Teledyne OT-3 User Manual
Trace Oxygen Analyzer
OPERATING INSTRUCTIONS FOR
MODEL OT-3MODEL OT-3
Trace Oxygen Analyzer
P/N M74173
10/28/2001
ECO#
DANGER
Toxic gases and or flammable liquids may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
Hazardous voltages exist on certain components internally which may persist
for a time even after the power is turned off and disconnected.
Only authorized personnel should conduct maintenance and/or servicing.
Before conducting any maintenance or servicing, consult with authorized
supervisor/manager.
Teledyne Analytical Instruments i
Model OT-3
Copyright © 2000 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, 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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Trace Oxygen Analyzer
Specific Model Information
The instrument for which this manual was supplied may
incorporate one or more options not supplied in the standard instrument.
Commonly available options are listed below, with check boxes. Any
that are incorporated in the instrument for which this manual is supplied
are indicated by a check mark in the box.
Instrument Serial Number: _______________________
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Model OT-3
Important Notice
Model OT-3 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:
No
Symbol
STAND-BY: Instrument is on Stand-by, but circuit is
active
GROUND: Protective Earth
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 Electrical Shock
Note: Additional information in the form of notes are
included which emphasize specific topics regarding the
present discussion.
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Trace Oxygen Analyzer
This instrument is designed for CL1 DIV II hazardous locations. 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 this
equipment are 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 Teledyne, no
responsibility by Teledyne, its affiliates, and agents for damage or
injury from misuse or neglect of this equipment is implied or assumed.
CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE
PURPOSE AND IN THE MANNER DESCRIBED IN
THIS MANUAL.
IF YOU USE THE ANALYZER IN A MANNER OTHER
THAN THAT FOR WHICH IT WAS INTENDED,
UNPREDICTABLE BEHAVIOR COULD RESULT
POSSIBLY ACCOMPANIED WITH HAZARDOUS
CONSEQUENCES.
This manual provides information designed to guide you through
the installation, calibration and operation of your new analyzer. Please
read this manual and keep it available.
Occasionally, some instruments are customized for a particular
application or features and/or options added per customer requests.
Please check the front of this manual for any additional information in
the form of an Addendum which discusses specific information,
procedures, cautions and warnings that may be peculiar to your
instrument.
Manuals do get lost. Additional manuals can be obtained from
Teledyne at the address given in the Appendix. Some of our manuals are
available in electronic form via the internet. Please visit our website at:
www.teledyne-ai.com.
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Model OT-3
Table of Contents
List of Figures.............................................................................viii
Introduction....................................................................................1
1.1 Overview 1
1.2 Main Features of the Analyzer 1
1.3 Front Panel Description 2
1.4 Rear Panel Description 4
Operational Theory........................................................................6
2.1 Introduction 6
2.2 Micro-fuel Cell Sensor 6
2.2.1 Principles of Operation 6
2.2.2 Anatomy of a Micro-fuel Cell 7
2.2.3 Electrochemical Reactions 8
2.2.4 The Effect of Pressure 9
2.2.5 Calibration Characteristics 9
2.3 Electronics 10
2.3.1 General 10
2.3.2 Signal Processing 11
Installation ...................................................................................13
3.1 Unpacking the Analyzer 13
3.2 Location and Mounting 14
3.2.2 Installing the Micro-fuel Cell 14
3.3 Electrical Connections 14
3.3.1 Primary Input Power 15
3.3.2 Analog Outputs 15
3.3.3 Alarm Relays 16
3.3.4 Relay Ratings 17
3.3.5 Solid State Relay Output 18
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Trace Oxygen Analyzer
3.4 Gas Connections 18
3.5 Sample System 20
3.6 Installation Checklist 21
Operation......................................................................................23
4.1 Introduction 23
4.2 Using the Function and Data Entry Buttons 24
4.3 Setting the Analysis Ranges 24
4.3.1 HI Range 25
4.3.2 LO Range 25
4.4 Setting the Alarm Setpoints 25
4.4.1 Set Alarm 1 25
4.4.2 Set Alarm 2 26
4.4.3 Power Failure Alarm 26
4.5 Alarm Delay 26
4.6 Keypad Lockout 27
4.7 Selecting a Fixed Range or Autoranging 28
4.8 Calibration 28
4.9 Displaying Percent & PPM on the LED Display 29
4.10 Supplementary Information 29
Maintenance.................................................................................31
5.1 Replacing the Fuse 31
5.2 Sensor Installation or Replacement 32
5.2.1 When to Replace a Sensor 32
5.2.2 Ordering and Handling of Spare Sensors 33
5.2.3 Removing the Micro-fuel Cell 33
5.2.4 Installing a Micro-fuel Cell 34
5.2.5 Cell Warranty Conditions 35
Appendix ......................................................................................36
A.1 Specifications 36
A.2 Spare Parts List 37
A.3 Reference Drawing 38
A.4 Miscellaneous 38
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Model OT-3
List of Figures
Figure 1-1: Front Panel...................................................................3
Figure 1-2: Rear Panel (AC Version)..............................................5
Figure 1-3: Rear Panel (DC Version)..............................................5
Figure 2-1: Cross Section of a Micro-fuel Cell................................7
Figure 2-2: Characteristic MFC Input/Output Curve .....................10
Figure 2-3: Block Diagram of the Signal Processing Electronics..11
Figure 3-1: Electrical Connectors for AC Control Unit ..................15
Figure 3-2: Contact ID for FAILSAFE Relay Operation ..............166
Figure 3-3: Gas Connections.........................................................19
Figure 3-4: OT-3 Sample System.................................................21
Figure 4-1: Front Panel Control and Indicators.............................23
Figure 5-1: AC Fuse Replacement...............................................32
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Trace Oxygen Analyzer Introduction
Introduction
1.1 Overview
The Teledyne Electronic Technologies Analytical Instruments
(TET/AI) Model OT-3 is a microprocessor-based trace oxygen analyzer
for real-time measurement of the parts per million 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 OT-3 include monitoring natural gas pipelines, wellheads,
and compressor/blowers.
1.2 Main Features of the Analyzer
• The main features of the analyzer include:
• Insta-Trace sensor technology
• Stainless steel sample system (with PVC scrubber and
Nylon cell block)
• Pressure regulator
• Coalescing filter
• Acid gas scrubber (clear, rebuildable )
• Flow control restrictor
• Sample shut off valve
• Bypass/filter drain valve
• Flowmeter
• Viewing window
• Sample/Span selector valve
• NEMA 4 enclosure (15.8” x 11.8” x 8.1”).
• Viewing window 3300/OT-3 Control Unit
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Introduction OT-3
The Model 3300/OT-3 Control Unit has its own long list of features
including:
• Keypad lockout feature
• Two user settable fail-safe alarms (with a user settable 0-20
min. time delay )
• Two user settable ranges (from 0-10PPM – 0-9999PPM)
with user selectable auto-ranging.
• Power fail alarm
• SSR power output (Solid State Relay power available on AC
control units)
• Micro processor based electronics 8 bit ADC & 18 bit DAC
• Large 3 ½ digit LED O2 concentration read-out
• 7 button user interface keypad
• Alarm condition indicator LED
• 100-240 VAC 50/60 Hz power (optional 9-36VDC )
• 0-10 VDC output
• 4-20 mA output
• 0-10 VDC range ID output
• Electronic temperature compensation
• Optional RS323 interface
• Accuracy: +/- 2% of range (at constant temp.)
• Response time: 90% in 65 sec of less @ 25 degrees C
• Temperature range (0-50 degrees C)
1.3 Front Panel Description
All controls are accessible from the front panel. See Figure 1-1.
The front panel has seven push-button 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.
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Trace Oxygen Analyzer Introduction
Figure 1-1: Front Panel
Function Keys:
Seven push-button membrane switches are used to select the function
performed by the analyzer:
Set Alarm 1: Set Alarm 1 Hi or Low, and the concentration at
which alarm 1 activates.
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 0-9999ppm).
Set LO Range: Set the low analysis range for the instrument
(down to 0-10ppm).
Set Span: Span calibrate the analyzer.
Data Entry Keys: Two push-button 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:
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Introduction OT-3
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. The rear panels for the AC and DC versions are
different. Figure 1-2 shows the AC version while Figure 1-3 shows the
DC version.
Power Connection AC version:
100–240 VAC, at 50/60Hz. The connector housing includes the
fuse holder and AC Power cord receptacle.
Fuse Holder DC version:
Replacing the fuse is described in Chapter 5, Maintenance.
Analog Outputs:
0–10 VDC concentration output.
0–10 VDC range ID (or optional overrange) output.
4–20 mA DC concentration output, negative ground.
Alarm Connections:
Alarm 1, Alarm 2, and Power Failure Alarm connections.
Sensor Connector:
Internal Sampling System, Sensor Connector.
RS-232 Port:
Serial Digital Output of concentration and range signals.
SSR POWER (AC POWER UNITS ONLY):
+15 VDC power output for powering Solid State Relays.
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Trace Oxygen Analyzer Introduction
Figure 1-2: Rear Panel (AC Version)
Figure 1-3: Rear Panel (DC Version)
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Installation OT-3
Operational Theory
2.1 Introduction
The analyzer is composed of two subsystems:
• 3300/OT-3 control unit
• OT-3 sample sys.
The OT-3 sample system 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 3300/OT-3 control unit processes the sensor output and
translates it into electrical concentration, range, and alarm outputs, and a
trace 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 OT-3 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 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 Micro-fuel Cell is therefore a hybrid
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Trace Oxygen Analyzer Installation
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 a gas permeable membrane.
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
printed circuit board with concentric gold contacts.
Refer to Figure 2-1, Cross Section of a Micro-fuel Cell, which
illustrates the following internal description.
Figure 2-1: Cross Section of a Micro-fuel Cell
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 conductor connecting them, through some
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