OPERATING INSTRUCTIONS FOR Model 3190 Series 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 PERSIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED. ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING.
Copyright © 1999 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 917491580.
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.
Contents Introduction 1.1 1.2 1.3 1.4 Overview ........................................................................ 1-1 Main Features of the Analyzer ....................................... 1-1 Front Panel Description .................................................. 1-2 Rear Panel Description .................................................. 1-3 Operational Theory 2.1 Introduction .................................................................... 2-1 2.2 Micro-Fuel Cell Sensor ...................
4.4 Setting the Alarm Setpoints............................................ 4-3 4.4.1 HI Alarm ................................................................. 4-3 4.4.2 LO Alarm ................................................................ 4-3 4.4.3 Sensor Fail Alarm .................................................. 4-4 4.5 Selecting a Fixed Range or Autoranging ....................... 4-4 4.6 Calibration ..................................................................... 4-4 4.
vi Teledyne Analytical Instruments
Trace Oxygen Analyzer Introduction 1 Introduction 1.1 Overview The Teledyne Analytical Instruments (TAI) Model 3190 is a microprocessor-based trace oxygen analyzer for real-time measurement of trace amounts of oxygen in inert gases, or in a wide variety of gas mixtures. It features simple operation, fast response, and a compact, rugged construction. Typical applications of the Model 3190 are monitoring nitrogen generators and inert gas blanketing applications. 1.
1 Introduction • • • • • • Model 3190 Two concentration alarms with adjustable setpoints. Sensor failure alarm. RS-232 serial digital port for output of concentration and range data to a computer, terminal, or other digital device. Three analog outputs: two for measurement (0–10 V dc, and negative ground 4–20 mA dc) and one for range identification (0-10 V dc). Compact and rugged Control Unit with flush-panel case. Designed for indoor use. Front panel NEMA-4 rated.
Trace Oxygen Analyzer Introduction 1 • Set HI Alarm • Set LO Alarm • Set HI Range • Set LO Range • Span Set the concentration ABOVE which an alarm activates. Set the concentration BELOW which an alarm activates. Set the high analysis range for the instrument (up to 0-9999 ppm). Set the low analysis range for the instrument (down to 0-10 ppm). Span calibrate the analyzer.
1 Introduction Model 3190 Figure 1-2 Rear Panel (AC and DC versions) • Power Connection AC version: 100–240 V ac, at 50/60 Hz. The connector housing includes the fuse holder and the power switch. DC version: Requires between 10 and 36 V dc. Fuse Holder: Replacing the fuse is described in Chapter 5, Maintenance. • 1-4 Analog Outputs I/O Power Switch: Turns the instrument power ON (1) or OFF (0). 0–10 V dc concentration output. 0–10 V dc range ID (or optional overrange) output.
Trace Oxygen Analyzer • • • Introduction 1 Alarm Connections HI Alarm, LO Alarm, and Sensor Failure Alarm connections. RS-232 Port Serial digital output of concentration and range signals. External Probe Connects to the Remote Probe or remote Analysis Unit.
1 Introduction 1-6 Model 3190 Teledyne Analytical Instruments
Trace Oxygen Analyzer Operational Theory 2 Operational Theory 2.1 Introduction The analyzer is composed of two subsystems: 1. Analysis Unit with Micro-Fuel Cell Sensor 2. Control Unit with Signal Processing, Display and Controls The Analysis Unit is designed to accept the sample gas and direct it to the sensitive surface of the Micro-Fuel Cell sensor. The Micro-Fuel Cell is an electrochemical galvanic device that translates the amount of oxygen present in the sample into an electrical current.
2 Operational Theory Model 3190 stored within the cell, whereas in the Micro-Fuel Cell, one of the reactants (oxygen) comes from outside the device as a constituent of the sample gas being 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 The Micro-Fuel Cell is a cylinder only 1¼ inches in diameter and 1 inch thick.
Trace Oxygen Analyzer Operational Theory 2 At the top end of the cell is a diffusion membrane of Teflon, whose thickness is very accurately controlled. Beneath the diffusion membrane lies the oxygen sensing element—the cathode—with a surface area almost 4 cm2. 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.
2 Operational Theory Model 3190 2Pb + O2 → 2PbO (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 only likely components are the halogens.) 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. In the absence of oxygen, no current is generated. 2.2.
Trace Oxygen Analyzer Operational Theory 2 Figure 2-2. Characteristic Input/Output Curve for a Micro-Fuel Cell 2.3 Electronics 2.3.1 General The signal processing uses an Intel microcontroller with on-board RAM and 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.
2 Operational Theory Model 3190 Figure 2-3: Block Diagram of the Signal Processing Electronics In the presence of oxygen the cell generates a current. A current to voltage amplifier (I–E AMPL) converts this current to a voltage. The second stage amplifier (TEMP COMP) supplies temperature compensation for the oxygen sensor output. The temperature compensation amplifier incorporates a thermistor (THERM) that is physically located in the cell block.
Trace Oxygen Analyzer Installation 3 Installation Overvoltage Category II Installation of the analyzer includes: 1. Unpacking the system. 2. Mounting the Control Unit, External Sample Block, and MicroFuel Cell sensor. 3. Making the electrical connections. 5. Making the gas connections. 6. Testing the installation. CAUTIONS: Read this chapter in its entirety before installing the units. The Model 3190 is for or indoor use only. The sample must be free of entrained solids or water.
3 Installation Model 3190 shipped with all the materials you need to install and prepare the system for operation. CAUTION: Do not disturb the integrity of the cell package until the cell is to be used immediately. If the cell package is punctured prematurely and air is permitted to enter, cell life will be shortened. 3.2 Location and Mounting 3.2.1 Control Unit Installation The 3190 Control Unit is designed to be panel-mounted in a general purpose, indoor area, away from moisture and the elements.
Trace Oxygen Analyzer Installation 3 For special applications the Micro-Fuel Cell may also be of a different type than the standard A-2C, B-2C or Z-2C unit. If this is the case, the pertinent cell specifications will be given in the addendum. 3.2.3 Installing the Micro-Fuel Cell / Cell Block Orientation A Micro-Fuel Cell is included as a separate item. It must be installed prior to instrument use.
3 Installation Model 3190 Figure 3-1 Rear Panel Electrical Connectors for AC and DC Units Primary Input Power (AC version): The power cord receptacle, fuse block and Power switch are located in the same assembly. A 6-foot, standard AC power cord is supplied with the Control Unit. Insert the female plug end of the power cord into the power cord receptacle. The universal power supply allows direct connection to any 100-240 V ac, 50/60 Hz power source.
Trace Oxygen Analyzer Installation 3 fuse receptacle, to the right of the power terminal strip, holds a 0.5 A, very quick acting fuse. (See Fuse Replacement in chapter 5, Maintenance.) The Power switch is located below the fuse receptacle. WARNING: INSERT THE STRIPPED TIPS OF WIRES ENTIRELY INTO THE TERMINAL BLOCKS. DO NOT LEAVE EXPOSED WIRE OUTSIDE OF THE HOLES IN THE BLOCKS. CAUTION: The control unit chassis must be isolated from the grounding system of the DC input power.
3 Installation Model 3190 Figure 3-2: Contact ID for FAILSAFE Relay Operation The specific descriptions for each type of alarm are as follows: HI Alarm Configured as high alarm (actuates when concentration is above threshold). Can be set anywhere within the full range of the analyzer (0-9,999 ppm), but must be set ABOVE the threshold set for the LO Alarm. LO Alarm Configured as low alarm (actuates when concentration is below threshold).
Trace Oxygen Analyzer Installation 3 is keyed to fit only one way into the receptacle. Do not force it in. The other end of the cable is made of four separate wires. These should be connected to the terminal strip on the analysis unit as follows: Red: Black: Green: White: #1 #2 #3 } #4 The green and white connectors can be interchanged, but be consistent. Refer to the Final Assembly, Dwg. C-64641. 3.
3 Installation 3-8 Model 3190 Teledyne Analytical Instruments
Trace Oxygen Analyzer Operation 4 Operation 4.1 Introduction Once the analyzer has been mounted, the gas lines connected and the electrical connections made, the Analyzer can be configured for your application. This involves setting the system parameters: • Defining the user selectable analysis ranges. • Setting alarm setpoints. • Calibrating the instrument. All of these functions are performed via the front panel controls, shown in Figure 4-1.
4 Operation Model 3190 Buttons When no buttons on the Analyzer are being pressed, the instrument is in the Analyze mode. It is monitoring the amount of oxygen in the sample gas that is flowing through the Remote Probe. When one of the Function Buttons is being pressed, the Analyzer is in the Setup mode or the Calibration mode.
Trace Oxygen Analyzer Operation 4 4.3.1 HI Range Setting the HI Range fullscale value defines the LEAST sensitive analysis range to be used. To set the HI Range: 1. Press the SET HI RANGE Function button once. 2. Immediately (within 5 seconds) press either the ∆ or ∇ button to raise or lower the displayed value, as required, until the display reads the desired fullscale concentration. 4.3.2 LO Range Setting the LO Range fullscale value defines the MOST sensitive range to be used. To set the LO Range: 1.
4 Operation Model 3190 2. Within 5 seconds, press either the ∆ or ∇ button to raise or lower the displayed value, as required, until the display reads the desired concentration. 4.4.2 LO Alarm Setting the LO Alarm sets the value BELOW which the LO alarm will activate. To set the LO Alarm: 1. Press the SET LO ALARM Function button once. 2. Within 5 seconds, press either the ∆ or ∇ button to raise or lower the displayed value, as required, until the display reads the desired concentration. 4.4.
Trace Oxygen Analyzer Operation 4 Procedure: 1. Expose the sensor to ambient air or instrument grade air (20.9 % oxygen). Allow time for the sampling system to purge and the analyzer to achieve equilibrium. Note: If the analyzer output goes above the high alarm setpoint or below the low alarm setpoint, the front panel ALARM Indicator, beneath the SET Function buttons, will blink. When the SPAN key is pressed to enter SPAN mode, Alarm indicator stops blinking. 2. Press the SPAN button once. 3.
4 Operation 4.8 Model 3190 “SetL” mode in the LED display When you turn on the unit, it displays “8.8.8.8” for a couple of seconds. This is to have an inspection that all segments of the display are all right. After the first two seconds, the LED display will show “SetL” and alternate with a countdown starting at 34.0. This countdown is to let the electronics settle and do a zero calibration of the electronics. Flowing “zero” gas or a sensor is not needed for this instrument adjustment.
Trace Oxygen Analyzer Maintenance 5 Maintenance Overvoltage Category II Aside from normal cleaning and checking for leaks, the Model 3190 should not require any maintenance beyond replacement of expended MicroFuel Cells, and perhaps a blown fuse. Routine maintenance includes occasional recalibration, as described in chapter 4, Operation. 5.1 Replacing the Fuse 5.1.1 AC Powered Units When a fuse blows, check first to determine the cause, then replace the fuse using the following procedure: 1.
5 Maintenance Model 3190 open the spare fuse compartment, push on one end until it slides out. 4. Remove the blown fuse and replace it with a 5×20 mm 0.5 A, 250 VAC, IEC time lag (T) fuse (P/N F1128) for AC units. 5. Replace the fuse holder into its receptacle, pushing in firmly until it clicks. 5.1.2 DC Powered Units In units with DC power, the fuse is located on the rear panel above the ON/OFF switch. 1. Open the fuse holder by unscrewing and removing the cap marked FUSE. 2.
Trace Oxygen Analyzer Maintenance 5 CAUTION: Read the section Cell Warranty Conditions, below, before replacing the cell. CAUTION: After replacing the Micro-Fuel Cell, the analyzer must be recalibrated. See Calibration in chapter 4. 5.2.2 Ordering and Handling of Spare Sensors To have a replacement cell available when it is needed, TAI recommends that one spare cell be purchased when the current cell 's warranty period is approximately two thirds over. CAUTION: Do not stockpile cells.
5 Maintenance Model 3190 3. Unscrew the cell-retainer cap from the cell block by turning it counterclockwise until it is free. Figure 5-2: Exploded View of MFC and Cell Block 4. Slowly withdraw the cap from the block. The cell should come out with the cap. 5. Carefully pull the cell off of the cap. DO NOT TOUCH THE SCREENED END OF THE CELL OR ANY FLUID THAT MAY BE LEAKING FROM IT. 6. Dispose of the cell in a safe manner, in accordance with all applicable ENVIRONMENTAL AND SAFETY laws. 5.2.
Trace Oxygen Analyzer Maintenance 5 1. Disconnect the Power Source from the Control Unit. 2. Remove the new Micro-Fuel Cell from its protective bag. 3. Examine the O-ring at the base of the threaded portion of the cellretainer cap, and replace it if it is worn of damaged. 3. Replace the cell on the end of cell-retainer cap, which is designed to fit snugly into the rim on the screen side of the cell. 4.
5 Maintenance 5-6 Model 3190 Teledyne Analytical Instruments
Trace Oxygen Analyzer Appendix Appendix A.1 Specifications Overvoltage Category II Ranges: Signal Output: Range ID: Display: Alarms: System Operating Temp: Accuracy: Response Time: System Power Requirement: System Enclosure: Two user selectable ranges can be set between 0-10 ppm and 0-9,999 ppm oxygen. Default ranges are 0-100 ppm and 0-1,000 ppm oxygen, and a 0-25 % (nominal) Air Calibration Range. Voltage: 0–10 V dc, negative ground Current: 4-20 mA, negative ground 0-10 V dc.
Appendix Model 3190 Sensor Type: Analysis Unit: (95.3 mm H × 177.8 mm W). Face plate rated to NEMA-4. Class A-2C, B-2C, and Z-2C 4.0" H × 6.0" W × 2.5" D (101.6 mm × 152.4 mm × 63.5 mm) A.
Trace Oxygen Analyzer Appendix A.3 Drawing List C-64772 C-64641 D-65666 B-65992 Outline diagram Final Assembly (and interconnection diagram) Control Unit Assembly Analysis unit outline A.4 Miscellaneous The symbol: ~ is used on the rear panel of the model 3190 to signify volts alternating current (V ac). NOTE: The MSDS on this material is available upon request through the Teledyne Environmental, Health and Safety Coordinator.
Appendix A-4 Model 3190 Teledyne Analytical Instruments
