Teledyne 326, 327, 328 User Manual
Models 326, 7, & 8
Oxygen Analyzers
Instruction Manual
Teledyne Analytical Instruments
P/N M33776
6/29/95
i
Notice
Important safety information is to be found on
the following page, under the title
Notice
manual under the title
, and on the last three pages of this
Material Safety Data
Important
Be sure all personnel involved in the installation and operation of this equipment understand this information and are impressed
with its importance.
Note
Specific Application Information for the instrument with which this manual is supplied
is on page iv just prior to the Table of Con-
.
tents.
ii
Teledyne Analytical Instruments
Copyright © 1994 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 Brown Engineering 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), 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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iii
Specific Application DataSpecific Application Data
Specific Application Data
Specific Application DataSpecific Application Data
TAI Sales Order Number:
Customer Order Number:
Instrument Model Number:
Instrument Serial Number:
Micro-Fuel Cell Class:
Accuracy:
Response and Recovery:
Operating Temperature Range:
Range of Analysis:
Output Signal Voltage:
Output Signal Current:
Alarm Setpoint #1:
Alarm Setpoint #2:
Special Features (may be covered by addendum.):
iv
Teledyne Analytical Instruments
Table of Content
1 Introduction
1.0 Series Description ....................................................................... 1-1
1.1 Model Designations .................................................................... 1-2
1.2 Models 326R Description ........................................................... 1-2
1.3 Models 327R Description ........................................................... 1-3
1.4 Models 327RAC/RBC Description............................................. 1-3
1.5 Models 328R Description ........................................................... 1-4
1.6
2 Operational Theory
2.1 Principles of Operation ............................................................... 2.1
2.1.1 Micro-Fuel Cell Sensor................................................ 2.3
2.1.2 Sample System............................................................. 2.3
2.1.3 Electronics and Signal Processing ............................... 2.5
3 Operations
3.1 Front Panel Controls................................................................... 3.1
3.2 Modes of Operation .................................................................... 3.2
Cold Start-Up ....................................................................... 3.5
Calibration Zeroing ............................................................... 3.6
Calibration Using Span Gas .................................................. 3.8
Select Active Sensor ............................................................. 3.11
Install Sensor and Test Alternate Sensor .............................. 3.12
O2 Range Set-Up................................................................... 3.14
Set-up Alarms ....................................................................... 3.15
Logger Set-Up ...................................................................... 3.17
Set-Up Clock Functions........................................................ 3.19
Changing Passwords For Remote
Monitoring and Control ............................................ 3.21
System Statistics ................................................................... 3.23
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4 Installation
4.1 Unpacking the Analyzer.............................................................. 4.1
4.2 Micro-Fuel Cell Installation or Replacement .............................. 4.2
4.3 Electrical Connections ................................................................ 4.2
Front Panel............................................................................ 4.4
Rear Panel ............................................................................. 4.4
Voltage Selection.................................................................. 4.6
Fuse Changing....................................................................... 4.7
Parallel and Serial Ports ........................................................ 4.8
4.4 Gas Line Connections ................................................................. 4.9
4.5 Installation Checklist................................................................... 4.10
5 Maintenance & Troubleshooting
5.1 Routine Maintenance .................................................................. 5.1
5.2 Troubleshooting.......................................................................... 5.2
Appendices
A.1 Specifications Sheet ................................................................... A.1
A.2 Spare Parts List .......................................................................... A.3
A.3 Material Safety Data Sheet ........................................................ A.4
vi
Teledyne Analytical Instruments
IntroductionIntroduction
Introduction
IntroductionIntroduction
326, 327, and 328) analyzers use a unique Micro-Fuel Cell to measure the
concentration of oxygen in a gas stream. The analyzer can be housed in a
compact equipment case, a 19-inch rack mount unit, an explosion-proof
bulkhead-mounted enclosure, or separately from the panel-mounted control
unit.
Model 326/327/328Model 326/327/328
Model 326/327/328
Model 326/327/328Model 326/327/328
Introduction
The Teledyne Analytical Instruments (TAI) Model 326 series (Models
The Micro-Fuel Cell (U.S. Patent No. 3,429,796) is a maintenance-free,
disposable, solid-state unit whose performance and usable life are guaranteed by TAI. The cell consumes oxygen from the gas around it and generates a proportional microampere current. The low level signal is then amplified by a solid-state, integrated circuit (IC) amplifier. The resulting DC
signal drives a temperature compensation circuit for the cell, and an integral
meter. The output signal is available at the analyzers terminal strip and is
linear over the specified ranges of analysis. It is suitable for driving a highimpedance recording device.
The Micro-Fuel Cell responds accurately to the presence of oxygen,
regardless of flowrate. The measuring cell does not generate an output
current unless oxygen is present in the sample gas. Therefore, the instrument has an absolute zero, and no zero gas is required to standardize the
analyzer. The analyzer can be calibrated using atmospheric air as a span
gas, providing one of the three ranges of analysis encompasses the oxygen
content of air.
The Model 326 series analyzers have three standard ranges: 0–5 % O
0=10 % O2, and 0–25 % O2.
In some instances an outer enclosure may contain the analyzer and other
related devices, such as sample system components or other analyzers.
These special designs are supported by special drawings included with the
standard drawings at the rear of the instruction manual. Use those drawings
in conjunction with the standard drawings, and note any differences.
,
2
Specific models in the 326 series are described in the following paragraphs. Be sure to read the description of the model you have purchased.
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See
Specific Application Information
Table of Contents.
The basic model number of each of the analyzers (326, 327, and 328)
has a suffix that describes the options included. Suffixes for the standard
options are listed below.
R: Electronic motherboard designed with receptacles for
A: Panel mount
B: Bulkhead mount
O: Isolated current output
-2: Dual alarm setpoint
X: Special configuration as specified at the time of order.
C: CENELEC (Comité Européen de Normalisation
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1.1 Model Designation
standardized plug-in support circuitry, such as linearized or
custom output modules.
Electrotecnique) version.
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for your instrument in front of the
Section 1Section 1
Section 1
Section 1Section 1
1.2 Models 326R Description
The Model 326R is a general purpose version designed for use in nonhazardous areas. The electronics circuits, Micro-Fuel Cell, and other sample
handling components are all packaged as a single unit. In some applications,
such as the Model 9150 Flue Gas system, the immediate enclosure may not
be used, since the entire system is housed in a system enclosure. In those
cases the electronics are mounted upon a backplate, rather than within the
Model 326 enclosure.
Mounting styles for the analyzer include panel mount (Model 326RA),
surface or bulkhead mount (Model 326RB), and bulkhead mount NEMA-4
(Model 326RBN). Though the physical appearance differs according to the
mounting style, analyzer functions are the same.
Sample flow controls for the Model 326R are mounted on a gas selector
panel below or to the right of the front panel. Electrical controls and
terminal strip are accessible from the back of the analyzer in the 326RA and
behind the front panel, which swings open, in the 326RB. The sensor is
located behind the door on the front panel of the analyzer. The flow rate is
displayed by a flowmeter, which is mounted on, to the right of, or behind
the control panel. In other cases, a separate panel may be used to contain
valves for sample selection and flow control. When the analyzer is used as
part of a system, various means of sample handling may be used A piping
1-2
Teledyne Analytical Instruments
IntroductionIntroduction
Introduction
IntroductionIntroduction
diagram is then included with the drawings in the instruction manual to
illustrate the sample flow path.
specific explosion-proof design is dependent on area classification and the
specific installation. For example, the analysis section of the 327R containing the Micro-Fuel Cell, and related conditioning components, can be
housed in an explosion-proof enclosure. If the sensor is placed within the
process or in a flow-through block, such that the explosion-proof classification is maintained, then no analysis section enclosure may be necessary.
aluminum enclosure with a screw-on cover, and is separate from the control
unit, which can be either panel mounted (327RA) or bulkhead mounted
(326RB). The sensor and the electrical interconnections are accessed by
removing the cover on the explosion-proof analysis section. Interconnecting
wiring is fed through sealed fittings in the wall of the enclosure. A sample/
calibrate selector valve and a flow control/flow meter are normally attached
to the outer right-hand wall of the enclosure. The entire analysis section
conforms to the area classification specified at the time of purchase (usually
Class I, Div. I, Group D).
Model 326/327/328Model 326/327/328
Model 326/327/328
Model 326/327/328Model 326/327/328
1.3 Models 327R Description
Model 327R is a semi-explosion-proof version of the 326R series. The
The standard Model 327R analysis section is a bulkhead-mounted, cast
The control unit is designed for remote mounting in nonhazardous areas
and is basically the same control unit as is used for the Model 326R, except
that the measuring cell and related sample handling components are placed
in the analysis section. Panel mount (327RA) and bulkhead mount (327RB)
styles are available for the control unit.
1.4 Models 327RAC/327RBC Description
The 327RAC and 327RBC models have separate control, analysis, and
probe units. The analysis units can be controlled remotely.
In models approved by CENELEC (Comité Européen de Normalisation
Electronique), safety-barrier boxes isolate the probes from the control units,
making them intrinsically safe. In addition, the probes are approved by
BASEEFA (British Approvals Service for Electrical Equipment in Flammable Atmospheres).
The control unit of the 327RAC/RBC has an integral meter, power onoff switch and range switch, protective fuses, sample path selection capability, calibration (span) control, and the various plug-in printed circuit boards
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used to provide both the optional circuitry and the standard electronics
features of the analyzer.
1.5 Models 328R Description
Model 328R is a fully explosion-proof version of the Model 326R and is
completely contained in one or more explosion-proof enclosures as needed
to house the specific components used. Since both the electronics control
and the sample analysis sections of the analyzer must meet hazardous area
classification, they are normally enclosed in a single enclosure and fitted
with explosion-proof operators for switches and potentiometers. These
protrude through the sealed enclosure, which also has a viewing window to
allow observation of the measurement meter.
A commonly used option with the Model 328R is the gas selector panel.
The panel provides selection and flow control of sample or span gas. Sealed
connectors carry the selected gas to the measuring cell inside the explosionproof instrument enclosure.
Section 1Section 1
Section 1
Section 1Section 1
1.6 Models 328RC Description
The Model 328RC Trace Oxygen Analyzer was designed to meet
CENELEC operating standards for European use.
The Model 328RC is housed in an explosion-proof enclosure with a
BASEEFA EExdIIBT6 rating. So that the explosion-proof enclosure does
not have to be opened, the span adjustment, range selection, and alarm
setpoint controls are placed on the exterior of the enclosure.
The analyzer has a separate probe that is attached to a control unit. The
control unit contains safety barriers (see Chapter 2 for more information).
Note:Note:
Note:
Note:Note:
If installed, safety barriers should always be used. It is the user’sIf installed, safety barriers should always be used. It is the user’s
If installed, safety barriers should always be used. It is the user’s
If installed, safety barriers should always be used. It is the user’sIf installed, safety barriers should always be used. It is the user’s
responsibility for installing the probe in an appropriate sampleresponsibility for installing the probe in an appropriate sample
responsibility for installing the probe in an appropriate sample
responsibility for installing the probe in an appropriate sampleresponsibility for installing the probe in an appropriate sample
system and protecting it from environmental factors such as tem-system and protecting it from environmental factors such as tem-
system and protecting it from environmental factors such as tem-
system and protecting it from environmental factors such as tem-system and protecting it from environmental factors such as temperature and RFI.perature and RFI.
perature and RFI.
perature and RFI.perature and RFI.
The Model 328RC contains modular plug-in-type printed circuit boards
(PCB) for temperature regulation, voltage-to-current conversion, comparator alarms, power supplies, and oxygen amplifier circuit. The plug-in PCBs
greatly enhance troubleshooting and repair, since entire circuits can be
stocked as spare parts.
Some of the PCBs contain calibration adjustments, which are shown on
the board schematics. For example, the meter is adjusted with a potentiometer on the motherboard.
1-4
Note:Note:
Note:
Note:Note:
Before supplying power to the analyzer, be sure to check the wiringBefore supplying power to the analyzer, be sure to check the wiring
Before supplying power to the analyzer, be sure to check the wiring
Before supplying power to the analyzer, be sure to check the wiringBefore supplying power to the analyzer, be sure to check the wiring
Teledyne Analytical Instruments
IntroductionIntroduction
Introduction
IntroductionIntroduction
design features do vary in accordance with customer requirements, checkdesign features do vary in accordance with customer requirements, check
design features do vary in accordance with customer requirements, check
design features do vary in accordance with customer requirements, checkdesign features do vary in accordance with customer requirements, check
the Specific Application Information, and any addendumsthe Specific Application Information, and any addendums
the Specific Application Information, and any addendums
the Specific Application Information, and any addendumsthe Specific Application Information, and any addendums
manual, where the distinctive features of your instrument are recorded.
0-25 % oxygen. A rotary switch on the control panel is used to select the
desired analysis range. The standard instrument ranges have been chosen to
best cover the oxygen content of flue gas. Upon request at the time the
order is placed, any range or ranges of analysis from 0-1 % up to 0-100 %
oxygen can be provided.
Model 326/327/328Model 326/327/328
Model 326/327/328
Model 326/327/328Model 326/327/328
against the interconnection diagram.against the interconnection diagram.
against the interconnection diagram.
against the interconnection diagram.against the interconnection diagram.
1.7 Standard Features
The following features apply to the standard 326 series analyzers. Since
included in this
1.7.1 Ranges of Analysis1.7.1 Ranges of Analysis
1.7.1 Ranges of Analysis
1.7.1 Ranges of Analysis1.7.1 Ranges of Analysis
The ranges of analysis for standard instruments are 0-5 %, 0-10 %, and
The oxygen content of atmospheric air (20.9 %) falls within the 0-25 %
range. It is recommended for calibration because it eliminates the need for a
span gas. Note, however, that a span gas is required, if the air around the
analysis unit cannot be used to span the instrument (as in hazardous locations), or if an instrument is ordered without the 0-25 % calibration range.
1.7.2 Meter Readout1.7.2 Meter Readout
1.7.2 Meter Readout
1.7.2 Meter Readout1.7.2 Meter Readout
Standard models are equipped with an accurate (±1/2 % linearity)
3-inch analog meter calibrated to show the concentration of the target gas in
the sample. A linear scale provides reliable, accurate readout of the analysis
at any point on the scale. The resolution and accuracy of the meter eliminates the necessity of an accessory readout device, unless permanent recording or remote indication is required. Digital panel meters are used
when requested by the customer.
1.7.3 Output Signal1.7.3 Output Signal
1.7.3 Output Signal
1.7.3 Output Signal1.7.3 Output Signal
For those applications requiring a remote indication and/or recording of
the sample oxygen, a linear output signal of 0–1 V dc is available at no extra
charge. Unless otherwise specified, the output signal will be 0–1 V dc .
The standard voltage output signal is not suitable for driving low impedance devices. Accessory equipment must have an input impedance of
10,000 ohms or more. Refer to the Current Output (E to I Converter)
section later in this chapter for information on that option.
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Inaccuracies caused by varying temperature conditions are inherent in
most methods of analysis employing transducers. To correct for this, a
system composed of a combination of temperature compensation and
control is used in the 326 series.
To protect the Micro-Fuel Cell against damage from low ambient
temperatures and reduce the range required for the compensation circuit,
the analyzer is equipped with a thermostatically controlled heating system
that will not permit the interior of the instrument to drop below 70 °F.
To eliminate the inaccuracies accompanying the positive temperature
coefficient of the Micro-Fuel Cell, a specially selected thermistor and
network of precision resistors is utilized to produce a negative coefficient of
matching characteristics. The variable element (thermistor) in the compensation network is physically located in the same assembly as the Micro-Fuel
Cell, so that both devices are exposed to essentially the same temperature
conditions.
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1.7.4 Temperature Control and Compensation1.7.4 Temperature Control and Compensation
1.7.4 Temperature Control and Compensation
1.7.4 Temperature Control and Compensation1.7.4 Temperature Control and Compensation
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Section 1Section 1
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Compensation techniques for high temperature conditions (up to 125
°F), allow the user to disturb the integrity of the analyzer (by opening the
door or front panel) without the equalibration time that would normally
accompany systems employing only high temperature control. In addition,
the life of the Micro-Fuel Cell is extended by not subjecting it to the high
ambient temperature that would be required in an exclusively temperaturecontrolled system.
1.7.5 Modular Electronics1.7.5 Modular Electronics
1.7.5 Modular Electronics
1.7.5 Modular Electronics1.7.5 Modular Electronics
The electronic components are mounted on a plug-in printed circuit
board, as are the various optional electronic features, for fast, simple repair.
Although circuit failure is unlikely, plug-in capability of the critical elements
of the circuit facilitates instant solution in the event of a semiconductor
failure—providing the customer backs up his instrument with the recommended spare. The faulty circuit board may then be returned to the factory
for repairs. Having an available spare part is usually more economical the
services of highly trained service personnel. The printed circuit assemblies
are preset and adjusted to be instantly interchanged.
1.8 Optional Features
is placed.
1-6
The following optional features are only available at the time the order
Teledyne Analytical Instruments
IntroductionIntroduction
Introduction
IntroductionIntroduction
alarm and/or control relay circuits with setpoints that are adjustable over the
selected analysis range. The contacts of the relay are available for interconnection with customer circuitry at the terminal strip provided.
integral control circuitry can be arranged so that the relay is energized
above or below the setpoint. Unless otherwise specified, the control relay in
a single setpoint instrument actuates (de-energizes) when the oxygen concentration rises above the setpoint, and the relays in a double setpoint
instrument actuate (de-energize) when the oxygen level is outside the
portion of the analysis range between the two setpoints. These configurations can be used for power supply failure alarms as well as an oxygen
alarm. The Form “C” relay contacts are rated at 3 A (noninductive).
Model 326/327/328Model 326/327/328
Model 326/327/328
Model 326/327/328Model 326/327/328
1.5.1 Integral Alarm Circuitry1.5.1 Integral Alarm Circuitry
1.5.1 Integral Alarm Circuitry
1.5.1 Integral Alarm Circuitry1.5.1 Integral Alarm Circuitry
A number -1 or -2 appended to the model number indicates one or two
The setpoint is set by a potentiometer with a calibrated-dial. The
1.8.2 E to I Converter1.8.2 E to I Converter
1.8.2 E to I Converter
1.8.2 E to I Converter1.8.2 E to I Converter
TBE also offers a current output signal, so that current-to-pneumatic
devices, as well as low impedance current indicating and/or recording
equipment, may be driven directly without the need of accessory equipment.
The current output option is indicated by an “I” in the model number if
the instrument has a grounded current output option, or an “O” if the
output is isolated. This letter designation will be immediately followed by a
one or two digit number which specifies the maximum output. Thus, O-20
signifies an isolated 4 to 20 mA dc current output. The most common
current outputs used are 1 to 5, 4 to 20, and 10 to 50 mA dc.
By special order, isolated voltage outputs from 0–1 mV up to 0–1 V dc
can be provided.
Some common current outputs are:
1. 1–5 mA dc suitable for devices with from 0 to 6000 ohms impedance.
2. 4–20 mA dc suitable for devices with from 0 to 1500 ohms impedance.
3. 10–50 mA dc suitable for devices with from 0 to 600 ohms impedance.
1.8.3 Optional Feature Packaging1.8.3 Optional Feature Packaging
1.8.3 Optional Feature Packaging
1.8.3 Optional Feature Packaging1.8.3 Optional Feature Packaging
Both the integral-alarm and E-to-I converter options are plug-in printed
circuit boards for quick replaceability. When either or both the options are
employed in an instrument, a highly-regulated differential power supply
(also a plug-in type printed circuit board) is included to supply the positive
and negative voltage required by the semiconductor circuitry.
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Section 1
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1-8
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