Teledyne 3000MA User Manual

Percent Oxygen Analyzer

OPERATING INSTRUCTIONS FOR

Model 3000MA

P er cent Oxygen Anal yzer

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 PER-

SIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.
ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING.

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

Teledyne Analytical Instruments

P/N M71700

04/27/00

ECO:# 00-0000

i

Model 3000MA

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.

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 specifically 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.

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Teledyne Analytical Instruments

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.

Instrument Serial Number _______________________

includes the following options:

❑❑

❑ 3000MA-C: In addition to all standard features, this model also has

❑❑

separate ports for zero and span gases, and built-in
control valves. The internal valves are entirely under the
control of the 3000MA electronics, to automatically
switch between gases in synchronization with the
analyzer’s operations

❑❑

❑ 3000MA-M: In models with this option, the 4-20 mA Analog Current

❑❑

output is active. (In the standard units, it is not active.)

❑❑

❑ 19" Rack Mnt: The 19" Relay Rack Mount units are available with

❑❑

either one or two 3000 series analyzers installed on a
19" panel, and ready to mount in a standard rack.

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iii

Model 3000MA

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 Front P anel (Operator Interface)..................................... 1-3

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

1.7 Rear Panel (Equipment Interf ace).................................. 1-5

2 Operational Theory

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

2.2 Precise Paramagnetic Sensor........................................ 2-1

2.2.1 Principles of Operation ............................................ 2-1

2.3 Cross Interface............................................................... 2-3

2.4 Sample System.............................................................. 2-5

2.5 Electronics and Signal Processing ................................ 2-6

Table of Contents

3 Installation

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

3.2 Mounting the Analyzer ................................................... 3-1

3.3 Rear Panel Connections................................................ 3-2

3.3.1 Gas Connections ................................................... 3-3

3.3.2 Electrical Connections........................................... 3-4

3.3.3 Remote Probe Connector ...................................... 3-9

3.4 Testing the System.........................................................3-10

4 Operation

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

4.2 Using the Data Entry and Function Buttons ................... 4-2

4.3 The

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

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

4.3.3 Passw ord Protection.............................................. 4-5

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

System

4.3.3.1 Entering the Password................................... 4-6

4.3.3.2 Installing or Changing the Password ............. 4-7

Span

Function ..................................................... 4-3

Functions...................................................... 4-10

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Percent Oxygen Analyzer

4.4.1 Span Cal................................................................ 4-11

4.4.1.1 Auto Mode Spanning ..................................... 4-10

4.4.1.2 Manual Mode Spanning................................. 4-11

4.5 The

4.6 The

4.6.1 Setting the Analog Output Ranges......................... 4-15

4.6.2 Autoranging Analysis............................................. 4-15

4.6.3 Fixed Range Analysis ............................................ 4-15

4.7 The

4.8 Signal Output ................................................................. 4-16

Maintenance

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

5.2 Fuse Replacement ......................................................... 5-1

5.3 System Self Diagnostic Test........................................... 5-2

5.4 Major Internal Components............................................ 5-3

5.5 Cleaning ........................................................................ 5-4

5.6 Troubleshooting ............................................................. 5-4

Alarms
Range

Function ...................................................... 4-14

Analyze

Function...................................................... 4-12

Function.................................................... 4-16

Appendix

A-1 Model 3000MA Specifications ....................................... A-1

A-2 Recommended 2-Year Spare Parts List ......................... A-3

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

A-4 19-Inch Relay Rack Panel Mount................................... A-4

A-5 Zero Functions............................................................... A-5

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v

Model 3000MA

D ANGER

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 . 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
T eledyne, no responsibility b y T eledyne, its affiliates, and agents
for damage or injury from misuse or neglect of this equipment is
implied or assumed.

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Teledyne Analytical Instruments

Percent Oxygen Analyzer Introduction 1

Introduction

1.1 Overview

The Teledyne Analytical Instruments Model 3000MA 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
3000MA General Purpose flush-panel and/or rack-mount units only. These
units are for indoor use in a nonhazardous environment.

1.2 Typical Applications

A few typical applications of the Model 3000MA are:

• Monitoring inert gas blanketing

• Air separation and liquefaction

• Chemical reaction monitoring

• Semiconductor manufacturing

• Petrochemical process control

• Quality assurance

• Gas analysis certification.

1.3 Main Features of the Analyzer

The Model 3000MA Percent Oxygen Analyzer is sophisticated yet
simple to use. The main features of the analyzer include:

• A 2-line alphanumeric display screen, driven by microprocessor
electronics, that continuously prompts and informs the operator.

• High resolution, accurate readings of oxygen content from low
percent levels through 100 %. Large, bright, meter readout.

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1 Introduction Model 3000MA

• 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 %.

• 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.

• Two adjustable concentration alarms and a system failure alarm.

• Extensive self-diagnostic testing, at startup and on demand, with
continuous power-supply monitoring.

• Two way RFI protection.

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

• Analog outputs for percent-of-range and for range identification.
0–1 V dc. (Isolated 4–20 mA dc optional)

• Convenient and versatile, steel, flush-panel or rack-mountable
case with slide-out electronics drawer.

1.4 Model Designations

3000MA: Standard model.
3000MA-C: In addition to all standard features, this model also has

separate ports for zero and span gases, and built-in control
valves. The internal valves are entirely under the control of
the 3000MA electronics, to automatically switch between
gases in synchronization with the analyzer’s operations.

3000MA-M: This model has current output signals (4-20 mA) for percent-

of-range and range ID, in addition to voltage outputs.

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Percent Oxygen Analyzer Introduction 1

Digital Meter

Door Latch

Alphanumeric
Display

Data Entry Buttons

Figure 1-1: Model 3000MA Front Panel

Sample System
Flow Indicator

Standby Sw itch

Function Buttons

1.5 Front Panel (Operator Interface)

The standard 3000MA 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, an
alphanumeric display, and a window for viewing the sample flowmeter.

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1 Introduction Model 3000MA

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.

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

input data to the instrument via the alphanumeric VFD display:

• Left & Right Arrows Select between functions currently

displayed on theVFD screen.

• Up & Down Arrows Increment or decrement values of

functions currently displayed.

• Enter Moves VFD display on to the next screen in a series. If

none remains, returns to the

• Escape Moves VFD display back to the previous screen in a

series. If none remains, returns to the

Digital Meter Display: The meter display is a LED device that

produces large, bright, 7-segment numbers that are legible in any lighting
environment. It produces a continuous readout from 0-100 %. It is accurate
across all ranges without the discontinuity of analog range switching.

Alphanumeric Interface Screen: The VFD screen is an easy-to-use

interface from operator to analyzer. It displays values, options, and messages
that give the operator immediate feedback.

Flowmeter: Monitors the flow of gas past the sensor. Readout is 0 to

1000 standard cubic centimeters per minute (SCCM).

 Standby Button: The Standby turns off the display and outputs,

but circuitry is still operating.

Analyze

screen.

Analyze

screen.

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.

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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 Recognizing Difference Between LCD &
VFD

LCD has GREEN background with BLACK characters. VFD has
DARK background with GREEN characters. In the case of VFD - NO
CONTRAST ADJUSTMENT IS NEEDED.

1.7 Rear Panel (Equipment Interface)

The rear panel, shown in Figure 1-2, contains the gas and electrical
connectors for external inlets and outlets. The Zero and Span gas connectors,
and the Current signal outputs are optional and may not appear on your
instrument. The connectors are described briefly here and in detail in the
Installation chapter of this manual.

Figure 1-2: Model 3000MA Rear Panel

• Power Connection Universal AC power source.

• Gas Inlet and Outlet One inlet (must be externally valved)

and one exhaust out.

• Analog Outputs 0-1 V dc concentration output, plus

0-1 V dc range ID.

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1 Introduction Model 3000MA

• Alarm Connections 2 concentration alarms and 1 system

alarm.

• RS-232 Port Serial digital concentration signal output

and control input.

• Remote Probe Used in the 3000MA for controlling

external solenoid valves only.

• Remote Span/Zero Digital inputs allow external control of

analyzer calibration. (See Note, below.)

• Calibration Contact To notify external equipment that

instrument is being calibrated and
readings are not monitoring sample.

• Range ID Contacts Four separate, dedicated, range relay

contacts. Low, Medium, High, Cal.

• Network For future expansion. Not implemented

at this printing.

Optional:

• Calibration Gas Ports Separate fittings for zero, span and

sample gas input, and internal valves
for automatically switching the gases.

• Current Signal Output Additional isolated 4-20 mA dc plus

4-20 mA dc range ID.

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.

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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. The Paramagnetic Sensor is an electromechanical device that
translates the amount of oxygen present in the sample into an electrical
signal. The electronic signal processing, display and control subsystem
simplifies operation of the analyzer and accurately processes the sampled
data. The microprocessor controls all signal processing, input/output and
display functions for the analyzer.

2.2 Precise Paramagnetic Sensor

2.2.1 Principles of Operation

The heart of the 3000MA is a paramagnetic type oxygen sensor that is
maintanance free and has a long lifetime. Oxygen has a very high magnetic
sucseptibility compared to other gases and thus displays a particularly para­magnetic behavior. A small glass dumbbell filled with nitrogen and rotating
on a taut platinum wire is suspended in an inhomogneous magnetic field.
This glass dumbbell is diamagnetic and tends to rotate out of the magnetic
field. The strength of the resulting torque determined by an susceptibility of
the sample gas. This torque is compensated for by a counter torque induced
by an electrically charged platinum coil on the dumbbell. The zero position
of the dumbbell is controlled by means of an optical system consisting of a
light source, a mirror at the dumbbell axis and a pair of detectors. The
difference between the compensating currents required to bring the dumb-

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2 Operational Theory Model 3000MA

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. The measuring cell has a measuring
volume of approximately 3 cm

3

Sensor

(side view shown)

The Paramagnetic sensor enclosure holds not only the sensing elements,
but the temperature controller electronics, heating elements, sensor electron­ics, and preamplifier. The Electronics and heating elements require a separate
power source, from the rest of the 3000MA capable of delivering 1.5 amps
approximately at 24 volts dc. The output of the sensor is roughly calibrated
to be 0 to 1 volt DC for the the range of 0 to 100 % 02. The true calibration
of the sensor is carried out by the microprocessor as described later in chap­ter 4. The electrical interconnections to the sensor are done through a 15 pin
D connector. Some signals from the sensor are not connected. They are only
useful for troubleshooting, by trained personnel, as test points.

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Percent Oxygen Analyzer Operational Theory 2

Sensor

(rear view shown)

Pin out:

1 -15Vdc test pin (Not connected)
2 +15Vdc test pin (Not connected)
3 Measuring ground
4 Not used
5 Preamplifier output ~0- 1 Vdc
6 Not used
7 24 Vdc return, power ground
8 Collector of transistor switching heating element (Not con-

nected)
9 Fault signal: <0 Vdc= OK, >4.6 Vdc = Fault (Not connected)
10 Not used
11 Negative reference voltage (Not connected)
12 Positive reference voltage (Not connected)
13 Nominal temperature voltage signal (Not connected)
14 Actual temperature voltage signal (Not connected)
15 +24 Vdc power.

2. 3 Cross Interference

As mentioned previously, the selectivity of the measuring system is

based on the extraordinarily high magnetic susceptibility of Oxygen com­pared to other gases. In most cases the presence of other gases can be ig­nored but significant errors can occur when the sensor is calibrated with a
mixture of oxygen and nitrogen and the sample gas consists mainly of other
gases with considerable magnetic susceptibility. In this case, the reading
shows a measured value even if the sample gas contains no Oxygen. It is
actually displaying the cross sensitivity to another gas.

The following table shows the cross sensitivity of some gases when

changing from pure nitrogen to 100% of one of the gases listed.

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2 Operational Theory Model 3000MA

Gas Cross Gas Cross

Sensitivity Sensitivity
in vol. % in vol. %

Acetylene C
Allene C3H

4

Ammonia NH

2H2

3

-0.24 Hydrogen chloride HCI -0.30

-0.44 Hydrogen fluoride HF +0.10

-0.26 Hydrogen iodide HI -1.10
Argon Ar -0.22 Hydrogen sulphide H2S -0.39
Bromine Br

2

1.2 Butadiene C4H

1.3 Butadiene C4H
n-Butane C4H

10

6
6

-1.30 Iodine I -2.40

-0.49 Isobutane C4H

-0.49 Isopantane C5H

10

12

-1.11

-1.11 Krypton Kr -0.51
I-Butane C4H8 -085 Laughing gas N2O -0.20
cis 2-Butane C4H
trans 2-Butane C
Carbon dioxide CO

8

4H8

2

Carbon monoxide CO +0.06 Nitric acid HNO
Chlorine Cl
Cyclo hexane C6H
Ethane C2H
Ethylene C2H

2

12

6

4

Helium He +0.30 Propane C3H
n-Heptane C7H
n-Hexane C6H
Hydrogen H

16

14

2

-0.89 Methane CH

4

-0.20

-0.92 Neon Ne +0.13

-0.27 Neopentane C5H

12

3

-0.77 Nitrogen dioxide NO

2

-1.49
+0.43
+28.00

-1.56 Nitrous oxide NO +40.00

-0.43 n-Octane C8H

-0.26 n-Pentane C5H

8

-2.10 Propylene C3H

18

12

6

-2.50

-1.45

-0.86

-0.55

-1.70 Vinyl chloride -0.63

+0.24 Water H2O -0.02

Hydrogen bromide HBr -.0.61 Xenon Xe -0.95

-1.49

With gas mixtures the components are weighted according to their

proporational volumes.

The cross interference with a gas mixture can be determined in advance if the

concentration of the individual background gases is known.

Example:

Cross sensitivity calculation for a gas mixture:

The gas to be measured consists of 10 % CO2, 40 % of N2, and 50%

of Ar.

C02: -0.27 x 10% = -0.027
Ar: -0.22x5O%= -0.11

TOTAL CROSS INTERFERENCE -0.137

Calculation of the zero value:

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Teledyne Analytical Instruments

Percent Oxygen Analyzer Operational Theory 2

(0% 02) - (Cross Interference Value) = Zero Point Value

0%-(-0.137) = +0.137%0

2

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 3000MA 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. The sample encounters almost no dead space. This minimizes
residual gas pockets that can interfere with low percent range analysis.

The sample system for the standard instrument incorporates ¼ inch tube
fittings for sample inlet and outlet connections at the rear panel. For metric
system installations, 6 mm adapters are available with each instrument to be
used if needed. The sample or calibration gas flowing through the system is
monitored by a flowmeter downstream from the sensor.

The gases delivered to the instrument should be at constant pressures and
flow rates and must exit freely into the ambient atmosphere. The Span, Zero
and Sample gases should be delivered at constant pressures of about 10 psig
(Range 5-20). The flow rate must be maintained at about 700 cc/minute (Range
500-900) and must exit freely into atmospheric pressure.

Span In

Zero In

Sample In

In vacuum service the
restrictor should be
placed here.

Exhaust Out

Figure 2-4 is the flow diagram for the sampling system. In the standard
instrument, calibration gases (zero and span) can be connected directly to the
Sample In port by teeing to the port with appropriate valves. The shaded por­tions of the diagram show the components added when the –C options are
ordered. The solenoid valves, when supplied, are installed inside the 3000MA
enclosure and are regulated by the instruments internal electronics.

Components in the shaded area are in
the -C option (internal control valves)
only and are not shown in the piping
diagram above.

Cell

Solenoid
Valves

Flowmeter

Restrictor

In normal service the
restrictor should be
placed here.

Figure 2-4: Flow Diagram

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2 Operational Theory Model 3000MA

2.5 Electronics and Signal Processing

The Model 3000MAPercent 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.

Figure 2-5: Location of Electronic Components

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. These boards are accessible after re­moving the back panel. Figure 2-7 is a block diagram of the Analyzer
electronics.

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Percent Oxygen Analyzer Operational Theory 2

Sensor Amplifier

Sensor

24V Power

Supply

Auto

Range

Self Test
Signal

Power

Supply

System

Failure

Alarm

Displays

A to D

Converter

Micro-

Processor

0-1 V

Concentration

D to A

Converter

Range

0-1 V

Figure 2-6: Block Diagram of the Model 3000MA Electronics

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2-7