Teledyne 3300PB User Manual

OPERATING INSTRUCTIONS FOR

Model 3300PB

Percent Oxygen Analyzer

SERIES 3300 PERCEN T OXYGEN

SPA N

SPA N

SAMPLE

Teledyne Analytical Instruments

D ANGER

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 M69228

11/29/00

ECO # 00-0497

i

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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Teledyne Analytical Instruments

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

3.3.1 Installing the Micro-Fuel Cell ................................. 3-5

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

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4.4 Setting the Alarm Setpoints............................................ 4-3

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

5.2 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 W arranty Conditions ....................................... 5-4

Appendix

A.1 Specifications ................................................................ A-1

A.2 Spare Parts List ............................................................. A-2

A.3 Reference Drawing........................................................ A-3

A.4 Miscellaneous................................................................ A-3

A.5 Material Safety Data Sheet ............................................ A-3

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Teledyne Analytical Instruments

DANGER

COMBUSTIBLE GAS USAGE WARNING

This is a general purpose instrument designed for usage in a
nonhazardous 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.

The customer should ensure that the principles of operating of
this equipment is 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
T eledyne, no responsibility by Teledyne, its affiliates, and a gents
for damage or injury from misuse or neglect of this equipment is
implied or assumed.

Teledyne Analytical Instruments

v

Model 3300PB complies with all of the requirements of the
Commonwealth of Europe (CE) for Radio Frequency Interference,
Electromagnetic Interference (RFI/EMI), and Low Voltage Directive
(LVD).

The following International Symbols are used throughout the Instruc­tion Manual for your visual and immediate warnings and when you
have to attend CAUTION while operating the instrument:

STAND-BY, Instrument is on Stand-by,
but circuit is active

GROUND

Protective Earth

vi

CAUTION, The operator needs to refer to the manual
for further information. Failure to do so may
compromise the safe operation of the equipment.

CAUTION, Risk of Electric Shock

Teledyne Analytical Instruments

Percent Oxygen Analyzer Introduction 1

Introduction

1.1 Overview

The Teledyne Electronic Technologies Analytical Instruments (TETAI)
Model 3300PB is a microprocessor-based percent oxygen analyzer for real­time 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 3300PB 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 %, with 0-100% range optional. Large, bright, light­emitting-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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1-1

1 Introduction Model 3300PB

• 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, wall mounted NEMA-4 rated
enclosure.

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.

SERIES 3300 PERCENT OXYGEN

SPAN

SPAN

SAMPLE

Teledyne Ana lytical Instruments

Figure 1-1: Front Panel

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

1-2

• Set Alarm 1 Set Alarm 1 Hi or Low, and the concentration at

which alarm 1 activates.

Teledyne Analytical Instruments

Percent Oxygen Analyzer Introduction 1

• Set Alarm 2 Set the Alarm 2 Hi or Low, and the

concentration to which alarm 2 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. The
connectors are described briefly here and in detail in the Installation chapter of
this manual.

Figure 1-2 Rear Panel

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1-3

1 Introduction Model 3300PB

• Power Connection AC version: 100–240 V ac, at 50/60Hz.

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 Alarm 1, Alarm 2, and Sensor Failure Alarm
connections.

• Sensor Connector Internal Sampling System, Sensor
Connector.

1-4

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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 3300PB 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 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 3300PB

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 and temperature
compensation network (restrictors and thermistor) on a printed circuit board.

Refer to Figure 2-1, Basic Elements of a Micro-Fuel Cell, which illus­trates the following internal description.

Electrical Co nn ector

Circuit Board
with temperature comp ens ation netwo rk.

Anode

Cathode
Teflo n Me mbr a n e

Screen

Clamp

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.

The space between the active elements is filled by a structure saturated with
electrolyte. Cathode and anode are wet by this common pool. They each have a

2-2

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Percent Oxygen Analyzer Operational Theory 2

conductor connecting them, through some electrical circuitry, to one of the
external contacts in the connector receptacle, which is on the top of the cell.

2.2.3 Electrochemical Reactions

The sample gas diffuses through the Teflon membrane. Any oxygen in the
sample gas is reduced on the surface of the cathode by the following HALF
REACTION:

+ 2H2O + 4e

O

2

––

–

––

→ 4OH

––

–

––

(cathode)

(Four electrons combine with one oxygen molecule—in the presence of
water from the electrolyte—to produce four hydroxyl ions.)

When the oxygen is reduced at the cathode, lead is simultaneously oxidized
at the anode by the following HALF REACTION:

2(Pb + 2OH

––

–

––

) → 2(Pb+2 + H2O) + 4e

––

–

––

(anode)

(Two electrons are transferred for each atom of lead that is oxidized. TWO
ANODE REACTIONS balance one cathode reaction to transfer four elec­trons.)

The electrons released at the surface of the anode flow to the cathode
surface when an external electrical path is provided. The current is proportional
to the amount of oxygen reaching the cathode. It is measured and used to
determine the oxygen concentration in the gas mixture.

The overall reaction for the fuel cell is the SUM of the half reactions above,
or:

2Pb + O2 → 2PbO

(These reactions will hold as long as no gaseous components capable of
oxidizing lead are present in the sample. The only likely components are the
halogens—iodine, bromine, chlorine and fluorine.)

The output of the fuel cell is limited by (1) the amount of oxygen in the cell
at the time and (2) the amount of stored anode material.

In the absence of oxygen, no current is generated.

2.2.4 The Effect of Pressure

In order to state the amount of oxygen present in the sample as a percent­age of the gas mixture, it is necessary that the sample diffuse into the cell under
constant pressure.

If the pressure changes, the rate that oxygen reaches the cathode through
the diffusing membrane will also increase. The electron transfer, and therefore the

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2-3

2 Operational Theory Model 3300PB

external current, will increase, even though the proportion of oxygen has not
changed.

Fortunately, Dalton's Law confirms that every gas in a mixture contributes
the same pressure to the mixture that it would exert if it were alone in the same
amount in that same volume. This means that as long as the total pressure of the
sample remains constant, the mixture can change, but the diffusion of the oxygen
will be affected only by the concentration of the oxygen.

For this reason, the sample system supplying sample gas to the cell should
be designed to keep the pressure on the diffusion membrane constant.

2.2.5 Calibration Characteristics

Given that the total pressure of the sample gas at the surface of the Micro­Fuel Cell input is constant, a convenient characteristic of the cell is that the
current produced in an external circuit of constant impedance is directly propor­tional to the rate at which oxygen molecules reach the cathode, and this rate is
directly proportional to the concentration of oxygen in the gaseous mixture. In
other words it has a linear characteristic curve, as shown in Figure 2-2. Measur­ing circuits do not have to compensate for nonlinearities.

Figure 2-2. Characteristic Input/Output Curve for a Micro-Fuel Cell

In addition, since there is zero output in the absence oxygen, the character­istic curve has an absolute zero. The cell itself does not need to be zeroed.

2-4

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Percent Oxygen Analyzer Operational Theory 2

2.3 Electronics

2.3.1 General

The signal processing uses an Intel microcontroller with on-board RAM

and ROM to control all signal processing, input/output, and display functions for
the analyzer. System power is supplied from a universal power supply module
designed to be compatible with most international power sources.

The power supply circuitry is on the Power Supply PCB, which is mounted

vertically, just behind the rear panel of the Control Unit.

The signal processing electronics including the sensor amplifier,
microcontroller, analog to digital, and digital to analog converters are located on
the Main PCB, which is mounted vertically, just behind the front panel of the
Control Unit.

2.3.2 Signal Processing

Figure 2-3 is a block diagram of the signal processing electronics described
below.

Millivolt

Potput

MFC

Microamp

Output

TEMPERATURE
COMPEN SATION
NETWORK ON
SENSOR PCB

I-22 Se nsor

SENSOR

AMPLIFIER

KEYBOARD

A D C

MICRO­CONTROL­LER

E–I CONV

Concentration

D A C

DISPLAY

RELAYS

4–20 mA dc

0–10 V dc

RANGE ID

ALARMS

RELAYS

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

Teledyne Analytical Instruments

ALARMS

2-5

2 Operational Theory Model 3300PB

In the presence of oxygen the cell generates a current. The sensor has an

internal thermistor compensation network.

The output of the sensor is converted to voltage millivolt range. This output
is fed to a volatge amplifier. The internal thermistor network provides tempera­ture compensation of the sensor output. The resistance of the network changes
with temperature, compensating for the changes of the microfuel cell output to
temperature.

The output from the temperature compensation amplifier is sent to an
analog to digital converter (ADC), and the resulting digital concentration signal is
sent to the microcontroller.

The digital concentration signal along with input from the front panel buttons
(KEYBOARD) is processed by the microcontroller, and appropriate output
signals are directed to the display and alarm relays. The same digital information
is also sent to a 12-bit digital to analog converter (DAC) that produces the 0-10
V dc analog concentration signal and the 0-10 V dc analog range ID output. A
current to voltage converter (E–I CONV) produces the 4-20 mA dc analog
concentration signal.

2-6

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Percent Oxygen Analyzer Installation 3

Installation

Installation of the analyzer includes:

1. Unpacking the system.

2. Mounting the Control Unit to a wall

3. Installing the Micro-Fuel Cell

4. Making the electrical connections.

5. Making the gas connections.

6. Testing the installation.

CAUTIONS: Read this chapter in its entirety before installing the units.

For indoor use only.
The Sample must be free of entrained solids or water. How-

ever, a high humidity sample is ideal, since it will prevent
water loss from the cell electrolyte.

The Micro-Fuel Cell sensor electrolyte is caustic. Do not
attempt to open it. Leaking or exhausted cells should be
disposed of in accordance with local regulations. Refer to the
Material Safety Data Sheet in the Appendix.

Any damage or scarring of the delicate permeable membrane
on the sensing end of the cell will require cell replacement.
Prevent contact with membrane by any solid object.

3.1 Unpacking the Analyzer

As soon as you receive the instrument, carefully unpack and inspect
Control Unit, External Probe, and any included accessories for damage.
Immediately report any damage to the shipping agent. The analyzer is
shipped with all the materials you need to install and prepare the system for
operation.

CAUTION: Do not disturb the integrity of the cell package until the cell is to

actually be used. If the cell package is punctured and air is
permitted to enter, cell-life will be compromised.

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3 Installation Model 3300PB

3.2 Location and Mounting

3.2.1 Control Unit Installation

The 3300PB Control Unit is designed to be wall-mounted, in a general
purpose, area. The unit should be installed at viewing level in a sheltered
area.

Refer to the Outline diagram D-69220 for the physical dimensions of
the analyzer.

3.2.2 Installing the Micro-Fuel Cell

A Micro-Fuel Cell is included as a separate item. It must be installed
prior to instrument use.

Also, once it is expended, or if the instrument has been idle for a
lengthy period, the Micro-Fuel Cell will need to be replaced.

To install or replace the Micro-Fuel Cell, follow the procedures in
Chapter 5, Maintenance.

3.3 Electrical Connections

Figure 3-1 shows the Model 3300PB rear panel of the control unit.
For detailed pinouts, see the wiring/interconnection drawings in the Draw­ings section at the rear of this manual. To gain access to the terminal blocks,
the analyzer door screws must be lossened, and the door opened.

3-2

Figure 3-1 Electrical Connectors for AC Control Unit

Teledyne Analytical Instruments

Percent Oxygen Analyzer Installation 3

Primary Input Power: The power strip supplied inside the analyzer.

Connect ground to terminal 1, neutral to terminal 3, and hot to terminal 2.
Make sure female plug end is inserted in the control unit power receptacle.

The universal power su pply allows direct connection to any 100-240
VAC, 50/60Hz power source. The fuse block, to the right of the power cord
receptacle, accepts two 5x20mm 0.5 A, 250V,time-lag (T) fuse. (See Fuse
Replacement in chapter 5, Maintenance.)

The Power switch is located on the right-hand end of the power source
input receptacle assembly.

AC Power Terminal Strip

Analog Outputs: There are three DC output signal connectors with
screw terminals on the panel. There are two wires per output with the polar­ity noted. See Figure 3-3. The outputs are:

0–10 V % Range: Voltage rises with increasing oxygen concentration,

from 0 V at 0 percent oxygen to 10 V at full scale
percent oxygen. (Full scale = 100% of programmed
range.)

0–10 V Range ID: 03.33 V = Low Range, 06.66 V = High Range,

10 V = Air Cal Range.

4–20 mA % Range: Current increases with increasing oxygen concentra-

tion, from 4 mA at 0 percent oxygen to 20 mA at full
scale percent oxygen. (Full scale = 100% of pro­grammed range.)

Alarm Relays: The three alarm-circuit connectors are screw terminals
for making connections to internal alarm relay contacts. There is one set of
contacts for each type of alarm. Contacts are Form C, with normally open
and normally closed contact connections capable of switching up to 0.5
ampere at 125 VAC into a resistive load (2A for 30 VDC).

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3 Installation Model 3300PB

The alarm relay circuits are designed for failsafe operation, meaning the
relays are energized during normal operation. If power fails the relays de­energize (alarms activated).

The contact connections are indicated diagrammatically on the rear
panel as Normally Closed, Common, and Normally Open. Figure 3-2
explains how these act in failsafe operation.

Alarm ! and Alarm 2 can both be configured as either HI or LO. A
HI alarm will activate when concentration is above treshold, while a LO
alarm will activate concentration is below treshhold.

Figure 3-2: Contact ID for FAILSAFE Relay Operation

The specific descriptions for each type of alarm are as follows:
Alarm #1 Programmable as high or low alarm (actuates when

concentration is above threshold). Can be set anywhere
between 0 and 25 %, but must be set ABOVE the thresh­old set for the LO Alarm.

Alarm #2 Programmable as high or low alarm (actuates when

concentration is below threshold). Can be set anywhere
from 0 to 25 %.

Sensor Fail Actuates when the output of the Micro-Fuel Cell sensor

falls below the acceptable level (0.05% O2).

CAUTION: There could be hazardous voltage at the alarms termi-

nals, even when power is removed from the instrument.

Internal Sensor Wiring: The receptacle for the analysis unit cable is
located in the lower left-hand corner of the rear panel. The 6-pin polarized
connector is keyed to fit only one way into the receptacle. Do not force it in.
The other end of the cable has two terminal connectors. This should be
connected to the header on the top of the sensor.

3-4

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Percent Oxygen Analyzer Installation 3

3.3.1 RS-232 Port Option

The digital signal output is a standard RS-232 serial communications
port used to connect the analyzer to a computer, terminal, or other digital
device. The pinouts are listed in Table 1.

Table 1: RS-232 Signals

RS-232 Sig RS-232 Pin Purpose

RD 2 Received Data

TD 3 Transmitted Data

COM 5 Common

The data sent is status information, in digital form, updated every two
seconds. Status is reported in the following order:

• The concentration in percent

• The range in use

Each status output is followed by a carriage return and line feed.

The RS-232 protocol allows some flexibility in its implementation.
Table 2 lists certain RS-232 values that are required by the 3300PB imple­mentation.

Table 2: Required RS-232 Options

Parameter Setting

Baud 2400

Byte 8 bits

Parity none

Stop Bits 1

Message Interval 2 seconds

The RS232 terminals must not be connected
to any AC line source, or any source of
hazardous voltage.

3.4 Gas Connections

The standard Model 3300PB has two inlets and one outlet fixture only.
Calibration gasses can be connected into the "Span" inlet. All of the sample
connections are 1/8 inch brass fittings.

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3 Installation Model 3300PB

A switching valve is provided to feed the analysis unit with either

sample or gas.

A flowmwter and flow controller valve are part of the system and will

assist in setting the flow of the gas.

Sample flow should be adjusted to 2 SCFH. The sample vent connec­tion should not restrict the sample flow. The sensor is designed to operate at
atmospheric pressure. Restricting the sample vent line will result in pressur­izing the sensor and altering the O2 reading.

The pressure required will depend on the sampling system. When
venting into a constant pressure, such as the atmosphere, controlling input
pressure is simple. If you are venting into a system of varying pressure, then
some form of pressure regulation is required to maintain a constant pressure.

Sampel and Span pressure is not to exceed 50 psig (345 Kpa).

3-6

Figure 3-3: Piping Diagram

(standard piping diagfram for positive pressure service)

Teledyne Analytical Instruments

Percent Oxygen Analyzer Installation 3

3.4.1 Vacuum Service Option

For vacuum service pluming reference figure 3-4. The vacuum service
option is recommended for applications in which the sample source is not
pressurized. The customer must supply a pump and bypass system to com­plete the sample system. The sample inlet and outlet pressure must be
maintained at a constant pressure for proper performance. If the sample inlet
or vent pressure will not be held constant during the process, a pressure
regulator must be used to regulate the pressure across the cell.

Adjust the flow rate on a vacuum service system as follows:

Select Sample with the three-way control valve and open the flow
control valve on the analyzer to full flow (located on the analyzer flow
meter). Open the pump bypass valve, and turn on the pump. Readjust the
pump by-pass valve to limit the maximum flow rate to full scale on the
flowmeter with the flowmeter valve fully open. Adjust the analyzer flow
control valve (flowmeter valve) to a flow-rate of approximately 2 SCFH).
Select Span and verify that the span and Sample gas are at different pres­sures. The calibration accuracy will be adversely affected if the Span and
Sample gases are at differing pressures.

If the span gas is provided from pressurized source, a control valve
must be added between the analyzer and the span gas source. This valve is
used to adjust the span flow rate to match the sample flow rate. Do not
adjust the span flow rate with the flow control valve located on the analyzer
for units with vacuum service options.

Customer Supplied Parts

Figure 3-4: Piping Diagram for Vacuum Service Option

Teledyne Analytical Instruments

3-7

3 Installation Model 3300PB

3.5 Installation Checklist

Before connecting the instrument to the power source and turning it on,

make sure you have:

• Correctly installed the Sample and Exhaust gas lines

• Opened the isolation valves

• Checked for leaks

• Set the sample pressure to 5–10 psig (34.5-68.9 Kpa), nominal
(for non-vacuum service units)

• Set the flow

Once the above checks have been made, you can connect to the power

source. The instrument is now ready for operation.

3-8

Teledyne Analytical Instruments

Percent Oxygen Analyzer Operation 4

Operation

4.1 Introduction

Once the analyzer has been mounted, the gas lines connected and the
electrical connections made, the Analyzer can be configured for your appli­cation. This involves setting the system parameters:

• Defining the user selectable analysis ranges.

• Setting alarm setpoints.

• Calibrating the instrument.

All of these functions are performed via the front panel controls, shown
in Figure 4-1.

Analyzing for the percent oxygen level in the gas passing through the
cell block is the default mode of operation. As long as no front panel buttons
are being pressed the Analyzer is analyzing.

SERIES 3300 PERCEN T OXYGEN

SPAN

SPAN

SAMPLE

Teledyne Analytical Instruments

Figure 4-1: Front Panel Controls and Indicators

Teledyne Analytical Instruments

4-1

4 Operation Model 3300PB

4.2 Using the Function and Data Entry
Buttons

When no buttons on the Analyzer are being pressed, the instrument is in
the Analyze mode. It is monitoring the percent of oxygen in the sample gas
that is flowing through the Remote Probe.

When one of the Function Buttons is being pressed, the Analyzer is in
the Setup mode or the Calibration mode.

The 4 Setup function buttons on the analyzer are:

• SET ALARM 1

• SET ALARM 2

• SET HI RANGE

• SET LO RANGE

The Calibration mode button is:

• SPAN

The Data Entry buttons (∆ and ∇) increment the values displayed on
the PERCENT OXYGEN meter while one of the Function buttons is being
held down.

• ∆ : Increments the displayed value upwards.

• ∇ : Increments the displayed value downwards.

Any of the functions can be selected at any time by holding down the
appropriate button.

Each function will be described in the following sections. Although the
operator can use any function at any time, the order chosen in this manual is
appropriate for an initial setup.

4.3 Setting the Analysis Ranges

The two user definable analysis ranges are both capable of being
adjusted for from 0-1% to 0-25% oxygen concentration. Whatever values are
selected, the analyzer automatically switches from the LO range to the HI
range when the oxygen concentration reaches 100% of the LO range
fullscale value, and it switches back to the LO range when the oxygen
concentration reaches 85% of the LO range fullscale value

Note: The HI Range setpoint MUST be set at a higher concentration percent-

age than the LO Range setpoint.

4-2

Teledyne Analytical Instruments

Percent Oxygen Analyzer Operation 4

4.3.1 HI Range

Setting the HI Range fullscale value defines the LEAST sensitive

analysis range to be used. To set the HI Range:

1. Press the SET HI RANGE Function button once.

2. Immediately (within 5 seconds) press either the ∆ or ∇ button to

raise or lower the displayed value, as required, until the display
reads the desired fullscale percent concentration.

4.3.2 LO Range

Setting the LO Range fullscale value defines the MOST sensitive range

to be used. To set the LO Range:

1. Press the SET LO RANGE Function button once.

2. Immediately (within 5 seconds) press either the ∆ or ∇ button to

raise or lower the displayed value, as required, until the display
reads the desired fullscale percent concentration.

4.4 Setting the Alarm Setpoints

The alarm setpoints can be adjusted over the full range of the analyzer
(0-25% oxygen content). They are set as a percent of oxygen content, so that
an alarm set to indicate 9.6 on the display will activate at 9.6% O2 on any O
range.

4.4.1 Set Alarm 1

Alarm 1 can be set either as a high or low alarm. To configure this
alarm to your preferences:

1. Press the SET ALARM 1 function button once.

2. The display will flash either HI or LO depending on what the
alarm was configured in the last time. If the alarm configuration
must be changed, use the Up or Down keys to toggle the alarm
from HI to LO or viceversa (if within 5 seconds no key is
pressed, the instrument will return to the sample mode and
display oxygen concentration).

2

3. To change the setting at which the alarm will be actuated, press
the SET ALARM 1 function button once more. The alarm
setpoint will flash on the LED display. Press either the Up or
Down keys to raise or lower the displayed value, as required,

Teledyne Analytical Instruments

4-3

4 Operation Model 3300PB

until the display reads the desired percent concentration. (if
within 5 seconds no key is pressed, the instrument will return to
the sample mode and display oxygen concentration).

After setting the value wait for the unit to time out of this mode (ap-

proximately 5 seconds) and return to displaying oxygen concentration.

4.4.2 Set Alarm 2

Alarm 2 can be set either as a high or low alarm. To configure this

alarm to your preferences:

1. Press the SET ALARM 2 function button once.

2. The display will flash either HI or LO depending on what the
alarm was configured in the last time. If the alarm configuration
must be changed, use the Up or Down keys to toggle the alarm
from HI to LO or viceversa (if within 5 seconds no key is
pressed, the instrument will return to the sample mode and
display oxygen concentration).

3. To change the setting at which the alarm will be actuated, press
the SET ALARM 2 function button once more. The alarm
setpoint will flash on the LED display. Press either the Up or
Down keys to raise or lower the displayed value, as required,
until the display reads the desired percent concentration. (if
within 5 seconds no key is pressed, the instrument will return to
the sample mode and display oxygen concentration)

After setting the value wait for the unit to time out of this mode (ap-

proximately 5 seconds) and return to displaying oxygen concentration.

4.4.3 Sensor Fail Alarm

The SENSOR FAIL alarm is factory set to a reading less than 0.05%
O2. Should this alarm trigger the ALARM Indicator below the SET Func­tion buttons will blink, and the alarm relay contact dedicated to this function
will change state.

4-4

Teledyne Analytical Instruments

Percent Oxygen Analyzer Operation 4

4.5 Selecting a Fixed Range or Autoranging

The Model 3300PB can operate in fixed high, fixed low, or

autoranging mode. To change modes:

1. Press and then release the SET HI RANGE and the SET LO
RANGE buttons simultaneously.

2. Immediately (within 5 seconds) press either the ∆ or ∇ button
until Auto, Lo, or Hi displays on the LCD, as desired.

After about three seconds, the analyzer resumes monitoring in the

selected range mode.

4.6 Calibration

Preliminary—If not already done: Power up the Analyzer and

allow the LED reading to stabilize. Set the Alarm setpoints and
the fullscale ranges to the desired values.

3300PB SpanProcedure:

1. Press the SPAN button once.

Note: The numeric LED starts flashing and will continue to flash for five

minutes before timing-out. During this five minutes interval, the LED
will continue to track gas through the analyzer.

2. Flow span gas of a known oxygen concentration into the
analyzer. The analyzer will begin to track the span gas.

Note: The alarms will not change state during span calibration.

3. When the meter stabilizes, use the UP/DOWN arrows to adjust
the analyzer span value to the exact percent O2 concentration in
the span gas.

Note: When an arrow button is first pressed, the LED begins flashing

slightly more rapidly and no longer tracks the span gas. Instead, it
responds to the UP/DOWN keystrokes.

Note: While the LED is flashing slightly more rapidly, the SPAN routine will

time-out in five seconds (instead of five minutes), if no further key­strokes are entered.

4. When the span value is set to the known concentration of O2 in
the span gas, stop pressing the keys and wait for five seconds.

Teledyne Analytical Instruments

4-5

4 Operation Model 3300PB

Note: When you stop pressing the UP/DOWN keys, the rapid flashing will

cease and the new span value will be acquired by the analyzer after
five seconds.

The alarms will only be nonresponsive for 60 seconds. This time­frame allows you to reintroduce sample gas into the analyzer.

5. Immediately flow sample into the analyzer.

Supplementary Information

If, during the Span Procedure, you pressed the SPAN button by mis­take, you must wait five minutes for the analyzer to resume analysis or you
can press the UP button and then the DOWN button. (Pressing the UP and
DOWN buttons causes the analyzer to time-out in five seconds instead of
five minutes).

If during the span procedure, you press the RANGE or ALARM
buttons:

- either the range or alarm routine will be activated.

- any changes to span will be rejected.

- the 60 second alarm delay will not occur, i.e., the alarms will be
responsive immediately.

CAUTION: TET/AI considers the action of pressing the ALARM or

RANGE buttons to be at your (the user’s) discretion. The user
should be aware that the alarms will become active within 5
seconds if the range or alarm bottoms are pressed during span.
This may result in false alarms if the span gas has not been fully
purged from the cell and sample lines.

4-6

Teledyne Analytical Instruments

Percent Oxygen Analyzer Maintenance 5

Maintenance

Aside from normal cleaning and checking for leaks at the gas connections,
the Model 3300PB should not require any maintenance beyond replacement of
expended Micro-Fuel Cells, and perhaps a blown fuse. Routine maintenance
includes occasional recalibration, as described in chapter 4, Operation.

5.1 Replacing the Fuse

Remove Power to Unit before replacing the fuse.

When a fuse blows, check first to determine the cause, then replace the
fuse using the following procedure:

1. Disconnect the AC power and place the power switch located on

the rear panel in the O position. Remove the power cord from the
receptacle.

2. The fuse receptacle is located in the power cord receptacle
assembly in the upper left-hand corner of the rear panel. See Figure
5-1.

FUSE

Figure 5-1: AC Fuse Replacement

3. Insert a small flat-blade screwdriver into the slot in the receptacle
wall nearest the fuse and gently pry open the fuse receptacle. The

Teledyne Analytical Instruments

5-1

5 Maintenance Model 3300PB

fuse holder will slide out. There are two fuses in use and are visible in
the clip.

4. Remove the bad fuse and replace it with a 0.5A, 250VAC, 5x20mm
IEC, time lag (T) fuse (P /N F1130).

5. Replace the fuse holder into its receptacle, pushing in firmly until it
clicks.

5.2 Sensor Installation or Replacement

5.2.1 When to Replace a Sensor

The Micro-Fuel Cell typically provide almost constant output through their
useful life, and then fall off sharply towards zero at the end. You will find that
very little adjustment will be required to keep the analyzer calibrated properly
during the duration of a given cell’s useful life.

If the sample being analyzed has a low oxygen concentration, cell failure
will probably be indicated by the inability to properly calibrate the analyzer. If
large adjustments are required to calibrate the instrument, or calibration cannot
be achieved within the range of the ∆∇ buttons, the cell may need replacing.
Read the section Cell Warranty Conditions, below, before replacing the cell.

In addition, if the front panel Percent Oxygen Meter displays “00.0” when
the unit is plugged in, and the power switch is in the ON position, the sensor
needs to be replaced.

IMPORTANT: After replacing the Micro-Fuel Cell, the analyzer must be

recalibrated. See

Calibration

in chapter 4.

5.2.2 Ordering and Handling of Spare Sensors

To have a replacement cell available when it is needed, TET/AI recom­mends that one spare cell be purchased shortly after the instrument is placed in
service, and each time the cell is replaced.

CAUTION: Do not stockpile cells. The warranty period starts on the day of

shipment. For best results, order a new spare cell when the
current spare is installed.

The spare cell should be carefully stored in an area that is not subject to
large variations in ambient temperature (75° F nominal), and in such a way as to
eliminate the possibility of incurring damage.

CAUTION: Do not disturb the integrity of the cell package until the cell is to

actually be used. If the cell package is punctured and air is permit­ted to enter, cell-life will be compromised.

5-2

Teledyne Analytical Instruments

Percent Oxygen Analyzer Maintenance 5

WARNING: The sensor used in the Model 3300PB uses electrolytes

which contain substances that are extremely harmful if
touched, swallowed, or inhaled. Avoid contact with ANY
fluid or powder in or around the unit. What may appear to be
plain water could contain one of these toxic substances. In
case of eye contact, immediately flush eyes with water for
at least 15 minutes. Call physician. (See Appendix, Material
Safety Data Sheet—MSDS).

5.2.3 Removing the Micro-Fuel Cell

To remove a spent or damaged Micro-Fuel Cell:

1. Disconnect the Power Source from the Unit.

2. Open analyzer door..

3. Unplug the connector from the spent cell.

4. Remove the spent cell by unscrewing it, counterclockwise, from the
cell block.

5. Dispose of the cell in a safe manner, and in accordance with local
laws.

5.2.4 Installing a Micro-Fuel Cell

To install a new Micro-Fuel Cell:

CAUTION: Do not scratch, puncture, or damage the sensing membrane of the

Micro-Fuel Cell sensor. Damage to the membrane will require
replacement of the sensor.

1. Disconnect the Power Source from the Unit.

2. Remove the new Micro-Fuel Cell from its protective bag, being
careful not to lose the O-ring at the base of the threaded portion of
the cell.

3. Open analyzer door.

4. Replace the cell on the cell holder by screwing it clockwise into the
cell block until it is held firmly in the socket.

5. Insert the cell block electrical connector plug into the socket in the
sensor.

Teledyne Analytical Instruments

5-3

5 Maintenance Model 3300PB

5.2.5 Cell Warranty Conditions

The Class I-22 Micro-Fuel cell is used in the Model 3300PB. This cell is a
long life cell and is warranted for 2 years (under specified operating conditions—
see Appendix) from the date of shipment. Note any Addenda attached to the
front of this manual for special information applying to your instrument.

With regard to spare cells, warranty period begins on the date of shipment.
The customer should stock only one spare cell per instrument at a time. Do not
attempt to stockpile spare cells.

If a cell was working satisfactorily, but ceases to function before the
warranty period expires, the customer will receive credit toward the purchase of
a new cell.

If you have a warranty claim, you must return the cell in question to the
factory for evaluation. If it is determined that failure is due to faulty workmanship

or material, the cell will be replaced at no cost to the customer.

NOTE: Evidence of damage due to tampering or mishandling will render the

cell warranty null and void.

5-4

Teledyne Analytical Instruments

Percent Oxygen Analyzer Appendix

Appendix

A.1 Specifications

Ranges: 0-3 % and 0-10 % oxygen (Standard

Ranges), and 0-25 % (nominal) Calibration
Range. User selectable % Ranges can be set
between 1% and 25 % oxygen (optional
100% range).

Signal Output: Voltage: 0–10 V dc, negative ground

Current: 4-20 mA, negative ground

Range ID: 0-10 V dc.

Display: Light emitting diode display.

Alarms: Two customer selectable high or low fully

adjustable alarms. One cell failure alarm.
Alarm relays form "C" contacts, dry contacts
rated at 2A for 30VDC, 0.5A for 115VAC.

System Operating Temp: 0-50 °C

Accuracy: ±2% of full scale at constant temperature

±5% of full scale through operating temp.
range once temp. equilibrium is reached. (At
3 % and higher user defined ranges.)

Response Time: 90% in less than 8 seconds at 25 °C.

System Power Requirements: AC (100-240 VAC, 50/60Hz), 10W

System Enclosure: Wall Mounting, NEMA-4 enclosure.

Dimensions (Approx.) 8 W x 10 H x 6 D.

Weight: 13.8lbs (6.4Kg).

Sensor Type: Micro Fuel Cell Class I-22.

Teledyne Analytical Instruments

A-1

Appendix Model 3300PB

A. 2 Spare Parts List

QTY. P/N DESCRIPTION

1 C-65220E PC Board, Main
1 C-65220F PC Board, Main for 0-100% range.
1 C-64586C PC Board, Power Supply, AC Version
1 C-44611-I-22 Micro-Fuel Cell, I-22
2 F-1130 Fuse (AC), ½A, 250 VAC, IEC Type T,

5 x 20mm

1 F-274 Flowmeter 0.3-3.0 SCFH

IMPORTANT: Orders for replacement parts should include the part number

and the model and serial number of the system for which the
parts are intended.

Send orders to:

TELEDYNE ELECTRONIC TECHNOLOGIES

Analytical Instruments

16830 Chestnut Street
City of Industry, CA 91749-1580

Telephone: [phone]
TWX: [phone] TDYANYL COID
Fax: [phone]

Web: www.teledyne-ai.com

or your local representative.

A-2

Teledyne Analytical Instruments

Percent Oxygen Analyzer Appendix

A.3 Reference Drawing

A-69265 Piping Diagram
D-69229 Outline Diagram

A.4 Miscellaneous

The symbol: ~ is used on the rear panel of the model 3300PB to signify

volts alternating current (V ac).

NOTE: The MSDS on this material is available upon request

through the Teledyne Environmental, Health and
Safety Coordinator. Contact at [phone]

Teledyne Analytical Instruments

A-3

Appendix Model 3300PB

A-4

Teledyne Analytical Instruments

Percent Oxygen Analyzer Appendix

A.5 Material Safety Data Sheet

Section I – Product Identification

Product Name: Micro-Fuel Cells

Mini-Micro-Fuel Cells, all classes
Super Cells, all classes except T–5F
Electrochemical Oxygen Sensors, all classes.

Manufacturer: Teledyne Electronic Technologies/Analytical Instruments

Address: 16830 Chestnut Street, City of Industry, CA 91749

Phone: [phone]

Technical Support: [phone]

Environment, Health

and Safety: [phone]

Date Prepared : 11/23/98

Section II – Physical and Chemical Data

Chemical and Common Names: Potassium Hydroxide (KOH), 15% (w/v)

Lead (Pb), pure

CAS Number: KOH 1310–58–3

Pb 7439–92–1

KOH (15% w/v) Pb (pure)

Melting Point/Range: –10 to 0 °C 328 °C

Boiling Point/Range: 100 to 115 °C 1744 °C

Specific Gravity: 1.09 @ 20 °C 11.34

pH: >14 N/A

Solubility in Water: Completely soluble Insoluble

Percent Volatiles by Volume: None N/A

Appearance and Odor: Colorless, odorless solution Grey metal,

odorless

Teledyne Analytical Instruments

A-5

Appendix Model 3300PB

Section III – Physical Hazards

Potential for fire and explosion: The electrolyte in the Micro-Fuel Cells
is not flammable. There are no fire or explosion hazards associated with
Micro-Fuel Cells.

Potential for reactivity: The sensors are stable under normal conditions of
use. Avoid contact between the sensor electrolyte and strong acids.

Section IV – Health Hazard Data

Primary route of entry: Ingestion, eye/skin contact

Exposure limits:OSHA PEL: .05 mg/cu.m. (Pb)

ACGIH TLV: 2 mg/cu.m. (KOH)

Effects of overexposure

Ingestion: The electrolyte could be harmful or fatal

if swallowed.
Oral LD50 (RAT) = 3650 mg/kg

Eye: The electrolyte is corrosive; eye contact

could result in permanent loss of vision.

Dermal: The electrolyte is corrosive; skin contact

could result in a chemical burn.

Inhalation: Liquid inhalation is unlikely.

Signs/symptoms of exposure: Contact with skin or eyes will cause a

burning sensation and/or feel soapy or
slippery to touch.

Medical conditions

aggravated by exposure: None

Carcinogenicity: NTP Annual Report on Carcinogens: Not

listed
LARC Monographs: Not listed
OSHA: Not listed

A-6

Other health hazards: Lead is listed as a chemical known to the

State of California to cause birth defects
or other reproductive harm.

Teledyne Analytical Instruments

Percent Oxygen Analyzer Appendix

Section V – Emergency and First Aid Procedures

Eye Contact: Flush eyes with water for at least 15 minutes and get im-

mediate medical attention.

Skin Contact: Wash affected area with plenty of water and remove

contaminated clothing. If burning persists, seek medical
attention.

Ingestion: Give plenty of cold water. Do not induce vomiting.

Seek medical attention. Do not administer liquids to an
unconscious person.

Inhalation: Liquid inhalation is unlikely.

Section VI – Handling Information

NOTE: The oxygen sensors are sealed, and under normal circumstances,

the contents of the sensors do not present a health hazard. The
following information is given as a guide in the event that a cell
leaks.

Protective clothing: Rubber gloves, chemical splash goggles.

Clean-up procedures: Wipe down the area several times with a wet pa-

per towel. Use a fresh towel each time.

Protective measures
during cell replacement:Before opening the bag containing the sensor

cell, check the sensor cell for leakage. If the sen­sor cell leaks, do not open the bag. If there is
liquid around the cell while in the instrument,
put on gloves and eye protection before remov­ing the cell.

Disposal: Should be in accordance with all applicable

state, local and federal regulations.

NOTE: The above information is derived from the MSDS provided by the

manufacturer. The information is believed to be correct but does
not purport to be all inclusive and shall be used only as a guide.
Teledyne Analytical Instruments shall not be held liable for any
damage resulting from handling or from contact with the above
product.

Teledyne Analytical Instruments

A-7