Teledyne 3220 User Manual

Oxygen Monitor System

T eledyne Analytical Instruments

3220

Oxygen Monitor System

P/N: M73831

ECO# 01-0267

10/05/01

Teledyne Analytical Instruments i

Model 3220

Instruction Manual

Model 3220

Multi-Channel

Oxygen
Monitor

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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Oxygen Monitor System

Teledyne Analytical Instruments iii

Model 3220

Copyright © 2001 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 (TAI) 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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Oxygen Monitor System

Specific Model Information

The Instrument for which this manual was supplied may incorporate
one or more options not present in the standard instrument. If such options
were specified at the time of purchase, an addendum describing the unique
features and specifics of the included options will be included with this
manual. Please check the frontmatter of this manual to see if an addendum
has been included.

Instrument Serial Number: _______________________

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Model 3220

Important Notice

The Model 3220 is a safety monitor, however, it is the responsibility
of the user to establish whether or not the total system of instrument,
environment, alarm components, and any other relevant devices actually
will assure safety under the particular circumstances of use.

Location of the equipment and sensors that will insure proper
operation is the responsibility of the user.

The safety checklist outlined below is only a guide. It is up to the user
to establish practical safety precautions given his/her own specific

circumstances. It is vital that the operator understand and test the

operation of the total system.

Safety Checklist

 Verify that the instrument is powered correctly.
 Verify that the instrument works properly (all functions).
 Verify that alarm conditions produce the intended results.
 Verify that unauthorized personnel cannot tamper with the

instrument or its auxiliary equipment.

 Institute routine test/calibration procedures.
 Identify and handle any potential problems in sampling or location.
 Train all operators to understand all operations and functions of the

analyzer and the system.

 Identify and handle any environmental or other influences that

could affect the operation of the instrument.

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Oxygen Monitor System

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.

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.

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

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Model 3220

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 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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Oxygen Monitor System

Table of Contents

Important Notice...........................................................................vi

Safety Checklist vi

Safety Messages .........................................................................vii

Table of Contents.........................................................................ix

List of Figures..............................................................................xii

List of Tables..............................................................................xiii

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

1.1 Overview 1

1.2 Description 1

1.2.1 System Chassis (19” Rack) 2

1.2.2 Control Unit 2

1.2.3 Channel Modules 2

1.2.3.1 Main Features of the Channel Module 2

1.2.4 Remote Probe Assemblies 4

Operational Theory .......................................................................6

2.1 Introduction 6

2.2 System Chassis 6

2.3 Control Unit 6

2.4 Channel Module 8

2.5 Micro-fuel Cell 10

2.5.1 Anatomy of a Micro-Fuel Cell 10

2.5.2 Electrochemical Reactions 12

2.5.3 The Effect of Pressure 12

2.5.4 Calibration Characteristics 13

2.5.4 Micro-Fuel Cell “Class” 14

2.5.4.1 Class A-3 Cell 14

2.5.4.2 Class A-5 Cell 14

2.5.4.3 Class B-1 Cell 14

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Model 3220

2.5.4.4 Class B-3 Cell 14

2.5.4.5 Class C-3 Cell 15

2.5.4.6 Hydrogen and/or Helium Service 15

Installation...................................................................................16

3.1 Unpacking the Analyzer 16

3.2 System Chassis 16

3.2.1 Location 16

3.2.2 Power 16

3.3 Electrical Connections 17

3.4 Probe Assemblies 17

3.5 Micro-Fuel Cell 18

3.6 Control Unit 19

3.6.1 Control Unit Fuses 19

3.6.2 Control Unit Jumper Settings 20

3.7 Channel Modules 22

3.7.1 Removing the Channel Module Cover 22

3.7.2 Changing the Fuse 22

3.7.3 Configuring the Internal Jumper Connections 23

Operation.....................................................................................25

4.1 Introduction 25

4.2 Control Unit Operation 25

4.2.1 System Power Switch and LED 25

4.2.2 Audible Alarm Switch and Bypass LED 25

4.2.3 Fuses 26

4.2.4 RS485 Port 26

4.3 Channel Module Front Panel Controls and Indicators 26

4.4 Calibration Procedures 30

4.4.1 Zero Calibrating a Single Sensor Channel Module 30

4.4.2 Span Calibrating a Channel Module 31

4.4.5 Using the “1MAN” Calibration Option 31

4.4.5.1 Zero and Span Calibrating a Channel Module 31

4.5 Alarm Configuration Procedures 32

4.5.1 Defining the Setpoint for Alarm 1 and Alarm 2 32

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Oxygen Monitor System

4.5.2 Configuring Alarm Relay Settings 33

4.5.2.1 Setting the Fail-safe or Non-Fail-safe Mode 33

4.5.2.2 Setting the Latching or Non-Latching Mode 33

4.5.2.3 Setting Alarms to Hi or Lo 34

4.6 Setting the ID Code 34

4.7 Enabling/Disabling the Pass Code 35

4.8 Range Set-Up 36

4.9 Cell Failure Set-Up 37

4.10 Routine Operation 38

4.11 FAIL Alarm Conditions 37

Failure and Error Codes..............................................................38

5.1 Failure Codes 38

5.2 Error Codes 38

Appendix......................................................................................40

A-1 Specifications 40
Recommended Spare Parts List 41
Drawing List 42
Index 45

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Model 3220

List of Figures

Figure 1-1: Model 3220 System......................................................1

Figure 1-2: Control Unit...................................................................2

Figure 1-3: The Channel Module..................................................... 3

Figure 2-1: Control Unit Front Panel................................................7

Figure 2-2: Control Unit Block Diagram...........................................7

Figure 2-3: Block Diagram of the Signal Processing Electronics.....9

Figure 2-4: Micro-fuel Cell.............................................................10

Figure 2-5: Cross Section of a Micro-fuel Cell...............................11

Figure 2-6: Characteristic Input/Output Curve for MFC.................13

Figure 3-1: Oxygen Probe Assembly.............................................18

Figure 3-2: Fuse Location .............................................................23

Figure 4-1: RS-485 Port on Control Unit .......................................26

Figure 4-2: Display Panel Configuration........................................29

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Oxygen Monitor System

List of Tables

Table 3-1: Control Unit Jumper Configuration...............................20

Table 3-2: Fail-safe/Non Fail-safe Alarm Configuration.................20

Table 3-3: External Alarm—Failsafe/Non-failsafe Configuration ...21

Table 3-4: External Alarm—Contact Closure.................................21

Table 3-5: External Alarm—Line Voltage to External Connection.21

Table 3-6: Channel Module Internal Jumper Settings ...................23

Table 3-7: RS-485 Jumper Settings..............................................24

Table 3-8: Jumper Settings for Channel Module Output ...............24

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Model 3220

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Oxygen Monitor System 1 Introduction

Introduction

1.1 Overview

The Teledyne Analytical Instruments (TAI) Model 3220 Oxygen
Monitor System is a multi-channel system that can be used for determining
the concentration of oxygen gas in an atmosphere at a number of remote
locations. The system provides alarm information when the oxygen
concentration exceeds user definable limits at any one or all of the remote
locations.

The oxygen gas content of the atmosphere is determined by a number
of remotely located sensors that may be strategically placed to monitor the
atmosphere surrounding their location.

The system is designed to provide indications of the state of each
sensor and to actuate individual external alarm indicators as well as alarms
common to all channels. The alarms are user-configurable.

1.2 Description

The 3220 system is comprised of a System Chassis, Control Unit,
Channel Modules, and Remote Probe Assemblies. Each System Chassis
contains one Control Unit and up to eight Channel Modules.

Figure 1-1: Model 3220 System

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1 Introduction Model 3220

1.2.1 System Chassis (19” Rack)

The System Chassis provides structural support and electrical
interconnection for the Control Unit and Channel Modules (up to eight
Channel Modules may be installed). The Channel Modules plug into the
sockets built into the System Chassis. Terminal strips at the rear of the
System Chassis provide for external electrical connections.

1.2.2 Control Unit

The Control Unit handles power distribution to the entire system. The
main power is controlled by a switch on the front panel and the system
fuses are accessible from the front. The Control Unit also contains common
alarm relays which indicate alarm conditions whenever any of the Channel
Modules alarm. The Control Unit is shown in Figure 1-2.

Figure 1-2: Control Unit

1.2.3 Channel Modules

Each Channel Module is a complete, self-contained instrument
including integral power supply and requires only external AC power
which it receives from the System Chassis socket. A channel is operational
when plugged into the System Chassis.

Because a Channel Module plugs into the Control Unit, channels can
easily be added to any control module with less than eight Channel
Modules even after installation to monitor additional locations. Channel
Modules in the same System Chassis may still be configured
independently. A Channel Module is shown in Figure 1-3.

1.2.3.1 MAIN FEATURES OF THE CHANNEL MODULE

The main features of the Channel Module include:

• High resolution LCD display readout

• Drop-in replacement for Model 322 instruments

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Oxygen Monitor System 1 Introduction

ZERO SPAN 1MAN

R1 R2 A F CF
A1 L H N LCH N FS
A2 L H N LCH N FS

PERCENT OXYGEN

ALARM 1

ALARM 2

FAIL

POWER

RUN

ENTER

SELECT

BYPASS

RESET

Figure 1-3: The Channel Module

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1 Introduction Model 3220

• 1MAN calibration capability

• Membrane switch control

• Microprocessor based electronics

• Two concentration alarms with adjustable set-points

• System failure alarm

• User-friendly touch key controls

• Passcode protection

• Failure codes and testpoints

• Two selectable analog outputs (0-10V DC or negative ground

4-20 mA DC

• Compact and versatile design: small footprint with accessible

internal PCBs

1.2.4 Remote Probe Assemblies

Each Control Unit allows for up to eight remote probe assemblies.
These assemblies can be of standard configuration (see Probe Assembly
Outline Drawing in the drawing section of the Appendix) or special design
(if equipped, unique features are described in an included addendum to this
manual) depending on the application requirement. In either case, the
probes can be located almost any distance (up to 1000 ft or more!) from the
System Chassis.

Each probe assembly, when placed into service, will contain a Micro­fuel Cell, a temperature compensating thermistor and auxiliary sample
handling equipment (if required). The Micro-fuel Cell is packaged in a gas
barrier bag and should not be installed in the probe assembly until after
installation of all other components of the system has been accomplished.

Temperature compensation is affected over the range 0-50°C and to an
accuracy of ±5% of full scale. If other than diffusion sampling is to be
employed, it is assumed that the sample gas will be brought to ambient
temperature. The cell and thermistor must always be kept at the same
temperature, otherwise the resultant differential temperature of these two
components can cause inaccuracies in excess of those specified.

If the ambient temperature at the probe assembly can drop below 0°C
(32°F), auxiliary heating should be employed. Normally this condition is
noted at the time of purchase and specially configured probes will have
been provided. TAI can provide sampling probes to cope with most all

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