Teledyne 3010MB User Manual

Percent Paramagnetic Oxygen Analyzer

OPERATING INSTRUCTIONS

Model 3010MB

Percent Paramagnetic

Oxygen Analyzer

Bulkhead Mount Control Unit, PN D-71385

Bulkhead Mount Analysis Unit, PN D-71394

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 xxxxxx

12/21/99

ECO: #99-0000

Model 3010MB

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 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 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.

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

conditions.

Teledyne Analytical Instruments

Percent Paramagnetic Oxygen Analyzer

Table of Contents

Specific Model Information ................................ iv

Preface................................................................ v

Part I: Control Unit, Model MB.............. Part I: 1-1

Part II: Analysis Unit, Model M ............ Part II: 1-1

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

Teledyne Analytical Instruments

iii

Model 3010MB

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 was supplied are indicated by a check mark in the box.

Instrument Serial Number: __________________________

Teledyne Analytical Instruments

Percent Paramagnetic Oxygen Analyzer

Preface

Overview

The Analytical Instruments Model 3010MB Percent Paramagnetic Oxygen Analyzer is a versatile microprocessor-based instrument for detecting parts-per-million (ppm) levels of oxygen in a variety of background gases. It is a “split architecture” instrument. This means that a general purpose Control Unit, designed for nonhazardous areas only, remotely controls a specially designed Analysis Unit, or remote probe.

Part I of this manual covers the Model 3010MB General Purpose NEMA 4 Bulkhead mount Control Unit only. This Control Unit is for outdoor/indoor use in a nonhazardous environment. The Analysis Units (or Remote Probes) it controls, can be designed for a variety of hazardous environments. Part II of this manual covers the 3010M Analysis Unit.

Typical Applications

A few typical applications of the Model 3010MB are:

• Monitoring inert gas blanketing

• Air separation and liquefaction

• Chemical reaction monitoring

• Semiconductor manufacturing

• Petrochemical process control

• Quality assurance

• Gas analysis certification.

Teledyne Analytical Instruments

Model 3010MB

Main Features of the Analyzer

The Model 3010MB 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.

• Stainless steel sample system.

• 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 0-5 % through 0-100 %) allow best match to users 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.

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

• Analog outputs for concentration and range identification. (0-1 VDC standard, and isolated 4–20 mADC)

Teledyne Analytical Instruments

Part I: Control Unit

OPERATING INSTRUCTIONS

Model 3010MB

Oxygen Analyzer

Part I: Control Unit

NEMA 4 Bulkhead Mount

Part Numbers: D-71385

Teledyne Analytical Instruments

Part I: i

Model 3010MB Percent Paramagnetic Oxygen Analyzer

Table of Contents

1 Introduction

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

1.2 Control Unit Inner Control Panel .................................... 1-1

1.3 Recognizing Difference Between LCD & VFD............... 1-3

1.4 Control Unit Interface Panel ........................................... 1-4

2 Operational Theory

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

2.2 Electronics and Signal Processing ................................ 2-1

3 Installation

3.1 Unpacking the Control Unit............................................ 3-1

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

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

3.4 Testing the System......................................................... 3-12

4 Operation

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

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

4.3 The

4.3.1 Tracking the O2 Readings during Calibration ......... 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 ...................................................... 4-10

4.3.7 Showing Negative Oxygen Readings.................... 4-10

4.4 The

4.4.1 Zero Cal................................................................. 4-11

System

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

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

Zero

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

and

Span

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

ii: Part I

Teledyne Analytical Instruments

Part I: Control Unit

4.4.1.1 Auto Mode Zeroing ........................................ 4-11

4.4.1.2 Manual Mode Zeroing.................................... 4-12

4.4.1.3 Cell Failure .................................................... 4-13

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

4.4.2.1 Auto Mode Spanning ..................................... 4-14

4.4.2.2 Manual Mode Spanning................................. 4-16

4.4.3 Span Failure .......................................................... 4-16

4.5 The

4.6 The

4.6.1 Setting the Analog Output Ranges......................... 4-19

4.6.2 Fixed Range Analysis............................................ 4-20

4.7 The

4.8 Signal Output ................................................................. 4-21

5 Maintenance

Alarms Range

Analyze

Function...................................................... 4-15

Function ...................................................... 4-18

Function.................................................... 4-20

5.1 Fuse Replacement ......................................................... 5-1

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

5.3 Major Internal Components............................................ 5-3

A Appendix

Model 3010MB Specifications ............................................... A-1

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Part I: iii

Model 3010MB Percent Paramagnetic Oxygen Analyzer

iv: Part I

Teledyne Analytical Instruments

Percent Paramagnetic Oxygen Analyzer Part I: Control Unit

Introduction

1.1 Overview

The Analytical Instruments Model 3010MB Analyzer Control Unit, together with a 3010M Analysis Unit, is a versatile microprocessor-based instrument for detecting percent amounts of oxygen in a variety of gases.

Part I, this part, of this manual covers the Model 3010MB series General Purpose NEMA 4 Bulkhead mount Control Units. (The Analysis Unit is covered in Part II of this manual.) The Control Unit and Analysis Unit is for indoor/outdoor use in a nonhazardous environment only.

1.2 Control Unit Inner Control Panel

The standard 3010MB Control Unit is housed in a rugged NEMA 4 metal case with all remote controls and displays accessible from the inner control panel. See Figure 1-1. The inner control panel has a digital meter, an alphanumeric display, and thirteen buttons for operating the analyzer.

Teledyne Analytical Instruments

Part I: 1-1

1 Introduction Model 3010MB

Outer Door

(Open)

Teledy ne Analy tic al Ins trument

Viewing Window

Outer Door

Latch

0.0 % Anlz AL-1

3010MB Series

Paramagnetic Oxygen Analyze

Figure 1-1: Front of Unmounted Control Unit

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.

1-2: Part I

• Zero Zero calibrate the analyzer.

• Alarms Set the alarm setpoints and attributes.

• Range Set up the 3 user definable ranges for the instrument.

Teledyne Analytical Instruments

Percent Paramagnetic Oxygen Analyzer Part I: Control Unit

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.

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

none remains, returns to the

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

series. If none remains, returns to the

Digital Meter Display: The meter display is a LED device that produces large, bright, 7-segment numbers that are legible in any lighting. It is accurate across all analysis ranges. The –MB model produce continuous readout from 0-1% through 0-100%.

Analyze

screen.

Analyze

screen.

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

I/OI/O

I/O Power Button: The red I/O button switches the instrument power

I/OI/O

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 must be disconnected to fully

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

Access Door: For access to the electronics and interface panel, the front panel swings open when the latch in the upper right corner of the panel is pressed all the way in with a narrow gauge tool. Accessing the main circuit board and other electronics requires unfastening the rear panel screws and sliding the unit out of the case.

1.3 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.

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Part I: 1-3

1 Introduction Model 3010MB

1.4 Control Unit Interface Panel

The Control Unit interface panel, shown in Figure 1-2, contains the electrical terminal blocks for external inputs and outputs. The input/output functions are described briefly here and in detail in the Installation chapter of this manual.

1-4: Part I

Figure 1-2: Model 3010MB Rear Panel

Teledyne Analytical Instruments

Percent Paramagnetic Oxygen Analyzer Part I: Control Unit

• Power Connection AC power source, 100-240VAC, 50/60

• Analog Outputs 0-1 V dc concentration and 0-1 V dc

range ID. Isolated 4-20 mA dc and 4-20 mA dc range ID.

• Alarm Connections 2 concentration alarms and 1 system

alarm.

• RS-232 Port Serial digital concentration signal output

and control input.

• Remote Probe Provides all electrical interconnect to the

Analysis Unit or Remote Probe.

• 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.

• Remote Probe Interfaces with an Analysis Unit or

Remote Probe (external sensor/sample system).

• Network I/O Serial digital communications for local

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

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

Auto-Cal control where possible. The internal clock in the Model 3010MB is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day.

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Part I: 1-5

1 Introduction Model 3010MB

1-6: Part I

Teledyne Analytical Instruments

Percent Paramagnetic Oxygen Analyzer Part I: Control Unit

Operational Theory

2.1 Introduction

The Model 3010MB Oxygen Analyzer Control Unit uses an 80C31 microcontroller with 32 kB of RAM and 128 kB of ROM to control all signal processing, input/output, and display functions for the Model 3010MB analyzer. (The sample system and Paramagnetic sensor are covered in Part II, Analysis Unit, in this manual.) System power is supplied from a universal power supply module designed to be compatible with any international power source.

2.2 Electronics and Signal Processing

All of the Analyzer electronics are located on Printed Circuit Board (PCB) assemblies inside the Control Unit chassis. The PCB locations are illustrated in section 5, Maintenance.

Refer to Figure 2-1, Block Diagram of the 3010MB CU Electronics:

In the presence of oxygen, the sensor (in the Analysis Unit) generates a current. A current to voltage amplifier (in the Control Unit) converts this current to a voltage.

The second stage amplifier amplifies the voltage. 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 as well as to the gas control valves in the Analysis Unit.

The same digital information is also sent to a 12 bit digital to analog converter that produces the 4-20 mA dc and the 0-1 V dc analog concentration signal outputs, and the analog range ID outputs.

The microprocessor monitors the power supply, and activates the system failure alarm if a malfunction is detected.

Teledyne Analytical Instruments

Part I: 2-1

2 Operational Theory Model 3010MB

Sensor*

*F rom Analysis Unit

To Analysis Unit Control V alv es

Current

to V oltage

Amplifier

Auto

Rang

Second

Stage

Amplifier

Power

Supply

System

F ailure

Alarm

Con

Display

Self Test Signal

Figure 2-1: Block Diagram of the 3010TB CU Electronics

2-2: Part I

Teledyne Analytical Instruments

Percent Paramagnetic Oxygen Analyzer Part I: Control Unit

Installation

Installation of Model 3010MB Analyzers includes:

1. Unpacking, mounting, and interconnecting the Control Unit and the Analysis Unit

2. Making gas connections to the system

3. Making electrical connections to the system

4. Testing the system.

This chapter covers installation of the Control Unit. (Installation of the

Analysis Unit is covered in Part II of this manual.)

3.1 Unpacking the Control Unit

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

3.2 Mounting the Control Unit

The Model 3010MB Control Unit is for indoor/outdoor use in a general purpose area. This Unit is NOT for any type of hazardous environments.

The standard model is designed for indoor/outdoor mounting. Figure 31 is an illustration of a Model 3010MB standard Control Unit front panel and mounting brackets located-two at the top and two at the bottom of the units frame.

Teledyne Analytical Instruments

Part I: 3-1

3 Installation Model 3010MB

NPT Fitting

supplied by

customer

0.0

AL-1

AC POWER IN

50/60 HZ

100-240V

3/4" NPT

ALARM OUTPUTS

DIGITAL INPUT SPAN ZERO

CAL. CONTACT RANGE

ID CONTACTS RS-232

SOLENOID RETUR

ANALOG OUTPUTS

REMOTE SENS O R

NET WORK

Figure 3-1: Front Panel of the Model 3010MB Control Unit

All operator controls are mounted on the inner control panel, which is hinged on the left edge and doubles as a door to provide access to the internal components of the instrument. The door will swing open when the button of the latch is pressed all the way in with a narrow gauge tool (less than 0.18 inch wide), such as a small hex wrench or screwdriver Allow

3/4" NPT

1" NPT

3-2: Part I

Teledyne Analytical Instruments

Percent Paramagnetic Oxygen Analyzer Part I: Control Unit

clearance for the door to open in a 90-degree arc of radius 11.75 inches. See Figure 3-2.

11.75

Figure 3-2: Required Front Door Clearance

3.3 Electrical Connections

Figure 3-3 shows the Control Unit interface panel. Connections for power, communications, and both digital and analog signal outputs are described in the following paragraphs. Wire size and maximum length data appear in the Drawings at the back of this manual.

Figure 3-3: Interface Panel of the Model 3010MB Control Unit

For safe connections, ensure that no uninsulated wire extends outside of the terminal blocks that 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.

Teledyne Analytical Instruments

Part I: 3-3

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