Teledyne 3000PB User Manual

Percent Oxygen Analyzer

OPERATING INSTRUCTIONS FOR

Model 3000PB

Percent Oxygen Analyzer

DANGER

HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING
SYSTEM.

PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.
HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST

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

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

Teledyne Analytical Instruments

P/N M66682

03/29/2006

ECO # 06-0059

i

Model 3000PB

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 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

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.......................................................... 1-3

1.5.1 Displays ................................................................. 1-6

1.5.2 Function Keys ........................................................ 1-6

1.5.3 Data Entry Keys..................................................... 1-6

1.5.4 I/O Power Button.................................................... 1-7

1.5.5 Access Door .......................................................... 1-7

1.6 Recognizing Difference Between LCD & VFD ............... 1-7

1.7 Equipment Interface....................................................... 1-7

1.7.1 Electrical Connector Panel..................................... 1-7

1.7.2 Gas Connector Panel............................................. 1-9

2 Operational Theory

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

2.2 Micro-Fuel Cell Sensor .................................................. 2-1

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

2.2.2 Anatomy of a Micro-Fuel Cell.................................. 2-2

2.2.3 Electrochemical Reactions...................................... 2-3

2.2.4 The Effect of Pressure............................................. 2-4

2.2.5 Calibration Characteristics ...................................... 2-4

2.2.6 Micro-Fuel Cell “Class”............................................ 2-5

2.3 Sample System.............................................................. 2-6

2.4 Electronics and Signal Processing ................................ 2-7

3 Installation

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

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

3.3 Electrical Connections ................................................... 3-3

3.3.1 Primar y 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.................................................... 3-9

3.3.7 Network I/O............................................................ 3-9

3.3.8 RS-232 PorT.......................................................... 3-9

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Model 3000PB

3.3.9 Remote Sensor and Solenoid Valves..................... 3-10

3.4 Installing the Micro-Fuel Cell.......................................... 3-12

3.5 Gas Connections ........................................................... 3-12

3.6 Testing the System ........................................................ 3-14

4 Operation

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

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

4.3 The System Function..................................................... 4-3

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

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

4.3.3 Password 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 Span Functions....................................................... 4-10

4.4.1 Cell Failure............................................................. 4-10

4.4.2 Span Cal ................................................................ 4-11

4.5 The Alarms Function...................................................... 4-12

4.6 The Range Function ...................................................... 4-15

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

4.6.2 Autoranging Analysis ............................................. 4-16

4.6.3 Fixed Range Analysis ............................................ 4-16

4.7 The Analyze Function .................................................... 4-17

4.8 Signal Output ................................................................. 4-17

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

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

4.4.2.1 Auto Mode Spanning ..................................... 4-11

4.4.2.2 Manual Mode Spanning................................. 4-12

Maintenance

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

5.2 Major Internal Components ........................................... 5-1

5.3 Cell Replacement .......................................................... 5-2

5.4 Fuse Replacement......................................................... 5-7

5.5 System Self Diagnostic Test........................................... 5-7

5.6 LCD Display................................................................... 5-8

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5.3.1 Storing and Handling Replacement Cells ............... 5-3

5.3.2 When to Replace a Cell ........................................... 5-3

5.3.3 Removing the Micro-Fuel Cell ................................. 5-4

5.3.4 Installing a New Micro-Fuel Cell.............................. 5-6

5.3.5 Cell Warranty........................................................... 5-6

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Percent Oxygen Analyzer

5.7 Troubleshooting.............................................................. 5-9

Appendix

A-1 Specifications................................................................. A-1

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

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

A-5 Applicatiopn Notes on Restrictors, Pressures & Flow.... A-5

A-6 The Zero Functions........................................................ A-8

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Model 3000PB

DANGER

COMBUSTIBLE GAS USAGE WARNING

This is a general purpose instrument designed for usage in a
nonhazardous area. It is the customer's responsibility to en­sure safety especially when combustible gases are being ana­lyzed since the potential of gas leaks always exist.

The customer should ensure that the principles of operating of
this equipment is well understood by the user. 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
Teledyne, no responsibility by Teledyne, its affiliates, and
agents for damage or injury from misuse or neglect of this
equipment is implied or assumed.

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Percent Oxygen Analyzer Introduction 1

Introduction

1.1 Overview

The Teledyne Analytical Instruments Model 3000PB Percent Oxygen
Analyzer is a versatile microprocessor-based instrument for detecting oxygen
in a variety of gases. This manual covers the Model 3000PB, percent oxy­gen, general purpose, bulkhead-mount units only.

1.2 Typical Applications

A few typical applications of the Model 3000PB 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 3000PB 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 %
levels through 100%. Large, bright, meter readout.

• Advanced Micro-Fuel Cell for percent analysis. Standard cell has
a six month warranty and an expected lifetime of eight months.

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1 Introduction Model 3000PB

• 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.

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

• Analog outputs for concentration and range identification.
(0-1 V dc standard, and isolated 4–20 mA dc optional.)

1.4 Model Designations

3000PB: Standard model.
3000PB-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 3000PB electronics, to automatically switch between
gases in synchronization with the analyzer’s operations

3000PB-S: Stainless steel cell block and sampling system.
3000PB-M: 4-20 mA dc Signal and Range ID outputs, in addition

to the standard voltage outputs.

All of the above options are available in combination. For example, the

-C and -V options are combined as Model 3000PB-C-V.

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Percent Oxygen Analyzer Introduction 1

1.5 Operator Interface

Figure 1-1 is an illustration of the front of the Model 3000PB Oxygen
Analyzer with the outer door open showing the control panel (which is also
the inner door).

All displays on the standard 3000PB are visible from outside the hous­ing. The instrument has a digital meter and an alphanumeric display, which
are viewed through a glass viewing window in the outer door of the main
housing, and a sample flowmeter on the gas control panel attached to the
main housing. They give the operator constant feedback from the instrument.

The operator controls are pushbutton membrane switches located
behind the outer door of the housing. All of them are reached by unlatching
and swinging open the outer door of the enclosure. They are described
briefly here and in greater detail in chapter 4, Operation.

Figure 1-2 shows the 3000PB with the outer door and inner door both
open. The inner door is opened for access to the electrical connections and to
the cell block which houses the Micro-Fuel Cell. Door-mounted components
are shown in chapter 5, Maintenance.

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1 Introduction Model 3000PB

(Pressing the latch button

will open the Inner Door)

Figure 1-1: Model 3000PB—Outer Door Open—Showing Control Panel

1-4

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Percent Oxygen Analyzer Introduction 1

Figure 1-2: Model 3000PB—Inner Door Open—Showing Internal Components

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1 Introduction Model 3000PB

1.5.1 Displays

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 0.2 to

2.4 standard liters per minute (SLPM).

1.5.2 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.

1.5.3 Data Entry Keys

Six touch-sensitive membrane switches are used to input data and

commands to the instrument via the alphanumeric VFD 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 display on to the next screen in a series. If

none remains, returns to the Analyze screen.

1-6

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

series. If none remains, returns to the Analyze screen.

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Percent Oxygen Analyzer Introduction 1

1.5.4 I/O Power Button

The red I/O button switches the instrument power between I (ON) and
O (a Keep-Alive state). In the O state, the instrument’s circuitry is operating,

but there are no displays or outputs.

CAUTION: The power cable must be unplugged to fully

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

1.5.5 Access Door

To access the electrical connector panel, or the cell block, the control
panel doubles as a door that can be unlatched and swung open (after unlatch­ing and swinging open the outer access door). See Figure 1-2.

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 Equipment Interface

1.7.1 Electrical Connector Panel

The electrical connector panel, shown in Figure 1-3, contains the
electrical connections for external inputs and outputs. The connectors are
described briefly here and in detail in the Installation chapter of this manual.

CAUTION: The power cable must be disconnected to fully

remove power from the instrument.

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1 Introduction Model 3000PB

3.0 AMAX

Figure 1-3: Electrical Connector Panel

Electrical Connections: The electrical connections on the electrical

connector panel are described briefly here, and in more detail in chapter 3
Installation.

• Power Connection 115 or 230 V ac, 50 or 60 Hz.

• 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.

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Percent Oxygen Analyzer Introduction 1

• RS-232 Port Serial digital concentration signal output

and control input.

• Remote Valves Used for controlling external solenoid

valves, if desired.

• Remote Sensor Used for external sensor and thermistor

• Remote Span/Zero Digital inputs allow external control of

analyzer calibration.

• 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 I/O Serial digital communications for local

network access. For future expansion.
Not implemented at this printing.

1.7.2 Gas Connector Panel

The gas connector panel, shown in Figure 1-4, contains the gas con­nections for external inlets and outlets. Those that are optional are shown
shaded in the figure. The connectors are described briefly here and in detail
in the Installation chapter of this manual.

Note:

For Additional information,

please, see page 1-4

Figure 1-4: Model 3000PB Gas Connector Panel

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1 Introduction Model 3000PB

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

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 3000PB electronics.

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

Auto-Cal control where possible. The internal clock in the
Model 3000PB 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. Micro-Fuel Cell 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 Micro-Fuel Cell is an electrochemical galvanic device that
translates the amount of oxygen present in the sample into an electrical
current. 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 Micro-Fuel Cell Sensor

2.2.1 Principles of Operation

The oxygen sensor used in the Model 3000PB series is a Micro-Fuel
Cell designed and manufactured by Analytical Instruments. It is a sealed
plastic disposable electrochemical transducer.

The active components of the Micro-Fuel Cell are a cathode, an anode,
and the 15% aqueous KOH electrolyte in which they are immersed. The cell
converts the energy from a chemical reaction into an electrical current in an
external electrical circuit. Its action is similar to that of a battery.

There is, however, an important difference in the operation of a battery
as compared to the Micro-Fuel Cell: In the battery, all reactants are 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

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2 Operational Theory Model 3000PB

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. It is made of extremely inert plastic, which can be placed confi­dently in practically any environment or sample stream. It is effectively
sealed, although one end is permeable to oxygen in the sample gas. The
other end of the cell is a contact plate consisting of two concentric foil rings.
The rings mate with spring-loaded contacts in the sensor block assembly and
provide the electrical connection to the rest of the analyzer. Figure 2-1
illustrates the external features.

Figure 2-1: Micro-Fuel Cell

Refer to Figure 2-2, Cross Section of a Micro-Fuel Cell, which illus­trates the following internal description.

Figure 2-2. Cross Section of a Micro-Fuel Cell (not to scale)

At the top end of the cell is a diffusion membrane of Teflon, whose
thickness is very accurately controlled. Beneath the diffusion membrane lies

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Percent Oxygen Analyzer Operational Theory 2

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. It is made of lead and has a
proprietary design which is meant to maximize the amount of metal available
for chemical reaction.

At the rear of the cell, just below the anode structure, is a flexible
membrane designed to accommodate the internal volume changes that occur
throughout the life of the cell. This flexibility assures that the sensing mem­brane remains in its proper position, keeping the electrical output constant.

The entire space between the diffusion membrane, above the cathode,
and the flexible rear membrane, beneath the anode, is filled with electrolyte.
Cathode and anode are submerged in this common pool. They each have a
conductor connecting them to one of the external contact rings on the contact
plate, which is on the bottom of the cell.

2.2.3 Electrochemical Reactions

The sample gas diffuses through the Teflon membrane. Any oxygen in
the sample gas is reduced on the surface of the cathode by the following
HALF REACTION:

O2 + 2H2O + 4e– → 4OH

–

(cathode)

(Four electrons combine with one oxygen molecule—in the presence of
water from the electrolyte—to produce four hydroxyl ions.)

When the oxygen is reduced at the cathode, lead is simultaneously
oxidized at the anode by the following HALF REACTION:

Pb + 2OH

–

→ Pb+2 + H2O + 2e

–

(anode)

(Two electrons are transferred for each atom of lead that is oxidized.
Therefore it takes two of the above anode reactions to balance one cathode
reaction and transfer four electrons.)

The electrons released at the surface of the anode flow to the cathode
surface when an external electrical path is provided. The current is propor­tional to the amount of oxygen reaching the cathode. It is measured and used
to determine the oxygen concentration in the gas mixture.

The overall reaction for the fuel cell is the SUM of the half reactions
above, or:

2Pb + O2 → 2PbO

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2 Operational Theory Model 3000PB

(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 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.

2.2.4 The Effect of Pressure

In order to state the amount of oxygen present in the sample as a per­centage of the gas mixture, it is necessary that the sample diffuse into the cell
under constant pressure.

If the total pressure increases, the rate that oxygen reaches the cathode
through the diffusing membrane will also increase. The electron transfer, and
therefore the external current, will increase, even though the oxygen concen­tration of the sample has not changed. It is therefore important that the
sample pressure at the fuel cell (usually vent pressure) remain constant
between calibrations.

2.2.5 Calibration Characteristics

Given that the total pressure of the sample gas at the surface of the
Micro-Fuel Cell input is constant, a convenient characteristic of the cell is
that the current produced in an external circuit is directly proportional to the
rate at which oxygen molecules reach the cathode, and this rate is directly
proportional to the concentration of oxygen in the gaseous mixture. In other
words it has a linear characteristic curve, as shown in Figure 2-3. Measuring
circuits do not have to compensate for nonlinearities.

In addition, since there is zero output in the absence oxygen, the charac­teristic curve has close to an absolute zero. In the percent ranges, the cell
itself does not need to be zeroed. In practical application zeroing is still used
to compensate for zero offsets in the electronics. (The electronics is zeroed
automatically when the instrument power is turned on.)

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Percent Oxygen Analyzer Operational Theory 2

Figure 2-3. Characteristic Input/Output Curve for a Micro-Fuel Cell

2.2.6 Micro-Fuel Cell “Class”

TBE manufactures Micro-Fuel Cells with a variety of characteristics to
give the best possible performance for any given sample conditions. A few
typical Micro-Fuel Cells are listed below with their typical use and electrical
specifications.

2.2.6.1 Class A-3 Cell

The class A-3 cell is for use in applications where it is exposed continu­ously to carbon dioxide concentrations between 1 % and 100 % in the
sample gas.

Nominal output in air is 0.20 mA, and 90 % response time is 45 s.
Expected life in flue gas is 8 months.

2.2.6.2 Class A-5 Cell

The class A-5 cell is for use in applications where it is exposed intermit­tently to carbon dioxide concentrations up to 100 % in the sample gas.

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2 Operational Theory Model 3000PB

Nominal output in air is 0.19 mA, and 90 % response time is 45 s.

Expected life in flue gas is 8 months.

2.2.6.3 Class B-1 Cell

The class B-1 cell is for use in applications where it is exposed to less

than 0.1 % of carbon dioxide, and where fast response is important.

Nominal output in air is 0.50 mA, and 90 % response time is 7 s.

Expected life in air is 8 months.

2.2.6.4 Class B-3 Cell

The class B-3 cell is for use in applications where a slightly longer

response time is acceptable in order to have a longer cell life.

Nominal output in air is 0.30 mA, and 90 % response time is 13 s.

Expected life in air is 12 months.

2.2.6.5 Class C-3 Cell

The class B-1 cell is for use in applications where it is exposed to less
than 0.1 % of carbon dioxide, and where a longer response time is accept­able in order to have a longer cell life.

Nominal output in air is 0.20 mA, and 90 % response time is 30 s.
Expected life in air is 18 months.

2.2.6.6 Hydrogen and/or Helium Service

If the sample gas contains 10 % or more hydrogen and/or helium,
“clamp” cells are used. These Micro-Fuel cells are identified by the suffix -C
added to the cell class number.

2.3 Sample System

The sample system delivers gases to the Micro-Fuel Cell sensor from
the analyzer rear panel inlet. Depending on the mode of operation either
sample or calibration gas is delivered.

The Model 3000PB 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 mini-

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Percent Oxygen Analyzer Operational Theory 2

mizes residual gas pockets that can interfere with very low level oxygen
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 supplied with each instrument. The
sample or calibration gas flow through the system is monitored by a flow­meter downstream from the cell.

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
portion of the diagram shows the components added when the –C option is
ordered. The valves, when supplied, are installed inside the NEMA enclo­sure and are regulated by the instrument's internal electronics.

Span In

Zero In

Sample In

In va c u u m service th e
restrictor should be
placed here.

Exhaust Out

Restrictor

In normal service the
restricto r s h o u ld b e
placed here.

Solenoid
Valves

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

Cell

Flowmeter

Figure 2-4: Flow Diagram

2.4 Electronics and Signal Processing

The signal processing and display electronics PCBs are mounted on the
back of the inner door. See Major Internal Components in chapter 5, for
illustration. The power supply module is mounted underneath the bottom end
of the Electrical Connector Panel.

The Model 3000PB 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. CE approved units for the European
market also contain an EMI filter. Figure 2-5 is a simplified block diagram of
the Analyzer electronics.

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2 Operational Theory Model 3000PB

Figure 2-5: Block Diagram of the Model 3000PB Electronics

In the presence of oxygen the cell generates a current. A current to
voltage amplifier converts this current to a voltage, and then the voltage is
amplified in the second stage amplifier.

The second stage amplifier also supplies temperature compensation for
the oxygen sensor output. This amplifier circuit incorporates a thermistor,
which is physically located in the cell block. The thermistor is a temperature

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Percent Oxygen Analyzer Operational Theory 2

dependent resistance that changes the gain of the amplifier in proportion to
the temperature changes in the block. This change is inversely proportional
to the change in the cell output due to the same temperature changes. The
result is a signal that is temperature independent. The output from the second
stage amplifier is sent to an 18 bit analog to digital converter controlled by
the microprocessor.

The digital concentration signal along with input from the control panel
is processed by the microprocessor, and appropriate control signals are
directed to the display, alarms and communications port. The same digital
information is also sent to a 12 bit digital to analog converter that produces
the 0-1 V dc analog percent-of-range signal output and the analog range ID
output. Models with the –M option also have a 4-20 mA dc percent-of-range
signal output and analog range ID output.

Signals from the power supply are also monitored by the microproces­sor, and the system failure alarm is activated if a malfunction is detected.

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Installation

Installation of the Model 3000PB Analyzer includes:

1. Unpacking

2. Mounting

3. Gas connections

4. Electrical connections

5. Installing the Micro-Fuel Cell

6. Testing the system.

3.1 Unpacking the Analyzer

The analyzer is shipped with all the materials you need to install and
prepare the system for operation. Carefully unpack the analyzer and inspect
it for damage. Immediately report any damage to the shipping agent.

3.2 Mounting the Analyzer

The Model 3000PB is designed for bulkhead mounting in nonhazard­ous environments. There are four mounting lugs—one in each corner of the
enclosure. The outline drawing, at the back of this manual, gives the mount­ing hole size and spacing. The drawing also contains the overall dimensions.
Do not forget to allow an extra 13/8" for the hinges.

Be sure to allow enough space in front of the enclosure to swing the
outer door open—a 11 3/4" radius, as shown in Figure 3-2.

All electrical connections are made via cables which enter the NEMA-4
housing through ports in its side. No conduit fittings are supplied. The
installer must provide two 3/4" NPT and two 1" NPT adapters and the
appropriate sealing conduit.

For gas connections, the unit is supplied with 1/4" tube fittings, and 6
millimeter adapters are supplied for metric system installations.

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Figure 3-1: Front View of the Model 3000PB (Simplified)

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Percent Oxygen Analyzer Installation 3

Figure 3-2: Required Front Door Clearance

3.3 Electrical Connections

Figure 3-3 shows the Model 3000PB Electrical Connector Panel. There
are terminal blocks for connecting power, communications, and both digital
and analog concentration outputs.

Figure 3-3: Electrical Connector Panel

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For safe connections, ensure that no uninsulated wire extends outside of
the connectors they are attached to. Stripped wire ends must insert com­pletely into terminal blocks. No uninsulated wiring should be able to come in
contact with fingers, tools or clothing during normal operation. Terminal
block can accept ware guage 20 to 10.

3.3.1 Primary Input Power

The universal power supply requires a 115 or 230 V ac, 50 or 60 Hz,
power source. The actual input voltage used must show in the window of the
VOLTAGE SELECTOR switch before the power source is connected. See
Figure 3-4 for detailed connections.

DANGER: Power is applied to the instrument's circuitry as

long as the instrument is connected to the power
source. The Standby function switches power on or
off to the displays and outputs only.

Figure 3-4: Primary Input Power Connections

3.3.2 Fuse Installation

The fuse holders accept 5 x 20 mm, 4.0 A, T type (slow blow) fuses.
Fuses are not installed at the factory. 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 eight DC output signal connectors on the ANALOG OUT­PUTS connector block. There are two connectors per output with the polar­ity noted. See Figure 3-5.

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Figure 3-5: Analog Output Connections

The outputs are:

0–1 V dc % of Range: Voltage rises linearly with increasing oxygen, from

0 V at 0 % to 1 V at 100 %. (Full scale = 100% of
programmable range.)

0–1 V dc Range ID: 0.25 V = Low Range, 0.5 V = Medium Range,

0.75 V = High Range, 1 V = Air Cal Range.

4–20 mA dc % Range: (-M Option) Current increases linearly with increas-

ing oxygen, from 4 mA at 0 % to 20 mA at full
scale 100 %. (Full scale = 100% of programmable
range.)

4–20 mA dc Range ID: (-M Option) 8 mA = Low Range, 12 mA = Me-

dium Range, 16 mA = High Range, 20 mA = Air
Cal Range.

Examples:

The analog output signal has a voltage which depends on the oxygen
concentration AND the currently activated analysis 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 selected
analysis range. For example, if the analyzer is set on a range that was defined
as 0–10 % O

, then the output would be as shown in Table 3-1.

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Table 3-1: Analog Concentration Output—Example

Voltage Signal Current Signal

% O

2

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, 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. 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)

LO 0.25 8
MED 0.50 12
HI 0.75 16
CAL (0-25%) 1.00 20

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 rear panel. They are
capable of switching up to 3 amperes at 250 V ac into a resistive load. See
Figure 3-6.

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Figure 3-6: Types of Relay Contacts

The connectors are:

Threshold Alarm 1: • Can be configured as high (actuates when concen-

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

• Can be configured as failsafe or nonfailsafe.

• Can be configured as latching or nonlatching.

• Can be configured out (defeated).

Threshold Alarm 2: • Can be configured as high (actuates when concen-

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

• Can be configured as failsafe or nonfailsafe.

• Can be configured as latching or nonlatching.

• Can be configured out (defeated).

System Alarm: Actuates when DC power supplied to circuits is

unacceptable in one or more parameters. Permanently
configured as failsafe and latching. Cannot be de­feated. Actuates if self test fails.

To reset a System Alarm during installation, discon-

nect power to the instrument and then reconnect it.

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

3.3.5 Digital Remote Cal Inputs

Remote Zero and Span Inputs: The REMOTE SPAN and RE-

MOTE 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.)

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

puts the analyzer into the Zero mode. Either side may be
grounded at the source of the signal. 0 to 1 volt across the
terminals allows Zero mode to terminate when done. A
synchronous signal must open and close the external zero
valve appropriately. See 3.3.9 Remote Sensor and Solenoid
Valves. (With the –C option, the internal valves automatically
operate synchronously.)

SPAN: Floating input. 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. 0 to 1 volt across the
terminals allows Span mode to terminate when done. A
synchronous signal must open and close the external span
valve appropriately. See 3.3.9 Remote Sensor and Solenoid
Valves. (With the –C option, the internal valves automatically
operate synchronously.)

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 3000PB Analyzer, the customer's controller must
monitor the CAL CONTACT relay.

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.

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.

For example:

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.

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Note: The remote probe connections (paragraph 3.3.9) provides

signals to ensure that the zero and span gas valves will be
controlled synchronously. If you have the –C Internal valve
option—which includes additional zero and span gas inputs—
the 3000PB automatically regulates the zero, span and sample
gas flow.

3.3.6 Range ID Relays

There are four dedicated RANGE ID CONTACT relays. The first
three ranges are assigned to relays in ascending order—Low range is as­signed to RANGE 1 ID, Medium range is assigned to RANGE 2 ID, and
High range is assigned to RANGE 3 ID. RANGE 4 ID is reserved for the
Air Cal Range (25%).

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.

3.3.8 RS-232 Port

The digital signal output is a standard RS-232 serial communications
port used to connect the analyzer to a computer, terminal, or other digital
device. The pinouts are listed in Table 3-3.

Table 3-3: RS-232 Signals

RS-232 Sig RS-232 Pin Purpose

DCD 1 Data Carrier Detect

RD 2 Received Data

TD 3 Transmitted Data

DTR 4 Data Terminal Ready

COM 5 Common

DSR 6 Data Set Ready

RTS 7 Request to Send
CTS 8 Clear to Send

RI 9 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

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• The range in use (HI, MED, LO)

• The span of the range (0-100 %, etc)

• Which alarms—if any—are disabled (AL–x DISABLED)

• Which alarms—if any—are tripped (AL–x ON).

Each status output is followed by a carriage return and line feed.

Three input functions using RS-232 have been implemented to date.

They are described in Table 3-4.

Table 3-4: Commands via RS-232 Input

Command Description
as<enter> Immediately starts an autospan.
az<enter> Immediately starts an autozero.
co<enter> Reports “Raw Cell Output” (current output of the sensor

itself) in μA. For example—

Raw Cell Output: 99

μμ

μA

μμ

st<enter> Toggling input. Stops/Starts any status message output from

the RS-232, until st<enter> is sent again.

The RS-232 protocol allows some flexibility in its implementation.
Table 3-5 lists certain RS-232 values that are required by the 3000PB imple­mentation.

Table 3-5: Required RS-232 Options

Parameter Setting

Baud 2400

Byte 8 bits

Parity none

Stop Bits 1

Message Interval 2 seconds

3.3.9 Remote Sensor and Solenoid Valves

The 3000PB is a single-chassis instrument, which has its own sensor
and, in the –C option, its own gas-control solenoid valves. However, The
REMOTE SENSOR and SOLENOID RETURN connectors are provided
for use with a remote sensor and/or sampling system, if desired. See Figures
3-7 and 3-8.

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Figure 3-7: Remote Sensor Connector Pinouts

Figure 3-8: Remote Solenoid Return Connector Pinouts

The voltage from these outputs is nominally 0 V for the OFF and
15 V dc for the ON conditions. The maximum combined current that can be
pulled from these output lines is 100 mA. (If two lines are ON at the same
time, each must be limited to 50 mA, etc.) If more current and/or a different
voltage is required, use a relay, power amplifier, or other matching circuitry
to provide the actual driving current.

In addition, each individual line has a series FET with a nominal ON
resistance of 5 ohms (9 ohms worst case). This could limit the obtainable
voltage, depending on the load impedance applied. See Figure 3-9.

Figure 3-9: FET Series Resistance

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3.4 Installing the Micro-Fuel Cell

The Micro-Fuel Cell is not installed in the cell block when the
instrument is shipped. It must be installed before the analyzer is placed in
service.

Once it is expended, or if the cell is exposed to air for too long, the
Micro-Fuel Cell will need to be replaced. The cell could also require replace­ment if the instrument has been idle for too long.

When the micro-Fuel Cell needs to be installed or replaced, follow the
procedures in chapter 5, Maintenance, for removing and installing cells.

3.5 Gas Connections

Before using this instrument, it should be determined if the unit will be
used for pressurized service or vacuum service and low pressure applica­tions. Inspect the restrictor kit that came with the unit. The kit consist of two
restrictors and a union for 1/4” diameter tubing. Notice that the two 1 3/4”
long, 1/4” diameter tubing are restrictors. It has an open end and a closed
end with a small circular orifice. The restrictor without the blue sticker is for
low pressure and vacuum service. For high pressure (5 to 50 psig) applica­tions, use the restrictor that has a blue sticker on the body.

For pressurized service, use the restrictor without the blue dot and union
from the restrictor kit and attach it to the Sample In port. The small circular
orifice should face away from the back of the unit (against the direction of
gas flow). Use the restrictor without the blue dot sticker in the same manner
for low pressure applications (less than 5 psig).

For vacuum service (5-10 in Hg), use the restrictor without the blue dot
sticker and union but attach it to the Exhaust Out port. The small circular
orifice should face toward the back of the unit (against the direction of gas
flow).

Remove the blue sticker from the restrictor before using.

WARNING: Operating the unit without restrictors can cause damage to t

the micro-fuel cell.

Figure 3-10 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, and 6 mm adapters
are supplied for metric system installations.

For a safe connection:

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Percent Oxygen Analyzer Installation 3

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. (This
may require an additional 1/8 turn beyond finger-tight.)

2. Hold the fitting body steady with a backup wrench, and with
another wrench rotate the nut another 11/4 turns.

Behind Panel

Figure 3-10: Gas Connector Panel

SAMPLE IN: In the standard model, gas connections are made at the

SAMPLE IN and EXHAUST OUT connections. Calibration gases must be

Tee'd into the Sample inlet with appropriate valves.

The gas pressure in should be reasonably regulated. Pressures between
3 and 40 psig are acceptable as long as the pressure, once established, will
keep the front panel flowmeter reading in an acceptable range (0.1 to 2.4
SLPM). Exact figures will depend on your process.

If greater flow is required for improved response time, install a bypass
in the sampling system upstream of the analyzer input.

Note: If you have the –V option, The above numbers apply instead to

the vacuum at the EXHAUST OUT connector, described be­low, with minus signs before the pressure readings.

ZERO IN and SPAN IN: These are additional ports, included on
models with the -C option, for inputting span gas and zero gas. There are
electrically operated valves inside for automatic switching between sample

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and calibration gases. These valves are completely under control of the
3000PB Electronics. They can be externally controlled only indirectly
through the Remote Cal Inputs, described below.

Pressure, flow, and safety considerations are the same as prescribed for

the SAMPLE IN inlet, above.

EXHAUST OUT: Exhaust connections must be consistent with the

hazard level of the constituent gases. Check Local, State, and Federal laws,
and ensure that the exhaust stream vents to an appropriately controlled area if
required.

Note: If your 3000PB has the –V option, see Sample In, above, for

gas pressure/flow considerations.

3.6 Testing the System

Before plugging the instrument into the power source:

• Check the integrity and accuracy of the gas connections. Make
sure there are no leaks.

• Check the integrity and accuracy of the electrical connections.
Make sure there are no exposed conductors

• Check that sample pressure is between 3 and 40 psig, according
to the requirements of your process.

• Check that the voltage selector switch on the Electrical
Connector Panel is in the appropriate position for your power
source.

Power up the system, and test it by performing the following

operations:

1. Repeat the Self-Diagnostic Test as described in chapter 4, section

4.3.5.

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Operation

4.1 Introduction

Once the analyzer has been installed, it can be configured for your

application. To do this you will:

• Set system parameters:

• Establish a security password, if desired, requiring operator to
log in.

• Establish and start an automatic calibration cycle, if desired.

• Calibrate the instrument.

• Define the three user selectable analysis ranges. Then choose
autoranging or select a fixed range of analysis, as required.

• Set alarm setpoints, and modes of alarm operation (latching,
failsafe, etc).

Before you configure your 3000PB these default values are in effect:

Ranges: LO = 1 %, MED = 5 %, HI = 10 %
Auto Ranging: ON
Alarm Relays: Defeated, 10 %, HI, Not failsafe, Not latching
Zero: Auto, every 0 days at 0 hours
Span: Auto, at 20.9 %, every 0 days at 0 hours

If you choose not to use password protection, the default password is

automatically displayed on the password screen when you start up, and you
simply press Enter for access to all functions of the analyzer.

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4.2 Using the Data Entry and Function
Buttons

Data Entry Buttons: The < > arrow buttons select options from the

menu currently displayed on the VFD screen. The selected option blinks.

When the selected option includes a modifiable item, the

buttons can be used to increment or decrement that modifiable item.

The Enter button is used to accept any new entries on the VFD screen.
The Escape button is used to abort any new entries on the VFD screen that
are not yet accepted by use of the Enter button.

Figure 4-1 shows the hierarchy of functions available to the operator via
the function buttons. The six function buttons on the analyzer are:

• Analyze. This is the normal operating mode. The analyzer

monitors the oxygen content of the sample, displays the percent
of oxygen, and warns of any alarm conditions.

• System. The system function consists of six subfunctions that

regulate the internal operations of the analyzer:

• Set LCD screen contrast

• Setup Auto-Cal

• Assign Password

• Initiate Self -Test

• Check software version

• View sensor output

Contrast Function is DISABLED

(Refer to Section 1.6)

ΔΔ

Δ∇ arrow

ΔΔ

• Log out.

• Zero. Used to set up a zero calibration.

• Span. Used to set up a span calibration.

• Alarms. Used to set the alarm setpoints and determine whether

each alarm will be active or defeated, HI or LO acting, latching,
and/or failsafe.

• Range. Used to set up three analysis ranges that can be switched

automatically with auto-ranging or used as individual fixed
ranges.

Any function can be selected at any time by pressing the appropriate
button (unless password restrictions apply). The order as presented in this
manual is appropriate for an initial setup.

Each of these functions is described in greater detail in the following
procedures. The VFD screen text that accompanies each operation is repro-

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Contrast Function is DISABLED

(Refer to Section 1.6)

Figure 4-1: Hierarchy of Functions and Subfunctions

duced, at the appropriate point in the procedure, in a Monospaced type
style. Pushbutton names are printed in Oblique type.

4.3 The System Function

The subfuctions of the System function are described below. Specific

procedures for their use follow the descriptions:

• Auto-Cal: Used to define an automatic calibration sequence

and/or start an Auto-Cal.

• PSWD: Security can be established by choosing a 5 digit

password (PSWD) from the standard ASCII character set. (See
Installing or Changing a Password, below, for a table of ASCII
characters available.) Once a unique password is assigned and
activated, the operator MUST enter the UNIQUE password to
gain access to set-up functions which alter the instrument's

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operation, such as setting the instrument span or zero setting,
adjusting the alarm setpoints, or defining analysis ranges.

After a password is assigned, the operator must log out to
activate it. Until then, anyone can continue to operate the
instrument without entering the new password.

Only one password can be defined. Before a unique password
is assigned, the system assigns TBEAI by default. This allows
access to anyone. After a unique password is assigned, to defeat
the security, the password must be changed back to TBEAI.

• Logout: Logging out prevents unauthorized tampering with

analyzer settings.

• More: Select and enter More to get a new screen with additional

subfunctions listed.

• Self–Test: The instrument performs a self-diagnostic test to

check the integrity of the power supply, output boards and
amplifiers.

• Version: Displays Manufacturer, Model, and Software Version

of instrument.

4.3.1 Setting the Display

Contrast Function is DISABLED

(Refer to Section 1.6)

If you cannot read anything on the display after first powering up:

1. Observe LED readout.

a. If LED meter reads all eights and periods, go to step 3.
b. If LED meter displays anything else, go to step 2.

2. Press I/O button twice to turn Analyzer OFF and ON again. LED

meter should now read all eights and periods.

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4.3.2 Setting up an Auto-Cal

When proper automatic valving is connected (see chapter 3, installa-

tion), the Analyzer can cycle itself through a sequence of steps that automati-

cally zero and span the instrument.

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

Auto-Cal control where possible. The internal clock in the
Model 3000PB is accurate to 2-3 %. Accordingly, internally
scheduled calibrations can vary 2-3 % per day.

To setup an Auto–Cal cycle:
Choose System from the Function buttons. The VFD will display five

subfunctions.

Contrast Function is DISABLED

(Refer to Section 1.6)

Contrast Auto—Cal
PSWD Logout More

Use < > arrows to blink Auto—Cal, and press Enter. A new screen for

Span/Zero set appears.

Span OFF Nxt: 0d 0h
Zero OFF Nxt: 0d 0h

Press < > arrows to blink Span (or Zero), then press Enter again. (You

won’t be able to set OFF to ON if a zero interval is entered.) A Span

Every ... (or Zero Every ...) screen appears.

Span Every 0 d
Start 0 h from now

ΔΔ

Use

Δ∇ arrows to set an interval value, then use < > arrows to move to

ΔΔ

the start-time value. Use

ΔΔ

Δ∇ arrows to set a start-time value.

ΔΔ

To turn ON the Span and/or Zero cycles (to activate Auto-Cal): Press

System again, choose Auto—Cal, and press Enter again. When the Span/
Zero screen appears, use the < > arrows to blink the Span (or Zero) OFF/
ON field. Use

ΔΔ

Δ∇ arrows to set the OFF/ON field to ON. You can now turn

ΔΔ

these fields ON because there is a nonzero span interval defined.

4.3.3 Password Protection

If a password is assigned, then setting the following system parameters

can be done only after the password is entered: span and zero settings,
alarm setpoints, analysis range definitions, switching between autoranging
and manual override, setting up an auto-cal, and assigning a new password.
However, the instrument can still be used for analysis or for initiating a self­test without entering the password.

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If you have decided not to employ password security, use the default
password TBEAI. This password will be displayed automatically by the
microprocessor. The operator just presses the Enter key to be allowed total
access to the instrument’s features.

NOTE: If you use password security, it is advisable to keep a copy of

the password in a separate, safe location.

4.3.3.1 Entering the Password

To install a new password or change a previously installed password,
you must key in and ENTER the old password first. If the default password
is in effect, pressing the ENTER button will enter the default TBEAI
password for you.

Press System to enter the System mode.

Contrast Auto—Cal
PSWD Logout More

Contrast Function is DISABLED

(Refer to Section 1.6)

Use the < > arrow keys to scroll the blinking over to PSWD, and press

Enter to select the password function. Either the default TBEAI password or
AAAAA place holders for an existing password will appear on screen

depending on whether or not a password has been previously installed.

T B E A I
Enter PWD

or

A A A A A
Enter PWD

The screen prompts you to enter the current password. If you are not
using password protection, press Enter to accept TBEAI as the default
password. If a password has been previously installed, enter the password
using the < > arrow keys to scroll back and forth between letters, and the

ΔΔ

Δ∇

ΔΔ

arrow keys to change the letters to the proper password. Press Enter to enter
the password.

If the password is accepted, the screen will indicate that the password
restrictions have been removed and you have clearance to proceed.

In a few seconds, you will be given the opportunity to change this
password or keep it and go on.

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Percent Oxygen Analyzer Operation 4

Change Password?
<ENT>=Yes <ESC>=No

Press Escape to move on, or proceed as in Changing the Password,

below.

4.3.3.2 Installing or Changing the Password

If you want to install a password, or change an existing password,
proceed as above in Entering the Password. When you are given the oppor­tunity to change the password:

Change Password?
<ENT>=Yes <ESC>=No

Press Enter to change the password (either the default TBEAI or the
previously assigned password), or press Escape to keep the existing pass­word and move on.

If you chose Enter to change the password, the password assignment
screen appears.

T B E A I
<ENT> To Proceed

or

A A A A A
<ENT> To Proceed

Enter the password using the < > arrow keys to move back and forth
between the existing password letters, and the

ΔΔ

Δ∇ arrow keys to change the

ΔΔ

letters to the new password. The full set of 94 characters available for pass­word use are shown in the table below.

Characters Available for Password Definition:

ABCDEFGHI J
KL MNOPQRST
UVWXYZ[¥]^
_` abcdef gh
i j kl mnopqr
st uvwxyz{ |
} → ! " #$%&' (
)*+'-./012
3456789: ; <
=>?@

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4 Operation Model 3000PB

When you have finished typing the new password, press Enter. A

verification screen appears. The screen will prompt you to retype your
password for verification.

A A A A A
Retype PWD To Verify

Wait a moment for the entry screen. You will be given clearance to

proceed.

A A A A A
<ENT> TO Proceed

Use the arrow keys to retype your password and press Enter when

finished. Your password will be stored in the microprocessor and the system
will immediately switch to the Analyze screen, and you now have access to
all instrument functions.

If all alarms are defeated, the Analyze screen appears as:

0.0 % Anlz
Range: 0 — 10

If an alarm is tripped, the second line will change to show which alarm

it is:

0.0 % Anlz
AL—1

Note: If you log off the system using the logout function in the

system menu, you will now be required to re-enter the
password to gain access to Span, Zero, Alarm, and Range
functions.

4.3.4 Logout

The Logout function provides a convenient means of leaving the

analyzer in a password protected mode without having to shut the instrument
off. By entering Logout, you effectively log off the instrument leaving the
system protected against use until the password is reentered. To log out,
press the System button to enter the System function.

Contrast Auto—Cal
PSWD Logout More

Contrast Function is DISABLED

(Refer to Section 1.6)

Use the < > arrow keys to position the blinking over the Logout func-

tion, and press Enter to Log out. The screen will display the message:

Protected Until
Password Reentered

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4.3.5 System Self-Diagnostic Test

The Model 3000PB has a built-in self-diagnostic testing routine. Pre­programmed signals are sent through the power supply, output board and
sensor circuit. The return signal is analyzed, and at the end of the test the
status of each function is displayed on the screen, either as OK or as a
number between 1 and 3. (See System Self Diagnostic Test in chapter 5 for
number code.)

The self diagnostics are run automatically by the analyzer whenever the
instrument is turned on, but the test can also be run by the operator at will.
To initiate a self diagnostic test during operation:

Press the System button to start the System function.

Contrast Function is DISABLED

(Refer to Section 1.6)

Contrast Auto—Cal
PSWD Logout More

Use the < > arrow keys to blink More, then press Enter.

Version Self—Test
Cell Output: ### μA

Use the < > arrow keys again to move the blinking to the Self–Test
function. 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.

Power: OK Analog: OK
Preamp: 3

The module is functioning properly if it is followed by OK. A number
indicates a problem in a specific area of the instrument. Refer to Chapter 5
Maintenance and Troubleshooting for number-code information. The results
screen alternates for a time with:

Press Any Key
To Continue...

Then the analyzer returns to the initial System screen.

4.3.6 Version Screen

Move the < > arrow key to More and press Enter. With Version
blinking, press Enter. The screen displays the manufacturer, model, and
software version information.

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4.4 The Span Functions

The analyzer is calibrated using span gas.

NOTE: Zero is not necessary for Percent (%) level measurements.

Additional information on Zero functions is provided in the
Appendix A-6 of this manual.

Although the instrument can be spanned using air, a span gas with a
known oxygen concentration in the range of 70–90% of full scale of the
range of interest is recommended. Since the oxygen concentration in air is

20.9 %, therefore 20.9% is ideal calibration.

Connect the calibration gases to the analyzer according to the instruc­tions given in Section 3.4.1, Gas Connections, observing all the prescribed
precautions.

Shut off the gas pressure before connecting it to the analyzer, and
be sure to limit the pressure to 40 psig or less when turning it back on.

Readjust the gas pressure into the analyzer until the flowrate (as read on
the analyzer’s SLPM flowmeter) settles between 0.5 and 2.4 SLPM (ap­proximately 1-5 scfh).

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 4.3.3 to enter your password. Once you have gained clearance to
proceed, you can enter the Zero or Span function.

4.4.1. Cell Failure

When the sensor in the 3000PB begins to fail, the analyzer will usually
require more and more frequent calibration. If the 3000PB analysis readings
drift downward uncharacteristically, try recalibration. If recalibration raises
the readings temporarily only, the cell may be failing.

You can check the output of the cell itself by going to the System
function, selecting More, and pressing Enter. The cell output reading will be
on the second line of the display.

Version Self—Test

Cell Output: ### μA

The “good” reading depends on the class of cell your analyzer is using.

Although the B-1 cell is standard in the 3000PB, check Specific Model

Information in the Front Matter in this manual for the class of cell you
purchased. Then check Cell Replacement in chapter 5 Maintenance, and do

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Percent Oxygen Analyzer Operation 4

the prescribed calculations. If a weak cell is indicated, replace the cell as
described.

4.4.2 Span Cal

The Span button on the control panel is used to span calibrate the

analyzer. Span calibration can be performed using the automatic mode,
where an internal algorithm compares consecutive readings from the sensor
to determine when the output matches the span gas concentration. Span
calibration can also be performed manual mode, where the operator deter­mines when the span concentration reading is acceptable and then manually
exits the function.

4.4.2.1 Auto Mode Spanning

Press Span to enter the span function. The screen that appears allows

you to select whether the span calibration is to be performed automatically or
manually. Use the

ΔΔ

Δ∇ arrow keys to toggle between AUTO and MAN span

ΔΔ

settling. Stop when AUTO appears, blinking, on the display.

Span: Settling: AUTO
<ENT> For Next

Press Enter to move to the next screen.

Span Val: 20.90
<ENT>Span <UP>Mod #

Use the

the < > arrow keys to blink the digit you are going to modify. Use the

ΔΔ

Δ∇ arrow keys to enter the oxygen-concentration mode. Use

ΔΔ

ΔΔ

Δ∇

ΔΔ

arrow keys again to change the value of the selected digit. When you have
finished typing in the concentration of the span gas you are using (20.90 if
you are using air), press Enter to begin the Span calibration.

#### % Span
Slope=#### ppm/s

The beginning span value is shown in the upper left corner of the

display. As the span reading settles, the screen displays and updates informa­tion on Slope. Spanning automatically ends when the span concentration
corresponds, within tolerance, to the value of the span gas concentration.
Then the instrument automatically returns to the analyze mode.

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4 Operation Model 3000PB

4.4.2.2 Manual Mode Spanning

Press Span 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
<ENT> For Next

Use the Δ∇ keys to toggle between AUTO and MAN span settling.
Stop when MAN appears, blinking, on the display. Press Enter to move to
the next screen.

Span Val: 20.90
<ENT>Span <UP>Mod #

Press Δ (<UP>) to permit modification (Mod #) of span value.

Use the arrow keys to enter the oxygen concentration of the span gas
you are using (20.90 if you are using air). The < > arrows chose the digit,
and the Δ∇ arrows choose the value of the digit.

Press Enter to enter the span value into the system and begin the span
calibration.

Once the span has begun, the microprocessor samples the output at a
predetermined rate. It calculates the difference between successive samplings
and displays this difference as Slope on the screen. It takes several seconds
for the first Slope value to display. Slope indicates rate of change of the
Span reading. It is a sensitive indicator of stability.

#### % Span
Slope=#### ppm/s

When the Span value displayed on the screen is sufficiently stable,
press Enter. (Generally, when the Span reading changes by 1 % or less of
the full scale of the range being calibrated for a period of five minutes it is
sufficiently stable.) Once Enter is pressed, the Span reading changes to the
correct value. The instrument then automatically enters the Analyze func­tion.

4.5 The Alarms Function

The Model 3000PB is equipped with 2 fully adjustable concentration
alarms and a system failure alarm. Each alarm has a relay with a set of form
“C" contacts rated for 3 amperes resistive load at 250 V ac. See Figure in
Chapter 3, Installation and/or the Interconnection Diagram included at the
back of this manual for relay terminal connections.

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Percent Oxygen Analyzer Operation 4

The system failure alarm has a fixed configuration described in chapter

3 Installation.

The concentration alarms can be configured from the control panel as

either high or low alarms by the operator. The alarm modes can be set as

latching or non-latching, and either failsafe or non-failsafe, or, they can be
defeated altogether. The setpoints for the alarms are also established using

this function.

Decide how your alarms should be configured. The choice will depend

upon your process. Consider the following four points:

1. Which if any of the alarms are to be high alarms and which if any
are to be low alarms?

Setting an alarm as HIGH triggers the alarm when the oxygen
concentration rises above the setpoint. Setting an alarm as LOW
triggers the alarm when the oxygen concentration falls below the
setpoint.

Decide whether you want the alarms to be set as:

• Both high (high and high-high) alarms, or

• 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. Are either of the alarms to be latching?
In latching mode, once the alarm or alarms trigger, they will

remain in the alarm mode even if process conditions revert back
to non-alarm conditions. This mode requires an alarm to be
recognized before it can be reset. In the non-latching mode, the
alarm status will terminate when process conditions revert to non­alarm conditions.

4. Are either of the alarms to be defeated?
The defeat alarm mode is incorporated into the alarm circuit so

that maintenance can be performed under conditions which
would normally activate the alarms.

The defeat function can also be used to reset a latched alarm.
(See procedures, below.)

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4 Operation Model 3000PB

If you are using password protection, you will need to enter your

password to access the alarm functions. Follow the instructions in section

4.3.3 to enter your password. Once you have clearance to proceed, enter the
Alarm function.

Press the Alarm button on the control panel to enter the Alarm func-

tion. Make sure that AL–1 is blinking.

AL—1 AL—2
Choose Alarm

Set up alarm 1 by moving the blinking over to AL–1 using the < >

arrow keys. Then press Enter to move to the next screen.

AL—1 1.00 % HI
Dft—N Fs—N Ltch—N

Five parameters can be changed on this screen:

• Value of the alarm setpoint, AL–1 #### % (oxygen)

• Out-of-range direction, HI or LO

• Defeated? Dft–Y/N (Yes/No)

• Failsafe? Fs–Y/N (Yes/No)

• Latching? Ltch–Y/N (Yes/No).

• To define the setpoint, use the < > arrow keys to move the

blinking over to AL–1 ####. Then use the Δ∇ arrow keys to
change the number. Holding down the key speeds up the
incrementing or decrementing. (Remember, the setpoint units are
percent-of-oxygen.)

• To set the other parameters use the < > arrow keys to move the

blinking over to the desired parameter. Then use the Δ∇ arrow
keys to change the parameter.

• Once the parameters for alarm 1 have been set, press Alarms
again, and repeat this procedure for alarm 2 (AL–2).

• To reset a latched alarm, go to Dft– and then press either Δ two
times or ∇ two times. (Toggle it to Y and then back to N.)

–OR –

Go to Ltch– and then press either Δ two times or ∇ two times.
(Toggle it to N and back to Y.)

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Percent Oxygen Analyzer Operation 4

4.6 The Range Function

The Range function allows the operator to program up to three concen­tration ranges to correlate with the DC analog outputs. If no custom ranges
are defined by the user, the instrument defaults to:

Low = 0–1.00 %
Med = 0–5.00 %
High = 0–10.00 %.

The Model 3000PB is set at the factory to default to autoranging. In this
mode, the microprocessor automatically responds to concentration changes
by switching ranges for optimum readout sensitivity. If the current range
limits are exceeded, the instrument will automatically shift to the next higher
range. If the concentration falls slightly below full scale of the next lower
range, the instrument will switch to that range. A corresponding shift in the
DC percent-of-range output, and in the range ID outputs, will be noticed.

The autoranging feature can be overridden so that analog output stays
on a fixed range regardless of the oxygen concentration detected. If the
concentration exceeds the upper limit of the range, the DC output will
saturate at 1 V dc.

However, the digital readout and the RS-232 output of the concentra­tion are unaffected by the fixed range. They continue to read accurately with
full precision. See Control Panel description (Operator Interface) in Chapter

1.

4.6.1 Setting the Analog Output Ranges

To set the ranges, enter the range function mode by pressing the
Range button on the control panel.

L—1.00 M—5.00
H—10.00 Mode—AUTO

Use the < > arrow keys to blink the range to be set: low (L), medium
(M), or high (H).

Use the Δ∇ arrow keys to enter the upper value of the range (all ranges
begin at 0 %). Repeat for each range you want to set. Press Enter to accept
the values and return to Analyze mode. (See note below.)

Note: The ranges must be increasing from low to high. For example,

if range 1 is set as 0–1 % and range 2 is set as 0–10 %, range 3
cannot be set as 0–5 % since it is lower than range 2.

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4 Operation Model 3000PB

4.6.2 Autoranging Analysis

Set your analysis ranges as in 4.6.1, above. Leave Mode in Auto, or

use the arrow buttons to change back to Auto.

When operating in autoranging, if the oxygen concentration in your
sample goes ABOVE your HIGHEST range setting, the analyzer will go
into the special 25 % cal range.

However, if one of your range settings is below 0-25 % and another is
set above 0-25 %, the special 0-25 % Air Cal range will NOT activate as the
oxygen level goes through 25 %. Nevertheless, if the oxygen concentration
in your sample goes ABOVE your HIGHEST range setting, the analyzer
will THEN drop back down into the special 25 % cal range.

Once the oxygen concentration drops back down into your highest
range setting, the analyzer will automatically switch back to that range.

CAUTION: While the analyzer is in the Air Cal range, the oxygen

reading cannot go over 25 %, even if the oxygen
concentration is higher than 25 %.

4.6.3 Fixed Range Analysis

The autoranging mode of the instrument can be overridden, forcing the
analyzer DC outputs to stay in a single predetermined range.

To switch from autoranging to fixed range analysis, enter the range
function by pressing the Range button on the control panel.

Use the < > arrow keys to move the blinking over AUTO.

Use the Δ∇ arrow keys to switch from AUTO to FX/LO, FX/MED, or
FX/HI to set the instrument on the desired fixed range (low, medium, or
high).

L—1.00 M—5.00
H—10.00 Mode—FX/LO

or

L—1.00 M—5.00
H—10.00 Mode—FX/MED

or

L—1.00 M—5.00
H—10.00 Mode—FX/HI

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Percent Oxygen Analyzer Operation 4

Press Escape to re-enter the Analyze mode using the fixed range.

NOTE:When performing analysis on a fixed range, if the oxygen

concentration rises above the upper limit (or default value) as
established by the operator for that particular range, the
output saturates at 1 V dc. However, the digital readout and
the RS-232 output continue to read the true value of the oxy­gen concentration regardless of the analog output range.

4.7 The Analyze Function

Normally, all of the functions automatically switch back to the Analyze

function when they have completed their assigned operations. Pressing the

Escape button in many cases also switches the analyzer back to the Ana­lyze function. Alternatively, you can press the Analyze button at any time

to return to analyzing your sample.

4.8 Signal Output

The standard Model 3000PB Percent Oxygen Analyzer is equipped
with two 0–1 V dc analog output terminals accessible on the back panel (one
concentration and one range ID). The –MA option also has two isolated 4–
20 mA dc current outputs (one concentration and one range ID).

See Rear Panel in Chapter 3, Installation, for illustration.

The signal output for concentration is linear over the currently selected
analysis range. For example, if the analyzer is set on range that was defined
as 0–10 % O

, then the output would be:

2

Voltage Signal Current Signal

% O

Output (V dc) Output (mA dc)

2

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

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4 Operation Model 3000PB

The analog output signal has a voltage which depends on the oxygen
concentration AND the currently activated analysis 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.

To provide an indication of the range, a second pair of analog output
terminals are used. They generate a steady preset voltage (or current if you
have current outputs) to represent a particular range. The following table
gives the range ID output for each analysis range:

Range Voltage (V) Current (mA)

LO 0.25 8
MED 0.50 12
HI 0.75 16
CAL (0-25%) 1.00 20

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Percent 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 Micro-Fuel cells and
fuses, and recalibration. For recalibration, see Section 4.4 The Zero and
Span Functions.

WARNING: SEE WARNINGS ON TITLE PAGE OF THIS MANUAL.

5.2 Major Internal Components

All internal components are accessed by unlatching and swinging
open both the inner and outer doors, as described earlier. The major inter­nal component locations are shown in Figure 3-1, the cell block is illus­trated in Figure 3-2, and the fuse receptacle is shown in Figure 3-3

The 3000PB contains the following major internal components:

• Micro-Fuel Cell

• Nylon cell block

• Customer Interface PCB (Power Supply on bottom surface)

• Preamp PCB (Contains Microprocessor)

• Front Panel PCB (Contains Displays)
5 digit LED meter
2 line, 20 character, alphanumeric, VFD display

• Solenoid Operated Gas Control Valves (–C option only).

See the drawings in the Drawings section in back of this manual

for details.

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5 Maintenance Model 3000PB

Figure 5-1: Major Internal Components

5.3 Cell Replacement

The Micro-Fuel Cell is a sealed electrochemical transducer with no
electrolyte to change or electrodes to clean. When the cell reaches the end
of its useful life, it is replaced. The spent fuel cell should be discarded in
accordance with to all applicable safety and environmental regulations.
This section describes fuel cell care as well as when and how to replace it.

The Class B-1 Micro-Fuel Cell is used in the standard Model 3000PB.
If any other cell is supplied with your instrument, check the front of this
manual for any addenda applying to your special model.

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Percent Oxygen Analyzer Maintenance 5

5.3.1 Storing and Handling Replacement Cells

To have a replacement cell available when it is needed, it is recom­mended that one spare cell be purchased 4-5 months after commissioning
the 3000PB, or shortly before the end of the cell's warranty period.

CAUTION: Do not stockpile cells. The warranty period starts

on the day of shipment.

The spare cell should be carefully stored in an area that is not subject
to large variations in ambient temperature (75 °F nominal) or to rough
handling.

WARNING: THE SENSOR USED IN THE MODEL 3000PB PER-

CENT OXYGEN ANALYZER USES ELECTROLYTES
WHICH CONTAIN TOXIC SUBSTANCES, MAINLY
LEAD AND POTASSIUM HYDROXIDE, THAT CAN BE
HARMFUL IF TOUCHED, SWALLOWED, OR IN­HALED. AVOID CONTACT WITH ANY FLUID OR
POWDER IN OR AROUND THE UNIT. WHAT MAY
APPEAR TO BE PLAIN WATER COULD CONTAIN
ONE OF THESE TOXIC SUBSTANCES. IN CASE OF
EYE CONTACT, IMMEDIATELY FLUSH EYES WITH
WATER FOR AT LEAST 15 MINUTES. CALL PHYSI­CIAN. (SEE APPENDIX, MATERIAL SAFETY DATA
SHEET.)

5.3.2 When to Replace a Cell

When the sensor in the 3000PB begins to fail, the analyzer will
usually require more and more frequent calibration. If the 3000PB analysis
readings drift downward uncharacteristically, try recalibration. If recalibra­tion raises the readings temporarily only, suspect the cell.

Before replacing the cell:

a. Check for leaks downstream from the cell, where oxygen may

be leaking into the system.
b. Check your span gas to make sure it is within specifications.
c. If there are no leaks and the span gas is OK, check the output of

the cell itself by going to the System function, selecting More,

and pressing Enter. The cell output reading will be on the

second line of the display.

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Version Self—Test
Cell Output: ###

μμ

μA

μμ

The “good” reading depends on the class of cell your analyzer is

using.

Although the B-1 cell is standard in the 3000PB, check Specific

Model Information in the Front Matter in this manual for the class of
cell you purchased. Then check Table 5-1, the Cell Indices table below,

and do the prescribed calculations. If the resulting value is below the Cell
Output reading, replace the cell.

To find out if the cell is too weak:

1. Flow span gas through the analyzer, and allow time to purge.

2. With span gas flowing, read the raw output of the cell from the

System function display.

3. Divide the raw output reading by the percent oxygen
concentration of your span gas.

If the quotient is less than the Index value for the cell class you are

using, replace the cell.

Table 5-1: Cell Indices

Cell Class Index

A-3 1.818
A-5 1.818
B-1 4.545
B-3 3.716
B-5 1.244
B-7 1.515
C-3 2.488
C-5 0.606

5.3.3 Removing the Micro-Fuel Cell

The Micro-Fuel Cell is located inside the nylon cell block behind the

inner door of the unit. (See Figure 5-1). To remove an existing cell:

1. Remove power to the instrument by unplugging the power cord
at the power source.

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Percent Oxygen Analyzer Maintenance 5

2. Unlatch and open the outer and inner doors.

3. Leave the cell block installed. Pull up on the probe, with a slight
rocking motion, to release it from the probe receptacle.

4. Do not remove the O-rings unless they are worn and no longer hold the
probe tightly. (If worn, replace them.)

Figure 5-2: Exploded View of Cell Block and Micro-Fuel Cell

5. When it is free, unscrew the cap from the nylon probe. Hold the probe
vertically to prevent dropping the cell out of the probe.

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5 Maintenance Model 3000PB

6. Remove the cell from the probe, and dispose of it in an
environmentally safe manner.

5.3.4 Installing a New Micro-Fuel Cell

CAUTION: Do not touch the sensing surface of the cell. It is

covered with a delicate Teflon membrane that can
leak when punctured. The sensor must be replaced
if the membrane is damaged.

Before installing a new cell, check the O-ring in the base of the cell

holder. Replace if worn or damaged.

1. Place the Cell in the Probe with the sensing surface facing
outward (toward the screen in the Cap).

2. Screw the Probe Cap onto the Probe until it stops.

3. With the O-rings in place, push the assembled Probe down into
the Cell Holder—Cap Down—with a slight rocking motion
until it is seated on the bottom of the holder. This forces the
holder into position and forms a gas-tight seal.

5.3.5 Cell Warranty

The Class B-1 Micro-Fuel cell is standard in the Model 3000PB. This
cell is a long life cell and is warranted for 6 months from the date of
shipment. The customer should purchase only one spare cell (per section

5.3.1). Do not attempt to stockpile spare cells.

If any cell other than the B-1 is supplied with your instrument, check
Specific Model Information in the front of this manual for any special
information applying to your cell.

Caution: The B-1 cell is not designed for applications where

CO

is a major component in the sample, however

2

slight amounts will not adversely effect the cell
performance.

If a cell was working satisfactorily, but ceases to function before the
warranty period expires, the customer will receive credit toward the pur­chase of a new cell.

If you have a warranty claim, you must return the cell in question to
the factory for evaluation. If it is determined that failure is due to faulty

workmanship or material, the cell will be replaced at no cost to you.

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Percent Oxygen Analyzer Maintenance 5

Note: Evidence of damage due to tampering or mishandling will

render the cell warranty null and void.

5.4 Fuse Replacement

The 3000PB requires two 5 × 20 mm, 4 A, T type (Slow Blow) fuses.
The fuses are located inside the main housing on the Electrical Connector
Panel, as shown in Figure 5-3. To replace a fuse:

1. Disconnect the Unit from its power source.

2. Place a small screwdriver in the notch in the fuse holder cap,
push in, and rotate 1/4 turn. The cap will pop out a few
millimeters. Pull out the fuse holder cap and fuse, as shown in
Figure 5-3.

3.0 AMAX

Figure 5-3: Removing Fuse Cap and Fuse from Holder

2. Replace fuse by reversing process in step 1.

5.5 System Self Diagnostic Test

1. Press the System button to enter the System function.

2. Use the arrow keys to move to More, and press Enter.

3. Use the arrow keys to move to Self-Test, and press Enter.

The screen will follow the running of the diagnostic.

RUNNING DIAGNOSTIC
Testing Preamp — 83

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During preamp testing there is a countdown in the lower right corner

of the screen. When the testing is complete, the results are displayed.

Power: OK Analog: OK
Preamp: 2

The module is functioning properly if it is followed by OK. A number

indicates a problem in a specific area of the instrument. Refer to Table 5-1
for number-code information. The results screen alternates for a time with:

Press Any Key
To Continue...

The following failure codes apply:

Table 5-1: Self Test Failure Codes

Power

0OK
1 5 V Failure
2 15 V Failure
3 Both Failed

Analog

0OK
1 DAC A (0–1 V Concentration)
2 DAC B (0–1 V Range ID)
3 Both Failed

Preamp

0OK
1 Zero too high
2 Amplifier output doesn't match test input
3 Both Failed

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5.6 Troubleshooting

Problem:

Erratic readings of the Oxygen concentration as reported by the analyzer.

Possible Cause:

The analyzer may have been calibrated in an inaccurate fashion.

Solution:

Turn the analyzer off, then back on again. Press the System key when
prompted by the analyzer "Press System for default Values". This will
return the analyzer to its default settings in calibration and zero values. If
erratic behavior continues replace the sensor.

Possible Cause:

Atmospheric Oxygen may be diffusing in through the vent and affecting
the oxygen level which the sensor sees.

Solution:

Increase flow rate and/or length or vent tubing in order to dilute of mini­mize the diffusion of oxygen from the vent back to the sensor.

Problem:

Inaccurate zero operation (i.e. the user has zeroed the analyzer accidentally
on gas much higher than one would normally use for a zero gas).

Solution:

Turn the analyzer off, then back on again. Press the System key when
prompted by the analyzer "Press System for default Values". This will
return the analyzer to its default settings in calibration and zero values.
Now proceed to carefully calibrate and zero the analyzer.

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Percent Oxygen Analyzer Appendix

Appendix

A-1 Specifications

Packaging: General Purpose, NEMA-4, Bulkhead mount.

Sensor: Class B-1 percent analysis Micro-Fuel Cell.

Cell Block: Nylon. (Stainless steel available.)

Ranges: Three user definable ranges from 0-1 % to 0-

100 %, plus air calibration range of 0-25 %.
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 op-

tional, electrically operated valves.)

Alarms: One system-failure alarm contact to detect

power failure.
Two adjustable concentration threshold alarms

with fully programmable setpoints.

Diagnostics: Start-up and on-demand, self testing function

initiated by keyboard or remote command.

Displays: 2 line by 20 alphanumeric, VFD screen, and

one 5 digit LED display.

Digital Interface: Full duplex RS-232 communications port.

Power: Universal power supply 110/220 VAC at 50/

60 Hz

Operating Temperature: 0-50 °C

Teledyne Analytical Instruments

A-1

Appendix Model 3000PB

Accuracy: ±2% of full scale at constant temperature.

±5% of full scale over operating temperature
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.

Optional:

4-20 mA dc percent-of-range, isolated
4-20 mA dc range ID, isolated

Password Access: Can be user-configured for password

protection.

A-2

Teledyne Analytical Instruments

Percent Oxygen Analyzer Appendix

A-2 Recommended 2-Year Spare Parts List

Qty Part Number Description

1 C62959 Display PCB
1 C65295 Customer Interface PCB

1 C62368-B Percent Preamplifier Board
1* C73870-C Main PCB (Standard)
1* C73870-B Main PCB (4-20 mA option)
3 F1295 Fuse, 4A, 250V, 5×20 mm, T (Slow

Blow)
2 O38 O-ring
1 C6689-B1 Micro-Fuel Cell (For options see **)

* Order -B or -C, not both.

** Check Specific Model Information in front matter of this

manual for cell options.

A minimum charge is applicable to spare parts orders.

Note: Orders for replacement parts should include the part number

(if available) and the model and serial number of the instru­ment for which the parts are intended.

Orders should be sent to:

TELEDYNE ANALYTICAL INSTRUMENTS
16830 Chestnut Street
City of Industry, CA 91749-1580

Phone [phone], Fax [phone]
TWX [phone] TDYANYL COID

Web: www.teledyne-ai.com

or your local representative.

Teledyne Analytical Instruments

A-3

Appendix Model 3000PB

A-3 Drawing List

D66682 Final Assembly Drawing
D66674 Outline Drawing
D66675 Wiring Diagram

NOTE: The MSDS on this material is available upon request

through the Teledyne Environmental, Health and
Safety Coordinator. Contact at [phone]

A-4

Teledyne Analytical Instruments

Percent Oxygen Analyzer Appendix

A-5

3000 SERIES ANALYZERS

APPLICATION NOTES ON RESTRICTORS,

PRESSURES, AND FLOW RECOMMENDATIONS

3000 series analyzers require reasonably regulated sample pressures.

While the 3000 analyzers are not sensitive to variations of incoming pressure
(provided they are properly vented to atmospheric pressure) The pressure must
be maintained as to provide a useable flow rate trough the analyzer. Any line
attached to sample vent should be 1/4 or larger in diameter.

FLOW RATE RECOMMENDATIONS:

A usable flow rate for a 3000 series analyzer is one which can be

measured on the flowmeter. This is basically .2 - 2.4 SLPM . The optimum flow
rate is 1 SLPM (mid scale). Note: response time is dependent on flow rate, a
low flow rate will result in slow response to O2 changes in the sample stream.
The span flow rate should be the approximately same as the sample flow rate.

CELL PRESSURE CONCERNS:

The sensors used in 3000 series analyzers are optimized to function at

atmospheric pressure. At pressures other than atmospheric the diffusion rate of
O2 will be different than optimum value. Higher pressures will produce faster O2
diffusion rates resulting in higher O2 reading and shorter cell life. To use a 3000
series analyzer at a cell pressure other than atmospheric, the analyzer must be
calibrated with a known calibration gas at the new cell pressure to adjust for the
different diffusion rate. Cell pressures below 2/3 atmospheric are not recom­mended because as they tend to cause excessive internal expansion which may
result in seal failure.

For operation at cell pressures other than atmospheric care must be

taken not to change the sample pressure rapidly or cell damage may occur. For
cell pressures above atmospheric, caution must be exercised to avoid over
pressuring the cell holder. ( percent analyzers will require some type of cell
retainer to prevent the cell from being pushed out by the pressure .) For opera­tion at pressures below atmospheric pressure a suffix C ( clamped) cell is
required.

RESTRICTION DEVICES:

For proper operation, all 3000 series analyzers require a flow restriction

device. This device is typically a restrictor or a valve. This restriction device
serves two functions in the sample path. The first function is to limit the flow rate
of the sample through the analyzer. A restrictor is chosen to operate over a range
of pressures and provide a useable flow rate over that range.

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Appendix Model 3000PB

The second function that the restriction device provides is a pressure
drop. This device is selected to provide the only significant pressure drop in the
sample path.

RESTRICTOR KIT

The current revision of the 3000 series analyzers are supplied with a kit
containing two restrictors and a union which are user installed. These parts
supplied to give the end user more flexibility when installing the analyzer. The
restrictor kit is suitable for high and low positive pressure applications as well as
vacuum service ( atmospheric pressure sample) applications ( see manual for
installation instructions). The standard restrictor ( BLUE DOT ) is recommended
for pressures between 5 PSIG and 50 PSIG. For positive low pressure appli­cation ( 5 psig or less ) the un-marked restrictor is better suited . For none
pressurized sample applications the marked restrictor should be used and
configured for vacuum service. Note: for extremely low positive pressure appli­cations ( less then 2 psig) the vacuum service configuration should provide higher
performance ( higher flow rates). For vacuum service the end user must supply
a vacuum pump and a by-pass valve for the pump. A vacuum level of 5 -10
inches of mercury should provide the optimum flow rate. CAUTION: flow

restrictors have very small orifices and may be plugged by small par­ticles ( .005” dia or larger) A sample filter must be included in the sample
line prior to the restrictor! ( a 60 micron filter is recommended)

3000PB EXAMPLES:

Example 1, with a incoming pressure of 10 psig the std restrictor (blue
dot) will provide a flow rate of .76 SLPM. Up-stream of the restrictor the
sample line pressure will be 10 psig, while down stream ( including the cell) the
pressure will be at atmospheric pressure.( analyzer vented to atmospheric
pressure) Note, all other pressure drops in the sample path are insignificant at
these flow rates. This insures that the cell operates at atmospheric pressure. At
very high flow rates ( off scale of flow-meter), pressure drops other than the
restriction device could become significant , and result in pressurizing the cell.

Example 2, A 3000PB is configured for vacuum service as follows. The
un-marked restrictor is placed in the sample vent port. The down stream end of
the restrictor is then connected to a vacuum pump and by-pass valve. The by­pass valve is adjusted to provide a flow rate of 1 SLPM. The sample pressure
between the pump and the restrictor will be approximately -7 inches of mercury,
while the pressure in the balance of the sample system including the cell will be
approximately at atmospheric pressure. ( provided the sample flow into the
analyzer is not blocked.)

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Teledyne Analytical Instruments

Percent Oxygen Analyzer Appendix

BY-PASS:

To improve the system response, a by-pass can be added to increase the sample
flow rate to the analyzer by a factor of ten. A by-pass provides a sample flow path around
the analyzer of 2 - 18 SCFH. typically.

CALIBRATION GAS:

3000 series analyzer requirements for units with Auto-Cal options. The customer

must supply a control valves (or restrictors) for any SPAN or ZERO gas source which is
attached to the Auto-Cal ports. The valve should be adjusted to the same flow rate as the
sample gas . When restrictors are used, the gas pressure must be adjusted to achieve the
proper flow rate.

OPERATION WITHOUT A RESTRICTOR DEVICE:

Operation without a restrictor device is not recommend as mentioned above. A
3000PB without any flow restrictor device was tested on 11-19-97. This results in a flow
rate of 2.4 SLPM @ 1 PSIG. This is a cv of 0.023 for the standard sample sys.

REFERENCE: FLOW_1.XLS & FLOW_2.XLS for information on flow rates at

various pressures.

TAI PART NUMBERS

RESTRICTOR KIT: A68729
UNION (SS) U11
LP. RESTRICTOR R2323 ( LOW PRESSURE / VAC. SERVICE )
STD.. RESTRICTOR R2324 BLUE DOT
NUT N73
FERRULE F73
FERRULE F74 BOTH FERRULES ARE

REQUIRED

CONVERSIONS:

1 PSI = 2.04 INCHES OF MERCURY (in. Hg.)
1 SCFH = 0.476 SLPM

Teledyne Analytical Instruments

A-7

Appendix Model 3000PB

A-6 Zero Cal

The Zero button on the control panel is used to enter the zero calibra-

tion 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. Make sure the zero
gas is connected to the instrument.

Auto Mode Zeroing

Press Zero to enter the zero function mode. The screen allows you to

select whether the zero calibration is to be performed automatically or manu­ally. Use the Δ∇ arrow keys to toggle between AUTO and MAN zero
settling. Stop when AUTO appears, blinking, on the display.

Zero: Settling: AUTO
<ENT> To Begin

Press Enter to begin zeroing.

#### % Zero
Slope=#### ppm/s

The beginning zero level is shown in the upper left corner of the dis-

play. As the zero reading settles, the screen displays and updates information
on Slope (unless the Slope starts within the acceptable zero range and does
not need to settle further).

Then, and whenever Slope is less than 0.08 for at least 3 minutes,

instead of Slope you will see a countdown: 1 Left, 0 Left, and so forth.
These are five steps in the zeroing process that the system must complete,
AFTER settling, before it can go back to Analyze.

#### % Zero
1 Left=### ppm/s

The zeroing process will automatically conclude when the output is

within the acceptable range for a good zero. Then the analyzer automatically
returns to the Analyze mode.

Manual Mode Zeroing

Press Zero to enter the Zero function. The screen that appears allows

you to select between automatic or manual zero calibration. Use the Δ∇ keys

A-8

Teledyne Analytical Instruments

Percent Oxygen Analyzer Appendix

to toggle between AUTO and MAN zero settling. Stop when MAN appears,
blinking, on the display.

Zero: Settling: Man
<ENT> To Begin

Press 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. The microprocessor samples the output at a prede­termined rate. It calculates the differences between successive samplings and
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 pressing 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, press Enter. In a
few seconds, the screen will update.

Once span settling completes, the information is stored in the

microprocessor, and the instrument automatically returns to the Analyze
mode.

Teledyne Analytical Instruments

A-9

Appendix Model 3000PB

A-10

Teledyne Analytical Instruments

Percent Oxygen Analyzer Appendix

A-4 Material Safety Data Sheet

Section I – Product Identification

Product Name: Micro-Fuel Cells and Super Cells, all classes except A-2C, A-3,

and A-5.

Electrochemical Oxygen Sensors, all classes except R-19.
Mini-Micro-Fuel Cells, all classes.

Manufacturer: TELEDYNE Analytical Instruments

Address: 16830 Chestnut Street

City of Industry, CA 91749-1580

Phone: [phone]

Customer Service: Extension 222

Environmental Health and Safety: Extension 230

Customer Srvce 24 Hr Emergency: 1-800-759-7243 (Pager)

Date Prepared : 04/26/95

Section II – Hazardous Ingredients/Composition

Material or
Component C.A.S. # Quantity OSHA PEL ACGIH
TLV

Lead (Pb) 7439-92-1 3–20 gms 0.05 mg/m

3

Potassium Hydroxide 1310-58-3 1–5 ml None 2 mg/m
Solution 15% (KOH)

Section III – Physical/Chemical Characteristics

Material
Appearance
or Compo­nent

Lead

Boiling
Point (°C)

1744

Specific
Gravity

11.34

Vapor
Pres­sure

na

Melting
Point
(°C)

328

Density

na

Evap.
Rate

na

Solubility
in Water

Insoluble

0.15 mg/m

3

Odor

Solid, silver
gray, odorless

3

Potassium
Hydroxide

1320

2.04

Complete

na

360

na

na

Teledyne Analytical Instruments

White or
slightly
yellow,
no odor

A-11

Appendix Model 3000PB

Section IV – Fire and Explosion Hazard Data

Flash Point: na Flammable Limits: na LEL: na UEL: na
Extinguishing Media: Use extinguishing media appropriate to surrounding fire

conditions. No specific agents recommended.

Special Fire Fighting
Equipment:

Wear NIOSH/OSHA approved self-contained breathing
apparatus and protective clothing to prevent contact with
skin and eyes.

Unusual Fire and Explosion
Hazards:

Emits toxic fumes under fire conditions.

Section V – Reactivity Data

Stability: Stable
Incompatibilities: Aluminum, organic materials, acid chlorides, acid

anhydrides, magnesium, copper. Avoid contact with acids

Hazardous Decomposition of
Byproducts:

Hazardous Polymerization: Will not occur.
Conditions to Avoid:

and hydrogen peroxide > 52%.
Toxic fumes

Section VI – Health Hazard Data

Routes of Entry: Inhalation: Highly unlikely

Ingestion: May be fatal if swallowed.

Skin: The electrolyte (potassium hydroxide) is corrosive; skin

contact may cause irritation or chemical burns.

Eyes: The electrolyte (potassium hydroxide) is corrosive; eye

contact may cause irritation or severe chemical burns.

Acute Effects: The electrolyte is harmful if swallowed, inhaled or

adsorbed through the skin. It is extremely destructive to
tissue of the mucous membranes, stomach, mouth, upper
respiratory tract, eyes and skin.

Chronic Effects: Prolonged exposure with the electrolyte has a destruc-

tive effect on tissue.
Chronic exposure to lead may cause disease of the blood

and blood forming organs, kidneys and liver, damage to
the reproductive systems and decrease in fertility in men
and women, and damage to the fetus of a pregnant
woman. Chronic exposure from the lead contained in this
product is extremely unlikely.

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Teledyne Analytical Instruments

Percent Oxygen Analyzer Appendix

Signs and Symptoms of
Exposure:

Carcinogenicity: Lead is classified by the IARC as a class 2B carcinogen

OSHA: Where airborne lead exposures exceed the OSHA action

NTP: na
Medical Conditions Generally

Aggravated by Exposure:

Emergency First Aid Procedures:

Contact of electrolyte with skin or eyes will cause a
burning sensation and/or feel soapy or slippery to touch.

Other symptoms of exposure to lead include loss of sleep,
loss of appetite, metallic taste and fatigue.

(possibly carcinogenic to humans)

level, refer to OSHA Lead Standard 1910.1025.

Lead exposure may aggravate disease of the blood and
blood forming organs, hypertension, kidneys, nervous
and possibly reproductive systems. Those with preexist­ing skin disorders or eye problems may be more suscep­tible to the effects of the electrolyte.

In case of contact with the skin or eyes, immediately flush
with plenty of water for at least 15 minutes and remove all
contaminated clothing. Get medical attention immediately.

If ingested, give large amounts of water and DO NOT
INDUCE VOMITING. Obtain medical attention immedi­ately.

If inhaled, remove to fresh air and obtain medical attention
immediately.

Section VII – Precautions for Safe Handling and Use

NOTE: The oxygen sensors are sealed, and under normal circum-

stances, the contents of the sensors do not present a health
hazard. The following information is given as a guide in the
event that a cell leaks.

Protective measures
during cell replacement:

Cleanup Procedures: Wipe down the area several times with a wet paper towel.

Before opening the bag containing the sensor cell, check
the sensor cell for leakage. If the sensor cell leaks, do
not open the bag. If there is liquid around the cell while
in the instrument, wear eye and hand protection.

Use a fresh towel each time. Contaminated paper towels
are considered hazardous waste.

Teledyne Analytical Instruments

A-13

Appendix Model 3000PB

Section VIII – Control Measures

Eye Protection: Chemical splash goggles
Hand Protection: Rubber gloves
Other Protective Clothing: Apron, face shield
Ventilation: na

Section IX – Disposal

Both lead and potassium hydroxide are considered poisonous substances and are regulated under
TSCA and SARA Title III.

EPA Waste Number: D008
California Waste Number: 18 1
DOT Information: RQ Hazardous Waste Solid N.O.S. (Lead) Class 9

NA3077 PG III
Follow all Federal, State and Local regulations.

Section X – References

Material Safety Data Sheets from J.T. Baker Chemical, Aldrich, Malinckrodt, ASARCO
U.S. Department of Labor form OMB No. 1218-0072
Title 8 California Code of Regulations
TSCA
SARA Title III
CFR 49
CFR 29
CFR 40

NOTE: The above information is believed to be correct and is offered for your

information, consideration, and investigation. It should be used as a
guide. Teledyne Brown Engineering Analytical Instruments shall not
be held liable for any damage resulting from handling or from contact
with the above product.

A-14

Teledyne Analytical Instruments