Failure ............4-10 4.4.2 Span Cal ..............4-11 4.4.2.1 Auto Mode Spanning ........4-11 4.4.2.2 Manual Mode Spanning ......... 4-12 4.5 The Alarms Function ............4-13 4.6 The Range Function ............4-15 4.6.1 Setting the Analog Output Ranges......

  • Page 12: Introduction

    3010P Analysis Unit, is a versatile microprocessor-based instrument for detecting percent amounts of oxygen in a variety of gases. Part I, this part, of this manual covers the Model 3010PA series General Purpose flush-panel and/or rack-mount Control Units. (The Analy- sis Unit is covered in Part II of this manual.) The Control Unit is for indoor...
  • Page 13 1 Introduction Model 3010 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: • Analyze Perform analysis for oxygen content of a sample gas. • System Perform system-related tasks (described in detail in chapter 4, Operation.).

  • Page 14: 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 15 1 Introduction Model 3010 Figure 1-2: Model 3010PA Rear Panel • Power Connection Universal AC power source. • Analog Outputs 0-1 V dc concentration and 0-1 V dc range ID. Optional isolated 4-20 mA dc and 4-20 mA dc range ID.
  • Page 16 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 3010PA is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. Part I: 1-5...
  • Page 17 1 Introduction Model 3010 1-6: Part I...

  • Page 18: 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 3010PA 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 19 2 Operational Theory Model 3010 Figure 2-1: Block Diagram of the 3010PA CU Electronics 2-2: Part I...

  • Page 20: 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 optional 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 0-1 V dc and the optional 4-20 mA dc analog concentration signal outputs, and the analog range ID outputs.
  • Page 21 2 Operational Theory Model 3010 2-4: Part I...

  • Page 22: Installation

    Immediately report any damage to the shipping agent. Mounting the Control Unit The Model 3010PA 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 23 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 24: Rear Panel Connections

    Oxygen Analyzer Part I: Control Unit 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 7.625 inches. See Figure 3-3. Figure 3-3: Required Front Door Clearance Rear Panel Connections Figure 3-4 shows the Control Unit rear panel.
  • Page 25 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 26 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 27 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 28 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 29 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 3010PA. Table 3-2: Required RS-232 Options Parameter Setting Baud 2400 Byte 8 bits Parity none Stop Bits...
  • Page 30 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 31 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 32: 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 33: Using The Data Entry And Function Buttons

    4 Operation Model 3010 Using the Data Entry and Function Buttons Data Entry Buttons: The < > arrow buttons select options from the menu currently being displayed on the VFD screen. The selected option blinks. When the selected option includes a modifiable item, the arrow buttons can be used to increment or decrement that modifiable item.

  • Page 34: The System Function

    Oxygen Analyzer Part I: Control Unit Contrast Function is DISABLED (Refer to Section 1.3) Figure 4-1: Hierarchy of Functions and Subfunctions Each of these functions is described in greater detail in the following procedures. The VFD screen text that accompanies each operation is repro- duced, at the appropriate point in the procedure, in a type style.

  • Page 35: Setting The Display

    4 Operation Model 3010 activated, the operator MUST enter the UNIQUE password to gain access to set-up functions which alter the instrument's operation, such as setting the instrument span or zero setting, adjusting the alarm setpoints, or defining analysis ranges. After a password is assigned, the operator must log out to activate it.

  • Page 36: 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 3010PA is accurate 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 37: Entering The Password

    4 Operation Model 3010 If you have decided not to employ password security, use the default password TBEAI. This password will be displayed automatically by the microprocessor. The operator just presses the Enter key to be allowed total access to the instrument’s features. NOTE: If you use password security, it is advisable to keep a copy of the password in a separate, safe location.

  • Page 38: Installing Or Changing The Password

    Oxygen Analyzer Part I: Control Unit Press Escape to move on, or proceed as in Changing the Password, below. 4.3.3.2 Installing or Changing the Password If you want to install a password, or change an existing password, proceed as above in Entering the Password. When you are given the oppor- tunity to change the password: Press Enter to change the password (either the default TBEAI or the previously assigned password), or press Escape to keep the existing pass-...

  • Page 39: Logout

    4 Operation Model 3010 When you have finished typing the new password, press Enter . A verification screen appears. The screen will prompt you to retype your password for verification. Wait a moment. The entry screen will give you clearance to proceed. Use the arrow keys to retype your password and press Enter when finished.

  • Page 40: System Self-Diagnostic Test

    Part I: Control Unit 4.3.5 System Self-Diagnostic Test The Model 3010PA 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 41: Version Screen

    Zero or Span function. 4.4.1. Cell Failure When the sensor in the 3010PA begins to fail, the analyzer will usually require more and more frequent calibration. If the 3010PA analysis readings drift downward uncharacteristically, try recalibration. If recalibration raises the readings temporarily, the cell may be failing.

  • Page 42: Span Cal

    Part I: Control Unit The “good” reading depends on the class of cell your analyzer is using. Although the B-1 cell is standard in the 3010PA, check Specific Model Information in the Front Matter in this manual for the class of cell you purchased.

  • Page 43: Manual Mode Spanning

    4 Operation Model 3010 tion on Slope. Spanning automatically ends when the span output corre- 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 44: The Alarms Function

    Part I: Control Unit The Alarms Function The Model 3010PA 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 45 4 Operation Model 3010 The defeat alarm mode is incorporated into the alarm circuit so that maintenance can be performed under conditions which would normally activate the alarms. The defeat function can also be used to reset a latched alarm. (See procedures, below.) If you are using password protection, you will need to enter your password to access the alarm functions.

  • Page 46: The Range Function

    0–5 % High 0–10 %. The Model 3010PA 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 47: Fixed Range Analysis

    4 Operation Model 3010 Use the arrow keys to enter the upper value of the range (all ranges begin at 0 %). Repeat for each range you want to set. Press Enter to accept the values and return to Analyze mode. (See note below.) Note: The ranges must be increasing from low to high, for example, if range 1 is set for 0–10 % and range 2 is set for 0–100 %, range 3 cannot be set for 0–50 % since it is lower than range 2.

  • Page 48: The Analyze Function

    Signal Output The standard Model 3010PA Oxygen Analyzer are equipped with two 0-1 V dc analog output terminals accessible on the back panel (one concen- tration and one range ID). Two isolated 4-20 mA dc current outputs (one concentration and one range ID), in addition to the voltage outputs, are optional.
  • Page 49 4 Operation Model 3010 Interpretation of the analog output signal depends on the voltage (or current) AND the currently activated analysis range. To relate the signal output to the actual concentration, it is necessary to know what range the instrument is currently on, especially when the analyzer is in the autoranging mode.

  • Page 50: 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 51: 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 52: Major Internal Components

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

  • Page 53: 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 54 Part II: Analysis Unit OPERATING INSTRUCTIONS 3010 Model Oxygen Analyzer Part II: Analysis Unit NEC Type Part Number D-65479 Part II: i...
  • Page 55 Model 3010P Oxygen Analyzer Table of Contents 1 Introduction 1.1 Overview ................ 1-1 1.2 Gas Connector Panel............. 1-1 1.3 Electrical Connector Panel ..........1-2 2 Operational Theory 2.1 Introduction ..............2-1 2.2 Micro-Fuel Cell Sensors ..........2-1 2.2.1 Principles of Operation........... 2-1 2.2.2 Anatomy of a Micro-Fuel Cell ........
  • Page 56 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 .......... 5-3 5.2.3 Removing the Micro-Fuel Cell ......... 5-4 5.2.4 Installing a New Micro-Fuel Cell ......
  • Page 57 Model 3010P Oxygen Analyzer iv: Part II...

  • Page 58: Introduction

    Oxygen Analyzer Part II: Analysis Unit Introduction Overview The Analytical Instruments Model 3010P Analysis Unit is a versatile remotely controlled instrument for detecting oxygen in a variety of back- ground gases. Details are recorded in Specifications in the Appendix to this manual.

  • Page 59: Electrical Connector Panel

    1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction Model 3010 Figure 1-1: Cutaway View of 3010P 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 60 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 61 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction Model 3010 1-4: Part II...

  • Page 62: 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 63: 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 1 inch thick.

  • Page 64: Electrochemical Reactions

    Oxygen Analyzers Part II: Analysis Units The cathode has many perforations to ensure sufficient wetting of the upper surface with electrolyte, and it is plated with an inert metal. The anode structure is below the cathode. It is made of lead and has a proprietary design which is meant to maximize the amount of metal available for chemical reaction.

  • Page 65: The Effect Of Pressure

    2 Operational Theory Model 3010 (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 66: 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 sample conditions. A few typical Micro-Fuel Cells are listed below with their typical use and electrical specifications.

  • Page 67: Sample System

    If the sample gas contains 10 % or more hydrogen and/or helium, only “clamp” cells are used. These Micro-Fuel cells are identified by the suffix -C added to the cell class number. NOTE: Teledyne offers Sample System The sample system delivers gases to the Micro-Fuel Cell sensor from the Analysis Unit Gas Control Panel inlets.
  • Page 68 Oxygen Analyzers Part II: Analysis Units Span In Components in the shaded area are in the -C option (internal control valves) only and are not shown in the piping diagram above. Zero In Sample In Cell Solenoid Valves In vacuum service the Flowmeter restrictor should be In normal service the...
  • Page 69 2 Operational Theory Model 3010 2-8: Part II...

  • Page 70: Installation

    Oxygen Analyzer Part II: Analysis Unit Installation Installation of the Model 3010P 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 71: 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 72 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 73: Electrical Connector Panel

    3 Installation Model 3010 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). Exact figures will depend on your process.
  • Page 74 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 75 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. (See drawing D-64950 for wire recommendations.) Figure 3-5: 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.

  • Page 76: 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, or if the cell is exposed to air for too long, the Micro-Fuel Cell will need to be replaced.
  • Page 77 3 Installation Model 3010 3-8: Part II...

  • Page 78: 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 79: System Self Diagnostic Test

    4 Operation Model 3010P 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 20.90 %, the cell can take a long time to recover if the instrument is used for low level oxygen analysis immediately following calibration in air.

  • Page 80: 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 81 4 Operation Model 3010P The “good” reading depends on the class of cell your analyzer is using. Although the B-1 cell is standard in the 3010P, check Specific Model Information in the Front Matter in this manual for the class of cell you purchased.

  • Page 82: Maintenance

    Oxygen Analyzers Part II: Analysis Units 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 Control Unit are covered in Part I, chapter 5 of this manual.

  • Page 83: Cell Replacement

    Maintenance Models 3010P 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 according to local regulations.

  • Page 84: When To Replace A Cell

    Oxygen Analyzers Part II: Analysis Units 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 HARMFUL IF TOUCHED, SWALLOWED, OR INHALED. AVOID CONTACT WITH ANY FLUID OR POWDER IN OR AROUND THE UNIT.

  • Page 85: Removing The Micro-Fuel Cell

    Maintenance Models 3010P 2. With span gas flowing, read the raw output of the cell from the System function display. 3. Divide the raw output reading by the percent oxygen concentration of your span gas. If the quotient is less than the Index value for the cell class you are using, replace the cell.
  • Page 86 Oxygen Analyzers Part II: Analysis Units 5. When it is free, unscrew the Cap from the Probe. Hold the Probe vertically to prevent dropping the cell out of the probe. 6. Remove the Cell from the Probe, and dispose of it in an environmentally safe manner.

  • Page 87: Installing A New Micro-Fuel Cell

    Maintenance Models 3010P 5.2.4 Installing a New Micro-Fuel Cell CAUTION: Do not touch the sensing surface of the cell. It is covered with a delicate Teflon membrane that can leak when punctured. The sensor must be re- placed if the membrane is damaged. 1.

  • Page 88: System Self Diagnostic Test

    Oxygen Analyzers Part II: Analysis Units 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 milli- meters.
  • Page 89 Maintenance Models 3010P 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 Preamp Zero too high Amplifier output doesn't match test input Both Failed 5-8: Part II...
  • Page 90 Oxygen Analyzers Appendix OPERATING INSTRUCTIONS 3010PA Model Oxygen Analyzers Appendix Flush Mount Control Unit, PN CU64596B NEC Type Analysis Unit, PN AU65479 Appendix: A-1...
  • Page 91 Appendix Models 3010PA Contents A-1 Model 3010PA Specifications ........A-3 A-2 Recommended 2-Year Spare Parts List ......A-4 A-3 Drawing List ..............A-6 A-4 19-Inch Relay Rack Panel Mount ........A-6 A-5 Application notes on Restrictors, Pressures, & Flow ..A-6 A-6 The Zero Functions ............
  • Page 92 Oxygen Analyzers Appendix Appendix A-1 Model 3010PA 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).
  • Page 93 Appendix Models 3010PA 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 94 Orders for replacement parts should include the part number (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...
  • Page 95 D-64596B: Final Assembly/Outline Drawing, Control Unit, Percent Oxygen D-65479: Final Assembly/Outline Drawing, Analysis Unit, Percent Oxy- 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 A-6: Appendix...
  • Page 96 Oxygen Analyzers 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 97 ( off scale of flow-meter), pressure drops other than the restriction device could become significant , and result in pressurizing the cell. Example 2, A 3010PA 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 98 Operation without a restrictor device is not recommend as mentioned above. A 3010PA 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.6...

  • Page 99: Manual Mode Zeroing

    Appendix Models 3010PA Zero Cal The Zero button on the front panel is used to enter the zero calibration function. Zero calibration can be performed in either the automatic or manual mode. In the automatic mode, an internal algorithm compares consecutive readings from the sensor to determine when the output is within the accept- able range for zero.
  • Page 100 Oxygen Analyzers Appendix Press Enter to begin the zero calibration. After a few seconds the first of five zeroing screens appears. The number in the upper left hand corner is the first-stage zero offset. The microprocessor samples the output at a prede- termined rate.
  • Page 101 Appendix Models 3010PA A-12: Appendix...
  • Page 102 Micro-Fuel Cells and Super Cells, all classes except A-2C, A-3, and A-5. Electrochemical Oxygen Sensors, all classes except R-19. Mini-Micro-Fuel Cells, all classes. Manufacturer: Teledyne Analytical Instruments Address: 16830 Chestnut Street, City of Industry, CA 91749 Phone: (818) 961-9221 Customer Service:...
  • Page 103 Appendix Models 3010PA Section IV – Fire and Explosion Hazard Data Flash Point: Flammable Limits: LEL: UEL: Extinguishing Media: Use extinguishing media appropriate to surrounding fire conditions. No specific agents recommended. Special Fire Fighting Wear NIOSH/OSHA approved self-contained breathing Equipment: apparatus and protective clothing to prevent contact with skin and eyes.
  • Page 104 Oxygen Analyzers Appendix Signs and Symptoms of Contact of electrolyte with skin or eyes will cause a Exposure: burning sensation and/or feel soapy or slippery to touch. Other symptoms of exposure to lead include loss of sleep, loss of appetite, metallic taste and fatigue. Carcinogenicity: Lead is classified by the IARC as a class 2B carcinogen (possibly carcinogenic to humans)
  • Page 105 NOTE: The above information is believed to be correct and is offered for your information, consideration, and investigation. It should be used as a guide. Teledyne Analytical Instruments shall not be held liable for any damage resulting from handling or from contact with the above product.

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