Teledyne 3290 Instruction Manual
OPERATING INSTRUCTIONS FOR
Model 3290
Percent Oxygen Analyzer
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 M64643
08/06/99
ECO # 99-0323
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Copyright © 1999 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
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.
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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Contents
Introduction
1.1 Overview........................................................................ 1-1
1.2 Main Features of the Analyzer ....................................... 1-1
1.3 Front Panel Description.................................................. 1-2
1.4 Rear Panel Description.................................................. 1-3
Operational Theory
2.1 Introduction .................................................................... 2-1
2.2 Micro-Fuel Cell Sensor .................................................. 2-1
2.2.1 Principles of Operation .......................................... 2-1
2.2.2 Anatomy of a Micro-Fuel Cell................................. 2-2
2.2.3 Electrochemical Reactions .................................... 2-3
2.2.4 The Effect of Pressure............................................ 2-3
2.2.5 Calibration Characteristics ...................................... 2-4
2.3 Electronics ..................................................................... 2-5
2.3.1 General.................................................................. 2-5
2.3.2 Signal Processing .................................................. 2-5
Installation
3.1 Unpacking the Analyzer................................................. 3-1
3.2 Location and Mounting .................................................. 3-2
3.2.1 Control Unit Installation.......................................... 3-2
3.2.2 External Probe Installation..................................... 3-2
3.2.3 Installing the Micro-Fuel Cell ................................. 3-2
3.3 Electrical Connections................................................... 3-3
3.4 Gas Connections ........................................................... 3-6
3.5 Installation Checklist...................................................... 3-6
Operation
4.1 Introduction .................................................................... 4-1
4.2 Using the Function and Data Entry Buttons ................... 4-2
4.3 Setting the Analysis Ranges.......................................... 4-2
4.3.1 HI Range ............................................................... 4-2
4.3.2 LO Range .............................................................. 4-3
4.4 Setting the Alarm Setpoints............................................ 4-3
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4.4.1 Alarm 1 .................................................................. 4-3
4.4.2 Alarm 2 .................................................................. 4-3
4.4.3 Sensor Fail Alarm .................................................. 4-4
4.5 Selecting a Fixed Range or Autoranging ....................... 4-4
4.6 Calibration ..................................................................... 4-4
Maintenance
5.1 Replacing the Fuse........................................................ 5-1
5.1.1 AC Powered Units ................................................. 5-1
5.1.2 DC Powered Units ................................................. 5-2
5.2 Sensor Installation or Replacement ............................... 5-2
5.2.1 When to Replace a Sensor.................................... 5-2
5.2.2 Ordering and Handling of Spare Sensors.............. 5-3
5.2.3 Removing the Micro-Fuel Cell ............................... 5-3
5.2.4 Installing a Micro-Fuel Cell .................................... 5-3
5.2.5 Cell Warranty Conditions ....................................... 5-4
Appendix
A.1 Specifications ................................................................ A-1
A.2 Spare Parts List ............................................................. A-2
A.3 Reference Drawing........................................................ A-3
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Percent Oxygen Analyzer Introduction 1
Introduction
1.1 Overview
The Teledyne Electronic Technologies Analytical Instruments (TETAI)
Model 3290 is a microprocessor-based percent oxygen analyzer for real-time
measurement of the percent of oxygen in inert gases, or in a wide variety of gas
mixtures. It features simple operation, fast response, and a compact, rugged
construction. Typical applications of the Model 3290 are monitoring nitrogen
generators and inert gas blanketing applications.
1.2 Main Features of the Analyzer
The main features of the analyzer include:
• High resolution, accurate readings of oxygen content from 0-1 %
through 0-25 %. Large, bright, light-emitting-diode meter readout.
• Simple pushbutton controls.
• Nylon cell holder.
• Advanced Micro-Fuel Cell, for percent analysis, has a two year
warranty and an expected lifetime of four years.
• Unaffected by oxidizable gases.
• Fast response and recovery time.
• Microprocessor based electronics: 8-bit CMOS microprocessor
with on-board RAM and 16 KB ROM.
• Two user selectable ranges (from 0-1 % through 0-25 %) allow best
match to users process and equipment.
• Air-calibration range for convenient spanning at 20.9 %.
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1 Introduction Model 3290
• Operator can select Autoranging, which allows the analyzer to
automatically select the proper preset range for a given
measurement, or he can lock the analyzer onto a single range.
• Two concentration alarms with adjustable setpoints.
• Sensor failure alarm.
• Three analog outputs: two for measurement (0–10 V dc, and
negative ground 4–20 mA dc) and one for range identification
(0-10 V dc).
• Compact and rugged Control Unit with flush-panel case. Designed
for indoor use. Front panel NEMA-4 rated.
• External Probe can be located six feet or more away, depending on
the existing electromagnetic noise level.
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
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activates.
Percent Oxygen Analyzer Introduction 1
• Set LO Alarm Set the concentration BELOW which an alarm
activates.
• Set HI Range Set the high analysis range for the instrument (up
to 0-25 %).
• Set LO Range Set the low analysis range for the instrument
(down to 0-1 %).
• Span Span calibrate the analyzer.
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 setpoints, 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 Installation chapter of this manual.
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1 Introduction Model 3290
1-4
Figure 1-2 Rear Panel (AC and DC versions)
• Power Connection AC version: 100–240 V ac, at 50/60 Hz.
The connector housing includes the fuse
holder and the power switch.
Fuse Holder: Replacing the fuse is
described in Chapter 5, Maintenance.
I/O Power Switch: Turns the instrument
power ON (1) or OFF (0).
• Analog Outputs 0–10 V dc concentration output.
0–10 V dc range ID (or optional overrange)
output.
4–20 mA dc concentration output, negative
ground.
• Alarm Connections HI Alarm, LO Alarm, and Sensor Failure
Alarm connections.
• External Probe Connects to the Remote Probe or remote
Analysis Unit.
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Percent Oxygen Analyzer Introduction 1
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1 Introduction Model 3290
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Percent Oxygen Analyzer Operational Theory 2
Operational Theory
2.1 Introduction
The analyzer is composed of two subsystems:
1. Analysis Unit with Micro-Fuel Cell Sensor
2. Control Unit with Signal Processing, Display and Controls
The Analysis Unit is designed to accept the sample gas and direct it to the
sensitive surface of the Micro-Fuel Cell sensor. The Micro-Fuel Cell is an
electrochemical galvanic device that translates the amount of oxygen present in
the sample into an electrical current.
The Control Unit processes the sensor output and translates it into electrical
concentration, range, and alarm outputs, and a percent oxygen meter readout. It
contains a microcontroller that manages all signal processing, input/output, and
display functions for the analyzer.
2.2 Micro-Fuel Cell Sensor
2.2.1 Principles of Operation
The oxygen sensor used in the Model 3290 is a Micro-Fuel Cell designed
and manufactured by TAI. It is a sealed, disposable electrochemical transducer.
The active components of the Micro-Fuel Cell are a cathode, an anode,
and the 15% aqueous KOH electrolyte in which they are immersed. The cell
converts the energy from a chemical reaction into an electrical potential that can
produce a current in an external electrical circuit. Its action is similar to that of a
battery.
There is, however, an important difference in the operation of a battery as
compared to the Micro-Fuel Cell: In the battery, all reactants are stored within
the cell, whereas in the Micro-Fuel Cell, one of the reactants (oxygen) comes
from outside the device as a constituent of the sample gas being analyzed. The
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2 Operational Theory Model 3290
Micro-Fuel Cell is therefore a hybrid between a battery and a true fuel cell. (All
of the reactants are stored externally in a true fuel cell.)
2.2.2 Anatomy of a Micro-Fuel Cell
The Micro-Fuel Cell is made of extremely inert plastic (which can be
placed confidently in practically any environment or sample stream). It is effectively sealed, though one end is permeable to oxygen in the sample gas. At the
permeable end a screen retains a diffusion membrane through which the oxygen
passes into the cell. At the other end of the cell is a connector. The connector
mates with a miniature phone jack that provides electrical connection to the
Control Unit.
Refer to Figure 2-1, Basic Elements of a Micro-Fuel Cell, which illustrates the following internal description.
Figure 2-1. Basic Elements of a Micro-Fuel Cell (not to scale)
At the sensing end of the cell is a diffusion membrane, whose thickness is
very accurately controlled. Near the diffusion membrane lies the oxygen sensing
element—the cathode.
The anode structure is larger than the cathode. It is made of lead and is
designed to maximize the amount of metal available for chemical reaction.
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