OPERATING INSTRUCTIONS FOR
MODEL 3000ZA-3X
Trace Oxygen Analyzer
P/N M77579
11/29/11
DANGER
Toxic gases and or flammable liquids may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
Hazardous voltages exist on certain components internally which may persist
for a time even after the power is turned off and disconnected.
Only authorized personnel should conduct maintenance and/or servicing.
Before conducting any maintenance or servicing, consult with authorized
supervisor/manager.
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Trace Oxygen Analyzer
Specific Model Information
The instrument for which this manual was supplied may
incorporate one or more options not supplied in the standard instrument.
Commonly available options are listed below, with check boxes. Any
that are incorporated in the instrument for which this manual is supplied
are indicated by a check mark in the box.
Instrument Serial Number: _______________________
Options Included in the Instrument with the Above Serial Number:
3000ZA-C:
In addition to all the standard features,
this model also has separate ports for
zero and span gases, and built-in
control valves. The internal valves are
entirely under the control of the
3000ZA electronics to automatically
switch between gases in
synchronization with the analyxer’s
operation.
3000ZA-Rack Mnt: The 19" Relay Rack Mount units are
available with either one or two 3000
series analyzers installed in a standard
19" panel and ready to mount in a
standard rack.
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3000ZA-3X
Important Notice
Model 3000ZA complies with all of the requirements of the
Commonwealth of Europe (CE) for Radio Frequency Interference,
Electromagnetic Interference (RFI/EMI), and Low Voltage Directive
(LVD).
The following International Symbols are used throughout the
Instruction Manual. These symbols are visual indicators of important
and immediate warnings and when you must exercise CAUTION while
operating the instrument. See also the Safety Information on the next
page.
STAND-BY: Instrument is on Stand-by, but circuit is active
GROUND: Protective Earth
CAUTION: The operator needs to refer to the manual for
further information. Failure to do so may compromise the
safe operation of the equipment.
CAUTION: Risk of Electrical Shock
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Trace Oxygen Analyzer
Safety Messages
Your safety and the safety of others is very important. We have
provided many important safety messages in this manual. Please read
these messages carefully.
A safety message alerts you to potential hazards that could hurt you
or others. Each safety message is associated with a safety alert symbol.
These symbols are found in the manual and inside the instrument. The
definition of these symbols is described below:
GENERAL WARNING/CAUTION: Refer to the
instructions for details on the specific danger. These cautions
warn of specific procedures which if not followed could
cause bodily Injury and/or damage the instrument.
CAUTION: HOT SURFACE WARNING: This warning is
specific to heated components within the instrument. Failure
to heed the warning could result in serious burns to skin and
underlying tissue.
WARNING: ELECTRICAL SHOCK HAZARD: Dangerous
voltages appear within this instrument. This warning is
specific to an electrical hazard existing at or nearby the
component or procedure under discussion. Failure to heed
this warning could result in injury and/or death from
electrocution.
Technician Symbol: All operations marked with this
symbol are to be performed by qualified maintenance
personnel only.
NOTE: Additional information and comments regarding a
specific component or procedure are highlighted in the form
of a note.
No
Symbol
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3000ZA-3X
CAUTION:
THE ANALYZER SHOULD ONLY BE USED FOR THE
PURPOSE AND IN THE MANNER DESCRIBED IN
THIS MANUAL.
IF YOU USE THE ANALYZER IN A MANNER OTHER
THAN THAT FOR WHICH IT WAS INTENDED,
UNPREDICTABLE BEHAVIOR COULD RESULT
POSSIBLY ACCOMPANIED WITH HAZARDOUS
CONSEQUENCES.
This manual provides information designed to guide you through
the installation, calibration and operation of your new analyzer. Please
read this manual and keep it available.
Occasionally, some instruments are customized for a particular
application or features and/or options added per customer requests.
Please check the front of this manual for any additional information in
the form of an Addendum which discusses specific information,
procedures, cautions and warnings that may be peculiar to your
instrument.
Manuals do get lost. Additional manuals can be obtained from
Teledyne Analytical Instruments at the address given in the Appendix.
Some of our manuals are available in electronic form via the internet.
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Trace Oxygen Analyzer
This is a general purpose instrument designed for use in a non-hazardous
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 unauthorized substitution of
any component may adversely affect the safety of this instrument.
Since the use of this instrument is beyond the control of Teledyne
Analytical Instruments, no responsibility by Teledyne Analytical
Instruments, its affiliates, and agents for damage or injury from misuse
or neglect of this equipment is implied or assumed.
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3000ZA-3X
Table of Contents
Safety Messages.............................................................v
Introduction.....................................................................1
1.1 Overview
1
1
1
2
3
5
1.2 Typical Applications
1.3 Main Features of the Analyzer
1.4 Model Designations
1.5 Front Panel (Operator Interface)
1.6 Rear Panel (Equipment Interface)
Operational Theory.........................................................7
2.1 Introduction
2.2 ZrO2 Sensor
7
7
7
8
9
9
2.2.1 Principles of Operation
2.3 Sample System
2.4 Zirconium Oxide Sensor Application Notes
2.5 Electronics and Signal Processing
Installation.....................................................................13
3.1 Unpacking the Analyzer
3.2 Mounting the Analyzer
3.3 Rear Panel Connections
3.3.1 Gas Connections
13
13
15
15
17
17
18
24
26
3.3.2 Electrical Connections
3.3.2.1 Primary Input Power
3.3.2.2 50-Pin Equipment Interface Connector
3.3.2.3 RS-232 Port
3.4 Installing the Zirconium Oxide Sensors
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Trace Oxygen Analyzer
3.5 Testing the System
26
Operation.......................................................................27
4.1 Introduction
27
28
28
28
29
29
29
30
30
30
30
32
33
33
34
34
34
36
36
36
37
37
37
38
38
39
39
39
40
40
4.2 Using the Data Entry and Function Buttons
4.2.1 Style Conventions
4.2.2 Keys Description
4.2.2.1 Arrow Keys
4.2.2.2 ENTER
4.2.2.3 ESCAPE
4.2.2.4 Special Function Keys
4.3 Menu/Screen Structure
4.3.1 Analyze Screen
4.3.2 System Menu
4.3.3 Password routine
4.3.4 Logout Routine
4.3.5 Model Routine
4.3.6 Self-Test Routine
4.3.7 Filter Routine
4.3.8 Analog-Out Adjust Routine
4.3.9 Auto-Calibration Timer
4.3.10 Change Stream
4.4 Span Menu
4.4.1 Span Sensor
4.4.2 Span Value
4.4.3 Span Timer
4.4.4 Span Finish
4.4.5 Span Begin
4.5 Zero Menu
4.5.1 Zero Finish
4.5.2 Zero Value
4.5.3 Zero Begin
4.5.4 Zero Timer
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3000ZA-3X
4.6 Alarms Menu
4.6.1 Alarm Active
41
41
41
42
42
42
43
43
44
44
4.6.2 Alarm Polarity
4.6.3 Alarm Failsafe
4.6.4 Alarm Latching
4.6.5 Alarm Setpoint
4.7 Range Menu
4.7.1 Range Select
4.7.2 Manual Range Select
4.7.3 Range Setpoints
Maintenance..................................................................45
5.1 Routine Maintenance
5.2 Sensor Replacement
5.2.1 Removing the Sensor
5.3 Fuse Replacement
5.4 System Self Diagnostic Test
5.5 Major Internal Components
5.6 Cleaning
45
45
45
47
48
49
50
50
5.7 Troubleshooting
Appendix .......................................................................53
A-1 Specifications
53
55
56
56
57
A-2 Recommended 2-Year Spare Parts List
A-3 Drawing List
A-4 19-inch Relay Rack Panel Mount
A.5 Application Notes
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Trace Oxygen Analyzer
List of Figures
Figure 1-1: Model 3000ZA Front Panel
Figure 1-2: Model 3000ZA Rear Panel
Figure 2-1: Model 3000ZA Sample System
Figure 2-2: Flow Diagram with Options
Figure 2-3: Component Location
3
5
8
9
11
12
14
14
15
18
23
24
31
47
47
48
49
56
Figure 2-4: Electronic Block Diagram
Figure 3-1: Front Panel of the Model 3000TA
Figure 3-2: Required Front Door Clearance
Figure 3-3: Rear Panel of the Model 3000ZA
Figure 3-4: Equipment Interface Connector Pin Arrangement
Figure 3-5: Remote Probe Connections
Figure 3-6: FET Series Resistance
Figure 4-1: Hierarchy of Available Functions
Figure 5-1: Sensor Block with Middle Sensor Installed
Figure 5-2: Removing Fuse Block from Housing
Figure 5-3: Installing Fuses
Figure 5-4: Rear Panel Removal
Figure A-1: Single and Dual 19" Rack Mounts
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3000ZA-3X
List of Tables
Table 3-1: Analog Output Connections
Table 3-2: Alarm Relay Contact Pins
Table 3-3: Remote Calibration Connections
Table 3-4: Range ID Relay Connections
Table 3-5: Commands via RS-232 Input
Table 3-6: Required RS-232 Options
Table 5-1: Self-Test Result Display
Table 5-2: Troubleshooting
19
20
21
22
25
25
48
50
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Trace Oxygen Analyzer
Introduction
Introduction
1.1 Overview
The Teledyne Analytical Instruments Model 3000ZA Trace
Oxygen 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 3000ZA General Purpose flush-
panel and/or rack-mount units with CE mark. These units are for indoor
use in a non-hazardous environment.
1.2 Typical Applications
A few typical applications of the Model 3000ZA are:
Monitoring inert gas blanketing
Air separation and liquefaction
Chemical reaction monitoring
Semiconductor manufacturing
Petrochemical process control
Quality assurance
Gas analysis certification.
1.3 Main Features of the Analyzer
The Model 3000ZA Trace Oxygen Analyzer is sophisticated yet
simple to use. The main features of the analyzer include:
A 2-line alphanumeric display screen, driven by
microprocessor electronics that continuously prompts
and informs the operator.
High resolution, accurate readings of oxygen content for
low ppm levels. Large, bright, meter readout.
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Introduction
3000ZA-3X
Three Zirconium oxide sensors to provide higher range
of analysis flexibility. The analyzer can cover ranges as
low as 0-10 ppm or as high as 0-95%.
No reference gas required
Versatile analysis over a wide range of applications.
Microprocessor based electronics: 8-bit CMOS
microprocessor with 32 kB RAM and 128 kB ROM.
Three user definable output ranges (from 0-1 ppm
through 0-95%) allow best match to users process and
equipment.
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.
Two adjustable concentration alarms and a system
failure alarm.
Extensive self-diagnostic testing, at startup and on
demand, with continuous power-supply monitoring.
CE compliance
RS-232 serial digital port for use with a computer or
other digital communication device.
Four analog outputs: two for measurement (0–1 VDC
and isolated 4–20 mA DC) and two for range
identification.
Convenient and versatile, steel, flush-panel or rack-
mountable case with slide-out electronics drawer.
1.4 Model Designations
3000ZA:
Standard model for sample under pressure
3000ZA-C: In addition to all the standard features, this
model also has separate ports for zero and
span gases, and built-in control valves. The
internal valves are entirely under the control
of the 3000ZA electronics to automatically
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Trace Oxygen Analyzer
Introduction
switch between gases in synchronization
with the analyzer’s operation.
3000ZA-M:
3000ZA-V:
This model has current output signals (4-20-
mA) for ppm range and range ID, in
addition to voltage outputs.
Gas flow through the cell block in this
model is driven by vacuum downstream
from the cell block instead of upstream
pressure. The internal restrictor is located
downstream from the cell block to support
this configuration. All other standard
features are present in this model.
1.5 Front Panel (Operator Interface)
The standard 3000ZA 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.
Figure 1-1: Model 3000ZA Front Panel
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Introduction
3000ZA-3X
Function Keys:
Six touch-sensitive membrane switches are used to change the specific
function performed by the analyzer:
Analyze Perform analysis for oxygen content of a sample
gas.
System Perform system-related tasks (described in detail
in chapter 4, Operation.).
Span
Zero
Span calibrate the analyzer.
Zero calibrate the analyzer.
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 Select between functions currently
displayed on the VFD screen.
Up & Down Arrows Increment or decrement values of
functions currently displayed.
Enter Advances VFD display to the next screen in a series
or returns to the Analyze screen if none remain.
Escape Backs VFD display to the previous screen in a series
or returns to the Analyze screen if none remain.
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 0-250 ppm. 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.
Flowmeter:
Monitors the flow of gas past the sensor. Readout is 0.2 to 2.4 standard
liters per minute (SLPM).
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Trace Oxygen Analyzer
Introduction
Standby Button
:
The Standby turns off the display and outputs but circuitry is still
operating.
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 ZrO sensors, the front panel swings open when the
2
latch in the upper right corner of the panel is pressed 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
optional and may not appear on your instrument. The connectors are
described briefly here and in detail in Chapter 3 Installation.
Figure 1-2: Model 3000ZA Rear Panel
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Introduction
3000ZA-3X
Power Connection Universal AC power source.
Gas Inlet and Outlet One inlet (must be externally valved)
and one exhaust out. Three inlets
when option “C” is ordered.
9-Pin RS-232 Port
Serial digital concentration signal
output and control input.
50-Pin Equipment Interface Port
Analog Outputs: 0–1 VDC oxygen concentration plus
0-1 VDC range ID
Alarm Connections: 2 concentration alarms and 1
system alarm.
Remote Valve: Used in the 3000ZA for controlling
external solenoid valves only.
Remote Span/Zero: Digital inputs allow external
control of analyzer calibration.
Calibration Contact: To notify external equipment that
instrument is being calibrated and readings are not
monitoring sample.
Range ID Contacts: Four separate, dedicated, range
relay contacts. Low, Medium, High, Cal.
Network I/O: Serial digital communications for local
network access. For future expansion. Not currently
implemented.
Optional
Calibration Gas Ports: Separate fittings for zero, span, and
sample gas input, internal valves
for automatic gas switching.
Current Signal Output: Additional isolated 4–20 mA
DC plus 4–20 mA DC range ID.
Note: If you require highly accurate Auto-Cal timing, use external
Auto-Cal control where possible. The internal clock in the
Model 3000ZA is accurate to 2-3 %. Accordingly, internally
scheduled calibrations can vary 2-3 % per day.
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Trace Oxygen Analyzer
Operational Theory
Operational Theory
2.1 Introduction
The analyzer is composed of three subsystems:
1. Three Zirconium Oxide (ZrO2) Sensors. Each one has a
specific range of analysis: Low range sensor of 0-200
ppm, medium range sensor of 0-2 %, and high range
sensor of 0-95%.
2. Sample System
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 ZrO2 sensor is a 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 ZrO2 Sensor
2.2.1 Principles of Operation
Teledyne’s zirconium oxide sensor is a miniature solid state sensor.
It uses a stabilized zirconia disc as an electrolyte with a sensing
electrode (the cathode) and a counter electrode (the anode) on each side
of the disc. The zirconia is heated to a temperature of about 500°C via a
built-in heater. By applying a suitable reference voltage (approximately
0.75 volt) across the cathode and anode, the heated zirconia acts as an
electrolyte which is capable of moving oxygen ions within its crystalline
structure. This allows for the reduction of oxygen molecules reaching
the cathode and the generation of a current equivalent to the parts per
million oxygen in the sample gas.
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Operational Theory
3000ZA-3X
One of the three sensors has been modified (0-200 ppm range) to
sense low levels of oxygen—less than 1 ppm and generate a current
proportional to the concentration. The sensor is designed for long term
stability and an operating life of 5 years.
2.3 Sample System
The sample system delivers gases to the ZrO2 sensors, located on
the cell block, from the analyzer rear panel inlet. Depending on the
mode of operation either sample or calibration gas is delivered.
The Model 3000ZA 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
compression 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 2-1 shows the piping layout for the standard model.
Figure 2-2 shows the flow diagram for sampling systems used for
the three configurations offered as options for this instrument. In the
standard instrument, calibration gases can be connected directly to the
Sample In port by teeing to the port with appropriate valves.
Figure 2-1: Model 3000ZA-3X Sample System
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Trace Oxygen Analyzer
Operational Theory
Figure 2-2: Flow Diagram with Options
2.4 Zirconium Oxide Sensor Application Notes
The following sample gases require conditioning prior to entering
the sensors:
Flammable gases such as methane, alcohol and carbon
monoxide may cause a measurement error. They must be
filtered from the sample gas before entering the cell.
Gases containing halogen atoms (F, Cl, Br, etc.) such as
Freon, must be filtered before entering the cell. The sensor
will be damaged by the decomposition of Freon.
Gases containing SOx, H2S, silicone vapor and adhesives
must not enter the sensor. These components adversely affect
the performance of the sensor.
Dust and oil should be filtered from the sample gas.
Water vapor in contact with the sensor will damage the
sensor. Use a moisture trap or filter to remove any water
vapor in the sample.
2.5 Electronics and Signal Processing
The Model 3000ZA Trace Oxygen Analyzer uses an 8031
microcontroller with 32 kB of RAM and 128 kB of ROM to control all
signal processing, input/output, and display functions for the analyzer.
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Operational Theory
3000ZA-3X
System power is supplied from a universal power supply module designed
to be compatible with any international power source. Figure 2-3 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 removing the back panel. Figure 2-4 is a block
diagram of the analyzer electronics.
In the presence of oxygen the zirconia sensor generates a current. A
current to voltage amplifier converts this current to a voltage, which is
amplified in the second stage amplifier. The output from the second
stage amplifier is sent to an 18 bit analog to digital converter controlled
by the microprocessor. In the block diagram only one sensor is shown,
but in reality there are three separate amplifier circuits for each sensor.
The output of each sensor is then multiplexed to the analog to digital
converter.
The high operating temperature of the ZrO2 sensor is required for
proper operation of the sensor. The amplifier PCB contains a circuit that
drives the heater embedded in the sensor. The voltage across the heater
rises slowly to avoid damaging the heater/sensor assembly. After a few
minutes, the sensor will be at the proper operating temperature.
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 VDC 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
Operational Theory
Figure 2-3: Component Location
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Operational Theory
3000ZA-3X
Figure 2-4: Electronic Block Diagram
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Trace Oxygen Analyzer
Installation
Installation
Installation of the Model 3000ZA Analyzer includes:
1. Unpacking
2. Mounting
3. Gas connections
4. Electrical connections
5. Installing the sensor
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 3000ZA 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 standard front panel (the 3000ZA is
similar) and mounting bezel. There are four mounting holes—one in each
corner of the rigid frame. Drawings at the back of this manual illustrate
the dimensions and mounting hole spacing for this unit.
On special order, a 19" rack-mounting panel can be provided. For
rack mounting, one or two 3000 series analyzers can be flush-panel
mounted on the rack panel. See Appendix for dimensions of the
mounting panel.
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Installation
3000ZA-3X
Figure 3-1: Front Panel of the Model 3000TA (Model 3000ZA similar)
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
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Trace Oxygen Analyzer
Installation
As a precaution, open the cell block to check that all sensors are
firmly mounted or have not come loose during shipping.
3.3 Rear Panel Connections
Figure 3-3 shows the Model 3000ZA rear panel. There are ports for
gas, power, and equipment interface. The Zero In and Span In ports are
not included on the standard model but are available as options.
Figure 3-3: Rear Panel of the Model 3000ZA with Span and Zero Ports
3.3.1 Gas Connections
Before using this instrument, it should be determined if the unit will
be used for pressurized service or vacuum service and low pressure
applications. The kit included with the instrument contains two
restrictors and a union for 1/4” diameter tubing. Notice that there are
two 1-3/4” long, 1/4” diameter restrictors. There is an open end and a
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Installation
3000ZA-3X
closed end with a small circular orifice. The restrictor without the blue
sticker is for low pressure applications and vacuum service. For high
pressure applications (5-50 psig) use the restrictor that has a blue sticker
on the body.
Pressurized service: Connect the restrictor with the blue dot
to the Sample In port. The small circular orifice should face
AWAY from the back of the unit (against the direction of gas
flow).
Note: Remove the blue sticker from the restrictor before using.
Low pressure applications: (Less than 5 psig). Connect the
restrictor without the blue sticker in the same manner.
Vacuum Service: For applications involving pressure less
than 5-10 in Hg) connect the restrictor without the blue
sticker to the Exhaust Out port. The small circular orifice
should face TOWARD the back of the unit (against the
direction of gas flow).
CAUTION: OPERATING THE UNIT WITHOUT RESTRICTORS CAN
CAUSE DAMAGE TO THE SENSOR.
The unit is manufactured with 1/4” tube fittings and includes 6 mm
adapters for metric system installations. For a safe connection:
1. Insert the tube into the fitting and finger tighten the nut until
the tubing cannot be rotated freely by hand in the fitting. This
may require an additional 1/8 turn beyond finger tight.
2. Hold the fitting body steady with a backup wrench. Using
another wrench, rotate the nut another 1-1/4 turns.
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.
The inlet gas pressure should be reasonably regulated. Pressures
between 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
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Installation
pressure, (less than 2 psig) vacuum service plumbing is recommended.
Exact figures will depend on your process.
If greater sample flow is required for improved response time,
install a bypass in the sampling system upstream of the analyzer input.
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, if required.
ZERO IN and SPAN IN (Optional):
These are additional ports for inputting span and zero gas. There are
electrically operated valves inside for automatic switching between
calibration and sample gases. These valves are completely under control
of the 3000ZA electronics. They can be externally controlled only
indirectly through the remote cal inputs as described below. Note
however that each sensor is calibrated separately. Thus three span gas
mixtures are needed. It is recommended to leave connected the one for
the range that is used most, and calibrate the other two sensors manually.
Pressure, flow, and safety considerations are the same as prescribed for
the SAMPLE IN inlet above.
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 PRIMARY INPUT POWER
The power cord receptacle and fuse block are located in the same
assembly. Insert the power cord into the power cord receptacle.
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CAUTION:
3000ZA-3X
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
OUTPUTS ONLY.
The universal power supply requires an 85–250 VAC, 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 Replacement in Chapter 5, Maintenance.)
3.3.2.2 50-PIN EQUIPMENT INTERFACE CONNECTOR
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.
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 VDC % 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 VDC Range ID: 0.20 V = Low Range, 0.5 V =
Medium Range, 0.80 V = High
Range.
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Installation
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: 7.2 mA = Low Range
12 mA = Medium Range
16.8 mA = High Range
Table 3-1: Analog Output Connections
Pin
3
Function
+ Range ID, 4-20 mA, floating
– Range ID, 4-20 mA, floating
+ ppm Range, 4-20 mA, floating
– ppm Range, 4-20 mA, floating
+ Range ID, 0-1 VDC
4
5
6
8
23
24
7
– Range ID, 0-1 V dc, negative ground
+ ppm Range, 0-1 VDC
– ppm Range, 0-1 VDC, 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 VAC into a
resistive load. The connectors are:
Threshold Alarm 1:
Can be configured as high (actuates when concentration
is above threshold), or low (actuates when concentration
is below threshold).
Can be configured as failsafe or non-failsafe.
Can be configured as latching or non-latching.
Can be configured out (defeated).
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Threshold Alarm 2:
Can be configured as high (actuates when concentration
is above threshold), or low (actuates when concentration
is below threshold).
Can be configured as failsafe or non-failsafe.
Can be configured as latching or non-latching.
Can be configured out (defeated).
System Alarm:
Actuates when DC power supplied to circuits is
unacceptable in one or more parameters. Permanently
configured as failsafe and latching. Cannot be defeated.
Actuates if self test fails.
(Reset by pressing
Then press again and any other button Up and Down
simultaneously to resume.
button to remove power to relay.
Further detail can be found in Chapter 4, Section 4.6.
Table 3-2: Alarm Relay Contact Pins
Pin
45
28
46
42
44
43
36
20
37
Contact
Threshold Alarm 1, normally closed contact
Threshold Alarm 1, moving contact
Threshold Alarm 1, normally open contact
Threshold Alarm 2, normally closed contact
Threshold Alarm 2, moving contact
Threshold Alarm 2, normally open contact
System Alarm, normally closed contact
System Alarm, moving contact
System Alarm, normally open contact
Digital Remote Cal Inputs: Accept 0 V (off) or 24 VDC (on) inputs for
remote control of calibration. (See Remote Calibration Protocol below.)
See Table 3-3 for pin connections.
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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 option internal valves
operate automatically.)
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 –C option internal
valves operate automatically.)
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 3000ZA 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.
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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 close again.
For example:
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.
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 3000ZA automatically regulates the zero, span
and sample gas flow.
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. 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
Spare Contact
Spare Contact
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Network I/O: Pins 13 (+) and 29 (–) are for 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.
Remote Valve Connections: The 3000ZA 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
The voltage from these outputs is nominally 0 V for the OFF and
15 VDC 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.
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Figure 3-6: FET Series Resistance
3.3.2.3 RS-232 PORT
The digital signal output is a standard, full duplex 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 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
Command
as<enter>
az<enter>
st<enter>
Description
Immediately starts an autospan.
Immediately starts an autozero.
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 3000ZA
implementation.
Table 3-6: Required RS-232 Options
Parameter
Baud
Setting
2400
8 bits
none
1
Byte
Parity
Stop Bits
Message Interval
2 seconds. When CRC opens
again, zero and span are done,
and the sample is being analyzed.
Range ID Relays: There are three dedicated Range ID relay contacts.
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.
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.
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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).
3.4 Installing the Zirconium Oxide Sensors
If the ZrO2 sensors are not installed in the cell block when the
instrument is shipped, they must be installed before the analyzer is
placed in service. If they are not installed, the sensors will be packaged
with their Teledyne Analytical Instruments part number marked on the
bag.
When the ZrO2 sensor needs to be installed or replaced, follow the
procedures in Section 5.2.
If sensors were installed at the factory, remove the cover, by
loosening the eight screws that secure it and check that each sensor is
firm in its respective socket.
3.5 Testing the System
Before applying power to the instrument:
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 Section 3.3.1).
Power up the system, and test it by repeating the Self-
Diagnostic Test as described in Chapter 4, Section 4.3.5.
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Operation
4.1 Introduction
Once the analyzer has been installed, it can be configured for your
application. To do this you will:
Set system parameters.
Establish a security password, if desired, requiring the
operator to log in.
Establish and start an automatic calibration cycle, if desired.
Calibrate the instrument.
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 3000ZA, these default values are in
effect:
Ranges: R1 = 100 ppm, R2 = 1.00 %, R3 = 100 %
(although sensor maxes out around 95% O2).
Auto Ranging: ON
Alarm Relays: Active, 80.00 and 90.00 ppm, HI, Not failsafe,
Not latching.
Zero: Auto, every 7 days at 12 hours, disabled.
Span: Auto, every 7 days at 12 hours, disabled.
Span values: High sensor = 85%, Medium sensor = 2 %, and
Low sensor= 80 ppm. Span Timer 7 min.
Password: TAI
If you choose not to use password protection, the default password
is automatically displayed on the password screen when you start up and
you have access to all functions of the analyzer.
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4.2 Using the Data Entry and Function Buttons
4.2.1 Style Conventions
The following typeface conventions are used when referring to
screen names, key presses and screen readout:
Screens:
Arial 12 pt. type in capital letters.
Example: ANALYZE or MAIN
screen or menu.
Key presses:
<key> The particular keystroke to
enter is placed between < and >.
Example: <ENTER> or
<ESCAPE> or <UP> or
<DOWN>.
Only when the keystroke is to be
entered will it be placed between
the brackets. If discussing a
particular key it will be typed
using all caps. Example: this is the
ENTER key.
Screen Modes:
Times New Roman 12 pt. italic.
Example: Analysis Mode or Setup
Mode.
Screen Readout:
Arial Narrow, 12 pt bold.
Example: AUTOCAL or Zero in 12
days.
4.2.2 Keys Description
Note: All menus time out after 45 seconds elapse with no button
presses, the analyzer returns to the ANALYSIS SCREEN,
if parameters have been altered but not saved (with the
ENTER key), the alterations are lost.
Navigation and Data Entry is possible using the UP and DOWN
KEYS, the ENTER key, the ESCAPE key and the 7 special function
keys (ANALYZE, SYSTEM, SPAN, ZERO, ALARMS, RANGE, and
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STANDBY. It is important to read and understand the MENU
STRUCTURE section to fully understand navigation and data entry.
4.2.2.1 ARROW KEYS
Pressing the ARROW KEYS select menus and modifies values.
1. Item Selection Menus are identified by the flashing arrow
on the left. In Item Selection Menus the UP/DOWN arrow
keys move to the next lower or upper item.
2. Item Modification Menus are identified by a flashing
parameter/descriptor. In Item Modification Menus, the
UP/DOWN arrow keys increment or decrement numeric
values or toggle ON/OFF, YES/NO, or ENABLE/DISABLE
type values.
4.2.2.2 ENTER
The ENTER key is used in several context-sensitive ways.
1. In an Item Selection Menu the ENTER key selects the line
indicated by the arrow, and enters the Item Modification
Menu.
2. In an Item Modification Menu the ENTER key accepts the
displayed value as the new parameter and returns to the Item
Selection Menu.
4.2.2.3 ESCAPE
The ESCAPE key is used in several context-sensitive ways.
1. In an Item Selection Menu the ESCAPE key restores the
next higher Item Selection Menu in the hierarchy of menus
(with the Analyze Mode as the final, highest screen
available).
2. In an Item Modification Menu the ESCAPE key returns to
the Item Selection Menu and restores the original value of
the parameter (discarding the displayed/modified value).
3. In sequential operations such as the Password Entry
Routine the ESCAPE key restores the original value of the
parameter and backs up to the previous letter or operation in
the sequence.
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4.2.2.4 SPECIAL FUNCTION KEYS
Pressing any of the 7 Function keys (ANALYZE / SYSTEM /
SPAN / ZERO / ALARMS /RANGE / STANDBY) Cause the display
to show the top level menu for the respective function. If another menu
operation was being performed, any modified parameters (that had not
yet been accepted by using the ENTER key) will be discarded and
replaced by the original values.
4.3 Menu/Screen Structure
The 3000 screen setup consists of several classes of screens and
items. No item occupies more than 1 line. It is important to read and
understand the NAVIGATION AND DATA ENTRY section to fully
understand the menu structure.
4.3.1 Analyze Screen
The ANALYSIS SCREEN displays the following:
Line 1:
-
-
-
-
The O2 concentration in ppm or '%' (percent)
If in Span calibration the message "SPAN".
If in Zero calibration the message "ZERO".
Otherwise, the message "ANLZ".
Line 2 (display mode 1):
-
-
-
-
-
-
If Alarm 1 is alarming, the message "AL-1".
If Alarm 2 is alarming, the message "AL-2".
If in Range 1 the message "R1: 0-nnnn.nn ppm".
If in Range 2 the message "R2: 0-nnnn.nn ppm".
If in Range 3 the message "R3: 0-nnnn.nn ppm".
or, if range is in percent, "Rx: 0-nnn.nn %".
4.3.2 System Menu
The SYSTEM screen can be accessed by pressing the SYSTEM
key and it has the following functions:
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-----------------------
PASSWORD
LOGOUT
MODEL
SELF TEST
FILTER
ANALOG-OUT ADJUST
AUTO-CALIBRATION
CHANGE STREAM
-----------------------
Figure 4-1: Hierarchy of Available Functions
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4.3.3 Password routine
-----------------------
Enter Password
'T' 'A' 'I'
-----------------------
If the password is 'TAI' then the letters 'T' 'A' 'I' will be supplied to
the user when this screen is entered. This is an 'easy guess' password. If
the password is any other string, then the letters 'A' 'A' 'A' will be
supplied regardless of the actual password. The user must then adjust
the letters to the correct password.
Pressing ENTER advances to the next letter. When at the 3rd letter,
Pressing ENTER causes the letters to be compared to the actual
password. If the letters don't match, the user is told 'Password Incorrect'.
If the letters match the password, then all menu items now become
available and the user is offered the chance to change the password by
means of the following screens.
-----------------------
-> Change Password
-----------------------
Pressing ESCAPE causes a return to the Analyze Mode.
Pressing ENTER proceeds as follows.
-----------------------
Enter New Password
'T' 'A' 'I'
-----------------------
Old password is supplied as starting letters. Enter password.
-----------------------
Reenter New Password
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'A' 'A' 'A'
-----------------------
The user is prompted to re-enter the password and the letters are
restored to 'A' 'A' 'A'. This prevents the user from accidentally setting
the password to an unintended (and, perhaps unguessable) password.
-----------------------
Password Mismatch
-----------------------
The entered and re-entered password did not match. No change
was made to the original password.
-----------------------
Password Changed!
-----------------------
The password is replaced by the entered password.
4.3.4 Logout Routine
-----------------------
Restrict Access?
ENTER-YES ESCAPE-NO
-----------------------
Pressing ENTER causes access to most menus to now be restricted.
4.3.5 Model Routine
-----------------------
3000 ZO-x3 Analyzer
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V1.0
-----------------------
Entering the MODEL screen causes the above screen to be
displayed for 3 seconds. There are no modifiable parameters.
4.3.6 Self-Test Routine
-----------------------
Begin Self-Test?
ENTER-YES ESCAPE-NO
-----------------------
Pressing ENTER causes the analyzer to run the same diagnostic
that runs on start-up. See section 5.4 for results display.
4.3.7 Filter Routine
-----------------------
Digital Filter
->Index: 5
-----------------------
Pressing ENTER causes the number after 'Index:' to start
flashing. Then pressing UP or DOWN selects a number ranging from 1
to 10. Lower filter values cause the analyzer to converge on new inputs
more quickly, but also allow more noise in the sample.
4.3.8 Analog-Out Adjust Routine
-----------------------
4-20mA Offset: 0
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4-20mA Gain: 0
4-20mA Limit: FALSE
Track in Cal: Yes
-----------------------
4-20mA Offset: Pressing ENTER causes the number after 'Offset:'
to start flashing. Then pressing UP or DOWN selects a number ranging
from –341 to 500. The analog output may be sampled using a DMM at
this time. When the parameter is zero, the analog voltage output should
be very close to 0.0 (4.00 madc if the 4-20 madc is being adjusted).
Adjusting the parameter up or down causes the analog output to go up or
down respectively. When in Analyze mode, this offset value is added to
the analog output as determined by percentage of range. Note that due to
difference in electronic offsets between both analog outputs, the 0-1 vdc
and the 4-20 madc, only one may be adjusted. In other words adjusting
the 0-1 vdc output to have 0.00 vdc output may lead the 4-20 madc
output to have an offset.
4-20mA Gain: Pressing ENTER causes the number after 'Offset:'
to start flashing. Then pressing UP or DOWN selects a number ranging
from –500 to 500. The analog output may be sampled using a DMM at
this time. When the parameter is zero, the analog output should be very
close to 1.00 vdc or 20.0mA plus the offset caused by the Offset
parameter (above). Adjusting the parameter up or down causes the
analog output to go up or down respectively. When in Analyze mode,
this gain value is factored with the analog output as determined by
percentage of range .
The Offset and Gain parameters are unitless numbers. Their effect
is determined empirically using a DMM. They affect the analog output
according to the following formula:
Output = ([% of Range] * GAIN) + OFFSET
4-20mA Limit: Pressing ENTER causes TRUE/FALSE to start
flashing. Then pressing UP or DOWN toggles the value. When TRUE,
the analog output cannot put less than 4mA out of the analog output
(during ANALYZE MODE). When FALSE, the output may be lower than
4mA by approximately 10%.
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Track in Cal: Analog output tracking during calibration user
preference setting. The setting is remembered after power is turned off.
Select “Yes” to have analog output track during calibration (either span
or zero). Select “No” to hold analog output to last reading before
entering calibration mode. If analog output is not tracking during
calibration, it will hold the output for a minute after the end of
calibration to allow calibration gas to be purged out by sample gas.
4.3.9 Auto-Calibration Timer
This function sets the timer for auto calibration. It is useful when
control valves are available and the remote valve control outputs are used.
Note that if used, only one sensor may be calibrated. Whatever sensor is
selected from the span menu. So make sure to pre-select the sensor on
section 4.4.1
4.3.10 Change Stream
Use this function with cal valve option to switch on any valve:
Analyze, Zero or Span. This will allow the user to check the analyzer
response to cal gas without entering calibration mode.
4.4 Span Menu
The SYSTEM screen is as follows:
-----------------------
Span Sensor: Low
Span 200 ppm
Span Timer: 7 min.
Span AUTO Finish
Span Begin
-----------------------
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Operation
4.4.1 Span Sensor
-----------------------
->Span Sensor: High
-----------------------
Pressing ENTER causes the selection after 'Sensor:' to start flashing
(Low / Mid / High). Then pressing UP or DOWN selects a different
sensor. Note that the span value directly below will change according to
which sensor is currently selected.
The high sensor covers ranges from 2 to 95% O2. Span gas that is
near the top of this scale should be used to calibrate this sensor.
The medium sensor covers ranges from 200 ppm to 2% O2. Span
gas that is near the top of this scale should be used to calibrate this
sensor.
The low sensor covers ranges from 0 to 100 ppm O2. Span gas that
is near the top of this scale should be used to calibrate this sensor.
4.4.2 Span Value
-----------------------
->Span 85%
-----------------------
Pressing ENTER causes the number after 'Span' to start flashing.
The number has a range of 1 ppm to 100% and should be set equal to the
concentration of the span gas used. This number corresponds to the
sensor selected above. Pressing UP or DOWN adjusts the number.
4.4.3 Span Timer
-----------------------
->Span Timer: 7 min.
-----------------------
This function sets the hold time in span mode before the analyzer
actually performs the span. Adjust to give enough time to purge with
span gas.
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4.4.4 Span Finish
-----------------------
->Span AUTO Finish
-----------------------
Pressing ENTER causes the AUTO or MANUAL after 'Span' to start
flashing. Pressing UP or DOWN toggles the value. The value
determines the method by which the span settling period is complete and
a span calculation is automatically performed. If the value is MANUAL,
then when the span begins, the user is prompted to press ENTER at the
time he/she determines the sensor has settled on the span sample. If the
value is AUTO, the analyzer will automatically countdown the time when
the sensor has settled on the span sample, and will proceed to calculate
the new span slope, and return to ANALYZE MODE. The timer is now
fixed at 7 minutes. Note that the user may press ENTER to complete the
span even though the value is AUTO.
4.4.5 Span Begin
-----------------------
->Span Begin
-----------------------
-----------------------
Begin Span?
ENTER-YES ESCAPE-NO
-----------------------
Pressing ENTER causes the screen to prompt to begin the span
routine (as displayed above). Pressing ENTER again causes the
analyzer to commence the span routine, and begin analyzing in SPAN
MODE.
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Operation
4.5 Zero Menu
The ZERO screen is as follows:
-----------------------
Zero 0.00 ppm
Zero Timer: 7 min.
Zero Auto Finish
Zero Begin
-----------------------
4.5.1 Zero Finish
-----------------------
->Zero AUTO Finish
-----------------------
Pressing ENTER causes the AUTO or MANUAL after 'Zero' to start
flashing. Pressing UP or DOWN toggles the value. The value
determines the method by which the zero settling period is complete and
a zero calculation is automatically performed. If the value is MANUAL,
then when the zero begins, the user is prompted to press ENTER at the
time he/she determines the sensor has settled on the zero sample. If the
value is AUTO, the analyzer automatically countdowns the time when
the sensor has settled on the zero sample, and will proceed to calculate
the new zero offset, and return to ANALYZE MODE. The timer is now
fixed to 7 minutes. Note that the user may press ENTER to complete the
span even though the value is AUTO.
4.5.2 Zero Value
-----------------------
->Zero 0.00 ppm
-----------------------
Pressing ENTER causes the number after 'Zero' to start flashing.
The number has a range of 0 ppm to 100 ppm and should be set equal to
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any offset of the zero gas used. Pressing UP or DOWN adjusts the
number.
4.5.3 Zero Begin
-----------------------
->Zero Begin
-----------------------
-----------------------
Begin Zero?
ENTER-YES ESCAPE-NO
-----------------------
Pressing ENTER causes the screen to prompt to begin the zero
routine (as displayed above). Pressing ENTER again causes the
analyzer to commence the zero routine, and begin analyzing in ZERO
MODE.
4.5.4 Zero Timer
-----------------------
->Zero Timer: 7 min.
-----------------------
This function sets the hold time in zero mode before the analyzer
actually performs the zero adjustment. Give enough time to purge the
analyzer with zero gas.
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Operation
4.6 Alarms Menu
The ALARMS screen is as follows:
-----------------------
AL-1 ACTIVE
AL-1 HIGH
AL-1 NON-FAILSAFE
AL-1 NON-LATCHING
AL-1 20.00 ppm
AL-2 ACTIVE
AL-2 HIGH
AL-2 NON-FAILSAFE
AL-2 NON-LATCHING
AL-2 50.00 ppm
-----------------------
Note that alarm functionality explanation below applies to both
AL-1 and AL-2 identically.
4.6.1 Alarm Active
-----------------------
->AL-1 ACTIVE
-----------------------
Pressing ENTER causes the word ACTIVE or DEFEATED to start
flashing. Then pressing UP or DOWN toggles between the 2 words.
Defeating an alarm causes the alarm to return to a non-alarming
condition and prevents further tripping of the alarm.
4.6.2 Alarm Polarity
-----------------------
->AL-1 HIGH
-----------------------
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Pressing ENTER causes the word HIGH or LOW to start flashing.
Then pressing UP or DOWN toggles between the 2 words. When HIGH,
the alarm will trip if O2 concentration is above the setpoint as discussed
below.
4.6.3 Alarm Failsafe
-----------------------
->AL-1 FAILSAFE
-----------------------
Pressing ENTER causes the word FAILSAFE or NON-FAILSAFE to
start flashing. Then pressing UP or DOWN toggles between the 2
words. When FAILSAFE, the alarm relay will be energized in a non-
tripped state, and de-energized when tripped.
4.6.4 Alarm Latching
-----------------------
->AL-1 LATCHING
-----------------------
Pressing ENTER causes the word LATCHING or NON-LATCHING to
start flashing. Then pressing UP or DOWN toggles between the 2
words. When LATCHING, an alarm will remain tripped until defeated;
even if the O2 concentration returns to a level that does not trip the
alarm. When NON-LATCHING, a tripped alarm will become un-tripped if
the O2 concentration returns to a non-tripping level.
4.6.5 Alarm Setpoint
-----------------------
->AL-1 80.00 ppm
-----------------------
Pressing ENTER causes the setpoint concentration to start flashing.
Then pressing UP or DOWN adjusts the setpoint up or down
respectively. Setpoints may range from 0.00 ppm to 100.00 %.
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Operation
4.7 Range Menu
The RANGE screen is as follows:
-----------------------
Range Select: Auto
Man Rng: R1
R1: 0-1000.00 ppm
R2: 0- 1.00%
R3: 0- 6.00%
-----------------------
4.7.1 Range Select
-----------------------
Range Select: Auto
-----------------------
Pressing ENTER causes the word Auto or Dgtl or Man to start
flashing. Then pressing UP or DOWN cycles through the 3 words.
When Auto is selected, the analyzer will select the range
automatically. The analyzer chooses the least range that will
accommodate the current O2 concentration. The analyzer will switch to
the next lower range (if available) when the concentration falls below
90% of the lower range setpoint and will switch to the next higher range
(if available) when the concentration exceeds the range's setpoint.
When Man(ual), the analyzer will remain in the range specified in
the 'Man Rng' field.
When Dgtl (Digital), the analyzer will select the range according to
the signals on the remote digital cal contacts on the rear panel (and
therefore disabling their original intent of being used aa remote
calibration initiation inputs).
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4.7.2 Manual Range Select
-----------------------
Man Rng: R1
-----------------------
Pressing ENTER causes the range R1 or R2 or R3 to start flashing.
Then pressing UP or DOWN cycles through the 3 ranges. The selected
range is the effective range if the Range Select (above) is set to
Man(ual).
4.7.3 Range Setpoints
-----------------------
R1: 0-1000.00 ppm
-----------------------
Pressing ENTER causes the value to the right of Rn: to start
flashing. Then pressing UP or DOWN adjusts the value. These are the
range setpoints for R1, R2, and R3. They may be set to a value in the
range of 1.00 ppm to 100% with the stipulation that the each range must
have a setpoint equal to or greater than the setpoint of the range below it
plus 1ppm.
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Maintenance
Maintenance
5.1 Routine Maintenance
Aside from normal cleaning and checking for leaks at the gas
connections, routine maintenance is limited to replacing the sensors and
fuses, and recalibration. For recalibration, see Section 4.4 Calibration.
WARNING: SEE WARNINGS ON THE TITLE PAGE OF THIS
MANUAL.
5.2 Sensor Replacement
The ZrO2 sensors are sealed transducers with no electrolyte to
change or electrodes to clean. When the sensor reaches the end of its
useful life, it is replaced. The spent sensor should be discarded
according to local regulations.
5.2.1 Removing the Sensor
The ZrO2 sensors is located inside the nylon cell block behind the
front panel.
To remove an existing cell (refer to Figure 5-1):
CAUTION:
POWER IS APPLIED TO THE INSTRUMENT
CIRCUITRY WHENEVER 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
OUTPUTS ONLY.
1. Remove power to the instrument by unplugging the power
cord at the power source.
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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. Remove the eight screws that hold the cover of the sensor
block. As you remove the cover make sure the O-rings stay
in place. If they drop, place them back carefully in the groove
found on the cell block, not on the cover. See Figure 5.1.
4. You can remove the sensor that you want to replace with
your fingers or using small pliers. Just pull the sensor straight
out.
CAUTION:
SENSORS MIGHT BE HOT! AFTER REMOVING
POWER. LET THE SENSORS COOL FOR A FEW
MINUTES.
5. Install the new sensors paying attention to relative position in
the sensor block. Note orientation of sensor tab aligning with
tab location on the silkscreen of the mounting PCB. Sensor is
held by friction of the pins sockets. The locations of the
Sensors are:
On the left side P/N S1439 (0-200 ppm range )
On the center P/N S1492 (0 – 2 % range )
On the right side P/N S1442 (0 – 95 % range )
CAUTION:
MAKE SURE OF THE CORRECT POSITION OF EACH
SENSOR. DO NOT PLACE A SENSOR IN THE
WRONG SOCKET OR THE ANALYZER WILL FAIL!
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Maintenance
Figure 5-1: Sensor Block with Middle Sensor Installed
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
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3000ZA-3X
2. To change between American and European fuses, remove
the single retaining screw then flip the Fuse Block over 180
degrees. Replace the screw.
3. Replace fuse as shown in Figure 5-3.
4. Reassemble housing as shown in Figure 5-2.
American Fuses
Figure 5-3: Installing Fuses
European Fuses
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 Items are tested:
Table 5-1: Self-Test Result Display
“5V - Test : GOOD”
“15V - Test : GOOD”
“DAC A - Test : GOOD”
“DAC B - Test : GOOD”
( +5VDC power supply )
(+/-15 VDC power supply )
(% of range analog output )
( Range ID analog output )
“Pre L - Test : GOOD” ( Tests offset of low range amplifier )
“Pre M - Test : GOOD” ( Tests offset of medium range amplifier)
“Pre H - Test : GOOD” ( Tests offset of high range amplifier )
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Maintenance
If any item above fails this test, it will be listed on the VFD
display followed by the “BAD” message instead of “GOOD”
5.5 Major Internal Components
The zirconium sensors block 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
Figures 2-1 and Figure 2-2 and the major electronic components
locations are shown in Figure 2-3, in Chapter 2.
CAUTION:
SEE WARNINGS ON THE TITLE PAGE OF THIS
MANUAL.
Figure 5-4: Rear Panel Removal
(Remove only those screws marked with an X)
The 3000ZA contains the following major components:
Analysis Section
Zirconium oxide sensors
Cell block
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Sample system
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 for
details.
5.6 Cleaning
If instrument is unmounted at time of cleaning, disconnect the
instrument 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 controlling your process.
5.7 Troubleshooting
Table 5-2: Troubleshooting
Problem
Possible Cause
Solution
Erratic readings of the Analyzer may have
oxygen concentration been calibrated in an
Recalibrate analyzer,
making sure the
proper gas is fed, the
proper sensor is
as reported by the
analyzer
inaccurate fashion.
selected, and the
proper value of span
gas is input.
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Trace Oxygen Analyzer
Maintenance
Atmospheric oxygen
Increase flow rate
diffusing through vent and/or length of vent
and altering the
oxygen level the
sensor sees
tubing to dilute or
minimize oxygen
diffusion from vent to
sensor.
Inaccurate zero
Turn analyzer off,
then back on again.
Press the UP and
DOWN key
simultaneously while
the instrument is
doing the warm up
count down.
operation (i.e. user has
zeroed the instrument
using a gas concen-
tration much higher
than normal for a zero
gas).
Press the ENTER to
confirm returning the
analyzer to factor
defaults.
Re-span each of the
sensors without doing
the zero.
If the analyzer seems
to be working Ok, up
to this point, retry to
zero.
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Maintenance
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
mountable plate (Optional).
Sensor: Three zirconium oxide sensor.
Cell Block: Nylon
Sample System: 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 programmable ranges from 0-1 ppm
to 0-100 % oxygen (note that the
maximum concentration of analysis is
95% O2)
Autoranging with range ID output.
Alarms: One system-failure alarm contact to detect
power failure.
Two adjustable concentration threshold
alarm contacts with fully programmable
setpoints.
Displays: 2-line by 20-character, VFD screen, and
one 5 digit LED display.
Digital Interface: Full duplex RS-232 communications port.
Power: Universal power supply 85-250 VAC, at
47-63 Hz.
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Operating Temperature: 5-35 °C
Accuracy: ±2% of full scale at constant temperature
(at calibrated range).
±5% of full scale over operating
temperature range, except 0-1 ppm
analysis range, once thermal equilibrium
is reached.
±0.2 ppm on 0-1 ppm analysis range, once
thermal equilibrium is reached.
Analog outputs: 0-1 VDC percent-of-range,
0-1 VDC 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
Maintenance
A-2 Recommended 2-Year Spare Parts List
Qty.
Part Number Description
1
1
1
1
1
2
C65507A
C62371-A
B77585A
C76925
F10
Back Panel Board
Front Panel Board
ZrO2 Amplifier Board
Main Computer Board
Fuse, 2A, 250V 3AG Slow Blow
F1296
Fuse, 2A, 250V 5x20mm
Slow Blow
1
1
1
1
1
A68314
S1439
Back Panel Connector Kit
Zirconium oxide sensor for 0- 200 ppm range
Zirconium oxide sensor for 0- 2 % range
Zirconium oxide sensor for 0- 95 % range
Restrictor kit
S1492
S1442
A68729
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
or your local representative.
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3000ZA-3X
A-3 Drawing List
D-77579 Final Assembly
D-75738 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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Maintenance
A.5 Application Notes
3000 SERIES ANALYZERS
APPLICATION NOTES ON RESTRICTORS,
PRESSURES, AND FLOW RECOMMENDATIONS
The 3000 series analyzers require reasonably regulated sample
pressures. While the 3000 analyzers are not sensitive to variations of
incoming pressure (provided they are properly vented to atmospheric
pressure) the pressure must be maintained to provide a useable flow rate
through the analyzer. Any line attached to sample vent should be ¼” or
larger in diameter.
FLOW RATE RECOMMENDATIONS:
A usable flow rate for a 3000 series analyzer is one which can be
measured on the flowmeter. This is basically 0.2 - 2.4 SLPM . The
optimum flow rate is 1 SLPM (mid scale). Note that response time is
dependent on flow rate; a low flow rate will result in slow response to
O2 changes in the sample stream. The span flow rate should be the
approximately same as the sample flow rate.
CELL PRESSURE CONCERNS:
The sensors used in 3000 series analyzers are optimized to function
at atmospheric pressure. At pressures other than atmospheric the
diffusion rate of O2 will be different than the optimum value. Higher
pressures will produce faster O2 diffusion rates resulting in higher O2
reading and shorter cell life. To use a 3000 series analyzer at a cell
pressure other than atmospheric, the analyzer must be calibrated with a
known calibration gas at the new cell pressure to adjust for the different
diffusion rate. Cell pressures below 2/3 atmospheric are not
recommended because they tend to cause excessive internal expansion
which may result in seal failure.
For operation at cell pressures other than atmospheric care must be
taken not to change the sample pressure rapidly or cell damage may
occur. For cell pressures above atmospheric, caution must be exercised
to avoid over pressuring the cell holder. (percent analyzers will require
some type of cell retainer to prevent the cell from being pushed out by
the pressure). For operation at pressures below atmospheric pressure a
suffix C (clamped) cell is required.
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RESTRICTION DEVICES:
For proper operation, all 3000 series analyzers require a flow
restriction device. This device is typically a restrictor or a valve. The
restriction device serves two functions in the sample path.
1. It is used to limit the flow rate of the sample through the
analyzer. A restrictor is chosen to operate over a range of
pressures and provide a useable flow rate over that range.
2. The restriction device provides a pressure drop. This device
is selected to provide the only significant pressure drop in the
sample path.
RESTRICTOR KIT
The current revision of the 3000 series analyzers are supplied with
a kit containing two restrictors and a union which are user installed.
These parts are supplied to give the end user more flexibility when
installing the analyzer. The restrictor kit is suitable for high and low
positive pressure applications as well as vacuum service applications
(see manual for installation instructions).
The standard restrictor (BLUE DOT) is recommended for pressures
between 5 and 50 PSIG. For positive low pressure application (5 psig or
less) the unmarked restrictor is better suited. For unpressurized sample
applications the marked restrictor should be used and configured for
vacuum service.
Note: For extremely low positive pressure applications (less then
2 psig) the vacuum service configuration should provide
higher performance (higher flow rates).
For vacuum service, the end user must supply a vacuum pump and
a by-pass valve for the pump. A vacuum level of 5–10 inches of
mercury should provide the optimum flow rate. CAUTION: flow
restrictors have very small orifices and may be plugged by small
particles (.005” dia or larger) A sample filter must be included in the
sample line prior to the restrictor! (A 60 micron filter is recommended).
3000TA EXAMPLES:
Example 1: With an incoming pressure of 10 psig the standard restrictor
(blue dot) will provide a flow rate of 0.76 SLPM. Upstream of the
restrictor the sample line pressure will be 10 psig, while down stream
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Maintenance
(including the cell) the pressure will be at atmospheric pressure
(analyzer vented to atmospheric pressure). Note, all other pressure
drops in the sample path are insignificant at these flow rates. This
insures that the cell operates at atmospheric pressure. At very high flow
rates (off scale of flow-meter), pressure drops other than the restriction
device could become significant, and result in pressurizing the cell.
Example 2: A 3000TA is configured for vacuum service as follows. The
unmarked restrictor is placed in the sample vent port. The downstream
end of the restrictor is then connected to a vacuum pump and by-pass
valve. The by-pass valve is adjusted to provide a flow rate of 1 SLPM.
The sample pressure between the pump and the restrictor will be
approximately -7 inches of mercury, while the pressure in the balance
of the sample system including the cell will be approximately at
atmospheric pressure (provided the sample flow into the analyzer is not
blocked).
BY-PASS:
To improve the system response, a by-pass can be added to increase
the sample flow rate to the analyzer by a factor of ten. A by-pass typically
provides a sample flow path around the analyzer of 2 - 18 SCFH.
CALIBRATION GAS:
3000 series analyzer requirements for units with Auto-Cal options
are as follows:
The customer must supply control valves (or restrictors) for any SPAN
or ZERO gas source which is attached to the Auto-Cal ports. The valve
should be adjusted to the same flow rate as the sample gas. When restrictors
are used, the gas pressure must be adjusted to achieve the proper flow rate.
OPERATION WITHOUT A RESTRICTOR DEVICE:
Operation without a restrictor device is not recommend as
mentioned above. A 3000TA without any flow restrictor device was
tested on 11-19-97. This results in a flow rate of 2.4 SLPM @ 1 PSIG.
This is a cv of 0.023 for the standard sample system.
REFERENCE: FLOW_1.XLS & FLOW_2.XLS for information on
flow rates at various pressures.
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Maintenance
3000ZA-3X
TAI PART NUMBERS
Restrictor kit:
Union (SS)
LP Restrictor
Std. Restrictor
Nut
A68729
U11
R2323 (low pressure / vac. service)
R2324 Blue dot
N73
F73
Ferrule
Ferrule
F74
Both ferrules are required
CONVERSIONS:
1 PSI
=
2.04 inches of mercury (in. Hg.)
0.476 SLPM
1 SCFH =
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