Teledyne 2010A User Manual

Thermal Conductivity Analyzer

OPERATING INSTRUCTIONS FOR

Model 2010A

Thermal Conductivity 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. BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/ MANAGER.

Teledyne Analytical Instruments

P/N M70194

07/19/05

ECO # 05-0131

Model 2010A

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.

Warranty

This equipment is sold subject to the mutual agreement that it is warranted by us free from defects of material and of construction, and that our liability shall be limited to replacing or repairing at our factory (without charge, except for transportation), or at customer plant at our option, any material or construction in which defects become apparent within one year from the date of shipment, except in cases where quotations or acknowledgments provide for a shorter period. Components manufactured by others bear the warranty of their manufacturer. This warranty does not cover defects caused by wear, accident, misuse, neglect or repairs other than those performed by Teledyne or an authorized service center. We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage which may result from its use or misuse.

We reserve the right to employ any suitable material in the manufacture of our apparatus, and to make any alterations in the dimensions, shape or weight of any parts, in so far as such alterations do not adversely affect our warranty.

Important Notice

This instrument provides measurement readings to its user, and serves as a tool by which valuable data can be gathered. The information provided by the instrument may assist the user in eliminating potential hazards caused by his process; however, it is essential that all personnel involved in the use of the instrument or its interface, with the process being measured, be properly trained in the process itself, as well as all instrumentation related to it.

The safety of personnel is ultimately the responsibility of those who control process conditions. While this instrument may be able to provide early warning of imminent danger, it has no control over process conditions, and it can be misused. In particular, any alarm or control systems installed must be tested and understood, both as to how they operate and as to how they can be defeated. Any safeguards required such as locks, labels,

or redundancy, must be provided by the user or specically requested of Teledyne at the

time the order is placed.

Therefore, the purchaser must be aware of the hazardous process conditions. The purchaser is responsible for the training of personnel, for providing hazard warning methods and instrumentation per the appropriate standards, and for ensuring that hazard warning devices and instrumentation are maintained and operated properly.

Teledyne Analytical Instruments, the manufacturer of this instrument, cannot accept responsibility for conditions beyond its knowledge and control. No statement expressed or implied by this document or any information disseminated by the manufacturer or its agents, is to be construed as a warranty of adequate safety control under the user’s

process conditions.

Teledyne Analytical Instruments

Thermal Conductivity Analyzer

Table of Contents

Specic Model Information ..................................iv

Part I: Control Unit, Model 2010A .......... Part I: 1-1

Part II: Analysis Unit, Model 2010A ...... Part II: 1-1

Appendix ...........................................................A-1

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iii

Model 2010A

Specic 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.

Instrument Serial Number: _______________________

Options Included in the Instrument with the Above Serial Number:

q C: Auto Calibration valves (zero/span/sample) built-in gas control

valves are electronically controlled to provide synchronization with the analyzer’s operations.

q G: Stainless steel cell block with nickel laments and Stainless

Steel ttings and tubing.

q H: Stainless steel cell block with gold laments for corrosive gas

streams and Stainless Steel ttings and tubing.

q K: 19” Rack Mount option with one or two analyzer Control

Units installed and ready to mount in a standard rack.

q K2: 19” Rack Mount option with two Control Units mounted.

q K3: 19” Rack Mount option with one Control Unit mounted and a

blank cover installed in the second Control Unit location.

q L: Gas selector panel consisting of sample/ref ow meters and

control valves for metering input of sample/calibrations support gases.

q F: Flame Arrestors for Class 1, Div. 1, Groups C/D service.

q P: Flame Arrestors for Class 1, Div. 1, Groups C/D service, and

Auto Cal valves option (Ref. C above) and GP use.

q Q: Flame Arrestors for Group B (hydrogen) service, and Auto Cal

valves option (Ref. C above)

q O: Flame Arrestors for Group B (hydrogen)

q R: Sealed Reference Cell

Teledyne Analytical Instruments

Thermal Conductivity Analyzer

Table of Contents

1 Introduction

1.1 Overview ......................................................................... 1-1

1.2 Typical Applications ......................................................... 1-2

1.3 Main Features of the Analyzer ........................................ 1-2

1.4 Model Designations ........................................................ 1-3

1.5 Operator Interface (Front Panel) .....................................

1.6 Recognizing Difference Between LCD & VFD ................ 1-5

1.7 Equipment Interface (Rear Panel) .................................. 1-5

1.8 Gas Connections ............................................................ 1-7

2 Operational Theory

2.1 Introduction ..................................................................... 2-1

2.2 Sensor Theory ................................................................ 2-1

2.2.1 Sensor Conguration ................................................ 2-1

2.2.2 Calibration ................................................................ 2-2

2.2.3 Effects of Flowrate and Gas Density ........................ 2-3

2.2.4 Measurement Results ..............................................2-3

2.3 Electronics and Signal Processing .................................. 2-3

2.4 Temperature Control ....................................................... 2-5

1-3

3 Installation

3.1 Unpacking the Analyzer .................................................. 3-1

3.2 Mounting the Control Unit ............................................... 3-1

3.3 Electrical Connections (Rear Panel) ............................... 3-3

3.3.1 Primary Input Power ................................................ 3-4

3.3.2 Fuse Installation ......................................................3-4

3.3.3 Analog Outputs ........................................................ 3-4

3.3.4 Alarm Relays ........................................................... 3-6

3.3.5 Digital Remote Cal Inputs ........................................ 3-7

3.3.6 Range ID Relays .....................................................3-8

3.3.7 Network I/O .............................................................. 3-8

3.3.8 RS-232 Port ............................................................. 3-9

3.3.9 Remote Probe Connector ........................................ 3-9

3.4 Testing the System ......................................................... 3-16

3.5 Warm Up at Power Up ................................................... 3-16

4 Operation

4.1 Introduction ..................................................................... 4-1

4.2 Using the Data Entry and Function Buttons .................... 4-1

4.3 The System Function ...................................................... 4-4

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Model 2010A

4.3.1 Setting the Display ................................................. 4-5

4.3.2 Setting up an Auto-Cal ............................................. 4-5

4.3.3 Password Protection ................................................ 4-6

4.3.3.1 Entering the Password .................................... 4-7

4.3.3.2 Installing or Changing the Password ..............

4.3.4 Logging Out .............................................................

4.3.5 System Self-Diagnostic Test .................................... 4-9

4.3.6 The Model Screen ................................................... 4-10

4.3.7 Checking Linearity with Algorithm ............................ 4-10

4.4 The

4.4.1 Zero Cal ...................................................................

4.4.2 Span Cal .................................................................. 4-14

4.5 The Alarms Function ...................................................... 4-16

4.6 The Range Select Function ............................................ 4-18

4.6.1 Manual (Select/Dene Range) Screen .................... 4-19

4.6.2 Auto (Single Application) Screen ............................. 4-19

4.6.3 Precautions .............................................................. 4-21

4.7 The Analyze Function ..................................................... 4-21

4.8 Programming .................................................................. 4-22

4.8.1 The Set Range Screen ............................................ 4-23

4.8.2 The Curve Algorithm Screen ................................... 4-25

4.9 Special Function Setup ................................................... 4-28

4.9.1 Output Signal Reversal ............................................ 4.28

4.9.2 Special - Inverting Output ........................................ 4-28

4.9.3 Special - Polarity Coding ......................................... 4-29

4.9.4 Special - Nonlinear Application Gain Preset ............ 4-29

Zero and Span Functions ........................................ 4-11

4.4.1.1 Auto Mode Zeroing ......................................... 4-12

4.4.1.2 Manual Mode Zeroing ..................................... 4-13

4.4.1.3 Cell Failure ...................................................... 4-14

4.4.2.1 Auto Mode Spanning ...................................... 4-15

4.4.2.2 Manual Mode Spanning .................................. 4-15

4.8.2.1 Checking the Linearization ............................. 4-25

4.8.2.2 Manual Mode Linearization ............................. 4-26

4.8.2.3 Auto Mode Linearization ................................. 4-27

4-7 4-9

4-12

Maintenance

5.1 Routine Maintenance ...................................................... 5-1

5.2 System Self Diagnostic Test ........................................... 5-1

5.3 VFD Display .................................................................... 5-2

5.4 Fuse Replacement .......................................................... 5-2

5.5 Major Internal Components ............................................. 5-3

5.6 Cleaning .......................................................................... 5-5

Teledyne Analytical Instruments

Thermal Conductivity Analyzer

5.7 Phone Numbers .............................................................. 5-5

Appendix

A-1 Specications .................................................................. A-1

A-2 Recommended 2-Year Spare Parts List ..........................

A-3 Drawing List .................................................................... A-4

A-4 TG Option Calibration..................................................... A-5

A-3

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vii

Model 2010A

DANGER

COMBUSTIBLE GAS USAGE WARNING

The customer should ensure that the principles of operating of this equipment are well understood by the user. Misuse of this product in any manner, tampering with its components, or unauthorized substitution of any component may adversely affect the safety of this instrument.

Since the use of this instrument is beyond the control of Tele-

dyne, no responsibility by Teledyne, its afliates, and agents

for damage or injury from misuse or neglect of this equipment is implied or assumed.

viii

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

Introduction

1.1 Overview

The Model 2010 is a family of split conguration conductivity analyz-

ers. Each analyzer consist of a Control Unit suitable for installation in a general purpose area, and a Analysis Unit which is housed in an explosionproof enclosure. The Analysis Unit enclosure is rated for NEMA 4/7 Class I, Div. 1, Groups B,C,D and is approved by U/L and CSA.

The Analytical Instruments Model 2010A Thermal Conductivity Analyzer is a versatile microprocessor-based instrument for measuring a component gas in a background gas, or in a specic mixture of background gases. It compares the thermal conductivity of a sample stream with that of a reference gas of known composition. The 2010A can—

• measure the concentration of one gas in a mixture of two gases.

• measuretheconcentrationofagasinaspecicmixtureofback

ground gases.

• measure the purity of a sample stream containing a single impurity or a mixture of impurities.

The standard 2010A is pre-programmed with automatic linearization algorithms for a large number of gases and gas mixtures. The factory can add to this data base for custom applications, and the sophisticated user can add his own unique applications.

This manual section covers the Model 2010A General Purpose ushpanel and rack-mount control units only. These control units are for indoor use in a nonhazardous environment.

Many of the Model 2010A features covered in this manual are optional, selected according to the customers specic application. Refer to the specic model information sheet (page IV) for the options incorporated in the instrument.

Teledyne Analytical Instruments

Part I 1-1

1 Introduction Model 2010A

1.2 Typical Applications

A few typical applications of the Model 2010A are:

• Power generation

• Air liquefaction

• Chemical reaction monitoring

• Steel manufacturing and heat treating

• Petrochemical process control

• Quality assurance

• Refrigeration and storage

• Gas proportioning control.

1.3 Main Features of the Analyzer

The main features of the Model 2010A Thermal Conductivity Ana-

lyzer include:

• Threeindependent,userdenable,analysisrangesallowupto

three different gas applications with one concentration range each, or up to three concentration ranges for a single gas appli-

cation,oranycombination.

• Specialrecalibrationrangeformultipleapplications.Recalibratingone,recalibratesall.

• Automatic, independent linearization for each range.

• Auto Ranging allows analyzer to automatically select the proper preset range for a given single application. Manual override al-

lowstheusertolockontoaspecicrangeofinterest.

• RS-232 serial digital port for use with a computer or other digital communications device.

• Sixadjustableconcentrationsetpointswithtwoalarmsanda

system failure alarm relay.

• Extensive self-diagnostic testing, at startup and on demand.

• A2-linealphanumericdisplayscreen,drivenbymicroprocessor

electronics, that continuously prompts and informs the operator.

• High resolution, accurate indication of target or impurity gas

• Standard, proven sensor cell design.

• Wide range of custom applications, ranges, and linearization.

1-2 Part

concentrationfromlarge,bright,meterreadout.(0-9999ppm through0-100%dependingontypesofgasinvolved.)

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

• Microprocessorbasedelectronics:8-bitCMOSmicroprocessor with32kBRAMand128kBROM.

• Autoandremotecalibrationcapabilities.

• Fouranalogoutputs:twoformeasurement(0–1VdcandIsolated4–20mAdc)andtwoforrangeidentication.

• Compactandversatiledesign:Smallfootprint,yetinternalcomponentsareaccessible.

1.4 Model Designations

The Model 2010A is ordinarily custom programmed at the factory to t the customer’s application. Many parameters, including the number of channels, the gas application, the materials specication of the sampling system, and others, are options. The most common options, are covered in this manual. See the Specic Model Information checklist in the front matter of this manual for those that apply to your Model 2010A analyzer. Some standard models that are not covered in this manual are listed here.

Models 2000A: Bothanalysissectionandcontrolunitareinasingle

general purpose enclosure.

Models 2020: Boththeanalysissectionandcontrolunitareinasingle

explosion proof enclosure.

1.5 Operator Interface (Front Panel)

The standard 2010A is housed in a rugged metal case with all controls and displays accessible from the front panel. See Figure 1-1. The front panel has thirteen buttons for operating the analyzer, a digital meter, and an alphanumeric display. They are described briey here and in detail in the Operations chapter of this manual.

Function Keys: Six touch-sensitive membrane switches are used to change the specic function performed by the analyzer:

• Analyze Perform analysis for target-gas 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.

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Part I 1-3

1 Introduction Model 2010A

Figure 1-1: Model 2010A Front Panel

• Alarms Setthealarmsetpointsandattributes.

• Range Setuptheuserdenablerangesfortheinstrument.

Data Entry Keys: Six touch-sensitive membrane switches are used to

input data to the instrument via the alphanumeric VFD (Vacuum Fluorescent Display) display:

• Left & Right Arrows Selectbetweenfunctionscurrently

displayedontheVFDscreen.

• Up & Down Arrows Incrementordecrementvaluesof

functions currently displayed.

• Enter MovesVFDontothenextscreeninaseries.Ifnone

remains, returns to the Analyze screen.

• Escape MovesVFDbacktothepreviousscreeninaseries.If

none remains, returns to the Analyze screen.

Digital Meter Display: The meter display is a VFD device that produces large, bright, 7-segment numbers that are legible in any lighting. It produces a continuous trace readout from 0-9999 ppm or a continuous

1-4 Part

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

percent readout from 1-100 %. It is accurate across all analysis ranges.

Alphanumeric Interface Screen: The VDF screen is an easy-to-use interface between operator and analyzer. It displays values, options, and messages that give the operator immediate feedback.

Standby Button: The Standby turns off the display and

outputs, but circuitry is still operating.

CAUTION: The power cable must be unplugged to fully

disconnect power from the instrument. When chassis is exposed or when access door is open and power cable is connected, use extra care to avoid contact with live electrical circuits.

Access Door: For access to the thermal conductivity sensor or the front panel electronics, 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 electronics circuit board requires unfastening rear panel screws and sliding the electronics drawer out of the case. (See chapter 5.)

1.6 Recognizing Difference Between LCD & VFD

LCD (Liquid Crystal Display) has GREEN background with BLACK characters. VFD has DARK background with GREEN characters. In the case of VFD (Vacuum Fluorescent Display) - NO CONTRAST ADJUST-

MENT IS NEEDED.

1.7 Equipment Interface (Rear Panel)

The rear panel, shown in Figure 1-2, contains the electrical connectors for external input and output. The connectors are described briey here and in detail in chapter 3, Installation.

Teledyne Analytical Instruments

Part I 1-5

1 Introduction Model 2010A

Figure 1-2: Model 2010A Rear Panel

• Power Connection 85-250VACpowersource.

• Analog Outputs 0-1Vdcconcentrationplus0-1Vdc

rangeID,andisolated4-20mAdcplus 4-20mAdcrangeID.

• Alarm Connections 2concentrationalarmsand1system

alarm.

• RS-232 Port Serial digital concentration signal out-

put and control input.

• Remote Probe Usedinthe2010Atointerfacetheex-

ternal Analysis Unit.

• Remote Span/Zero Digitalinputsallowexternalcontrolof

analyzercalibration.

• Calibration Contact To notify external equipment that in-

strumentisbeingcalibratedandreadings are not monitoring sample.

• Range ID Contacts Fourseparate,dedicated,range-identi-

cationrelaycontacts(01,02,03,CAL).

• Network I/O Serial digital communications for local

networkaccess.Forfutureexpansion.

Not implemented at this printing.

Note: If you require highly accurate Auto-Cal timing, use external

1-6 Part

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

Auto-Cal control where possible. The internal clock in the Model 2010A is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day.

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Part I 1-7

1 Introduction Model 2010A

1-8 Part

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

Operational Theory

2.1 Introduction

The analyzer is composed of two subsystems:

1. Thermal Conductivity Sensor

2. Electronic Signal Processing, Display and Control.

The sensor is a thermal conductivity comparator that continuously compares the thermal conductivity of the sample gas with that of a reference gas having a known conductivity.

The electronic signal processing, display and control subsystem simplifies operation of the analyzer and accurately processes the sampled data. A microprocessor controls all signal processing, input/output, and display functions for the analyzer.

2.2 Sensor Theory

For greater clarity, Figure 2-1 presents two different illustrations, (a) and (b), of the operating principle of the thermal conductivity cell.

2.2.1 Sensor Configuration

The thermal conductivity sensor contains two chambers, one for the reference gas of known conductivity and one for the sample gas. Each chamber contains a pair of heated filaments. Depending on its thermal conductivity, each of the gases conducts a quantity of heat away from the filaments in its chamber. See Figure 2-1(a).

The resistance of the filaments depends on their temperature. These filaments are parts of the two legs of a Wheatstone bridge circuit that unbalances if the resistances of its two legs do not match. See Figure 2-1(b).

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2 Operational Theory Model 2010A

Figure 2-1: Thermal Conductivity Cell Operating Principle

If the thermal conductivities of the gases in the two chambers are different, the Wheatstone bridge circuit unbalances, causing a current to flow in its detector circuit. The amount of this current can be an indication of the amount of impurity in the sample gas, or even an indication of the type of gas, depending on the known properties of the reference and sample gases.

The temperature of the measuring cell is regulated to within 0.1 °C by a sophisticated control circuit. Temperature control is precise enough to compensate for diurnal effects in the output over the operating ranges of the analyzer. (See Specifications in the Appendix for details.)

2.2.2 Calibration

Because analysis by thermal conductivity is not an absolute measurement, calibration gases of known composition are required to fix the upper and lower parameters (“zero” and “span”) of the range, or ranges, of analysis. These gases must be used periodically, to check the accuracy of the

analyzer.

During calibration, the bridge circuit is balanced, with zero gas against the reference gas, at one end of the measurement range; and it is sensitized with span gas against the reference gas at the other end of the measurement range. The resulting electrical signals are processed by the analyzer electronics to produce a standard 0-1V, or an isolated 4–20 mA dc, output signal, as described in the next section.

2-2 Part I

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Thermal Conductivity Analyzer Part I: Control Unit

2.2.3 Effects of Flowrate and Gas Density

Because the flowrate of the gases in the chambers affects their cooling of the heated filaments, the flowrate in the chambers must be kept as equal, constant, and low as possible.

When setting the sample and reference flowrate, note that gases lighter than air will have an actual flowrate higher than indicated on the flowmeter, while gases heavier than air will have an actual flowrate lower than indicated. Due to the wide range of gases that are measured with the Thermal Conductivity Analyzer, the densities of the gases being handled may vary considerably.

Then, there are limited applications where the reference gas is in a sealed chamber and does not flow at all. These effects must be taken in consideration by the user when setting up an analysis.

2.2.4 Measurement Results

Thermal conductivity measurements are nonspecific by nature. This fact imposes certain limitations and requirements. If the user intends to employ the analyzer to detect a specific component in a sample stream, the sample must be composed of the component of interest and one other gas (or specific, and constant, mixture of gases) in order for the measured heat-transfer differences to be nonambiguous.

If, on the other hand, the user is primarily interested in the purity of a process stream, and does not require specific identification of the impurity, the analyzer can be used on more complex mixtures.

2.3 Electronics and Signal Processing

The Model 2010A Thermal Conductivity Analyzer uses an 8031 microcontroller, Central Processing Unit—(CPU) 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. (See Major Internal Components in chapter 5 Maintenance for the location of the power supply and the main electronic PC boards.)

The signal processing electronics including the microprocessor, analog to digital, and digital to analog converters are located on the Motherboard at the bottom of the case. The Preamplifier board is mounted on top of the Motherboard as shown in the figure 5.4. These boards are accessible after

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Part I 2-3

2 Operational Theory Model 2010A

removing the back panel. Figure 2-2 is a block diagram of the Analyzer electronics.

Thermistor

Tem p erature

Control

Temperature

Control

Sensor

Heater

Differential

Amplifie r

Fine

Adjus tment

Selt-Test Signal to MUX

Variabl

Gain

Amplifie r

Auto-

Range

Coarse

Adjustm ent

A to D

Converter M U X

D ig itia l to

Analog

Converter

(DA C )

To CPU

0-1 V dc Concen tration and Range

4-20 mA dc Concen tration and Range

Alarm 1

Alarm 2

System F ailure Alarm

Keyboard

Displays

Figure 2-2: Block Diagram of the Model 2010A Electronics

2-4 Part I

Processing

Power

Supply

A to D C o n v

Teledyne Analytical Instruments

Central

Processing

Unit

(C P U )

RS-232

Range Contacts (4)

External Valve Control

Remote Span Control

Remote Zero Control

Cal

Contact

Thermal Conductivity Analyzer Part I: Control Unit

In the presence of dissimilar gases the sensor generates a differential voltage across its output terminals. A differential amplifier converts this signal to a unipolar signal, which is amplified in the second stage, variable gain amplifier, which provides automatic range switching under control of the CPU. The output from the variable gain amplifier is sent to an 18 bit analog to digital converter.

The digital concentration signal along with input from the Gas Selector Panel is processed by the CPU and passed on to the 12-bit DAC, which outputs 0-1 V dc Concentration and Range ID signals. An voltage-to-current converter provides 4-20 mA dc concentration signal and range ID outputs.

The CPU also provides appropriate control signals to the Displays, Alarms, and External Valve Controls, and accepts digital inputs for external Remote Zero and Remote Span commands. It monitors the power supply through an analog to digital converter as part of the data for the system failure alarm.

The RS-232 port provides two-way serial digital communications to and from the CPU. These, and all of the above electrical interface signals are described in detail in chapter 3 Installation.

2.4. Temperature Control

For accurate analysis the sensor of this instrument is temperature controlled to 60oC.

The Temperature Control keeps the temperature of the measuring cell regulated to within 0.1 degree C. A thermistor is used to measure the temperature, and a zero-crossing switch regulates the power in a cartridge-type heater. The result is a sensor output signal that is temperature independent.

A second temperature control system is used to maintain the Analysis Unit internal temperature at 220C minimum.

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2 Operational Theory Model 2010A

2-6 Part I

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Thermal Conductivity Analyzer Part I: Control Unit

Installation

Installation of the Model 2010A 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 ready to install and prepare for operation. Carefully unpack the analyzer and inspect it for damage. Immediately report any damage to the shipping agent.

3.2 Mounting the Control Unit

The Model 2010A Control Unit is for indoor use in a general purpose area. It is NOT for hazardous environments of any type. It must be protected from:

• Direct sunlight

• Drafts of air

• Shock and vibration

• Temperatures below 30 °F (-1 °C) or above 110 °F (43 °C).

Locate the 2010A as close as possible, subject to the above conditions, to the Analysis Unit.

The standard model is designed for ush panel mounting. Figure 3-1 is

an illustration of the 2010A standard front panel and mounting bezel. There are four mounting holes—one in each corner of the rigid frame. Figure 3-1a contains the hole pattern dimensions. See the outline drawing, at the back of this manual for overall dimensions.

On special order, a 19" rack-mounting panel can be provided. For rack

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mounting, one or two 2010A series analyzers are ush-panel mounted on

the rack panel. See Figure 3-1b for dimensions of the mounting panel.

HHinge

LLatch

Hinge

Figure 3-1a: Front Panel of the Model 2010A

Figure 3-1b: Single and Dual 19" Rack Mounts

All operator controls are mounted on the front panel, which is hinged on the left edge and doubles as the door that provides access to the sensor inside the instrument. The door is spring loaded and will swing open when the button in the center of the latch (upper right corner) is pressed 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 radius of 7.62 inches. See Figure 3-2.

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Figure 3-2: Required Front Door Clearance

3.3 Electrical Connections (Rear Panel)

Figure 3-3 shows the Model 2010A rear panel: power, communication, alarm relays, remote probe and control valves, analog concentration output and analog range indicators.

Figure 3-3: Rear Panel of the Model 2010A

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 ngers, tools or clothing during normal operation.

Use shielded cable, nominally 20 to 22 gauge wire (depending on

length), with shield grounded appropriately for the specic installation.

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3.3.1 Primary Input Power

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.

DANGER: POWER IS APPLIED TO THE INSTRUMENT'S CIR-

CUITRY AS LONG AS THE INSTRUMENT IS CONNECTED TO THE POWER SOURCE. THE RED I/O SWITCH ON THE FRONT PANEL IS FOR SWITCHING POWER ON OR OFF TO THE DISPLAYS AND OUTPUTS ONLY.

NOTE: AC POWER MAY BE PRESENT ON THE RELAY

CONTACTS WHEN THE POWER CORD IS REMOVED!

The Control Unit is universal power 100-240V, 50-60 Hz. The Analysis Unit requires 110 or 220 VAC and is selectable via switch located inside the explosion-proof enclosure.

3.3.2 Fuse Installation

The fuse block, at the right of the power cord receptacle, accepts US or European size fuses. A jumper replaces the fuse in the neutral line when the US size fuses are used. If the European size fuses are selected, both sides at the line will be fused. Be sure to install the proper fuse as part of installation. (See Fuse Replacement in chapter 5, maintenance.)

3.3.3 Analog Outputs

There are four DC output signal connectors with spring terminals on the panel. There are two wires per output with the polarity noted. See Figure 3-4. The outputs are:

0–1 V dc % of Range: Voltage rises linearly with increasing concentra-

tion, from 0 V at 0 concentration to 1 V at full scale. (Full scale = 100% of programmable range.)

0–1 V dc Range ID: 0.25 V = Range 1, 0.5 V = Range 2, 0.75 V =

Range 3, 1 V = Cal Range.

4–20 mA dc % Range: Current rises linearly with concentration, from 4

mA at 0 concentration to 20 mA at full scale. (Full scale = 100% of programmable range.)

4–20 mA dc Range ID: 8 mA = Range 1, 12 mA = Range 2, 16 mA =

Range 3, 20 mA = Range 4.

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Figure 3-4: Analog Output Connections

Examples:

The analog output signal has a voltage which depends on gas concen-

tration relative to the full scale of the 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.

The signal output for concentration is linear over the currently se-

lected analysis range. For example, if the analyzer is set on a range that

was dened as 0–10 % hydrogen, then the output would be as shown in

Table 3-1.

Table 3-1: Analog Concentration Output—Example

Percent Voltage Signal Current Signal

Hydrogen Output (V dc) Output (mA dc)

0 0.0 4.0 1 0.1 5.6 2 0.2 7.2 3 0.3 8.8 4 0.4 10.4 5 0.5 12.0 6 0.6 13.6 7 0.7 15.2 8 0.8 16.8 9 0.9 18.4 10 1.0 20.0

To provide an indication of the range, the Range ID analog output

(Continued)

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terminals are used. They generate a steady preset voltage (or current when using the current outputs) to represent a particular range. Table 3-2 gives the range ID output for each analysis range.

Table 3-2: Analog Range ID Output—Example

Range Voltage (V) Current (mA) Application Range 1 0.25 8 0-1 % H2 in N2

Range 2 0.50 12 0-10 % H2 in N2

Range 3 0.75 16 0-1 % H2 in Air

Range 4 (Cal) 1.00 20 0-1 % H2 in N2

3.3.4 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. The contact connections are indicated by diagrams on the rear panel. They are capable of switching up to 3 amperes at 250 V ac into a resistive load. See Figure 3-5. The connectors are:

Threshold Alarm 1: • Can be congured as high (actuates when concen

tration is above threshold), or low (actuates when concentration is below threshold).

• Can be congured as fail-safe or non-fail-safe.

• Can be congured as latching or nonlatching.

• Can be congured out (defeated).

Threshold Alarm 2: • Can be congured as high (actuates when concen

tration is above threshold), or low (actuates when concentration is below threshold).

• Can be congured as fail-safe or non-fail-safe.

• Can be congured as latching or nonlatching.

• Can be congured out (defeated).

System Alarm: Actuates when DC power supplied to circuits is

unacceptable in one or more parameters. Perma-

nently congured as fail-safe and latching. Cannot

be defeated.

Actuates when cell can not balance during zero cali

bration.

Actuates when span parameter out off its limited

parameter.

Actuates when self test fails.

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(Reset by pressing I/O button to remove power. Then

press I/O again and any other button EXCEPT Sys- tem to resume.

Further detail can be found in chapter 4, section 4-5.

Figure 3-5: Types of Relay Contacts

3.3.5 Digital Remote Cal Inputs

Accept 0 V (off) or 24 V dc (on) inputs for remote control of calibra-

tion. (See Remote Calibration Protocol below.)

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. A synchronous signal must open and close the external gas control valves appropriately. See 3.3.9 Remote Probe Connector. (With the –C option, the internal valves operate automatically.)

Span: Floating input. 5 to 24 V input across the + and – terminals

puts the analyzer into the Span mode. Either side may be grounded at the source of the signal. A synchronous signal must open and close the external gas control valves appropriately. See 3.3.9 Remote Probe Connector. (With the –C option, the internal valves operate automatically.)

Cal Contact: This relay contact is closed while analyzer is spanning

and/or zeroing. (See Remote Calibration Protocol below.)

Remote Calibration Protocol: To properly time the Digital Remote

Cal Inputs to the Model 2010A Analyzer, the customer's controller must monitor the Cal Relay Contact.

When the contact is OPEN, the analyzer is analyzing, the Remote Cal

Inputs are being polled, and a zero or span command can be sent.

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When the contact is CLOSED, the analyzer is already calibrating. It will ignore your request to calibrate, and it will not remember that request.

Once a zero or span command is sent, and acknowledged (contact closes), release it. If the command is continued until after the zero or span is complete, the calibration will repeat and the Cal Relay Contact (CRC) will close again.

When the contact is closed, the display would display the last reading of the gas concentration value and output signal would output the last reading from the sample gas (SAMPLE and HOLD).

For example:

1) Test the CRC. When the CRC is open, Send a zero command until the CRC closes (The CRC will close quickly.)

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 close quickly.)

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 connector (paragraph 3.3.9) provides sig-

nals to operate the zero and span gas valves synchronously. However, if you have the –C, -P, or -Q Internal valve option, which includes zero and span gas inputs, the 2010A automati-

cally selects the zero, span and sample gas ow.

3.3.6 Range ID Relays

Four dedicated Range ID relay contacts. For any single application they are assigned to relays in ascending order. For example: if all ranges have the same application, then the lowest range is assigned to the Range 1 ID relay, and the highest range is assigned to the Range 3 ID relay. Range 4 is the Cal Range ID relay.

3.3.7 Network I/O

A serial digital input/output for local network protocol. At this printing, this port is not yet functional. It is to be used in future versions of the instrument.

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Teledyne 2010A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual