Percent Oxygen Analyzer OPERATING INSTRUCTIONS FOR Model 3000MB Percent 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 PERSIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED. ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING.
Model 3000MB Copyright © 2000 Teledyne Analytical Instruments All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any other language or computer language in whole or in part, in any form or by any means, whether it be electronic, mechanical, magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-1580.
Percent Oxygen Analyzer Specific Model Information The instrument for which this manual was supplied may incorporate one or more options not included with the standard instrument. Commonly available options are listed below, with check boxes. Any that are incorporated in the instrument for which this manual is supplied are indicated by a check mark in the box.
Model 3000MB Table of Contents 1 Introduction 1.1 1.2 1.3 1.4 1.5 1.6 Overview ........................................................................ 1-1 Typical Applications ....................................................... 1-1 Main Features of the Analyzer ....................................... 1-1 Model Designations ....................................................... 1-2 Front Panel (Operator Interface) ..................................... 1-3 Interface Panel .............................
Percent Oxygen Analyzer 4.3.3.1 Entering the Password ................................... 4-6 4.3.3.2 Installing or Changing the Password ............. 4-7 4.3.4 Logout .................................................................... 4-8 4.3.5 System Self-Diagnostic Test .................................. 4-9 4.3.6 Version Screen ...................................................... 4-9 4.4 The Span Functions ...................................................... 4-10 4.4.1 Span Cal ..................
Model 3000MB DANGER COMBUSTIBLE GAS USAGE WARNING This is a general purpose instrument designed for usage in a nonhazardous area. It is the customer's responsibility to ensure safety especially when combustible gases are being analyzed since the potential of gas leaks always exist. The customer should ensure that the principles of operating of this equipment is well understood by the user.
Percent Oxygen Analyzer Introduction 1 Introduction 1.1 Overview The Teledyne Analytical Instruments Model 3000MB Percent Oxygen Analyzer is a versatile microprocessor-based instrument for detecting the percentage of oxygen in a variety of background gases. This manual covers the Model 3000MB General Purpose flush-panel and/or rack-mount units only. These units are for indoor use in a nonhazardous environment. 1.
1 Introduction Model 3000MB • Advanced Paramagnetic sensor, designed for percent oxygen analysis. Several options are available. • Versatile analysis over a wide range of applications. • Microprocessor based electronics: 8-bit CMOS microprocessor with 32 kB RAM and 128 kB ROM. • Three user definable output ranges (from 0-1% through 0-100 %) allow best match to users process and equipment. • Air-calibration range for convenient spanning at 20.9 %.
Percent Oxygen Analyzer Introduction 1 OUTER DOOR (OPEN) DIGITAL METER VIEWING WINDOW INNER DOOR LATCH OUTER DOOR LATCH CONTROL PANEL FLOWMETER GAS CONNECTION (LOCATED BEHIND GAS PANEL) GAS CONNECTOR PANEL Figure 1-1: Model 3000MB Front Panel 1.5 Front Panel (Operator Interface) The standard 3000MB is housed in a rugged metal case with all controls and displays accessible from the front panel. See Figure 1-1.
1 Introduction Model 3000MB 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.). • Span Span calibrate the analyzer. • Zero Zero calibrate the analyzer. • Alarms Set the alarm setpoints and attributes. • Range Set up the 3 user definable ranges for the instrument.
Percent Oxygen Analyzer Introduction 1 Access Door: To provide access to the sensor, the front panel swings open when the latch in the upper right corner of the panel is pressed all the way in with a narrow gauge tool. Accessing the main circuit board requires unfastening the rear panel screws and sliding the unit out of the case. 1.6 Interface Panel (Equipment Interface) The rear panel, shown in Figure 1-2, contains the gas and electrical connectors for external inlets and outlets.
1 Introduction 1-6 Model 3000MB Teledyne Analytical Instruments
Percent Oxygen Analyzer Operational Theory 2 Operational Theory 2.1 Introduction The analyzer is composed of three subsystems: 1. Paramagnetic Sensor 2. Sample System 3. Electronic Signal Processing, Display and Control The sample system is designed to accept the sample gas and transport it through the analyzer without contaminating or altering the sample prior to analysis.
2 Operational Theory Model 3000MB bell to the zero position in the presence of zero gas (i.e. no O2 present) or of sample gas is proportional to the partial pressure of oxygen in the sample gas. The sensor enclosure is temperature controlled to 55 degrees centigrade to insure that the magnetic susceptibility of oxygen in the sample is not affected by the ambient temperature.
Percent Oxygen Analyzer Operational Theory 2 Sensor (rear view shown) Pin out: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2.3 -15Vdc test pin (Not connected) +15Vdc test pin (Not connected) Measuring ground Not used Preamplifier output ~0- 1 Vdc Not used 24 Vdc return, power ground Collector of transistor switching heating element (Not connected) Fault signal: <0 Vdc= OK, >4.
2 Operational Theory Model 3000MB Gas Cross Sensitivity in vol. % Gas Cross Sensitivity in vol. % Acetylene C2H2 Allene C3H4 Ammonia NH3 Argon Ar Bromine Br2 1.2 Butadiene C4H6 1.3 Butadiene C4H6 n-Butane C4H10 I-Butane C4H8 cis 2-Butane C4H8 trans 2-Butane C4H8 Carbon dioxide CO2 Carbon monoxide CO Chlorine Cl2 Cyclo hexane C6H12 Ethane C2H6 Ethylene C2H4 Helium He n-Heptane C7H16 n-Hexane C6H14 Hydrogen H2 Hydrogen bromide HBr -0.24 -0.44 -0.26 -0.22 -1.30 -0.49 -0.49 -1.11 -085 -0.89 -0.92 -0.
Percent Oxygen Analyzer Operational Theory 2 (0% 02) - (Cross Interference Value) = Zero Point Value 0% -(-0.137) = +0.137%02 2.4 Sample System The sample system delivers gases to the sensor from the analyzer gas panel inlets. Depending on the mode of operation either sample or calibration gas is delivered. The Model 3000MB 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.
2 Operational Theory 2.5 Model 3000MB Electronics and Signal Processing The Model 3000MB Percent 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. System power is supplied from a universal power supply module designed to be compatible with any international power source. Figure 2-6 shows the location of the power supply and the main electronic PC boards.
Percent Oxygen Analyzer Operational Theory 2 Sensor Amplifier Sensor A to D Converter 24V Power Supply Auto Range Power Supply System Failure Alarm MicroProcessor Displays Self Test Signal 0-1 V 0-1 V Concentration D to A Converter Range Figure 2-6: Block Diagram of the Model 3000MB Electronics Teledyne Analytical Instruments 2-7
2 Operational Theory 2-8 Teledyne Analytical Instruments Model 3000MB
Percent Oxygen Analyzer Installation 3 Installation Installation of the Model 3000PB Analyzer includes: 1. Unpacking 2. Mounting 3. Gas connections 4. Electrical connections 5. Installing the Micro-Fuel Cell 6. Testing the system. 3.1 Unpacking the Analyzer The analyzer is shipped with all the materials you need to install and prepare the system for operation. Carefully unpack the analyzer and inspect it for damage. Immediately report any damage to the shipping agent. 3.
3 Installation Model 3000MB Figure 3-1: Front View of the Model 3000MB (Simplified) 3-2 Teledyne Analytical Instruments
Percent Oxygen Analyzer Installation 3 Figure 3-2: Required Front Door Clearance 3.3 Electrical Connections Figure 3-3 shows the Model 3000MB Electrical Connector Panel. There are terminal blocks for connecting power, communications, and both digital and analog concentration outputs.
3 Installation Model 3000MB For safe connections, ensure that no uninsulated wire extends outside of the connectors they are attached to. Stripped wire ends must insert completely into terminal blocks. No uninsulated wiring should be able to come in contact with fingers, tools or clothing during normal operation. Terminal block can accept ware guage 20 to 10. 3.3.1 Primary Input Power The universal power supply requires a 115 or 230 V ac, 50 or 60 Hz, power source.
Percent Oxygen Analyzer Installation 3 Figure 3-5: Analog Output Connections The outputs are: 0–1 V dc % of Range: Voltage rises linearly with increasing oxygen, from 0 V at 0 % to 1 V at 100 %. (Full scale = 100% of programmable range.) 0–1 V dc Range ID: 0.25 V = Low Range, 0.5 V = Medium Range, 0.75 V = High Range, 1 V = Air Cal Range. 4–20 mA dc % Range: (-M Option) Current increases linearly with increasing oxygen, from 4 mA at 0 % to 20 mA at full scale 100 %.
3 Installation Model 3000MB Table 3-1: Analog Concentration Output—Example Voltage Signal Output (V dc) % O2 0 1 2 3 4 5 6 7 8 9 10 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 Current Signal Output (mA dc) 4.0 5.6 7.2 8.8 10.4 12.0 13.6 15.2 16.8 18.4 20.0 To provide an indication of the range, a second pair of analog output terminals are used. They generate a steady preset voltage (or current when using the current outputs) to represent a particular range.
Percent Oxygen Analyzer Installation 3 Figure 3-6: Types of Relay Contacts The connectors are: Threshold Alarm 1: • 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 nonfailsafe. • Can be configured as latching or nonlatching. • Can be configured out (defeated).
3 Installation Model 3000MB ZERO: Floating input. 5 to 24 V input across the + and – terminals puts the analyzer into the Zero mode. Either side may be grounded at the source of the signal. 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 3.3.9 Remote Sensor and Solenoid Valves. (With the –C option, the internal valves automatically operate synchronously.) SPAN: Floating input.
Percent Oxygen Analyzer Installation 3 Note: The remote probe connections (paragraph 3.3.9) provides signals to ensure that the zero and span gas valves will be controlled synchronously. If you have the –C Internal valve option—which includes additional zero and span gas inputs— the 3000MB automatically regulates the zero, span and sample gas flow. 3.3.6 Range ID Relays There are four dedicated RANGE ID CONTACT relays.
3 Installation • • • • Model 3000MB The range in use (HI, MED, LO) The span of the range (0-100 %, etc) Which alarms—if any—are disabled (AL–x DISABLED) Which alarms—if any—are tripped (AL–x ON). Each status output is followed by a carriage return and line feed. Three input functions using RS-232 have been implemented to date. They are described in Table 3-4. Table 3-4: Commands via RS-232 Input Command Description as Immediately starts an autospan. az Immediately starts an autozero.
Percent Oxygen Analyzer Installation 3 Figure 3-7: Remote Sensor Connector Pinouts Figure 3-8: Remote Solenoid Return Connector Pinouts The voltage from these 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.
3 Installation 3.4 Model 3000MB Gas Connections Before using this instrument, it should be determined if the unit will be used for pressurized service or vacuum service and low pressure applications. Inspect the restrictor kit that came with the unit. The kit consist of two restrictors and a union for 1/4” diameter tubing. Notice that the two 1 3/4” long, 1/4” diameter tubing are restrictors. It has an open end and a closed end with a small circular orifice.
Percent Oxygen Analyzer Installation 3 Behind Panel Figure 3-10: Gas Connector Panel SAMPLE IN: In the standard model, gas connections are made at the SAMPLE IN and EXHAUST OUT connections. Calibration gases must be Tee'd into the Sample inlet with appropriate valves. The gas pressure in should be reasonably regulated. Pressures between 3 and 40 psig are acceptable as long as the pressure, once established, will keep the front panel flowmeter reading in an acceptable range (0.1 to 2.4 SLPM).
3 Installation Model 3000MB Pressure, flow, and safety considerations are the same as prescribed for the SAMPLE IN inlet, above. EXHAUST OUT: Exhaust connections must be consistent with the hazard level of the constituent gases. Check Local, State, and Federal laws, and ensure that the exhaust stream vents to an appropriately controlled area if required. Note: If your 3000MB has the –V option, see Sample In, above, for gas pressure/flow considerations. 3.
Percent Oxygen Analyzer Operation 4 Operation 4.1 Introduction Once the analyzer has been installed, it can be configured for your application. To do this you will: • • • • Set system parameters: • Establish a security password, if desired, requiring Operator to log in. • Establish and start an automatic calibration cycle, if desired. Calibrate the instrument. Define the three user selectable analysis ranges. Then choose autoranging or select a fixed range of analysis, as required.
4 Operation Model 3000MB 4.2 Using the Data Entry and Function Buttons Data Entry Buttons: The < > arrow buttons select options from the menu currently 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.
Percent Oxygen Analyzer Operation 4 Contrast Function is DISABLED (Refer to Section 1.6) Figure 4-1: Hierarchy of Functions and Subfunctions duced, at the appropriate point in the procedure, in a Monospaced type style. Pushbutton names are printed in Oblique type. 4.3 The System Function The subfuctions of the System function are described below. Specific procedures for their use follow the descriptions: • • Auto-Cal: Used to define an automatic calibration sequence and/or start an Auto-Cal.
4 Operation • • • • Model 3000MB 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. 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 TBEAI by default. This allows access to anyone.
Percent Oxygen Analyzer Operation 4 4.3.2 Setting up an Auto-Cal When proper automatic valving is connected (see chapter 3, installation), the Analyzer can cycle itself through a sequence of steps that automatically zero and span the instrument. Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. The internal clock in the Model 3000MA is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day.
4 Operation Model 3000MB 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. 4.3.3.
Percent Oxygen Analyzer Operation 4 Change Password? =Yes =No 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.
4 Operation Model 3000MB A A A A A Retype PWD To Verify Wait a moment for the entry screen. You will be given clearance to proceed. AAAAA TO Proceed Use the arrow keys to retype your password and press Enter when finished. 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: 0.
Percent Oxygen Analyzer Operation 4 4.3.5 System Self-Diagnostic Test The Model 3000MB has a built-in self-diagnostic testing routine. Preprogrammed 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. (See System Self Diagnostic Test in chapter 5 for number code.
4 Operation 4.4 Model 3000MB The Span Functions The analyzer is calibrated using span gas. NOTE: Zero is not necessary for Percent (%) level measurements. Additional information on Zero functions is provided in the Appendix A-6 of this manual. 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.
Percent Oxygen Analyzer Operation 4 Press Enter to move to the next screen. Span Val: 20.90 Span Mod # Use the ∆∇ arrow keys to enter the oxygen-concentration mode. Use the < > arrow keys to blink the digit you are going to modify. Use the ∆∇ arrow keys again to change the value of the selected digit. When you have finished typing in the concentration of the span gas you are using (20.90 if you are using air), press Enter to begin the Span calibration.
4 Operation Model 3000MB for the first Slope value to display. Slope indicates rate of change of the Span reading. It is a sensitive indicator of stability. #### Slope=#### % Span ppm/s When the Span value displayed on the screen is sufficiently stable, press Enter. (Generally, when the Span reading changes by 1 % or less of the full scale of the range being calibrated for a period of five minutes it is sufficiently stable.) Once Enter is pressed, the Span reading changes to the correct value.
Percent Oxygen Analyzer Operation 4 In failsafe mode, the alarm relay de-energizes in an alarm condition. For non-failsafe operation, the relay is energized in an alarm condition. You can set either or both of the concentration alarms to operate in failsafe or non-failsafe mode. 3. Are either of the alarms to be latching? In latching mode, once the alarm or alarms trigger, they will remain in the alarm mode even if process conditions revert to non-alarm conditions.
4 Operation • • • • Model 3000MB To define the setpoint, use the < > arrow keys to move the blinking over to AL–1 ####. Then use the ∆∇ arrow keys to change the number. Holding down the key speeds up the incrementing or decrementing. (Remember, the setpoint units are percent-of-oxygen.) To set the other parameters use the < > arrow keys to move the blinking over to the desired parameter. Then use the ∆∇ arrow keys to change the parameter.
Percent Oxygen Analyzer Operation 4 4.6.1 Setting the Analog Output Ranges To set the ranges, enter the range function mode by pressing the Range button on the front panel. L—1.00 M—5.00 H—10.00 Mode—AUTO Use the < > arrow keys to blink the range to be set: low (L), medium (M), or high (H). 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.
4 Operation Model 3000MB 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 AUTO. Use the ∆∇ arrow keys to switch from AUTO to FX/LO, FX/MED, or FX/ HI to set the instrument on the desired fixed range (low, medium, or high). L—1.00 H—10.00 M—5.00 Mode—FX/LO or L—1.00 M—5.00 H—10.00 Mode—FX/MED or L—1.00 M—5.00 H—10.
Percent Oxygen Analyzer Operation 4 The signal output for concentration is linear over the currently selected analysis range. For example, if the analyzer is set on range that was defined as 0–10 % O2, then the output would be: % O2 Voltage Signal Output (V dc) 0 1 2 3 4 5 6 7 8 9 10 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 Current Signal Output (mA dc) 4.0 5.6 7.2 8.8 10.4 12.0 13.6 15.2 16.8 18.4 20.
4 Operation 4-18 Model 3000MB Teledyne Analytical Instruments
Percent OxygenAnalyzer Maintenance 5 5.0 Maintenance Aside from normal cleaning and checking for leaks at the gas connections, routine maintenance is limited to replacing filter elements and fuses, and recalibration. WARNING: SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL. 5.1 Replacing the Fuse Remove Power to Unit before replacing the fuse. - Push and turn the Fuse Holder 1/2 turn to the left.
5 Maintenance 5.2 Model 3000MB System Self Diagnostic Test 1. Press the system button to enter the system mode 2. Use the < > arrow keys to move to More, and press Enter. 3. Use the < > arrow keys to move to Self-Test, and press Enter. The following failure codes apply: Table 5.2: Self-Test Failure Codes Power 0 OK 1 5V Failure 2 15V Failure 3 Both Failed Analog 0 OK 1 DAC A (0-1V Concentration) 2 DAC B (0-1V Range ID) 3 Both Failed Preamp 5.
Percent OxygenAnalyzer Maintenance 5 The 3000MB contains the following major components: Paramagnetic Sensor 2 x Power Supplies Microprocessor Displays 5 Digit, LED Meter. 2 line, 20 character, alphanumeric, VFD display. 5.4 Cleaning If the instrument is unmounted at the time of cleaning, disconnect the instrument form its power source. Close and latch the front panel, and front door. Clean outside surfaces with a soft cloth dampened slightly with plain clean water.
5 Maintenance Model 3000MB Increase the flow rate and/or length of tubing in order to dilute or minimize the diffusion of oxygen from the vent back to the analyzer. Problem: Inaccurate zero operation (i.e. the user has zeroed the analyzer accidentally on gas much higher than one would normally use for zero gas. Solution: Turn the analyzer off, then back on again. Press the system key when prompted by the analyzer "press system for default values".
Percent Oxygen Analyzer Appendix Appendix A-1 Model 3000MB Specifications Packaging: General Purpose • Nema 4 rated bulkhead mount enclosure. Sensor: Paramagnetic Sensor 90 % Response Time: 10 seconds at 25 °C (77 °F). Ranges: Three user definable ranges from 0-1 % to 0-100 %, plus air calibration range of 0-25 %. Alarms: One system-failure alarm contact to detect power failure. Two adjustable concentration threshold alarms with fully programmable setpoints.
Appendix Model 3000MB Analog outputs: 0-1 V dc percent-of-range (Standard) 0-1 V dc range ID (Standard) 4-20 mA dc—isolated— percent-of-range (Optional) 4-20 mA dc—isolated— range ID (Optional) Dimensions: 20.5” High x 13” Wide x 9” Tall (52.1 cm x 33 cm x 22.
Percent Oxygen Analyzer Appendix A-3 Drawing List D-73375 Outline Drawing D-73374 Interconnection Diagram Teledyne Analytical Instruments A-3
