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
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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
Teledyne Analytical Instruments
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
Teledyne Analytical Instruments
2-1
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
Teledyne Analytical Instruments
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
Teledyne Analytical Instruments
2-3
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