Teledyne 3000ZA2G User Manual
Trace Oxygen Analyzer
OPERATING INSTRUCTIONS FOR
MODEL 3000ZA2G
Trace Oxygen Analyzer
P/N M86303
11/14/2012
DANGER
Toxic gases and or flammable liquids may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
Hazardous voltages exist on certain components internally which may persist
for a time even after the power is turned off and disconnected.
Only a trained service technician should open the front door of this instrument.
Only a trained service technician should conduct maintenance and/or
servicing. Before conducting any maintenance or servicing, consult with
authorized supervisor/manager.
Teledyne Analytical Instruments i
3000ZA2G
Copyright © 2012 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 91748.
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 acknowledgements 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 Analytical Instruments 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 Analytical Instruments 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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Trace Oxygen Analyzer
Specific Model Information
The instrument for which this manual was supplied may
incorporate one or more options not supplied in the standard instrument.
Commonly available options are listed below, with check boxes. Any
that are incorporated in the instrument for which this manual is supplied
are indicated by a check mark in the box.
Instrument Serial Number: _______________________
Options Included in the Instrument with the Above Serial Number:
Auto Calibration: The Auto Cal option includes a manifold
with separate ports for sample in, zero and
span gases with solenoid control valves. The
internal valves are entirely under the control
of the 3000ZA2G electronics and can be
used to automatically switch between gases
in synchronization with the analyzer’s
operation.
4-20 mA Output: This option provides for additional analog
outputs for concentration and range
identification in the form of a 4-20 mA
current.
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3000ZA2G
Important Notice
Model 3000ZA2G complies with all of the requirements of the
Commonwealth of Europe (CE) for Radio Frequency Interference,
Electromagnetic Interference (RFI/EMI), and Low Voltage Directive
(LVD).
The following International Symbols are used throughout the
Instruction Manual. These symbols are visual indicators of important
and immediate warnings and when you must exercise CAUTION while
operating the instrument. See also the Safety Information on the next
page.
STAND-BY: Instrument is on Stand-by, but circuit is active
GROUND: Protective Earth
CAUTION: The operator needs to refer to the manual for
further information. Failure to do so may compromise the
safe operation of the equipment.
CAUTION: Risk of Electrical Shock
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Trace Oxygen Analyzer
Safety Messages
Your safety and the safety of others are very important. We have
provided many important safety messages in this manual. Please read
these messages carefully.
A safety message alerts you to potential hazards that could hurt you
or others. Each safety message is associated with a safety alert symbol.
These symbols are found in the manual and inside the instrument. The
definition of these symbols is described below:
GENERAL WARNING/CAUTION: Refer to the
instructions for details on the specific danger. These cautions
warn of specific procedures which if not followed could
cause bodily Injury and/or damage the instrument.
No
Symbol
CAUTION: HOT SURFACE WARNING: This warning is
specific to heated components within the instrument. Failure
to heed the warning could result in serious burns to skin and
underlying tissue.
WARNING: ELECTRICAL SHOCK HAZARD: Dangerous
voltages appear within this instrument. This warning is
specific to an electrical hazard existing at or nearby the
component or procedure under discussion. Failure to heed
this warning could result in injury and/or death from
electrocution.
Technician Symbol: All operations marked with this
symbol are to be performed by qualified maintenance
personnel only.
NOTE: Additional information and comments regarding a
specific component or procedure are highlighted in the form
of a note.
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3000ZA2G
CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE
PURPOSE AND IN THE MANNER DESCRIBED IN
THIS MANUAL.
IF YOU USE THE ANALYZER IN A MANNER OTHER
THAN THAT FOR WHICH IT WAS INTENDED,
UNPREDICTABLE BEHAVIOR COULD RESULT
POSSIBLY ACCOMPANIED WITH HAZARDOUS
CONSEQUENCES.
This manual provides information designed to guide you through
the installation, calibration and operation of your new analyzer. Please
read this manual and keep it available.
Occasionally, some instruments are customized for a particular
application or features and/or options added per customer requests.
Please check the front of this manual for any additional information in
the form of an Addendum which discusses specific information,
procedures, cautions and warnings that may be peculiar to your
instrument.
Manuals do get lost. Additional manuals can be obtained from
Teledyne Analytical Instruments at the address given in the Appendix.
Some of our manuals are available in electronic form via the internet.
Please visit our website at: www.teledyne-ai.com.
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Trace Oxygen Analyzer
This is a general purpose instrument designed for use in a non-hazardous
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 operation of this
equipment are well understood by the user. Misuse of this product in
any manner, tampering with its components, or unauthorized
substitution of any component may adversely affect the safety of this
instrument.
Since the use of this instrument is beyond the control of Teledyne
Analytical Instruments, no responsibility by Teledyne Analytical
Instruments, its affiliates, and agents for damage or injury from misuse
or neglect of this equipment is implied or assumed.
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3000ZA2G
Table of Contents
Safety Messages ............................................................. v
Introduction ..................................................................... 1
1.1 Overview 1
1.2 Typical Applications 1
1.3 Main Features of the Analyzer 1
1.4 Front Panel 2
1.5 Rear Panel (Equipment Interface) 5
Operational Theory ......................................................... 7
2.1 Introduction 7
2.2 ZrO2 Sensor 7
2.2.1 Principles of Operation 7
2.3 Sample System 10
2.4 Zirconium Oxide Sensor Application Notes 11
2.5 Electronics and Signal Processing 11
Installation ..................................................................... 15
3.1 Unpacking the Analyzer 15
3.2 Mounting the Analyzer 15
3.3 Rear Panel Connections 16
3.3.1 Gas Connections 17
3.3.2 Calibration Gas 18
3.3.3 Electrical Connections 18
3.3.3.1 Primary Input Power 18
3.3.3.2 50-Pin Equipment Interface Connector 19
3.3.3.3 RS-232 Port 25
3.4 Testing the System 26
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Trace Oxygen Analyzer
Operation....................................................................... 27
4.1 Introduction 27
4.2 Using the Data Entry and Function Buttons 28
4.3 The System Function 30
4.3.1 Tracking Oxygen Readings During Calibration and
Alarm Delay 31
4.3.2 Setting up an Auto-Cal 32
4.3.3 Password Protection 33
4.3.3.1 Entering the Password 34
4.3.3.2 Installing or Changing the Password 35
4.3.4 Logout 37
4.3.5 System Self-Diagnostic Test 38
4.3.6 Version Screen 39
4.3.7 Showing Negative Oxygen Readings 39
4.4 The Zero and Span Functions 40
4.4.1 Zero Cal 40
4.4.1.1 Auto Mode Zeroing 41
4.4.1.2 Manual Mode Zeroing 42
4.4.2 Span Cal 42
4.4.2.1 Auto Mode Spanning 42
4.4.2.2 Manual Mode Spanning 43
4.4.3 Span Failure 45
4.5 The Alarms Function 45
4.6 The Range Function 48
4.6.1 Setting the Analog Output Ranges 49
4.6.2 Fixed Range Analysis 49
4.7 The Analyze Function 50
4.8 Signal Output 50
Maintenance .................................................................. 53
5.1 Routine Maintenance 53
5.2 Sensor Replacement 53
5.3 Fuse Replacement 54
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3000ZA2G
5.4 System Self Diagnostic Test 55
5.5 Major Internal Components 55
5.6 Cleaning 56
5.7 Troubleshooting 56
Appendix ....................................................................... 57
A-1 Specifications 57
A-2 Recommended 2-Year Spare Parts List 59
A-3 Drawing List 60
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Trace Oxygen Analyzer
List of Figures
Figure 1-1: Model 3000ZA2G Front Panel 3
Figure 1-2: Model 3000ZA2G Rear Panel 5
Figure 2-1: Sensor Offset Voltage 9
Figure 2-2: Zirconia Sensor Assembly 10
Figure 2-3: Flow Diagram 11
Figure 2-4: Component Locations 13
Figure 2-5: Electronic Block Diagram 14
Figure 3-1: Model 3000ZA2G 15
Figure 3-2: Required Front Door Clearance 16
Figure 3-3: Model 3000ZA2G Rear Panel 16
Figure 3-4: Equipment Interface Connector Pin Arrangement 19
Figure 3-5: Remote Probe Connections 24
Figure 3-6: FET Series Resistance 25
Figure 5-1: Removing Fuse Block from Housing 54
Figure 5-2: Installing Fuses 54
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3000ZA2G
List of Tables
Table 3-1: Analog Output Connections 20
Table 3-2: Alarm Relay Contact Pins 21
Table 3-3: Remote Calibration Connections 22
Table 3-4: Range ID Relay Connections 23
Table 3-5: Commands via RS-232 Input 26
Table 3-6: Required RS-232 Options 26
Table 5-1: Self-Test Result Display 55
Table 5-2: Troubleshooting 56
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Trace Oxygen Analyzer Introduction
Introduction
1.1 Overview
The Teledyne Analytical Instruments Model 3000ZA2G Trace
Oxygen Analyzer is a versatile microprocessor-based instrument for
detecting oxygen from parts-per-million (ppm) level to 25% oxygen in
background gases consistent with the zirconium oxide sensor. This
manual covers the Model 3000ZA2G 19” rack-mount units with CE
mark. These units are for indoor use in a non-hazardous environment.
1.2 Typical Applications
A few typical applications of the Model 3000ZA2G 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 3000ZA2G Trace 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 for
low ppm levels. Large, bright, meter readout.
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Introduction 3000ZA2G
Zirconium oxide sensor to provide complete range of
analysis from 0-10 ppm to 0-25%.
Can be used without a flowing reference with only a
marginal performance impact.
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 0-10 ppm
through 0-25%) allow best match to the end user’s
process and equipment.
Auto ranging allows analyzer to automatically select the
proper preset range for a given measurement. Manual
override allows the user to lock onto a specific range of
interest.
Two adjustable concentration alarms and a system
failure alarm.
Extensive self-diagnostic testing at startup and on
demand with continuous power-supply monitoring.
CE compliance
RS-232 serial digital port for use with a computer or
other digital communication device.
A 0-1 VDC analog output for concentration plus a 0-1
VDC output for range identification.
Convenient and versatile with standard 19” rack-mount
analyzer with slide-out electronics drawer.
1.4 Front Panel
The standard 3000ZA2G is housed in a rugged metal case designed
for installation into a standard 19” equipment rack. All controls and
displays are accessible from the front panel. See Figure 1-1. The front
panel has thirteen buttons for operating the analyzer, a digital meter, an
alphanumeric display, a flowmeter, and sample flow control valve.
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Trace Oxygen Analyzer Introduction
Figure 1-1: Model 3000ZA2G Front Panel
Function Keys:
Six touch-sensitive membrane switches are used to change the specific
function performed by the analyzer:
Analyze Perform analysis for oxygen content of a sample
gas.
System Perform system-related tasks (described in detail
in chapter 4, Operation.).
Span Span calibrate the analyzer.
Zero Zero calibrate the analyzer.
Alarms Set the alarm setpoints and attributes.
Range Set up the 3 user definable ranges for the
instrument.
Data Entry Keys:
Six touch-sensitive membrane switches are used to input data to the
instrument via the alphanumeric VFD display:
Left & Right Arrows: Select between functions currently
displayed on the VFD screen.
Up & Down Arrows: Increment or decrement values of
functions currently displayed.
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Introduction 3000ZA2G
Enter: Advances VFD display to the next screen in a series
or returns to the Analyze screen if none remain.
Escape: Backs VFD display to the previous screen in a series
or returns to the Analyze screen if none remain.
Digital Meter Display:
The meter display is a Light Emitting Diode (LED) device that produces
large, bright, 7-segment numbers that are legible in any lighting. It produces
a continuous readout from 0-250 ppm. It is accurate across all analysis
ranges without the discontinuity inherent in analog range switching.
Alphanumeric Interface Screen:
The alphanumeric screen is a vacuum fluorescent display (VFD) screen
with an easy-to-use interface. 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).
Reference Flowmeter:
Monitors the flow of reference gas past the sensor. Readout is 0.2 to 2.4
standard liters per minute (SLPM).
Note: It is possible to use the analyzer without a flowing
reference but doing so will incur a marginal degradation in
performance. See Section 2.2.1. TAI recommends using a
flowing reference for best results.
Flow Control Valve:
The sample control valve allows precise adjustment over sample or
calibration gas flow to the analyzer.
Reference Flow Control Valve:
Control valve for the reference flow through the analyzer.
Standby Button
:
The Standby turns off the display and outputs but circuitry is still
operating.
CAUTION: THE POWER ENTRY SWITCH ON THE REAR OF THE
INSTRUMENT MUST BE TURNED OFF TO FULLY
DISCONNECT POWER FROM THE INSTRUMENT.
WHEN CHASSIS IS EXPOSED OR WHEN ACCESS
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Trace Oxygen Analyzer Introduction
V
(op
)
DOOR IS OPEN AND POWER CABLE IS CONNECTED ,
USE EXTRA CARE TO AVOID CONTACT WITH LIVE
ELECTRICAL CIRCUITS AND HOT SURFACES. ONLY
A TRAINED SERVICE TECHNICIAN SHOULD OPEN
THE FRONT DOOR.
Access Door:
For inspection of the instrument by a trained service technician , the
front panel swings open when the latch in the upper right corner of the
analyzer panel is pressed all the way in with a narrow gauge tool.
Accessing the main circuit board requires unfastening rear panel screws
and sliding the unit out of the case.
1.5 Rear Panel (Equipment Interface)
The rear panel, shown in Figure 1-2, contains the gas and electrical
connectors for external inlets and outlets. Some of those depicted are
optional and may not appear on your instrument. The connectors are
described briefly here and in detail in Chapter 3 Installation.
entilation
Auto Cal Valves
tional
Power Entry
Module w/ Fuse
Housing
Gas
Connections
RS-232 Port
50-Pin Equipment
Figure 1-2: Model 3000ZA2G Rear Panel
Power Connection Factory configured for either 115
VAC or 230 VAC operation , 50/60 Hz.
Connector
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Introduction 3000ZA2G
Sample Inlet and Outlet: One inlet (must be externally
valved) and one exhaust. Three inlets when auto calibration
option is present.
Reference Inlet and Outlet: Flowing air reference inlet and
exhaust.
9-Pin RS-232 Port: Serial digital concentration signal
output and control input.
50-Pin Equipment Interface Port:
Analog Outputs: 0–1 VDC oxygen concentration plus
0-1 VDC range ID
Alarm Connections: 2 concentration alarms and 1
system alarm.
Remote Valve: Used in the 3000ZA2G for controlling
external solenoid valves only.
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 currently
implemented.
Optional
Calibration Gas Ports: Separate fittings for zero, span, and
sample gas input, internal valves for automatic gas switching.
Current Signal Output: Additional isolated 4–20 mA DC
plus 4–20 mA DC range ID.
Note: If you require highly accurate Auto-Cal timing, use external
Auto-Cal control where possible. The internal clock in the
Model 3000ZA2G is accurate to 2-3 %. Accordingly,
internally scheduled calibrations can vary 30-45 minutes
per day.
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Trace Oxygen Analyzer Operational Theory
Operational Theory
2.1 Introduction
The analyzer is composed of three subsystems:
1. The zirconium oxide (ZrO
) sensor with a 0-25%
2
analysis range
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 ZrO
sensor is a device that translates the
2
amount of oxygen present in the sample into a voltage output. 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 ZrO2 Sensor
2.2.1 Principles of Operation
The zirconium oxide (ZrO2) sensor is a solid state sensor. It is a
voltage device with a logarithmic response. The sensor uses a stabilized
zirconia disc as an electrolyte with a sensing electrode (the cathode) and
a counter electrode (the anode) on each side of the disc and contains a
thermocouple. The sensor is designed to have a small sample of the
unknown gas passed inside the sensor tube. Air (20.95% oxygen)
surrounds the outside of the tube. A heater is mounted around the sensor
to keep the sensor hot. The sensor construction is shown in Figure 2.1.
CAUTION: THE SENSOR IS HOT. DO NOT TOUCH THE SENSOR
OR ALLOW FLAMMABLE MATERIAL TO COME IN
CONTACT WITH THE ASSEMBLY.
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Operational Theory 3000ZA2G
THE SENSOR ASSEMBLY REMAINS HOT EVEN IN
STANDBY MODE. REMOVE POWER FROM THE
INSTRUMENT AND ALLOW SENSOR TO COOL FOR
TWO HOURS BEFORE PERFORMING ANY
MAINTENANCE ON THE SENSOR.
The heater control is a time proportioning temperature controller
that maintains the thermocouple junction at the sensor operating
temperature of 575°C (1070°F).
When exposed to different oxygen partial pressures at the outside
and inside of the sensor, an EMF (E) is developed which obeys the
Nernst equation:
E
(mV)
RT
F
4
log
e
Inside P
O2
Ouside P
O2
Where T is the temperature (K) at the zirconia disc, R is the gas
constant, F is the Faraday constant and (PO2) Inside and (PO2) Outside
are the oxygen partial pressures at the inner and outer electrodes,
respectively, with the higher oxygen partial pressure electrode being
positive.
When dry air at atmospheric pressure, (21% oxygen) is used as a
reference gas at the inner electrode, the following equations are
obtained:
2
TxE
log10154.2(mV)
e
0.21
Ouside P
O2
Transposing this equation:
2
exp21.0(Atm) Outside %O
E421.46
T
The analyzer solves this equation, which is valid above the
minimum operating temperature.
The oxygen sensor assembly provides a means of exposing the
zirconia sensor to the atmosphere to be measured on the inside of the
sensor while maintaining air as a reference gas at atmospheric pressure
on the outside of the sensor.
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Trace Oxygen Analyzer Operational Theory
The sensor offset voltage changes with sample flowrate as shown in
Figure 2-1. Assuming that the environment remains constant and within
the specifications of the sensor, the difference in offset voltage between
a flowing reference gas at 200 ml/min and at 0 ml/min is nearly constant
over the operating range of sample flowrates (100-300 ml/min). This
offset is removed during calibration assuming that the sample flowrate
used in calibration is the same as the process flow. Hence the analyzer
can be used without a flowing reference gas during operation with only a
marginal degradation in performance. For best performance, a flowing
reference should be used.
Figure 2-1: Sensor Offset Voltage
The sensor assembly also provides the means of maintaining the
sensor operating temperature by surrounding the sensor tube with a
heater element, and measuring the temperature of the zirconia disc with
a thermocouple inside the sensor. (See Figure 2.2).
The logarithmic output of the sensor depends therefore on the
partial pressure of the oxygen in the sample gas.
The non-linear output is linearized by the system software and a
linear output signal is generated and used by the DAC circuit to produce
the requisite output signals.
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Operational Theory 3000ZA2G
Figure 2-2: Zirconia Sensor Assembly
2.3 Sample System
The sample system delivers gases to the ZrO2 sensor from the
analyzer rear panel inlet. Depending on the mode of operation either
sample or calibration gas is delivered.
The Model 3000ZA2G 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 system for the standard instrument incorporates 1/8”
tube fittings for sample inlet and outlet at the rear panel. The sample or
calibration gas that flows through the system is monitored by a
flowmeter downstream from the cell.
Figure 2-3 shows the flow diagram. Shaded portions of the diagram
pertain to instruments with other options as listed. In the standard
instrument, calibration gases can be connected directly to the Sample In
port by teeing to the port with appropriate valves.
Teledyne Analytical Instruments 10
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