OPERATING INSTRUCTIONS FOR
Model 3000TA-XL-EU
Trace Oxygen Analyzer
DANGER
HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING
SYSTEM.
PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.
HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST
FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.
P/NM69603
ONLYAUTHORIZEDPERSONNELSHOULDCONDUCTMAINTENANCEAND/ORSERVICING. BEFORE
CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/
MANAGER.
11/24/04
ECO#03-0126
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Trace Oxygen Analyzer
Specific Model Information
Theinstrumentforwhichthismanualwassuppliedmayincorporateoneor
moreoptionsnotsuppliedinthestandardinstrument.Commonlyavailable
optionsarelistedbelow,withcheckboxes.Anythatareincorporatedinthe
instrumentforwhichthismanualissuppliedareindicatedbyacheckmarkinthe
box.
InstrumentSerialNumber: _______________________
OptionsIncludedintheInstrumentwiththeAboveSerialNumber:
3000TA-XL-VS: InstrumentconfiguredforVacuumService
3000TA-XL-CV: Instrumentwithcalibrationvalves
19" Rack Mnt: The19"RelayRackMountunitsareavailablewith
eitheroneortwo3000TA-XLseriesanalyzersinstalled
inastandard19"panelandreadytomountina
standardrack.
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Model 3000TA-XL-EU
Model 3000TA-XL-EU complies with all of the requirements of
the Commonwealth of Europe (CE) for Radio Frequency Interfer-
ence, Electromagnetic Interference (RFI/EMI), and Low Voltage
Directive (LVD).
The following International Symbols are used throughout the Instruc-
tion 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
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
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Trace Oxygen Analyzer
Table of Contents
1 Introduction
1.1 Overview........................................................................ 1-1
1.2 Typical Applications ....................................................... 1-1
1.3 Main Features of the Analyzer ....................................... 1-1
1.4 Model Designations ....................................................... 1-2
1.5 Front Panel (Operator Interface) ..................................... 1-3
1.6 Rear Panel (Equipment Interface) .................................. 1-5
2 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.............................................. 2-4
2.2.5 Calibration Characteristics ...................................... 2-4
2.3 Sample System.............................................................. 2-5
2.4 Electronics and Signal Processing ................................ 2-8
3 Installation
3.1 Unpacking the Analyzer................................................. 3-1
3.2 Mounting the Analyzer ................................................... 3-1
3.3 Rear Panel Connections ................................................ 3-2
3.3.1 Gas Connections ................................................... 3-3
3.3.2 Electrical Connections ........................................... 3-4
3.3.2.1 Primary Input Power....................................... 3-4
3.3.2.2 50-Pin Equipment Interface Connector .......... 3-4
3.3.2.3 RS-232 Port ................................................... 3-9
3.4 Installing the Micro-Fuel Cell ......................................... 3-11
3.5 Testing the System......................................................... 3-11
4 Operation
4.1 Introduction .................................................................... 4-1
4.2 Using the Data Entry and Function Buttons ................... 4-2
4.3 The System Function ..................................................... 4-3
4.3.1 Tracking the O2 Readings during CAl & Alarm ....... 4-4
4.3.2 Setting up an Auto-Cal........................................... 4-5
4.3.3 Password Protection .............................................. 4-6
4.3.3.1 Entering the Password ................................... 4-7
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Model 3000TA-XL-EU
4.3.3.2 Installing or Changing the Password ............. 4-8
4.3.4 Logout.................................................................... 4-9
4.3.5 System Self-Diagnostic Test .................................. 4-9
4.3.6 Version Screen ...................................................... 4-10
4.4 Calibration of the Analyzer............................................. 4-11
4.4.1 Zero Cal ................................................................. 4-11
4.4.1.1 Auto Mode Zeroing ........................................ 4-12
4.4.1.2 Manual Mode Zeroing.................................... 4-12
4.4.1.3 Cell Failure .................................................... 4-13
4.4.2 Span Cal................................................................ 4-14
4.4.2.1 Auto Mode Spanning ..................................... 4-14
4.4.2.2 Manual Mode Spanning................................. 4-15
4.4.3 Span Failure .......................................................... 4-16
4.5 Switching of Sample Streams ........................................ 4-16
4.5.1 Special notes on hydrogen gas stream .................. 4-17
4.6 The Alarms Function...................................................... 4-17
4.7 The Range Function ...................................................... 4-19
4.7.1 Setting the Analog Output Ranges......................... 4-20
4.7.2 Fixed Range Analysis............................................ 4-20
4.8 The Analyze Function .................................................... 4-21
4.9 Signal Output ................................................................. 4-21
Maintenance
5.1 Routine Maintenance..................................................... 5-1
5.2 Cell Replacement .......................................................... 5-1
5.2.1 Storing and Handling Replacement Cells ............... 5-1
5.2.2 When to Replace a Cell ........................................... 5-2
5.2.3 Removing the Micro-Fuel Cell ................................. 5-2
5.2.4 Installing a New Micro-Fuel Cell.............................. 5-4
5.2.5 Cell Warranty ........................................................... 5-4
5.3 Fuse Replacement......................................................... 5-5
5.4 System Self Diagnostic Test........................................... 5-5
5.5 Major Internal Components............................................ 5-6
5.6 Cleaning ........................................................................ 5-7
5.7 Troubleshooting ............................................................. 5-8
Appendix
A-1 Model 3000TA-XL Specifications ................................... A-1
A-2 Recommended 2-Year Spare Parts List ......................... A-3
A-3 Drawing List ................................................................... A-4
A-4 19-Inch Relay Rack Panel Mount................................... A-4
A-5 Application Notes on Pressures and Flow ..................... A-5
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Trace Oxygen Analyzer
Appendix
A-6 Material Safety Data Sheet..................................................A-8
A-7 Installing and Replacing Micro Fuel Cell.........................A-12
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Model 3000TA-XL-EU
DANGER
COMBUSTIBLE GAS USAGE WARNING
This is a general purpose instrument designed for use 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 operation of
this equipment is well understood by the user. Misuse of this
product in any manner, tampering with its components, or unau-
thorized 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.
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Trace Oxygen Analyzer
Introduction 1
Introduction
1.1 Overview
The Teledyne Analytical Instruments Model 3000TA-XL Trace Oxy-
gen Analyzer is a versatile microprocessor-based instrument for detecting
oxygen at the parts-per-million (ppm) level in a variety of gases. This manual
covers the Model 3000TA-XL General Purpose flush-panel and/or rack-
mount units only. These units are for indoor use in a nonhazardous environ-
ment.
1.2 Typical Applications
A few typical applications of the Model 3000TA-XL are:
•
•
•
•
•
•
•
Monitoringinertgasblanketing
Airseparationandliquefaction
Chemicalreactionmonitoring
Semiconductormanufacturing
Petrochemicalprocesscontrol
Qualityassurance
Gasanalysiscertification.
1.3 Main Features of the Analyzer
The Model 3000TA-XL Trace Oxygen Analyzer is sophisticated yet
simple to use. The main features of the analyzer include:
•
A 2-line alphanumeric vacuum fluorescent display (VFD) screen,
drivenbymicroprocessorelectronics, thatcontinuouslyprompts
and informs the operator.
•
•
High resolution, accurate readings of oxygen content from low
ppm levels through 25%. Large, bright, meter readout.
Stainlesssteelcellblock.
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1 Introduction
Model 3000TA-XL-EU
•
Advanced Micro-Fuel Cell, designed for trace analysis, has a 0-1
ppm low range with less than a 0.2 ppm offset and six months
warranty and an expected lifetime of one year.
•
•
Versatile analysis over a wide range of applications.
Microprocessorbasedelectronics:8-bitCMOSmicroprocessor
with 32 kB RAM and 128 kB ROM.
•
•
•
Three user definable output ranges (from 0-1 ppm through 0-
250,000 ppm) allow best match to users process and equipment.
Air-calibration range for spanning at 20.9 % (209,000 ppm)
available.
Auto Ranging allows analyzer to automatically select the proper
preset range for a given measurement. Manual override allows
the user to lock onto a specific range of interest.
•
•
Twoadjustableconcentrationalarmsandasystemfailurealarm.
Extensive self-diagnostic testing, at startup and on demand, with
continuouspower-supplymonitoring.
•
•
Two way RFI protection.
RS-232 serial digital port for use with a computer or other digital
communicationdevice.
•
•
Four analog outputs: two for measurement (0–1 V dc and
Isolated 4–20 mA dc) and two for range identification.
Convenientandversatile, steel, flush-panelorrack-mountable
case with slide-out electronics drawer.
1.4 Model Designations
3000TA-XL: Standard model for sample under pressure
3000TA-XL-VS: Instrument configured for Vacuum Service
3000TA-XL-CV: Instrumentwithcalibrationvalves
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Trace Oxygen Analyzer
Introduction 1
1.5 Front Panel (Operator Interface)
The standard 3000TA-XL is housed in a rugged metal case with all
controls and displays accessible from the front panel. See Figure 1-1. The
front panel has thirteen buttons for operating the analyzer, a digital meter, an
alphanumeric display, and a window for viewing the sample flowmeter.
Function Keys: Six touch-sensitive membrane switches are used to
change the specific function performed by the analyzer:
Door Latch
Digital Meter
Alphanumeric
Display
Sample System
FlowIndicator
Standby Switch
Function Buttons
Data Entry Buttons
Figure 1-1: Model 3000TA-XL Front Panel
•
•
Analyze Perform analysis for oxygen content of a sample gas.
System Performsystem-relatedtasks(describedindetailin
chapter 4, Operation.).
•
•
Span
Zero
Span calibrate the analyzer.
Zero calibrate the analyzer.
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1 Introduction
Model 3000TA-XL-EU
•
•
Alarms Set the alarm setpoints and attributes.
Range Set up the 3 user definable ranges for the instrument.
Data Entry Keys: Six touch-sensitive membrane switches are used to
input data to the instrument via the alphanumeric VFD display:
•
•
•
•
Left & Right Arrows
Selectbetweenfunctionscurrently
displayed on the VFD screen.
Up & Down Arrows
Increment or decrement values of
functionscurrentlydisplayed.
Enter Moves VFD display on to the next screen in a series. If
none remains, returns to the Analyze screen.
Escape Moves VFD display back to the previous screen in a
series. If none remains, returns to the Analyze screen.
Digital Meter Display: The meter display is a Light Emitting Diode
(LED) device that produces large, bright, 7-segment numbers that are legible
in any lighting. It produces a continuous readout from 0-10,000 ppm and
then switches to a continuous percent readout from 1-25%. It is accurate
across all analysis ranges without the discontinuity inherent in analog range
switching.
Alphanumeric Interface Screen: The VFD screen is an easy-to-use
interface from operator to analyzer. It displays values, options, and messages
that give the operator immediate feedback.
NeedleValve: To adjust flow of gas sample
Flowmeter: Monitors the flow of gas past the sensor. Readout is 0.2 to
2.4 standard liters per minute (SLPM) of nitrogen
Standby Button: The Standby turns off the display and outputs,
butcircuitryisstilloperating.
CAUTION: The power cable must be unplugged to fully
disconnect power from the instrument. When
chassis is exposed or when access door is open
and power cable is connected, use extra care to
avoid contact with live electrical circuits .
Access Door: For access to the Micro-Fuel Cell, the front panel
swings open when the latch in the upper right corner of the panel is pressed
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Trace Oxygen Analyzer
Introduction 1
all the way in with a narrow gauge tool. Accessing the main circuit board
requires unfastening rear panel screws and sliding the unit out of the case.
1.6 Rear Panel (Equipment Interface)
The rear panel, shown in Figure 1-2, contains the gas and electrical
connectors for external inlets and outlets. Some of those depicted are op-
tional and may not appear on your instrument. The connectors are described
briefly here and in detail in chapter 3 Installation.
Figure 1-2: Model 3000TA-XL Rear Panel
•
•
•
Power Connection
Universal AC power source.
Gas Inlet and Outlet One inlet and one exhaust out.
Analog Outputs
0–1 V dc oxygen concentration plus 0-1
V dc range ID, and isolated 4–20 mA dc
oxygen concentration plus 4-20 mA dc
range ID.
•
Alarm Connections
2 concentration alarms and 1 system
alarm.
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1 Introduction
Model 3000TA-XL-EU
•
•
•
•
RS-232 Port
Serialdigitalconcentrationsignaloutput
and control input.
Remote Probe
Used in the 3000TA-XL for controlling
external solenoid valves only.
Remote Span/Zero
Digital inputs allow external control of
analyzercalibration.
Calibration Contact To notify external equipment that
instrument is being calibrated and
readings are not monitoring sample.
•
•
Range ID Contacts
Network I/O
Four separate, dedicated, range relay
contacts. Low, Medium, High, Cal.
Serialdigitalcommunicationsforlocal
network access. For future expansion.
Not implemented at this printing.
Note: If you require highly accurate Auto-Cal timing, use external
Auto-Cal control where possible. The internal clock in the
Model 3000TA-XL is accurate to 2-3 %. Accordingly, internally
scheduled calibrations can vary 2-3 % per day.
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Trace Oxygen Analyzer
Operational Theory 2
Operational Theory
2.1 Introduction
The analyzer is composed of three subsystems:
1. Micro-Fuel Cell Sensor
2. SampleSystem
3. Electronic Signal Processing, Display and Control
The sample system is designed to accept the sample gas and transport it
through the analyzer without contaminating or altering the sample prior to
analysis. The Micro-Fuel Cell is an electrochemical galvanic device that
translates the amount of oxygen present in the sample into an electrical
current. The electronic signal processing, display and control subsystem
simplifies operation of the analyzer and accurately processes the sampled
data. The microprocessor controls 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 3000TA-XL series is a Micro-
Fuel Cell, Model B-2CXL designed and manufactured by Analytical Instru-
ments. It is a sealed plastic 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 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)
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2 Operational Theory
Model 3000TA-XL-EU
comes from outside the device as a constituent of the sample gas being
analyzed. The 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 a cylinder only 1¼ inches in diameter and 1¼
inches thick. It is made of an extremely inert plastic, which can be placed
confidently in practically any environment or sample stream. It is effectively
sealed, although one end is permeable to oxygen in the sample gas. The
other end of the cell is a contact plate consisting of two concentric foil rings.
The rings mate with spring-loaded contacts in the sensor block assembly and
provide the electrical connection to the rest of the analyzer. Figure 2-1
illustratestheexternalfeatures.
Figure 2-1: Micro-Fuel Cell
Refer to Figure 2-2, Cross Section of a Micro-Fuel Cell, which illus-
tratesthefollowinginternaldescription.
Figure 2-2. Cross Section of a Micro-Fuel Cell (not to scale)
At the top end of the cell is a diffusion membrane of Teflon, whose
thickness is very accurately controlled. Beneath the diffusion membrane lies
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Trace Oxygen Analyzer
Operational Theory 2
the oxygen sensing element—the cathode—with a surface area almost 4 cm2.
The cathode has many perforations to ensure sufficient wetting of the upper
surface with electrolyte, and it is plated with an inert metal.
The anode structure is below the cathode. It is made of lead and has a
proprietary design which is meant to maximize the amount of metal available
forchemicalreaction.
At the rear of the cell, just below the anode structure, is a flexible
membrane designed to accommodate the internal volume changes that occur
throughout the life of the cell. This flexibility assures that the sensing mem-
brane remains in its proper position, keeping the electrical output constant.
The entire space between the diffusion membrane, above the cathode,
and the flexible rear membrane, beneath the anode, is filled with electrolyte.
Cathode and anode are submerged in this common pool. They each have a
conductor connecting them to one of the external contact rings on the contact
plate, which is on the bottom 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:
O2 + 2H2O + 4e– → 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:
Pb + 2OH– → Pb+2 + H2O + 2e–
(anode)
(Two electrons are transferred for each atom of lead that is oxidized.
Therefore it takes two of the above anode reactions to balance one cathode
reactionandtransferfourelectrons.)
The electrons released at the surface of the anode flow to the cathode
surface when an external electrical path is provided. The current is propor-
tional 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
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2 Operational Theory
Model 3000TA-XL-EU
(These reactions are specific to oxygen as long as no gaseous compo-
nents capable of oxidizing lead—such as iodine, bromine, chlorine and
fluorine—are present in the sample.)
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 in parts-
per-million or a percentage of the gas mixture, it is necessary that the sample
diffuse into the cell under constant pressure.
If the total pressure increases, the rate that oxygen reaches the cathode
through the diffusing membrane will also increase. The electron transfer, and
therefore the external current, will increase, even though the oxygen concen-
tration of the sample has not changed. It is therefore important that the
sample pressure at the fuel cell (usually vent pressure) remain relatively
constantbetweencalibrations.
2.2.5 Calibration Characteristics
Given that the total pressure of the sample gas on the surface of the
Micro-Fuel Cell input is constant, a convenient characteristic of the cell is
that the current produced in an external circuit 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 2-3. Measuring
circuits do not have to compensate for nonlinearities.
In addition, since there is zero output in the absence of oxygen, the
characteristic curve has close to an absolute zero (less than ± 0.2 ppm oxy-
gen). Depending upon the application, zeroing may still be used to compen-
sate for the combined zero offsets of the cell and the electronics.
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Trace Oxygen Analyzer
Operational Theory 2
Figure 2-3. Characteristic Input/Output Curve for a Micro-Fuel Cell
2.3 Sample System
The sample system delivers gases to the Micro-Fuel Cell sensor from
the analyzer rear panel inlet. Depending on the mode of operation either
sample or calibration gas is delivered.
The Model 3000TA-XL sample system is designed and fabricated to
ensure that the oxygen concentration of the gas is not altered as it travels
through the sample system.
The sample system for the standard instrument incorporates VCR tube
fittings for sample inlet and 1/4"outlet tube connections at the rear panel.
The sample or calibration gas that flows through the system is monitored by
a flowmeter downstream from the cell. Figure 2-4 shows the piping layout
and flow diagram for the standard model.
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2 Operational Theory
Model 3000TA-XL-EU
SAMPLE IN
EXHAUST
RIGHT SIDE
TOP
VCR
Sample In
Exhaust
Out
Cell
Block
Needle Valve
Flowmeter
Figure 2-4: Piping Layout
Figure 2-5 is the flow diagram for the sampling system. In the standard
instrument, calibration gases can be connected directly to the Sample In port
by teeing to the port with appropriate valves.
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Trace Oxygen Analyzer
Operational Theory 2
Figure 2-5: Flow Diagram-Sample Under Pressure
-Standard Model
-Do not exceed 10" Hg Vacuum-
Figure 2-5-1: Flow Diagram-Sample at Zero Pressure
-Model 3000TA-XL-VS
Figure 2-5-2: Flow Diagram-Sample Under Pressure
-Model 3000TA-XL-CV
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2 Operational Theory
Model 3000TA-XL-EU
2.4 Electronics and Signal Processing
The Model 3000TA-XL Trace Oxygen Analyzer uses an 8031 micro-
controller with 32 kB of RAM and 128 kB of 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 any international power source. Figure 2-6 shows the
location of the power supply and the main electronic PC boards.
The signal processing electronics including the microprocessor, analog
to digital, and digital to analog converters are located on the motherboard at
the bottom of the case. The preamplifier board is mounted on top of the
motherboard as shown in the figure. These boards are accessible after re-
moving the back panel. Figure 2-7 is a block diagram of the Analyzer
electronics.
Figure 2-6: Electronic Component Location Inside the Model 3000TA-XL
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Trace Oxygen Analyzer
Operational Theory 2
Figure 2-7: Block Diagram of the Model 3000TA-XL Electronics
In the presence of oxygen the cell generates a current. A current to
voltage amplifier converts this current to a voltage, which is amplified in the
secondstageamplifier.
The second stage amplifier also supplies temperature compensation for
the oxygen sensor output. This amplifier circuit incorporates a thermistor,
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2 Operational Theory
Model 3000TA-XL-EU
which is physically located in the cell block. The thermistor is a temperature
dependent resistor that changes the gain of the amplifier in proportion to the
temperature changes in the block. This change is inversely proportional to
the change in the cell output. The result is a signal that is temperature inde-
pendent within a specified tolerance. The output from the second stage
amplifier is sent to an 18 bit analog to digital converter controlled by the
microprocessor.
The digital concentration signal along with input from the control panel
is processed by the microprocessor, and appropriate control signals are
directed to the display, alarms and communications port. The same digital
information is also sent to a 12 bit digital to analog converter that produces
the 4-20 mA dc and the 0-1 V dc analog concentration signal outputs, and
the analog range ID outputs.
Signals from the power supply are also monitored, and through the
microprocessor, the system failure alarm is activated if a malfunction is
detected.
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Trace Oxygen Analyzer
Installation 3
Installation
Installation of the Model 3000TA-XL Analyzer includes:
1. Unpacking
2. Mounting
3. Gas connections
4. Electricalconnections
5. InstallingtheMicro-FuelCell
6. Testing the system.
3.1 Unpacking the Analyzer
The analyzer is shipped with all the materials you need to install and
prepare the system for operation. Carefully unpack the analyzer and inspect
it for damage. Immediately report any damage to the shipping agent.
3.2 Mounting the Analyzer
The Model 3000TA-XL is for indoor use in a general purpose area. It
is NOT for hazardous environments of any type.
The standard model is designed for flush panel mounting. Figure 3-1 is
an illustration of the 3000TA-XL standard front panel and mounting bezel.
There are four mounting holes—one in each corner of the rigid frame.
Drawing number D-62928, at the back of this manual, contains a panel
cutoutdiagram.
On special order, a 19" rack-mounting panel can be provided. For rack
mounting, one or two 3000XL series analyzers can be flush-panel mounted
on the rack panel. See Appendix for dimensions of the mounting panel.
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3 Installation
Model 3000TA-XL-EU
6.7"
10"
Figure 3-1: Front Panel of the Model 3000TA-XL
All operator controls, except the flow control needle valve, are mounted
on the control panel, which is hinged on the left edge and doubles as the
door that provides access to the sensor and cell block inside the instrument.
The door latch is spring loaded and will swing open when the button in the
center of the latch (upper right corner) is pressed all the way in with a narrow
gauge tool (less than 0.18 inch wide). Allow clearance for the door to open
in a 90-degree arc of radius 7.125 inches. See Figure 3-2.
Figure 3-2: Required Front Door Clearance
3.3 Rear Panel Connections
Figure 3-3 shows the Model 3000TA-XL rear panel. There are ports
for gas inlet and outlet, power, communication, and both digital and analog
concentrationoutput.
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Trace Oxygen Analyzer
Installation 3
Figure 3-3: Rear Panel of the Model 3000TA-XL
3.3.1 Gas Connections
NOTE: Do not remove plastic caps on VCR fittings, unless you are
ready to make connections.
The unit is manufactured with 1/4 inch tube fittings, and 6 mm adapters
are supplied for metric system installations. For a safe connection:
SAMPLE IN: In the standard model, gas connections are made at the
SAMPLE IN and EXHAUST OUT connections. Calibration gases must be
Tee'd into the Sample inlet with appropriate valves. A VCR fitting is pro-
vided for the inlet connection.
The inlet gas pressure should be reasonably regulated. Pressures be-
tween 2 and 50 psig are acceptable as long as the pressure, once established,
will keep the front panel flowmeter reading in an acceptable range (0.5 to 2.0
SLPM). For non-pressurized sample or very low pressure, (less than 2 psig)
vacuum service plumbing is recommended. (See next section: Vacuum
Service).
If greater sample flow is required for improved response time, install a
bypass in the sampling system upstream of the analyzer input.
VACUUM SERVICE: If the sample pressure is at atmospheric or
very low pressure, the instrument must be ordered with the vacuum service
option. This will ensure that the flow control valve is located on the exhaust
side of the Micro-Fuel Cell.
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EXHAUST OUT: Exhaust connections must be consistent with the
hazard level of the constituent gases. Check Local, State, and Federal laws,
and ensure that the exhaust stream vents to an appropriately controlled area,
ifrequired.
3.3.2 Electrical Connections
For safe connections, no uninsulated wiring should be able to come in
contact with fingers, tools or clothing during normal operation.
CAUTION: Use Shielded Cables. Also, use plugs that provide
excellent EMI/RFI protection. The plug case must be
connected to the cable shield, and it must be tightly
fastened to the analyzer with its fastening screws.
Ultimately, it is the installer who ensures that the
connections provide adequate EMI/RFI sielding.
3.3.2.1
PrimaryInputPower
The power cord receptacle and fuse block are located in the same
assembly. Insert the power cord into the power cord receptacle.
CAUTION: Power is applied to the instrument's circuitry as
long as the instrument is connected to the power
source. The red
switch on the front panel is for
switching power on or off to the displays and out-
puts only.
The universal power supply requires a 85–250 V ac, 47-63 Hz power
source.
Fuse Installation: The fuse block, at the right of the power cord
receptacle, accepts US or European size fuses. A jumper replaces the fuse in
whichever fuse receptacle is not used. Fuses are not installed at the factory.
Be sure to install the proper fuse as part of installation. (See Fuse Replace-
ment in chapter 5, maintenance.)
3.3.2.2
50-PinEquipmentInterfaceConnector
Figure 3-4 shows the pin layout of the Equipment Interface connector.
The arrangement is shown as seen when the viewer faces the rear panel of
the analyzer. The pin numbers for each input/output function are given
where each function is described in the paragraphs below.
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Trace Oxygen Analyzer
Installation 3
Figure 3-4: Equipment Interface Connector Pin Arrangement
Analog Outputs: There are four DC output signal pins—two pins per
output. For polarity, see Table 3-1. The outputs are:
0–1 V dc % of Range: Voltage rises linearly with increasing oxygen, from
0 V at 0 ppm to 1 V at full scale ppm. (Full scale =
100% of programmable range.)
0–1 V dc Range ID:
0.25 V = Low Range, 0.5 V = Medium Range,
0.75 V = High Range, 1 V = Air Cal Range.
4–20 mA dc % Range: Current increases linearly with increasing oxygen,
from 4 mA at 0 ppm to 20 mA at full scale ppm.
(Full scale = 100% of programmable range.)4–20
mA dc Range ID: 8 mA = Low Range, 12 mA =
Medium Range, 16 mA = High Range, 20 mA =
Air Cal Range.
Table 3-1: Analog Output Connections
Pin
3
Function
+ Range ID, 4-20 mA, floating
– Range ID, 4-20 mA, floating
+ % Range, 4-20 mA, floating
– % Range, 4-20 mA, floating
+ Range ID, 0-1 V dc
4
5
6
8
23 – Range ID, 0-1 V dc, negative ground
24 + % Range, 0-1 V dc
7
– % Range, 0-1 V dc, negative ground
Alarm Relays: The nine alarm-circuit connector pins connect to the
internal alarm relay contacts. Each set of three pins provides one set of Form
C relay contacts. Each relay has both normally open and normally closed
contact connections. The contact connections are shown in Table 3-2. They
are capable of switching up to 3 amperes at 250 V ac into a resistive load.
The connectors are:
Threshold Alarm 1: • Can be configured as high (actuates when concen-
tration is above threshold), or low (actuates when
concentrationisbelowthreshold).
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Model 3000TA-XL-EU
• Can be configured as failsafe or nonfailsafe.
• Can be configured as latching or nonlatching.
• Can be configured out (defeated).
Threshold Alarm 2: • Can be configured as high (actuates when concen-
tration is above threshold), or low (actuates when
concentrationisbelowthreshold).
• Can be configured as failsafe or nonfailsafe.
• Can be configured as latching or nonlatching.
• Can be configured out (defeated).
SystemAlarm:
Actuates when DC power supplied to circuits is
unacceptable in one or more parameters. Permanently
configured as failsafe and latching. Cannot be de-
feated. Actuates if self test fails.
(Reset by pressing
press again and any other button EXCEPT
Systemtoresume.
button to remove power. Then
Further detail can be found in chapter 4, section 4-5.
Table 3-2: Alarm Relay Contact Pins
Pin Contact
45 Threshold Alarm 1, normally closed contact
28 Threshold Alarm 1, moving contact
46 Threshold Alarm 1, normally open contact
42 Threshold Alarm 2, normally closed contact
44 Threshold Alarm 2, moving contact
43 Threshold Alarm 2, normally open contact
36 System Alarm, normally closed contact
20 System Alarm, moving contact
37 System Alarm, normally open contact
Digital Remote Cal Inputs: Accept 0 V (off) or 24 V dc (on) inputs
for remote control of calibration. (See Remote Calibration Protocol below.)
See Table 3-3 for pin connections.
Zero:
Floating input. 5 to 24 V input across the + and – pins puts
the analyzer into the Zero mode. Either side may be
grounded at the source of the signal. 0 to 1 volt across the
terminals allows Zero mode to terminate when done. A
synchronous signal must open and close the external zero
valve appropriately. See Remote Probe Connector. (The –C
optioninternalvalvesoperateautomatically.)
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Installation 3
Span:
Floating input. 5 to 24 V input across the + and – pins puts
the analyzer into the Span mode. Either side may be
grounded at the source of the signal. 0 to 1 volt across the
terminals allows Span mode to terminate when done. A
synchronous signal must open and close external span valve
appropriately. See Figure 3-5 Remote Probe Connector. (The
–Coptioninternalvalvesoperateautomatically.)
Cal Contact: This relay contact is closed while analyzer is spanning
and/or zeroing. (See Remote Calibration Protocol below.)
Table 3-3: Remote Calibration Connections
Pin
9
Function
+ Remote Zero
– Remote Zero
+ Remote Span
– Remote Span
Cal Contact
11
10
12
40
41
Cal Contact
Remote Calibration Protocol: To properly time the Digital Remote
Cal Inputs to the Model 3000TA-XL-EU Analyzer, the customer's controller
must monitor the Cal Relay Contact.
When the contact is OPEN, the analyzer is analyzing, the Remote Cal
Inputs are being polled, and a zero or span command can be sent.
When the contact is CLOSED, the analyzer is already calibrating. It
will ignore your request to calibrate, and it will not remember that request.
Once a zero or span command is sent, and acknowledged (contact
closes), release it. If the command is continued until after the zero or span is
complete, the calibration will repeat and the Cal Relay Contact (CRC) will
closeagain.
Forexample:
1) Test the CRC. When the CRC is open, Send a zero command
until the CRC closes (The CRC will quickly close.)
2) When the CRC closes, remove the zero command.
3) When CRC opens again, send a span command until the CRC
closes. (The CRC will quickly close.)
4) When the CRC closes, remove the span command.
When CRC opens again, zero and span are done, and the sample is
being analyzed.
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Note: The Remote Valve connections (described below) provides
signals to ensure that the zero and span gas valves will be
controlled synchronously. If you have the –C Internal valve
option—which includes additional zero and span gas inputs—
the 3000T automatically regulates the zero, span and sample
gas flow.
Range ID Relays: Four dedicated Range ID relay contacts. The first
three ranges are assigned to relays in ascending order—Low range is as-
signed to Range 1 ID, Medium range is assigned to Range 2 ID, and High
range is assigned to Range 3 ID. The fourth range is reserved for the Air Cal
Range (25%). Table 3-4 lists the pin connections.
Table 3-4: Range ID Relay Connections
Pin
21
38
22
39
19
18
34
35
Function
Range 1 ID Contact
Range 1 ID Contact
Range 2 ID Contact
Range 2 ID Contact
Range 3 ID Contact
Range 3 ID Contact
Range 4 ID Contact (Air Cal)
Range 4 ID Contact (Air Cal)
Network I/O: A serial digital input/output for local network protocol.
At this printing, this port is not yet functional. It is to be used for future
options to the instrument. Pins 13 (+) and 29 (–).
Remote Valve Connections: The 3000TA-XL is a single-chassis
instrument, which has no Remote Valve Unit. Instead, the Remote Valve
connections are used as a method for directly controlling external sample/
zero/span gas valves. See Figure 3-5.
Figure 3-5: Remote Probe Connections
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Installation 3
The voltage from these outputs is nominally 0 V for the OFF and
15 V dc for the ON conditions. The maximum combined current that can be
pulled from these output lines is 100 mA. (If two lines are ON at the same
time, each must be limited to 50 mA, etc.) If more current and/or a different
voltage is required, use a relay, power amplifier, or other matching circuitry
to provide the actual driving current.
In addition, each individual line has a series FET with a nominal ON
resistance of 5 ohms (9 ohms worst case). This can limit the obtainable
voltage, depending on the load impedance applied. See Figure 3-6
.
Figure 3-6: FET Series Resistance
3.3.2.3
RS-232Port
The digital signal output is a standard, full duplex RS-232 serial com-
munications port used to connect the analyzer to a computer, terminal, or
other digital device. It requires a standard 9-pin D connector.
The output data is status information, in digital form, updated every two
seconds. Status is reported in the following order:
•
•
•
•
•
The concentration in ppm or percent
The range in use (HI, MED, LO)
The span of the range (0-100 ppm, etc)
Which alarms—if any—are disabled (AL–x DISABLED)
Which alarms—if any—are tripped (AL–x ON).
Each status output is followed by a carriage return and line feed.
Three input functions using RS-232 have been implemented to date.
They are described in Table 3-5.
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Table 3-5: Commands via RS-232 Input
Description
Command
as<enter>
az<enter>
st<enter>
Immediatelystartsanautospan.
Immediatelystartsanautozero.
Toggling input. Stops/Starts any status message output from
the RS-232, until st<enter> is sent again.
The RS-232 protocol allows some flexibility in its implementation.
Table 3-6 lists certain RS-232 values that are required by the 3000TA
implementation.
Table 3-6: Required RS-232 Options
Parameter
Setting
Baud 2400
Byte
8 bits
Parity none
Stop Bits
1
MessageInterval 2 secondsWhen CRC opens again,
zero and span are done, and the sample is being analyzed.
Range ID Relays: There are four dedicated Range ID relay contacts.
The first three ranges are assigned to relays in ascending order—Low range
is assigned to Range 1 ID, Medium range is assigned to Range 2 ID, and
High range is assigned to Range 3 ID. The fourth range is reserved for the
Air Cal Range (25%).
Network I/O: A serial digital input/output for local network protocol.
At this printing, this port is not yet functional. It is to be used in future
options to the instrument.
RS-232 Port: 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. It requires a standard 9-pin D connector.
The data is status information, in digital form, updated every two
seconds. Status is reported in the following order:
•
•
•
•
•
The concentration in ppm or percent
The range in use (HI, MED, LO)
The span of the range (0-100 ppm, etc)
Which alarms—if any—are disabled (AL–x DISABLED)
Which alarms—if any—are tripped (AL–x ON).
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3.4 Installing the Micro-Fuel Cell
The Micro-Fuel Cell, Model B-2CXL is not installed in the cell block
when the instrument is shipped. Install it before the analyzer is placed in
service.
The Micro-Fuel cell is located inside the stainless steel cell block behind
the front panel (see Figure 3-8). To install the cell:
1. Remove power to the instrument by unplugging the power cord
at the power source.
2. Open the front panel door by pressing the release button on the
top right corner of the door all the way in with a narrow gauge
tool.
3. With one hand placed underneath the cell block ready to catch
the Micro-Fuel cell , lift up on the stainless steel gate in front of
the cell block. This releases the cell and cell holder from the
block. The cell and holder will fall out in your hand.
CAUTION:
The cell is shipped separately inside two bags filled with oxygen-free
inert gas. Extreme care must be taken to ensure that the cell is exposed to air
for the very minimum amount of time, including during installation.
As an example, an air exposure of 3 to 5 minutes may require 24 hours
or longer before the cell recovers to less than 0.5 ppm on an oxygen free
sample gas. On the other hand, if the air exposure is limited to less than 10
seconds, the recovery time will be reduced to two hours, or less.
3.5 Testing the System
Before plugging the instrument into the power source:
•
•
•
Check the integrity and accuracy of the gas connections. Make
sure there are no leaks.
Check the integrity and accuracy of the electrical connections.
Make sure there are no exposed conductors.
Check that inlet sample pressure is within the accepted range (see
section3.3.1).
Power up the system, and test it by performing the following operation:
1. Repeat the Self-Diagnostic Test as described in chapter 4, section
4.3.5.
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Lift Up
Cell Block
Gate
Micro-Fuel Cell
Figure 3-8: Removing the Micro-Fuel Cell
O-Ring
Cell Holder
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Operation 4
Operation
4.1 Introduction
Once the analyzer has been installed, it can be configured for your
application. To do this you will:
•
Setsystemparameters:
•
Establish a security password, if desired, requiring Operator
to log in.
•
Establish and start an automatic calibration cycle, if desired.
•
•
Calibratetheinstrument.
Define the three user selectable analysis ranges, then choose
autoranging or select a fixed range of analysis, as required.
•
Set alarm setpoints, and modes of alarm operation (latching,
failsafe,etc).
Before you configure your 3000TA-XL, these default values are in
effect:
Ranges: LO = 1 ppm, MED = 10 ppm, HI = 100 ppm.
Auto Ranging: ON
Alarm Relays: Defeated, 10.00 ppm, HI, Not failsafe, Not latching.
Zero: Auto, every 0 days at 0 hours.
Span: Auto, at 000,008.00 ppm, every 0 days at 0 hours.
If you choose not to use password protection, the default password is
automatically displayed on the password screen when you start up, and you
simply press Enter for access to all functions of the analyzer.
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4.2 Using the Data Entry and Function
Buttons
Data Entry Buttons: The < > arrow buttons select options from the
menu currently being displayed on the VFD screen. The selected option
blinks.
When the selected option includes a modifiable item, the Δ∇ arrow
buttons can be used to increment or decrement that modifiable item.
The Enter button is used to accept any new entries on the VFD screen.
The Escape button is used to abort any new entries on the VFD screen that
are not yet accepted by use of the Enter button.
Figure 4-1 shows the hierarchy of functions available to the operator via
the function buttons. The six function buttons on the analyzer are:
• Analyze. This is the normal operating mode. The analyzer
monitors the oxygen content of the sample, displays the percent
of oxygen, and warns of any alarm conditions.
• System. The system function consists of six subfunctions that
regulate the internal operations of the analyzer:
•
•
•
•
•
Auto-Cal setup
Passwordassignment
Self-Testinitiation
Checking software version
Logging out.
• Zero. Used to set up a zero calibration.
• Span. Used to set up a span calibration.
• Alarms. Used to set the alarm setpoints and determine whether
each alarm will be active or defeated, HI or LO acting, latching,
and/orfailsafe.
• Range. Used to set up three analysis ranges that can be switched
automatically with auto-ranging or used as individual fixed
ranges.
Any function can be selected at any time by pressing the appropriate
button (unless password restrictions apply). The order as presented in this
manual is appropriate for an initial setup.
Each of these functions is described in greater detail in the following
procedures. The VFD screen text that accompanies each operation is repro-
duced, at the appropriate point in the procedure, in a Monospacedtype
style. Pushbutton names are printed in Oblique type.
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Trace Oxygen Analyzer
Operation 4
ANALYZE
SYSTEM
Perform Oxygen
Analysis of
theSample
SPAN
TRAK/HLD
ZERO
Set Instrument
Span
ALARMS
Perform
Self-Diagnostic
Test
Set Instrument
Zero
RANG
E
Initiate
Automatic
Calibration
Set Alarm
Setpoints
Define Analysis
Ranges
ConfrigureMode
of Alarm
Operation
Set Password
Logout
ShowNegative
Figure 4-1: Hierarchy of Functions and Subfunctions
4.3 The System Function
The subfuctions of the System function are described below. Specific
procedures for their use follow the descriptions:
•
•
Auto-Cal: Used to define an automatic calibration sequence
and/or start an Auto-Cal.
PSWD: Security can be established by choosing a 5 digit
password (PSWD) from the standard ASCII character set. (See
Installing or Changing the Password, below, for a table of
ASCII characters available.) Once a unique password is assigned
and activated, the operator MUST enter the UNIQUE password
to gain access to set-up functions which alter the instrument's
operation, such as setting the instrument span or zero setting,
adjusting the alarm setpoints, or defining analysis ranges.
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Model 3000TA-XL-EU
After a password is assigned, the operator must log out to
activate it. Until then, anyone can continue to operate the
instrument without entering the new password.
Only one password can be defined. Before a unique password
is assigned, the system assigns TETAI by default. This allows
access to anyone. After a unique password is assigned, to defeat
the security, the password must be changed back to TETAI.
•
•
•
Logout: Logging out prevents unauthorized tampering with
analyzersettings.
More: Select and enter More to get a new screen with additional
subfunctionslisted.
Self–Test: The instrument performs a self-diagnostic test to
check the integrity of the power supply, output boards and
amplifiers.
•
•
•
Version: Displays Manufacturer, Model, and Software Version
ofinstrument.
Show Negative: The operator selects whether display can
show negative oxygen readings or not.
TRAK/HLD: The operator sets whether the instrument analog
outputs track the concentration change during calibration and sets
a time delay for the concentration alarms after calibration
4.3.1 Tracking the Oxygen Readings during Calibration
and Alarm delay
The user has the option of setting the preferenc as to whether the analog
outputs track the display readings during calibration or not. To set the prefer-
ence, press the System key once and the first System menu will appear in the
VFD display:
TRAK/HLD Auto-Cal
PSWD Logout More
TRAK/HLD should be blinking. To enter this system menu press the
Enter key once:
Output Sttng: TRACK
Alarm Dly: 10 min
Or
Output Sttng: HOLD
Alarm Dly: 10 min
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Operation 4
In the first line, TRACK or HOLD should be blinking. The operator
can toggle between TRACK and HOLD with the Up or Down keys. When
TRACK is selected, the analog outputs (0-1 VDC and 4-20 ma) and the
range ID contacts will track the instrument readings during calibration (either
zero or span). TRACK is the factory default.
When HOLD is selected, the analog outputs (0-1 VDC and 4-20 ma)
and the range ID contacts will freeze on their last state before entering one of
the calibration modes. When the instrument returns to the Analyze mode,
either by a successful or an aborted calibration, there will be a three-minute
delay before the analog outputs and the range ID contacts start tracking
again.
The concentration alarms freeze on their last state before entering
calibration regardless of selecting HOLD or TRACK. But, when HOLD is
selected the concentration alarms will remain frozen for the time displayed in
the second line of the TRAK/HLD menu after the analyzer returns to the
Analyze mode.
The factory default is three minutes, but the delay time is program-
mable. To adjust to delay time use the Left or Right arrow keys. When the
time displayed on the second line blinks, it can be adjusted by Pressing the
Up or Down keys to increase or decrease its value. The minimum delay is 1
minute, the maximum is 30.
This preference is stored in non-volatile memory so that it is recovered
if power is removed from the instrument.
4.3.2 Setting up an Auto-Cal
When proper automatic valving is connected (see chapter 3, installa-
tion), the Analyzer can cycle itself through a sequence of steps that automati-
callycalibratestheinstrument.
Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal
control where possible. The internal clock in the Model 3000TA-XL is
acurate to 2-3 %. Accordingly, internally scheduled calibrations can
vary 2-3 % per day.
To setup an Auto–Cal cycle:
CAUTION:
We do not recommend frequent Zero adjustments of the cell. A newly
installed cell may take 7-10 days of operation to reach a steady Zero
(typically less than 0.2 ppm). If required, the instrument may be zeroed
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Model 3000TA-XL-EU
after this initial stabilizing period and may be checked again after a addi-
tional 7-10 day frequency of zero adjustment is at the discretion of the user
(once a month is suggested).
Choose System from the Function buttons. The LCD will display five
subfunctions.
TRAK/HLDAuto—Cal
PSWDLogoutMore
Use < > arrows to blink Auto—Cal, and press Enter. A new screen for
Span/Zero set appears.
SpanOFFNxt: 0d0h
ZeroOFFNxt: 0d0h
Press < > arrows to blink Span(or Zero), then press Enter again. (You
won’t be able to set OFF to ON if a zero interval is entered.) A Span
Every ... (or Zero Every ...) screen appears.
SpanEvery0 d
Start0hfromnow
Use Δ∇ arrows to set an interval value, then use < > arrows to move to
the start-time value. Use Δ∇ arrows to set a start-time value.
To turn ON the Span and/or Zero cycles (to activate Auto-Cal): Press
System again, choose Auto—Cal, and press Enter again. When the Span/
Zero values screen appears, use the < > arrows to blink the Span (or Zero)
OFF/ONfield. Use Δ∇ arrows to set the OFF/ONfield to ON. You can
now turn these fields ONbecause there is a nonzero span interval defined.
4.3.3 Password Protection
If a password is assigned, then setting the following system parameters
can be done only after the password is entered: span and zero settings,
alarm setpoints, analysis range definitions, switching between autoranging
and manual override, setting up an auto-cal, and assigning a new password.
However, the instrument can still be used for analysis or for initiating a self-
test without entering the password.
If you have decided not to employ password security, use the default
password TETAI. This password will be displayed automatically by the
microprocessor. The operator just presses the Enter key to be allowed total
accesstotheinstrument’sfeatures.
NOTE: If you use password security, it is advisable to keep a copy of the
password in a separate, safe location.
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Operation 4
4.3.3.1
EnteringthePassword
To install a new password or change a previously installed password,
you must key in and ENTER the old password first. If the default password
is in effect, pressing the ENTER button will enter the default TETAI pass-
word for you.
Press System to enter the System mode.
TRAK/HLDAuto—Cal
PSWDLogoutMore
Use the < > arrow keys to scroll the blinking over to PSWD, and press
Enter to select the password function. Either the default TETAI password or
AAAAA place holders for an existing password will appear on screen
depending on whether or not a password has been previously installed.
TETAI
EnterPWD
or
AAAAA
EnterPWD
The screen prompts you to enter the current password. If you are not
using password protection, press Enter to accept TETAI as the default
password. If a password has been previously installed, enter the password
using the < > arrow keys to scroll back and forth between letters, and the Δ∇
arrow keys to change the letters to the proper password. Press Enter to enter
the password.
If the password is accepted, the screen will indicate that the password
restrictions have been removed and you have clearance to proceed.
PSWDRestrictions
Removed
In a few seconds, you will be given the opportunity to change this
password or keep it and go on.
ChangePassword?
<ENT>=Yes <ESC>=No
Press Escape to move on, or proceed as in Changing the Password,
below.
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Model 3000TA-XL-EU
4.3.3.2
InstallingorChangingthePassword
If you want to install a password, or change an existing password,
proceed as above in Entering the Password. When you are given the oppor-
tunity to change the password:
ChangePassword?
<ENT>=Yes <ESC>=No
Press Enter to change the password (either the default TETAI or the
previously assigned password), or press Escape to keep the existing pass-
word and move on.
If you chose Enter to change the password, the password assignment
screenappears.
TETAI
<ENT>ToProceed
or
AAAAA
<ENT>ToProceed
Enter the password using the < > arrow keys to move back and forth
between the existing password letters, and the Δ∇ arrow keys to change the
letters to the new password. The full set of 94 characters available for pass-
word use are shown in the table below.
Characters Available for Password Definition:
A
K
U
_
i
s
}
)
3
=
B
L
V
`
j
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When you have finished typing the new password, press Enter. A
verification screen appears. The screen will prompt you to retype your
passwordforverification.
AAAAA
RetypePWDToVerify
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Operation 4
Wait a moment for the entry screen. You will be given clearance to
proceed.
AAAAA
<ENT>TOProceed
Use the arrow keys to retype your password and press Enter when
finished. Your password will be stored in the microprocessor and the system
will immediately switch to the Analyze screen, and you now have access to
allinstrumentfunctions.
If all alarms are defeated, the Analyze screen appears as:
0.0 ppm Anlz
Range: 0—100
If an alarm is tripped, the second line will change to show which alarm
itis:
0.0 ppm Anlz
AL—1
NOTE: If you log off the system using the logout function in the system
menu, you will now be required to re-enter the password to gain
access to Span, Zero, Alarm, and Range functions.
4.3.4 Logout
The Logout function provides a convenient means of leaving the
analyzer in a password protected mode without having to shut the instrument
off. By entering Logout, you effectively log off the instrument leaving the
system protected against use until the password is reentered. To log out,
press the System button to enter the System function.
TRAK/HLDAuto—Cal
PSWDLogoutMore
Use the < > arrow keys to position the blinking over the Logout func-
tion, and press Enter to Log out. The screen will display the message:
ProtectedUntil
PasswordReentered
4.3.5 System Self-Diagnostic Test
The Model 3000TA-XL has a built-in self-diagnostic testing routine.
Pre-programmed signals are sent through the power supply, output board
and sensor circuit. The return signal is analyzed, and at the end of the test the
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Model 3000TA-XL-EU
status of each function is displayed on the screen, either as OK or as a
number between 1 and 3. (See System Self Diagnostic Test in chapter 5 for
number code.)
The self diagnostics are run automatically by the analyzer whenever the
instrument is turned on, but the test can also be run by the operator at will.
To initiate a self diagnostic test during operation:
Press the System button to start the System function.
TRAK/HLDAuto—Cal
PSWDLogoutMore
Use the < > arrow keys to blink More, then press Enter.
VersionSelf—Test
Use the < > arrow keys again to move the blinking to the Self–Test
function. The screen will follow the running of the diagnostic.
RUNNING DIAGNOSTIC
TestingPreamp—83
During preamp testing there is a countdown in the lower right corner of
the screen. When the testing is complete, the results are displayed.
Power:OK Analog:OK
Preamp:3
The module is functioning properly if it is followed by OK. A number
indicates a problem in a specific area of the instrument. Refer to Chapter 5
Maintenance and Troubleshooting for number-code information. The results
screen alternates for a time with:
PressAnyKey
ToContinue...
Then the analyzer returns to the initial System screen.
4.3.6 Version Screen
Move the < > arrow key to More and press Enter. With Version
blinking, press Enter. The screen displays the manufacturer, model, and
softwareversioninformation.
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Trace Oxygen Analyzer
Operation 4
4.4 Calibration of the Analyzer
The analyzer must be calibrated prior to its use. For most applications
where the desired range of measurement is 0 to 1 ppm, we recommend the
analyzer be calibrated using a span gas as detailed below:
Span Gas Calibration
Before the cell is ready for calibration, it must be purged with semple
gas to low oxygen levels preferably below 0.2 ppm. However, if the
oxygen contact of the sample gas is higher than 0.2 ppm, a zero gas such as
nitrogen with oxygen levels below 0.2 ppm may be required.
The recommended span gas concentration is between 7.0 to 9.0 ppm
oxygen in nitrogen, and will require calibration be performed in the 0-10
ppm analyzer range.
Air Calibration
If desired, a newly installed cell may be calibrated in air to 209,000
ppm. However, this practice is generally not recommended as the cell may
take 24 hours or longer to recover to less than 0.2 ppm after being exposed
to air for about 3 to 5 minutes.
4.4.1 Zero Cal
The B-2CXL cell has a zero offset of less than 0.2 ppm oxygen. Nor-
mally, the offset slowly decreases during the first 7 to 10 days of operation,
and is expected to reach a steady value after this time.
Generally, the value of the zero offset is part of the oxygen reading of
the sample gas as shown by the analyzer readout. As an example, a reading
of 0.5 ppm oxygen may include 0.4 ppm oxygen in the sample gas and a 0.1
ppm zero offset.
The determination of the zero offset requires the use of oxygen free gas
to the analyzer. We recommend the use of nitrogen gas with a scrubber to
assure oxygen levels below 0.02 ppm.
The user may decide to eliminate the zero offset for improved accu-
racy. If so desired the analyzer is equipped to provide this function. How-
ever, we do not recommend carying out the cal zero during the first 10 days
of the operation of the cell.
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4 Operation
Model 3000TA-XL-EU
The Zero button on the front panel is used to enter the zero calibration
function. Zero calibration can be performed in either the automatic or manual
mode. In the automatic mode, an internal algorithm compares consecutive
readings from the sensor to determine when the output is within the accept-
able range for zero. In the manual mode, the operator determines when the
reading is within the acceptable range for zero. Make sure the zero gas is
connected to the instrument. If you get a CELL FAILURE message skip to
section 4.4.1.3.
4.4.1.1
AutoModeZeroing
Press Zero to enter the zero function mode. The screen allows you to
select whether the zero calibration is to be performed automatically or manu-
ally. Use the Δ∇ arrow keys to toggle between AUTO and MAN zero
settling. Stop when AUTO appears, blinking, on the display.
Zero:Settling:AUTO
<ENT>ToBegin
Press Enter to begin zeroing.
#### PPM Zero
Slope=#### ppm/s
The beginning zero level is shown in the upper left corner of the dis-
play. As the zero reading settles, the screen displays and updates information
on Slope (unless the Slope starts within the acceptable zero range and does
not need to settle further).
Then, and whenever Slope is less than 0.08 for at least 3 minutes,
instead of Slope you will see a countdown: 5 Left, 4 Left, and so fourth.
These are five steps in the zeroing process that the system must complete,
AFTER settling, before it can go back to Analyze.
#### PPM Zero
4Left=### ppm/s
The zeroing process will automatically conclude when the output is
within the acceptable range for a good zero. Then the analyzer automatically
returns to the Analyze mode.
4.4.1.2
ManualModeZeroing
Press Zero to enter the Zero function. The screen that appears allows
you to select between automatic or manual zero calibration. Use the Δ∇ keys
to toggle between AUTO and MAN zero settling. Stop when MAN appears,
blinking, on the display.
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Operation 4
Zero:Settling:Man
<ENT>ToBegin
Press Enter to begin the zero calibration. After a few seconds the first
of five zeroing screens appears. The number in the upper left hand corner is
the first-stage zero offset. The microprocessor samples the output at a prede-
termined rate. It calculates the differences between successive samplings and
displays the rate of change as Slope= a value in parts per million per second
(ppm/s).
#### ppm Zero
Slope=#### ppm/s
NOTE: It takes several seconds for the true Slope value to display. Wait about
10 seconds. Then, wait until Slope is sufficiently close to zero before
pressing Enter to finish zeroing .
Generally, you have a good zero when Slope is less than 0.05 ppm/s
for about 30 seconds. When Slope is close enough to zero, press Enter. In a
few seconds, the screen will update.
Once zero settling is completed, the information is stored in the
microprocessor, and the instrument automatically returns to the Analyze
mode.
4.4.1.3
CellFailure
Cell failure in the 3000TA-XL is usually associated with inability to
zero the instrument down to a satisfactorily low ppm reading. When this
occurs, the instrument will still Zero, but the 3000TA-XL system alarm trips,
and the LCD displays a failure message.
#.# ppm Anlz
CELLFAIL/ZEROHIGH
Before replacing the cell:
a. Check your span gas to make sure it is within specifications.
b. Check for leaks up-stream from the cell, where oxygen may be
leaking into the system.
If there are no leaks and the span gas is within specification, replace the
cell as described in chapter 5, Maintenance.
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4 Operation
Model 3000TA-XL-EU
4.4.2 Span Cal
The Span button on the front panel is used to span calibrate the ana-
lyzer. Span calibration can be performed using the automatic mode, where
an internal algorithm compares consecutive readings from the sensor to
determine when the output matches the span gas concentration. Span cali-
bration can also be performed in manual mode, where the operator deter-
mines when the span concentration reading is acceptable and manually exits
thefunction.
4.4.2.1
AutoModeSpanning
Press Span to enter the span function. The screen that appears allows
you to select whether the span calibration is to be performed automatically or
manually. Use the Δ∇ arrow keys to toggle between AUTO and MAN span
settling. Stop when AUTO appears, blinking, on the display.
Span:Settling:AUTO
<ENT>ForNext
Press Enter to move to the next screen.
Calib.Holdingtime
Calhold: 5 min
This menue allows the operator to set the time the analyzer should be
held in the AUTO span mode, after the readings of the analyzer settle. Five
minutes is the default, but it could be adjusted anywhere from 1 to 60 min-
utes by using the UP or DOWN keys.
Press Enter to move to the next screen.
SpanVal:000008.00
<ENT>Span <UP>Mod #
Use the Δ∇ arrow keys to enter the oxygen-concentration mode. Use
the < > arrow keys to blink the digit you are going to modify. Use the Δ∇
arrow keys again to change the value of the selected digit. When you have
finished typing in the concentration of the span gas you are using, press
EntertobegintheSpancalibration.
#### ppm Span
Slope=#### ppm/s
The beginning span value is shown in the upper left corner of the
display. As the span reading settles, the screen displays and updates informa-
tion on Slope. Spanning automatically ends when the span output corre-
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Trace Oxygen Analyzer
Operation 4
sponds, within tolerance, to the value of the span gas concentration. Then the
instrumentautomaticallyreturnstotheanalyzemode.
4.4.2.2
ManualModeSpanning
Press Span to start the Span function. The screen that appears allows
you to select whether the span calibration is to be performed automatically or
manually.
Span:Settling:MAN
<ENT>ForNext
Use the Δ∇ keys to toggle between AUTO and MAN span settling.
Stop when MAN appears, blinking, on the display. Press Enter to move to
the next screen.
Press Enter to move to the next screen.
Calib.Holdingtime
Calhold: 5 min
This menue allows the operator to set the time the analyzer should be
held in the AUTO span mode. It does not have any effect in the MANual
mode. Just press Enter key to continue.
SpanVal:000008.00
<ENT>Span <UP>Mod #
Press Δ (<UP>) to permit modification (Mod #) of span value.
Use the arrow keys to enter the oxygen concentration of the span gas
you are using (209000.00 if you are using air). The < > arrows choose the
digit, and the Δ∇ arrows choose the value of the digit.
Press Enter to enter the span value into the system and begin the span
calibration.
Once the span has begun, the microprocessor samples the output at a
predeterminedrate. Itcalculatesthedifferencebetweensuccessivesamplings
and displays this difference as a Slope on the screen. It takes several seconds
for the first Slope value to display. Slope indicates the rate of change of the
Span reading. It is a sensitive indicator of stability.
#### % Span
Slope=#### ppm/s
When the Spanvalue displayed on the screen is sufficiently stable,
press Enter. (Generally, when the Spanreading changes by 1 % or less of
the full scale of the range being calibrated, for a period of ten minutes it is
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4 Operation
Model 3000TA-XL-EU
sufficiently stable.) Once Enter is pressed, the Spanreading changes to the
correct value. The instrument then automatically enters the Analyze func-
tion.
4.4.3 Span Failure
The analyzer checks the output of the cell at the end of the span. If the
raw output of the cell is less than 0.5 uA/ppm O2, the span will not be
accepted. The analyzer will return to the previous calibration values, trigger
the System Alarm, and display in the VFD:
SpanFailed!!
This message will be shown for five seconds and the instrument shall
return to the Analyze mode. In the upper right hand corner of the VFD
display “FCAL” will be shown. This message flag will help the operator
troubleshoot in case calibration was initiated remotely. To reset the alarm
and the flag message, the unit must be turned off by cycling the standby key
. It will not reset if the next span cycle is correct.
A trace cell is unlikely to fail span. As explained before, when the
sensor reaches the end of its useful life, the zero offset begins to rise until the
analyzer finds the zero unsatisfactory. Nevertheless, feeding the wrong span
gas or electronics failure could set this feature off at the end of the span.
Consider this before replacing the cell.
4.5 Switching of Sample Streams
The Model 3000TA-XL may be used to monitor more than one type of
sample gas, such as nitrogen and helium, or two streams of nitrogen contain-
ing low (less than 1 ppm) and high (5000 to 10,000 ppm) concentrations of
oxygen.
For these applications, we recommend the following parameters and
conditionsbefollowed:
1. While switching streams, such as between nitrogen and helium, both
the gas streams must be made to flow continuosly even through only one
stream is going through the analyzer at one time. Failure to do so may result
in spikes in output when the dead-ended stream is switched in. For more
discussion of this, read the Technical Bulletin - TB00001, dated 3-98. This
Bulletin is available upon request from TATAI.
2. The analyzer is capable of handling the switching of streams without
effecting the sensitivity of the cell. This switching of streams between
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Trace Oxygen Analyzer
Operation 4
nitrogen and helium will not require SPAN adjustment. However, care must
be taken to keep sample flow rates in the desired levels, as the flowmeter is
calibrated for air and nitrogen streams only.
3. The analyzer can withstand repeated switching of streams between
low oxygen levels of less than 1 ppm and high oxygen levels of 5000 to
10,000 ppm. Again, care must be taken to ensure proper and continuous
flows at all times.
4.5.1
Special Notes on Hydrogen Gas Stream
The standard oxygen cell, Model B-2CXL, though tested in nitrogen
gas streams is expected to perform well in hydrogen streams. Hovewer, for
certain applications such as continuous monitoring of very low levels of
oxygen in hydrogen, the user may request cells that have been specifically
tested in hydrogen streams. Consult Teledyne for further details.
4.6 The Alarms Function
The Model 3000TA-XL is equipped with 2 fully adjustable concentra-
tion alarms and a system failure alarm. Each alarm has a relay with a set of
form “C" contacts rated for 3 amperes resistive load at 250 V ac. See Figure
3-5 in Chapter 3, Installation and/or the Interconnection Diagram included at
the back of this manual for relay terminal connections.
The system failure alarm has a fixed configuration as described in
chapter3Installation.
The concentration alarms can be configured from the front panel as
either high or low alarms by the operator. The alarm modes can be set as
latching or non-latching, and either failsafe or non-failsafe, or, they can be
defeated altogether. The setpoints for the alarms are also established using
thisfunction.
Decide how your alarms should be configured. The choice will depend
upon your process. Consider the following four points:
1. Which if any of the alarms are to be high alarms and which if any
are to be low alarms?
Setting an alarm as HIGH triggers the alarm when the oxygen
concentration rises above the setpoint. Setting an alarm as LOW
triggers the alarm when the oxygen concentration falls below the
setpoint.
Decide whether you want the alarms to be set as:
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Model 3000TA-XL-EU
•
•
•
Both high (high and high-high) alarms, or
One high and one low alarm, or
Both low (low and low-low) alarms.
2. Are either or both of the alarms to be configured as failsafe?
In failsafe mode, the alarm relay de-energizes in an alarm
condition. For non-failsafe operation, the relay is energized in an
alarm condition. You can set either or both of the concentration
alarms to operate in failsafe or non-failsafe mode.
3. Are either of the alarms to be latching?
In latching mode, once the alarm or alarms trigger, they will
remain in the alarm mode even if process conditions revert back
to non-alarm conditions. This mode requires an alarm to be
recognized before it can be reset. In the non-latching mode, the
alarm status will terminate when process conditions revert to non-
alarmconditions.
4. Are either of the alarms to be defeated?
The defeat alarm mode is incorporated into the alarm circuit so
that maintenance can be performed under conditions which
would normally activate the alarms.
The defeat function can also be used to reset a latched alarm.
(See procedures, below.)
If you are using password protection, you will need to enter your
password to access the alarm functions. Follow the instructions in section
4.3.3 to enter your password. Once you have clearance to proceed, enter the
Alarm function.
Press the Alarm button on the front panel to enter the Alarm function.
Make sure that AL–1 is blinking.
AL—1 AL—2
ChooseAlarm
Set up alarm 1 by moving the blinking over to AL–1 using the < >
arrow keys. Then press Enter to move to the next screen.
AL—11000 ppm HI
Dft—N Fs—N Ltch—N
Five parameters can be changed on this screen:
•
Value of the alarm setpoint, AL–1 #### ppm (oxygen);
value can be set from 0.00 to 10,000.00 ppm
•
Out-of-range direction, HI or LO
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Trace Oxygen Analyzer
Operation 4
•
•
•
Defeated? Dft–Y/N (Yes/No)
Failsafe? Fs–Y/N (Yes/No)
Latching? Ltch–Y/N (Yes/No).
•
•
To define the setpoint, use the < > arrow keys to move the
blinking over to AL–1 ####. Then use the Δ∇ arrow keys to
change the number. Holding down the key speeds up the
incrementing or decrementing. (Remember, the setpoint units are
ppm O2.)
To set the other parameters use the < > arrow keys to move the
blinking over to the desired parameter. Then use the Δ∇ arrow
keys to change the parameter.
•
•
Once the parameters for alarm 1 have been set, press Alarms
again, and repeat this procedure for alarm 2 (AL–2).
To reset a latched alarm, go to Dft– and then press either Δ two
times or ∇ two times. (Toggle it to Y and then back to N.)
–OR –
Go to Ltch– and then press either Δ two times or ∇ two times.
(Toggle it to N and back to Y.)
4.7 The Range Function
The Range function allows the operator to program up to three concen-
tration ranges to correlate with the DC analog outputs. If no ranges are
defined by the user, the instrument defaults to:
Low = 0–1 ppm
Med = 0–10 ppm
High = 0–100 ppm.
The Model 3000TA-XL is set at the factory to default to autoranging.
In this mode, the microprocessor automatically responds to concentration
changes by switching ranges for optimum readout sensitivity. If the current
range limits are exceeded, the instrument will automatically shift to the next
higher range. If the concentration falls to below 85% of full scale of the next
lower range, the instrument will switch to that range. A corresponding shift
in the DC percent-of-range output, and in the range ID outputs, will be
noticed.
The autoranging feature can be overridden so that analog output stays
on a fixed range regardless of the oxygen concentration detected. If the
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4 Operation
Model 3000TA-XL-EU
concentration exceeds the upper limit of the range, the DC output will
saturate at 1 V dc (20 mA at the current output).
However, the digital readout and the RS-232 output of the concentra-
tion are unaffected by the fixed range. They continue to read accurately with
full precision. See Front Panel description in Chapter 1.
The automatic air calibration range is always 0-25 % and is not pro-
grammable.
4.7.1 Setting the Analog Output Ranges
To set the ranges, enter the range function mode by pressing the
Range button on the front panel.
L—1 M—10
H—100 Mode—AUTO
Use the < > arrow keys to blink the range to be set: low (L), medium
(M), or high (H).
Use the Δ∇ arrow keys to enter the upper value of the range (all ranges
begin at 0 ppm). Repeat for each range you want to set. Press Enter to
accept the values and return to Analyze mode. (See note below.)
Note: The ranges must be increasing from low to high, for example, if range
1 is set as 0–100 ppm and range 2 is set as 0–1,000 ppm, range 3
cannot be set as 0– 500 ppm since it is lower than range 2.
Ranges, alarms, and spans are always set in ppm units (over the entire
0-250,000 ppm range), even though all concentration-data outputs change
from ppm units to percent when the concentration is above 10,000 ppm.
4.7.2 Fixed Range Analysis
The autoranging mode of the instrument can be overridden, forcing the
analyzer DC outputs to stay in a single predetermined range.
To switch from autoranging to fixed range analysis, enter the range
function by pressing the Range button on the front panel.
Use the < > arrow keys to move the blinking over AUTO.
Use the Δ∇ arrow keys to switch from AUTO to FX/LO, FX/MED, or
FX/HI to set the instrument on the desired fixed range (low, medium, or
high).
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Trace Oxygen Analyzer
Operation 4
L—1 M—10
H—100 Mode—FX/LO
or
L—1 M—10
H—100 Mode—FX/MED
or
L—1 M—10
H—100 Mode—FX/HI
Press Escape to re-enter the Analyze mode using the fixed range.
NOTE: When performing analysis on a fixed range, if the oxygen concentra-
tion rises above the upper limit (or default value) as established by the
operator for that particular range, the output saturates at 1 V dc (or 20
mA). However, the digital readout and the RS-232 output continue to
read the true value of the oxygen concentration regardless of the
analog output range.
4.8 The Analyze Function
Normally, all of the functions automatically switch back to the Analyze
function when they have completed their assigned operations. Pressing the
Escape button in many cases also switches the analyzer back to the Ana-
lyze function. Alternatively, you can press the Analyze button at any time
to return to analyzing your sample.
4.9 Signal Output
The standard Model 3000TA-XL Trace Oxygen Analyzer is equipped
with two 0–1 V dc analog output terminals accessible on the back panel
(one concentration and one range ID), and two isolated 4–20 mA dc
current outputs (one concentration and one range ID).
See Rear Panel in Chapter 3, Installation, for illustration.
The signal output for concentration is linear over the currently selected
analysis range. For example, if the analyzer is set on range that was defined
as 0–100 ppm O2, then the output would be:
Voltage Signal Current Signal
ppm O2
Output (V dc)
Output (mA dc)
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4 Operation
Model 3000TA-XL-EU
0
10
20
30
40
50
60
70
80
90
100
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
4.0
5.6
7.2
8.8
10.4
12.0
13.6
15.2
16.8
18.4
20.0
The analog output signal has a voltage which depends on the oxygen
concentration AND the currently activated analysis range. To relate the
signal output to the actual concentration, it is necessary to know what range
the instrument is currently on, especially when the analyzer is in the
autorangingmode.
To provide an indication of the range, a second pair of analog output
terminals are used. They generate a steady preset voltage (or current when
using the current outputs) to represent a particular range. The following table
gives the range ID output for each analysis range:
Range
Voltage (V)
Current (mA)
LO
0.25
8
MED
0.50
0.75
1.00
12
16
20
HI
CAL (0-25%)
IMPORTANT: In the event of loss of flow through the analyzer, if the vent
is vented to a location of high oxygen content, oxygen will
back diffuse through the vent line and in most cases quickly
saturate the cell with oxygen which can then require a quite
long purge down time for the sensor when then exposed to
low oxygen concentrations. In the event that flow is to be
interrupted into the analyzer, it is suggested that the user do
one of the following:
1.
2.
Bag the sensor in nitrogen during this time
Install a shut off valve on the vent port of the ana-
lyzer or somewhere within the users sample system.
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Trace Oxygen Analyzer
Maintenance 5
Maintenance
5.1 Routine Maintenance
Aside from normal cleaning and checking for leaks at the gas connec-
tions, routine maintenance is limited to replacing Micro-Fuel cells and fuses,
and recalibration. For recalibration, see Section 4.4 Calibration.
WARNING: SEE WARNINGS ON THE TITLE PAGE OF THIS
MANUAL.
5.2 Cell Replacement
The B-2CXL Micro-Fuel Cell is a sealed electrochemical transducer
with no electrolyte to change or electrodes to clean. When the cell reaches
the end of its useful life, it is replaced. The spent fuel cell should be dis-
carded according to local regulations. This section describes fuel cell care as
well as when and how to replace it.
5.2.1 Storing and Handling Replacement Cells
To have a replacement cell available when it is needed, TAI recom-
mends that one spare cell be purchased 9-10 months after commissioning the
3000TA-XL, or shortly before the end of the cell's one year warranty period.
CAUTION: Do not stockpile cells. The warranty period starts on
the day of shipment.
The spare cell should be carefully stored in an area that is not subject to
large variations in ambient temperature (75 °F nominal) or to rough handling.
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5 Maintenance
Model 3000TA-XL-EU
WARNING: THE SENSOR USED IN THE MODEL 3000TA-XL
TRACE OXYGEN ANALYZER USES ELECTRO-
LYTES WHICH CONTAIN TOXIC SUBSTANCES,
MAINLY LEAD AND POTASSIUM HYDROXIDE,
THAT CAN BE HARMFUL IF TOUCHED, SWAL-
LOWED, 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.)
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, the cell will
require an excessively long time to reach zero after
installation(1-2weeks!).
5.2.2 When to Replace a Cell
Cell failure in the 3000TA-XL is usually characterized by a significant
increase in the zero offset of more than 1.0 ppm oxygen or the inability to
calibrate the sensor. When this occurs, the 3000TA-XL will still Zero but the
system alarm trips, and the LCD displays a failure message.
#.# ppm Anlz
CELL FAIL/ ZERO HIGH
Before replacing the cell:
a. Check your span gas to make sure it is within specifications.
b. Check for leaks up-stream from the cell, where oxygen may be
leaking into the system.
If there are no leaks and the span gas is within specification, replace the
cell.
5.2.3 Removing the Micro-Fuel Cell
The Micro-Fuel cell is located inside the stainless steel cell block behind
the front panel (see Figure 5-1). To remove an existing cell:
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Maintenance 5
1. Remove power to the instrument by unplugging the power cord
at the power source.
2. Open the front panel door by pressing the release button on the
top right corner of the door all the way in with a narrow gauge
tool.
3. With one hand placed underneath the cell block ready to catch
the Micro-Fuel cell , lift up on the stainless steel gate in front of
the cell block. This releases the cell and cell holder from the
block. The cell and holder will fall out in your hand.
NeedleValve
Lift Up
Cell Block
Gate
Micro-Fuel Cell
Cell Adaptor
Figure 5-1: Removing the Micro-Fuel
O-Ring
Cell Holder
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5 Maintenance
Model 3000TA-XL-EU
5.2.4 Installing a New Micro-Fuel Cell
Before installing a new cell, check the O-ring in the base of the cell
holder. Replace if worn or damaged.
1. Place the cell on the holder with the screen side facing down.
Note: There is a small location hole drilled in the holder. This hole
mates with a guide pin on the bottom rear of the cell block.
The hole in the cell block holder must align with the guide pin
on the cell block.
2. With O-ring in place, align the guide pin with the hole on the cell
holder. Then, with the holder, lift cell into the cell block.
3. Push the gate on the cell block down so that the slots on the side
of the gate engage the locating screws on the side of the block.
This forces the holder into position and forms a gas-tight seal.
5.2.5 Cell Warranty
The Class B-2CXL Micro-Fuel cell is used in the Model 3000TA-XL.
This cell is warranted for 6 months from the date of shipment. Note any
Addenda attached to the front of this manual for special information applying
toyourinstrument.
With regard to spare cells, warranty period begins on the date of ship-
ment. The customer should purchase only one spare cell (per section 5.2.1).
Do not attempt to stockpile spare cells.
The B-2CXL cell is not designed for applications where CO2 is a
major component in the sample, however concentrations of 1,000 ppm or
less will not adversely effect the cell performance. Consult TAI for the
appropriate cell for measuring trace oxygen in the presence of CO2.
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 work-
manship or material, the cell will be replaced at no cost to you.
Note: Evidence of damage due to tampering or mishandling will
render the cell warranty null and void.
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Maintenance 5
5.3 Fuse Replacement
1. Place small screwdriver in notch, and pry cover off, as shown in
Figure 5-2.
Figure 5-2: Removing Fuse Block from Housing
2. To change between American and European fuses, remove the
single retaining screw, flip Fuse Block over 180 degrees, and
replacescrew.
3. Replace fuse as shown in Figure 5-3.
4. Reassemble Housing as shown in Figure 5-2.
American Fuses
European Fuses
Figure 5-3: Installing Fuses
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5 Maintenance
Model 3000TA-XL-EU
5.4 System Self Diagnostic Test
1. Press the System button to enter the system mode.
2. Use the < > arrow keys to move to More, and press Enter.
3. Use the < > arrow keys to move to Self-Test, and press Enter.
The following failure codes apply:
Table 5-1: Self Test Failure Codes
Power
0
1
2
3
OK
5 V Failure
15 V Failure
Both Failed
Analog
0
1
2
3
OK
DAC A (0–1 V Concentration)
DAC B (0–1 V Range ID)
Both Failed
Preamp
0
1
2
3
OK
Zero too high
Amplifier output doesn't match test input
Both Failed
5.5 Major Internal Components
The Micro-Fuel cell is accessed by unlatching and swinging open the
front panel, as described earlier. Other internal components are accessed by
removing the rear panel and sliding out the entire chassis. See Figure 5-4,
below. The gas piping is illustrated in Figure 2-4, and the major electronic
components locations are shown in Figure 2-5, in chapter 2.
WARNING: SEE WARNINGS ON THE TITLE PAGE OF THIS
MANUAL.
The 3000TA-XL contains the following major components:
•
AnalysisSection
Micro Fuel Cell (B-2CXL)
Stainlesssteelcellblock
Samplesystem
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Maintenance 5
•
•
•
Power Supply
Microprocessor
Displays
5 digit LED meter
2 line, 20 character, alphanumeric, VFD display
RS-232 Communications Port.
•
See the drawings in the Drawings section in back of this manual
fordetails.
x
x
x
x
Figure 5-4: Rear-Panel Screws
To detach the rear panel, remove only the eight screws marked with an X.
5.6 Cleaning
If instrument is unmounted at time of cleaning, disconnect the instru-
ment from the power source. Close and latch the front-panel access door.
Clean outside surfaces with a soft cloth dampened slightly with plain clean
water. Do not use any harsh solvents such as paint thinner or benzene.
For panel-mounted instruments, clean the front panel as prescribed in
the above paragraph. DO NOT wipe front panel while the instrument is
controllingyourprocess.
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5 Maintenance
Model 3000TA-XL-EU
5.7 Troubleshooting
Problem:
Erratic readings of the Oxygen concentration as reported by the analyzer.
Possible Cause:
The analyzer may have been calibrated in an inaccurate fashion.
Solution:
Turn the analyzer off, then turn back on again. Press the System key when
prompted by the analyzer "Press System for default Values". This will
return the analyzer to its default settings in calibration and zero values. If
erratic behavior continues clean sensor contacts or replace the sensor.
Possible Cause:
Atmospheric Oxygen may be diffusing in through the vent and affecting the
oxygen level which the sensor sees.
Solution:
Increase flow rate and/or length or vent tubing in order to dilute or minimize
the diffusion of oxygen from the vent back to the sensor.
Problem:
Inaccurate zero operation (i.e. the user has zeroed the analyzer accidentally
on gas much higher than one would normally use for a zero gas).
Solution:
Turn the analyzer off, then back on again. Press the System key when
prompted by the analyzer "Press System for default Values". This will
return the analyzer to its default settings in calibration and zero values. Now
proceed to carefully calibrate and zero the analyzer.
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Appendix
Appendix
A-1 Specifications
Packaging: General Purpose
• Flush panel mount (Standard).
• Relay rack mount. Contains either one or
two instruments in one 19" relay rack
mountableplate(Optional).
Sensor: Teledyne B-2CXL trace analysis Micro-Fuel
Cell.
Cell Block: 316stainlesssteel.
SampleSystem: All wetted parts of 316 stainless steel.
90 % Response Time: 65 seconds at 25 °C (77 °F) on 10 ppm range
100 seconds on 1 ppm range
Ranges: Three user definable ranges from 0–1 ppm to 0–
250,000 ppm, plus air calibration range of 0-
250,000 ppm (25 %).
Autoranging with range ID output.
Alarms: One system-failure alarm contact to detect
power failure or sensor-zero failure.
Twoadjustableconcentrationthresholdalarm
contactswithfullyprogrammablesetpoints.
Displays: 2-line by 20-character, VFD screen, and one 5
digit LED display.
DigitalInterface: Full duplex RS-232 communications port.
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Model 3000TA-XL-EU
Power: Universal power supply 85-250 V ac, at
47-63 Hz.
OperatingTemperature: 5-35 °C
Accuracy: ±2% of full scale at constant temperature.
±5% of full scale over operating temperature
range, except 0-10 ppm and 0-1 ppm analysis
range, once thermal equilibrium is reached.
±0.1 ppm on 0-1 ppm analysis range, once
thermalequalibriumisreached.
Analog outputs: 0-1 V dcpercent-of-range,
0-1 V dc range ID.
4-20 mA dc(isolated) percent-of-range,
4-20 mA dc (isolated) range ID.
Dimensions: 19 cm high, 24.9 cm wide, 31 cm deep (6.96
in high, 8.7 in wide, 12.2 in deep).
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Trace Oxygen Analyzer
Appendix
A-2 Recommended 2-Year Spare Parts List
QTY.
PART NUMBER
DESCRIPTION
1
1
1
1
1
2
C65507A
C62371-B
C69367
C73870-A
F10
Back Panel Board
Front Panel Board
PreamplifierBoard(Instruction)
Main Computer Board
Fuse, 2A, 250V 3AG Slow Blow
F1296
Fuse, 2A, 250V 5x20mm (European)
Slow Blow
1
1
1
O165
O-ring
A68314
Back Panel Connector Kit
C6689-B2CXL
Micro-Fuel Cell (do not store for more
than 6 months)
1
B66378
B2C adaptor for cell block
A minimum charge is applicable to spare parts orders.
Note: Orders for replacement parts should include the part number (if
available) and the model and serial number of the instrument for
which the parts are intended.
Orders should be sent to:
Teledyne Analytical Instruments
16830 Chestnut Street
City of Industry, CA 91749-1580
Phone (626) 934-1500, Fax (626) 961-2538
TWX (910) 584-1887 TDYANYL COID
Web:
or your local representative.
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Appendix
Model 3000TA-XL-EU
A-3 Drawing List
D-69604 Outline Drawing
A-4 19-inch Relay Rack Panel Mount
Figure A-1: Single and Dual 19" Rack Mounts
(dimensions in mm)
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Trace Oxygen Analyzer
Appendix
A-5
3000XL SERIES ANALYZERS
APPLICATION NOTES ON
PRESSURES AND FLOW RECOMMENDATIONS
3000seriesanalyzersrequirereasonablyregulatedsamplepressures.
Whilethe3000analyzersarenotsensitivetovariationsofincomingpressure
(providedtheyareproperlyventedtoatmosphericpressure)Thepressuremust
bemaintainedastoprovideauseableflowratetroughtheanalyzer.Anyline
attachedtosampleventshouldbe1/4orlarger indiameter.
FLOW RATE RECOMMENDATIONS:
Ausableflowratefora3000XLseriesanalyzerisonewhichcanbe
measuredontheflowmeter.Thisisbasically 0.5-2.0SLPM.Theoptimum
flowrateis1SLPM (midscale). Note:responsetimeisdependentonflow
rate,alowflowratewillresultinslowresponsetoO2changesinthesample
stream.Thespanflowrateshouldbetheapproximatelysameasthesampleflow
rate.
CELL PRESSURE CONCERNS:
Thesensorsusedin3000XLseriesanalyzersareoptimized tofunction
atatmosphericpressure.Atpressuresotherthanatmosphericthediffusionrate
ofO2willbedifferentthanoptimumvalue.Higherpressureswillproducefaster
O2diffusionrates resultinginhigherO2reading andshortercelllife.Tousea
3000XLseriesanalyzeratacellpressureotherthanatmospheric,theanalyzer
mustbecalibratedwithaknowncalibrationgasatthenewcellpressureto
adjustforthedifferentdiffusionrate.Cellpressuresbelow2/3atmosphericare
notrecommendedbecausetheytendtocauseexcessiveinternalexpansion
whichmayresultinsealfailure.
Foroperationatcellpressuresotherthanatmosphericcaremustbe
takennottochangethesamplepressurerapidlyorcelldamagemayoccur.For
cellpressuresaboveatmospheric,cautionmustbeexercisedtoavoidover
pressuringthecellholder.
FLOWCONTROLVALVE:
All3000XLseriesanalyzershaveaflowcontroldevice.Thisdeviceisa
needlevalve,and servestwofunctionsinthesamplepath.Thefirstfunctionisto
limittheflowrateofthesamplethroughtheanalyzer.Theneedlevalveischosen
tooperateoveraspecificrangeofpressuresandprovideauseableflowrate
overthatrange.
Thesecond functionthattheneedlevalveprovidesisapressuredrop.
Thisdeviceisselectedtoprovidetheonlysignificant pressuredropinthe
samplepath.
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Appendix
Model 3000TA-XL-EU
BY-PASS:
Toimprovethesystemresponse, aby-passcanbeaddedtoincrease
thesampleflowratetotheanalyzerbyafactoroften.Aby-passprovidesa
sampleflowpatharoundtheanalyzerof 2-18SCFH.typically.
CONVERSIONS:
1 PSI
1 SCFH
=
=
2.04 INCHES OF MERCURY (in. Hg.)
0.476 SLPM
NOTE: The MSDS on this material is available upon request
through the Teledyne Environmental, Health and
Safety Coordinator. Contact at (626) 934-1592
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Trace Oxygen Analyzer
Appendix
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Appendix
Model 3000TA-XL-EU
A-6 Material Safety Data Sheet
Section I – Product Identification
Product Name: Micro-Fuel Cells and Super Cells, all classes except A-2C, A-3,
and A-5.
Electrochemical Oxygen Sensors, all classes except R-19.
Mini-Micro-FuelCells,allclasses.
Manufacturer: Teledyne Brown Engineering Analytical Instruments
Address:
Phone: (818) 961-9221
CustomerService: Extension 222
16830 Chestnut Street, City of Industry, CA 91749
EnvironmentalHealth
and Safety: Extension 230
Date Prepared : 04/26/95
Section II – Hazardous Ingredients/Composition
Materialor
Component
TLV
C.A.S. #
Quantity
OSHA PEL ACGIH
Lead (Pb)
7439-92-1
1310-58-3
3–20 gms
1–5 ml
0.05 mg/m3 0.15 mg/m3
PotassiumHydroxide
Solution 15% (KOH)
None
2 mg/m3
Section III – Physical/Chemical Characteristics
Material
Appearance
or Compo-
nent
Vapor
Pres-
sure
Odor
Specific
Gravity
Melting DensityEvap.Solubility
Boiling
Point (°C)
Point
(°C)
Rate in Water
Solid,silver
gray, odorless
11.34
2.04
Insoluble
Complete
na na
1744
1320
na
na
328
360
Lead
White or
slightly
yellow,
no odor
na na
Potassium
Hydroxide
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Trace Oxygen Analyzer
Appendix
Section IV – Fire and Explosion Hazard Data
Flash Point:
na
Flammable Limits:
na
LEL: na
UEL:
na
ExtinguishingMedia:
Use extinguishing media appropriate to surrounding fire
conditions. No specific agents recommended.
Special Fire Fighting
Equipment:
Wear NIOSH/OSHA approved self-contained breathing
apparatus and protective clothing to prevent contact with
skin and eyes.
Unusual Fire and Explosion
Hazards:
Emits toxic fumes under fire conditions.
Section V – Reactivity Data
Stability:
Stable
Incompatibilities:
Aluminum, organic materials, acid chlorides, acid
anhydrides, magnesium, copper. Avoid contact with acids
and hydrogen peroxide > 52%.
Hazardous Decomposition of
Byproducts:
Toxic fumes
Hazardous Polymerization:
Conditions to Avoid:
Will not occur.
Section VI – Health Hazard Data
RoutesofEntry:
Inhalation:
Ingestion:
Highly unlikely
May be fatal if swallowed.
Skin:
The electrolyte (potassium hydroxide) is corrosive; skin
contact may cause irritation or chemical burns.
Eyes:
The electrolyte (potassium hydroxide) is corrosive; eye
contact may cause irritation or severe chemical burns.
AcuteEffects:
The electrolyte is harmful if swallowed, inhaled or
adsorbed through the skin. It is extremely destructive to
tissue of the mucous membranes, stomach, mouth, upper
respiratory tract, eyes and skin.
ChronicEffects:
Prolonged exposure with the electrolyte has a destructive
effect on tissue.
Chronic exposure to lead may cause disease of the blood
and blood forming organs, kidneys and liver, damage to
the reproductive systems and decrease in fertility in men
and women, and damage to the fetus of a pregnant
woman. Chronic exposure from the lead contained in this
product is extremely unlikely.
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Appendix
Model 3000TA-XL-EU
Signs and Symptoms of
Exposure:
Contact of electrolyte with skin or eyes will cause a
burning sensation and/or feel soapy or slippery to touch.
Other symptoms of exposure to lead include loss of sleep,
loss of appetite, metallic taste and fatigue.
Carcinogenicity:
OSHA:
Lead is classified by the IARC as a class 2B carcinogen
(possibly carcinogenic to humans)
Where airborne lead exposures exceed the OSHA action
level, refer to OSHA Lead Standard 1910.1025.
NTP:
na
Lead exposure may aggravate disease of the blood and
blood forming organs, hypertension, kidneys, nervous
and possibly reproductive systems. Those with preexist-
ing skin disorders or eye problems may be more suscep-
tible to the effects of the electrolyte.
Medical Conditions Generally
Aggravated by Exposure:
Emergency First Aid Procedures:
In case of contact with the skin or eyes, immediately
flush with plenty of water for at least 15 minutes and
remove all contaminated clothing. Get medical attention
immediately.
If ingested, give large amounts of water and DO NOT
INDUCE VOMITING. Obtain medical attention immedi-
ately.
If inhaled, remove to fresh air and obtain medical
attention immediately.
Section VII – Precautions for Safe Handling and Use
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.
Before opening the bag containing the sensor cell, check
Protectivemeasures
duringcellreplacement:
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, wear eye and hand protection.
CleanupProcedures:
Wipe down the area several times with a wet paper towel.
Use a fresh towel each time. Contaminated paper towels
are considered hazardous waste.
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Trace Oxygen Analyzer
Appendix
Section VIII – Control Measures
Eye Protection:
Chemical splash goggles
Rubber gloves
Apron, face shield
na
HandProtection:
OtherProtectiveClothing:
Ventilation:
Section IX – Disposal
Both lead and potassium hydroxide are considered poisonous substances and are regulated under
TSCA and SARA Title III.
EPA Waste Number:
California Waste Number:
DOT Information:
D008
181
RQ Hazardous Waste Solid N.O.S. (Lead) Class 9
NA3077PGIII
Follow all Federal, State and Local regulations.
Section X – References
Material Safety Data Sheets from J.T. Baker Chemical, Aldrich, Malinckrodt, ASARCO
U.S. Department of Labor form OMB No. 1218-0072
Title 8 California Code of Regulations
TSCA
SARATitleIII
CFR 49
CFR 29
CFR 40
NOTE: The above information is believed to be correct and is offered for your
information, consideration, and investigation. It should be used as a guide.
Teledyne Brown Engineering Analytical Instruments shall not be held liable
for any damage resulting from handling or from contact with the above
product.
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Appendix
Model 3000TA-XL-EU
A7 - Installling and Replacing a new Insta-Trace
Micro-fuel Cell
Read completely before beginning the procedure
It is important to minimize the amount
Cell Block
of time a Teledyne Trace Oxygen
sensor is exposed to air during the
installation process. The quicker the
sensor can be installed into the unit,
the faster your sensor will recover to
low oxygen measurement levels.
Lift up Gate to
removed Cell
Holder.
CAUTION: Do not touch the sensing
surface of the cell. It is
covered with a delicate
Teflon membrane that can
leak when punctured. The
sensor must be replaced if
the membrane is damaged.
Micro fuel cell
Protective Film/
Seal Cover
(Located this side)
Check O-ring in the base of the cell holder
before installing a new cell. Replace it if
wornordamaged.
O-Ring
Cell Holder
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