Percent Paramagnetic Oxygen Analyzer OPERATING INSTRUCTIONS FOR Model 3020M Percent Paramagnetic 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 3020M Copyright © 1998 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 Paramagnetic Oxygen Analyzer Specific Model Information The instrument for which this manual was supplied may incorporate one or more options not supplied in 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 3020M 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 .......................................................... 1-2 1.5.1 UP/DOWN Switch .......................
Percent Paramagnetic Oxygen Analyzer 4 Operation 4.1 Introduction .................................................................... 4-1 4.2 Using the Controls ......................................................... 4-1 4.2.1 Mode/Function Selection ....................................... 4-2 4.2.1.1 Analysis Mode ............................................... 4-2 4.2.1.2 Setup Mode ................................................... 4-2 4.2.2 Data Entry ...............................................
Model 3020M Appendix A-1 Specifications ................................................................ A-1 A-2 Recommended 2-Year Spare Parts List ......................... A-3 A-3 Drawing List ...................................................................
Percent Paramagnetic Oxygen Analyzer Introduction 1 Introduction 1.1 Overview The Teledyne Analytical Instruments Model 3020M Percent Paramagnetic Oxygen Analyzer is a versatile microprocessor-based instrument for detecting oxygen in a variety of gases. This manual covers the Model 3020M, percent oxygen, explosion-proof, bulkhead-mount units only. 1.
1 Introduction Model 3020M • 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 0-5 % through 0-100 %) allow best match to users process and equipment. • Auto Ranging allows analyzer to automatically select the proper preset range for a given measurement. Manual override allows the user to lock onto a specific range of interest.
Percent Paramagnetic Oxygen Analyzer Introduction 1 controls are described briefly here and in greater detail in chapter 4. See Figure 1-1.
1 Introduction Model 3020M 1.5.1 UP/DOWN Switch Functions: The UP/DOWN switch is used to select the function to be performed. Choose UP or DOWN to scroll through the following list of twelve functions: • Auto-Cal Set up an automatic calibration sequence. • PWD Install a password to protect your analyzer setup. • Logout Locks Setup Mode. • Version Displays model and version of analyzer. • Self-Test Runs internal diagnostic program, displays results. • Span Span calibrate the analyzer.
Percent Paramagnetic Oxygen Analyzer Introduction 1 With a Value Selected: Enters the value into the analyzer as data. Advances VFD to next operation. (See Chapter 4 for details.) 1.5.3 Displays Digital Meter Display: The meter display is a LED device that produces large, bright, 7-segment numbers that are legible in any lighting. It produces a continuous readout from 0-100 %. It is accurate across all analysis ranges without the discontinuity inherent in analog range switching.
1 Introduction Model 3020M 100-240 V 50/60Hz 3.0A Max.
Percent Paramagnetic Oxygen Analyzer Introduction 1 Electrical Connections: The electrical connections on the electrical connector panel are described briefly here, and in more detail in chapter 3 Installation. • Power Connection 100-240 VAC, 50 or 60 Hz. • Analog Outputs 0-1 VDC concentration plus 0-1 V dc range ID. Additional, isolated 4-20 mA DC plus 4-20 mADC range ID available. • Alarm Connections 2 concentration alarms and 1 system alarm.
1 Introduction Model 3020M SCCM Figure 1-3: Model 3020M Gas Connector Panel • Gas Sample Inlet and Outlet One inlet and one exhaust out. Optional: • Calibration Gas Ports Separate fittings for zero, span and sample gas input, plus internal valves for automatically switching the gases in sync with the 3020M electronics. Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. The internal clock in the Model 3020M is accurate to 2-3 %.
Percent Paramagnetic 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 3020M 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 Paramagnetic 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 3020M 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 Paramagnetic 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 3020M 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 3020M Electronics and Signal Processing The Model 3020M 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 most international power sources. See chapter 5 Maintenance for the location of the power supply and the main electronic PC boards.
Percent Paramagnetic 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 2-5: Block Diagram of the Model 3020M Electronics Teledyne Analytical Instruments 2-7
2 Operational Theory 2-8 Teledyne Analytical Instruments Model 3020M
Percent Paramagnetic Oxygen Analyzer Installation 3 Installation Installation of the Model 3020M Analyzer includes: 1. Unpacking 2. Mounting 3. Gas connections 4. Electrical connections 5. 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 3020M CMSC Figure 3-1: Front View of the Model 3020M (Simplified) 3-2 Teledyne Analytical Instruments
Percent Paramagnetic Oxygen Analyzer Installation 3 Figure 3-2: Required Front Door Clearance 3.3 Electrical Connections Figure 3-3 shows the Model 3020M Electrical Connector Panel. There are terminal blocks for connecting power, communications, and both digital and analog concentration outputs. 100-240 V 50/60Hz 3.0A Max.
3 Installation Model 3020M 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. 3.3.1 Primary Input Power The universal power supply requires a 100-240 VAC, 50 or 60 Hz power source. See Figure 3-4 for detailed connections.
Percent Paramagnetic Oxygen Analyzer Installation 3 Figure 3-5: Analog Output Connections The outputs are: 0–1 VDC % of Range: Voltage rises linearly with increasing oxygen, from 0 V at 0 % to 1 V at full scale. (Full scale = 100% of programmable range.) 0–1 VDC Range ID: 0.25 V = Low Range, 0.5 V = Medium Range, 0.75 V = High Range, 1 V = Air Cal Range. 4–20 mADC % Range: (-M Option) Current increases linearly with increasing oxygen, from 4 mA at 0 % to 20 mA at full scale.
3 Installation Model 3020M 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 Paramagnetic Oxygen Analyzer Installation 3 3.3.4 Alarm Relays There are three alarm-circuit connectors on the alarm relays block (under RELAY OUTPUTS) 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. The contact connections are indicated by diagrams on the connector panel. They are capable of switching up to 3 amperes at 250 VAC into a resistive load.
3 Installation Model 3020M NOTE: Power may be present on this contacts even when power to analyzer has been removed since this contacts are wired by the customer. 3.3.5 Digital Remote Cal Inputs Remote Zero and Span Inputs: The REMOTE SPAN and REMOTE ZERO inputs are on the DIGITAL INPUT terminal block. They accept 0 V (OFF) or 24 V dc (ON) for remote control of calibration. (See Remote Calibration Protocol below.) ZERO: Floating input.
Percent Paramagnetic Oxygen Analyzer Installation 3 1) Test the CRC. When the CRC is open, Send a zero command until the CRC closes (The CRC will quickly close.) 2) When the CRC closes, remove the zero command. 3) When CRC opens again, send a span command until the CRC closes. (The CRC will quickly close.) 4) When the CRC closes, remove the span command. When CRC opens again, zero and span are done, and the sample is being analyzed. Note: The remote probe connections (paragraph 3.3.
3 Installation Model 3020M DTR COM DSR RTS CTS RI 4 5 6 7 8 9 Data Terminal Ready Common Data Set Ready Request to Send Clear to Send Ring Indicator The data sent is status information, in digital form, updated every two seconds. Status is reported in the following order: • The concentration in percent • 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).
Percent Paramagnetic Oxygen Analyzer Installation 3 3.3.9 Remote Sensor and Solenoid Valves The 3020M is a single-chassis instrument, which has its own sensor and, in the –C option, its own gas-control solenoid valves. The REMOTE SENSOR connector is not used, and the SOLENOID RETURN connectors are used (without the –C option) to synchronize external gas control valves. See Figure 3-7.
3 Installation 3.4 Model 3020M Gas Connections Figure 3-9 is an illustration of the Gas Connector Panel. Optional gas connections are shown in shaded blocks. The unit is manufactured with 1/4 inch tube fittings only. Adapters must be used for metric tubing. (At least 6 mm is recommended.) For a safe connection: 1. Insert the tube into the tube fitting, and finger-tighten the nut until the tubing cannot be rotated freely, by hand, in the fitting.
Percent Paramagnetic Oxygen Analyzer Installation 3 The gas pressure in should be regulated at about 10 psig. Pressures between 5 and 20 psig are acceptable as long as the pressure, once established, will keep the front panel flowmeter reading in an acceptable range of 700 cc/minute. If greater flow is required for improved response time, install a bypass in the sampling system upstream of the analyzer input.
3 Installation 3-14 Model 3020M Teledyne Analytical Instruments
Percent Paramagnetic 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: • • • • • Establish and start an automatic calibration cycle, if desired. (Electrically operated valves required.) Define the three user selectable analysis ranges. Then choose autoranging or select a fixed range of analysis, as required. Calibrate the instrument.
4 Operation Model 3020M The item that is between arrows on the screen is the item that is currently selectable by choosing ENTER (turn-and-release toward ENTER with the ESCAPE/ENTER control). In these instructions, to ENTER means to turn-and-release toward ENTER, and To ESCAPE means to turn-and-release towards ESCAPE. To scroll UP (or scroll DOWN) means to turn-and-release toward UP (or DOWN) as many times as necessary to reach the required menu item. 4.2.
Percent Paramagnetic Oxygen Analyzer Operation 4 Setup Mode AUTO-CAL Analysis Mode PSWD ANALYZE LOGOUT Perform Oxygen Analysis on Sample VERSION SELF-TEST Contrast Function is DISABLED Auto-Cal On/Off Span/Zero Timing (Refer to Section 1.
4 Operation Model 3020M 10 STANDBY: Remove power to outputs and displays, but maintain power to internal circuitry. 11 Sensor (Not Used). Any function can be selected at any time. Just scroll through the MAIN MENU with the DOWN/UP control to the appropriate function, and ENTER it. The analyzer will immediately start that function, unless password restrictions have been assigned. (Password assignment is explained further on.
Percent Paramagnetic Oxygen Analyzer 4.3 Operation 4 The AUTO-CAL Function 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 timing of your AUTO-CAL, use external AUTO-CAL control where possible. The internal clock in the Model 3020M is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day.
4 Operation Model 3020M analyze sample gas and report on alarm conditions without entering the password. • Only one password can be defined. • 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. • To defeat the security after a unique password is activated, the password must be changed back to TETAI.
Percent Paramagnetic Oxygen Analyzer Operation 4 Change Password? =Yes =No ESCAPE to move on, or proceed as in Changing the Password, below. 4.4.
4 Operation Model 3020M AAAAA Retype PWD To Verify Wait a moment for the entry () screen. You will be given clearance to proceed. AAAAA TO Proceed ENTER the letters of your new password. 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 Paramagnetic Oxygen Analyzer 4.7 Operation 4 The SELF-TEST Function The Model 3020M has a built-in self-testing diagnostic 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 Model 3020M Readjust the gas pressure into the analyzer until the flowrate (as read on the analyzer’s SCCM flowmeter) settles at 700 cc/minute. If you are using password protection, you will need to enter your password to gain access to either of these functions. Follow the instructions in section 4.4 to enter your password. Once you have gained clearance to proceed, you can ENTER the ZERO or SPAN function. 4.8.1 Span Cal SPAN is used to span calibrate the analyzer.
Percent Paramagnetic Oxygen Analyzer 4.8.1.2 Operation 4 Manual Mode Spanning ENTER SPAN from the MAIN MENU to start the SPAN function. The screen that appears allows you to select whether the span calibration is to be performed automatically or manually. Span: Settling:MAN For Next Use DOWN/UP to toggle between AUTO and MAN span settling. Stop when MAN appears on the display. Use ENTER to move to the next screen. Span Val: 20.
4 Operation Model 3020M If you have trouble zeroing, you may need to skip to section 4.8.1.3 Cell Failure. Auto Mode Zeroing Select ZERO to enter the ZERO function. The ZERO screen allows you to select whether the zero calibration is to be performed automatically or manually. Use the DOWN/UP control to toggle between AUTO and MAN zero settling. Stop when AUTO appears on the display. Zero: Settling: AUTO To Begin ENTER to begin zeroing.
Percent Paramagnetic Oxygen Analyzer Operation 4 displays the rate of change as Slope= a value in parts per million per second (ppm/s). #### % Zero Slope=#### ppm/s NOTE:It takes several seconds for the true Slope value to display. Wait about 10 seconds. Then, wait until Slope is sufficiently close to zero before using ENTER to finish zeroing. Generally, you have a good zero when Slope is less than 0.05 ppm/s for about 30 seconds. When Slope is close enough to zero, ENTER it.
4 Operation Model 3020M • One high and one low alarm, or • Both low (low and low-low) alarms. 2. Are either or both of the alarms to be configured as failsafe? 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.
Percent Paramagnetic Oxygen Analyzer • • • Operation 4 number. Holding the control on the DOWN or UP position, while the number changes, speeds up the incrementing or decrementing. (Remember, the setpoint units are always % O2.) To set the other parameters use ENTER to blink the desired parameter. Then use DOWN/UP to change the parameter. Once the parameters for the alarm have been set, ENTER the ALARM function again, and repeat this procedure for next alarm.
4 Operation Model 3020M The automatic air calibration range is always 0-25 % and is not programmable. 4.11.1 Setting the Analog Output Ranges To set the ranges, ENTER the RANGE function mode by selecting RANGE from the MAIN MENU. The RANGE screen appears. L—5.00 M—25.00 H—100.00 Mode—AUTO Use the DOWN/UP control to the range to be set: low (L), medium (M), or high (H). Use the DOWN/UP control to enter the upper value of the range (all ranges begin at 0 %). Repeat for each range you want to set.
Percent Paramagnetic Oxygen Analyzer Operation 4 L—5.00 M—25.00 H—100.00 Mode—FX/HI ESCAPE to re-enter the ANALYZE screen using the fixed range. Note: When performing analysis on a fixed range, if the oxygen concentration rises above the upper limit, as established by the setup, for that particular range, the output saturates at 1 V dc (20 mA at optional mA dc output).
4 Operation Model 3020M Use STANDBY whenever you want to power down without danger loosing all of the configuration you programmed into your instrument in the Setup Mode. 4.14 The Analysis Mode This is the normal operating mode of the analyzer. In this mode the analyzer is monitoring the sample, measuring and displaying the amount of oxygen, and reporting alarm conditions.
Percent Paramagnetic Oxygen Analyzer Maintenance 5 Maintenance 5.1 Routine Maintenance Aside from normal cleaning and checking for leaks at the gas connections, routine maintenance is limited to replacing Paramagnetic Sensor and fuses, and recalibration. For recalibration, see Section 4.4 The Zero and Span Functions. WARNING: SEE WARNINGS ON TITLE PAGE OF THIS MANUAL. 5.
5 Maintenance Model 3020M 24V Sensor Power Supply located behind Customer Interface Board. Display PCB Main PCB Preamp PCB Door Subassembly (Cross Section) Box Subassembly (Gas Connector Panel not shown) Customer Interface Panel (Electrical Connector Panel) Gas Control Valves Sensor Figure 5-1: Major Internal Components To swing open the cover panel, remove all screws. 5.3 Sensor Replacement The Paramagnetic Sensor is maintenance free, and has a long life.
Percent Paramagnetic Oxygen Analyzer Maintenance 5 Figure 5-2: Removing Fuse Cap and Fuse from Holder 2. Replace fuse by reversing process in step 1. 5.5 System Self Diagnostic Test Use the DOWN/UP control to scroll through the MAIN MENU to SELF-TEST. The screen will follow the running of the diagnostic. RUNNING DIAGNOSTIC Testing Preamp — 83 During preamp testing there is a countdown in the lower right corner of the screen. When the testing is complete, the results are displayed.
5 Maintenance Model 3020M Analog 0 1 2 3 OK DAC A (0–1 V Concentration) DAC B (0–1 V Range ID) Both Failed Preamp 0 1 2 3 OK Zero too high Amplifier output doesn't match test input Both Failed Note that preamp test does not tell anything about sensor condition. If preamp is ok but instrument is not performing then sensor, sensor power supply, and sensor interconnection cable are suspects. 5.
Percent Paramagnetic Oxygen Analyzer Appendix Appendix A-1 Specifications Packaging: Explosion-proof. Bulkhead mount. Sensor: Paramagnetic Sensor. Ranges: Three user definable ranges from 0-5 % to 0100 %. Autoranging with range ID output. Sample System: Flow indicator visible from front of unit. Positive pressure service. Vacuum service (optional). Auto Cal / Auto Zero. (Available with optional, electrically operated valves.) Alarms: One system-failure alarm contact to detect power failure.
Appendix Model 3020M 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. 4-20 mADC percent-of-range 4-20 mADC range ID. Password Access: Can be user-configured for password protection.
Percent Paramagnetic Oxygen Analyzer Appendix A-2 Recommended 2-Year Spare Parts List QTY. PART NUMBER DESCRIPTION 1 C62371B Display PCB 1 D70046 Customer Interface PCB 1 C70043 Percent Preamplifier Board 1* C62365-C Main PCB (NO 4-20 mA) 1* C62365-A Main PCB (4-20 mA) 4 F1295 Fuse, 4A, 250V, 5x20 mm, T (Slow Blow) A minimum charge is applicable to spare parts orders.
Appendix NOTE: A-4 Model 3020M The MSDS on this material is available upon request through the Teledyne Environmental, Health and Safety Coordinator.
Percent Paramagnetic Oxygen Analyzer A-5 Appendix Zero Cal The ZERO function on the MAIN MENU 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 acceptable range for zero. In the manual mode, the operator determines when the reading is within the acceptable range for zero.
Appendix Model 3020M Manual Mode Zeroing ENTER the ZERO function. The screen that appears allows you to select between automatic or manual zero calibration. Use DOWN/UP to toggle between AUTO and MAN zero settling. Stop when MAN appears on the display. Zero: Settling: Man To Begin 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.
