Teledyne 3190Z User Manual

Trace Oxygen Analyzer

OPERATING INSTRUCTIONS FOR

Model 3190Z

Trace Oxygen Analyzer

P/N M3190Z

6/09/09

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 authorized personnel should conduct maintenance and/or servicing.

Before conducting any maintenance or servicing, consult with authorized supervisor/manager.

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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 Instruments / 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 TI/AI 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 use r, an d serves as a tool b y whic h 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 TI/AI 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 Instruments/ 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

Safety Messages

Your safety and the safety of others is 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.

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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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 operation and maintenance 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 TI/AI 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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Table of Contents

Safety Messages .......................................................................... iii

Introduction ................................................................................... 1

1.1 Overview 1

1.2 Main Features of the Analyzer 1

1.3 Front Panel Description 2

1.4 Rear Panel Description 3

Operational Theory ....................................................................... 7

2.1 Introduction 7

2.2 Zirconium Oxide Sensors 7

2.2.1 Principles of Operation 7

2.2.2 The Effect of Pressure 8

2.3 Electronics 8

2.3.1 General 8

2.3.2 Signal Processing 9

3.1 Unpacking the Analyzer 11

3.2 Location and Mounting 12

3.2.1 Control Unit Installation 12

3.2.2 External Probe Installation 12

3.3 Electrical Connections 12

3.4 Gas Connections 16

3.5 Installation Checklist 16

Operation ..................................................................................... 17

4.1 Introduction 17

4.2 Using the Function and Data Entry Buttons 18

4.3 Setting the Analysis Ranges 18

4.3.1 HI Range 19

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4.3.2 LO Range 19

4.4 Setting the Alarm Setpoints 19

4.4.1 HI Alarm 19

4.4.2 LO Alarm 19

4.4.3 Sensor Fail Alarm 20

4.5 Selecting a Fixed Range or Autoranging 20

4.6 Calibration 20

4.7 LED Display on StartUp 21

Maintenance ................................................................................ 23

5.1 Replacing the Fuse 23

5.1.1 AC Powered Units 23

5.1.2 DC Powered Units 24

5.2 Sensor Installation or Replacement 24

5.2.1 When to Replace a Sensor 24 A.1 Specifications 25 A.2 Spare Parts List 26 A.4 Miscellaneous 27

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DANGER

COMBUSTIBLE GAS USAGE

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.

WARNING

The customer should ensure that the principles of operating 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 Instruments/ Analytical Instruments, referred as TI/AI, no responsibility by TI/AI, its affiliates, and agents for damage or injury from misuse or neglect of this equipment is implied or assumed.

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Trace Oxygen Analyzer Introduction

Introduction

1.1 Overview

The Teledyne Electronic Technologies Analytical Instruments (TETAI) Model 3190Z is a microprocessor-based trace oxygen analyzer for real-time measurement of trace amounts of oxygen in inert gases, or in a wide variety of gas mixtures. It features simple operation, fast response, and a compact, rugged construction.

1.2 Main Features of the Analyzer

The main features of the analyzer include:

• High resolution, accurate readings of oxygen content from 0-10

parts per million (ppm) through 0-1,000 ppm. Large, bright, light-emitting-diode meter readout

• Simple pushbutton controls

• Advanced Zirconium Oxide measuring technology sensors

• Fast response and recovery time

• Microprocessor based electronics: 8-bit CMOS with on-board

RAM and 16 KB ROM

• Two user selectable ranges (depending on sensor configuration)

allow best match to user’s process and equipment

• Operator can select auto-ranging, allowing the analyzer to

automatically select the proper preset range for a given measurement or lock the analyzer onto a single range

• Two concentration alarms with adjustable set-points

• Three analog outputs: two for measurement (0–10 VDC and

negative ground 4–20 mADC) and one for range identification (0-10 VDC).

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Introduction Model 3190Z

• Compact and rugged control unit with flush-panel case.

Designed for indoor use. Front panel NEMA-4 rated.

• External probe

1.3 Front Panel Description

All controls and displays except the power switch are accessible from the front panel. See Figure 1-1. The front panel has seven pushbutton membrane switches, a digital meter, and an alarm indicator LED for operating the analyzer. These features are described briefly here and in greater detail in Chapter 4 - Operation.

Figure 1-1: Front Panel

Function Keys: Seven pushbutton membrane switches are used to select the function performed by the analyzer:

• Set HI Alarm Set the concentration ABOVE which an

alarm activates.

• Set LO Alarm Set the concentration BELOW which

an alarm activates.

• Set HI Range Set the high analysis range for the

instrument (up to 0-1,000 ppm).

• Set LO Range Set the low analysis range for the

instrument (down to 0-1,000 ppm).

• Span Span-calibrate the analyzer.

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Data Entry Keys: Two pushbutton membrane switches are used to manually change measurement parameters of the instrument as they are displayed on the LED meter readout:

 Up Arrow Increment values of parameters upwards

as they are displayed on the LED readout.

• Down Arrow Increment values of parameters

downwards as they are displayed on the LED readout.

Digital LED Readout: The digital display is a LED device that produces large, bright, 7-segment numbers that are legible in any lighting environment. It has two functions:

• Meter Readout

As the meter readout, it displays the oxygen concentration currently being measured.

• Measurement Parameters Readout

It also displays user-definable alarm set-

points, ranges, and span calibration point when they are being checked or changed.

1.4 Rear Panel Description

The rear panel contains the electrical input and output connectors. Separate rear panel illustrations are shown in Figure 1-2 for the AC and DC powered versions of the instrument. The connectors are described briefly here and in detail in the Chapter 3 - Installation.

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