Teledyne Oxygen Equipment 3000PA User Manual

OPERATING INSTRUCTIONS FOR  
Model 3000PA  
Percent 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 PER-  
SIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.  
P/NM64573  
08/06/99  
ECO:#99-0323  
ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING.  
BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED  
SUPERVISOR/MANAGER.  
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Percent Oxygen Analyzer  
Specific Model Information  
Theinstrumentforwhichthismanualwassuppliedmayincorporateoneor  
moreoptionsnotincludedwiththestandardinstrument.Commonlyavailable  
optionsarelistedbelow,withcheckboxes.Anythatareincorporatedinthe  
instrumentforwhichthismanualissuppliedareindicatedbyacheckmarkinthe  
box.  
InstrumentSerialNumber _______________________  
includesthefollowingoptions:  
! 3000PA-C:  
Inadditiontoallstandardfeatures,thismodelalsohas  
separateportsforzeroandspangases,andbuilt-in  
controlvalves.Theinternalvalvesareentirelyunderthe  
controlofthe3000PAelectronics,toautomatically  
switchbetweengasesinsynchronizationwiththe  
analyzersoperations  
! 3000PA-S:  
Inmodelswiththisoption,allwettedpartsaremade  
from316stainlesssteel.  
! 3000PA-M:  
Inmodelswiththisoption,the4-20mAAnalogCurrent  
outputisactive.(Inthestandardunits,itisnotactive.)  
! 19" Rack Mnt: The19"RelayRackMountunitsareavailablewith  
eitheroneortwo3000seriesanalyzersinstalledona  
19"panel,andreadytomountinastandardrack.  
! Cell Class:  
___________________ See Maintenance for Specs.  
Enter Class Designation.  
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Model 3000PA  
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 Recognizing Difference Between LCD & VFD............... 1-5  
1.7 Rear Panel (Equipment Interface) .................................. 1-5  
2 OperationalTheory  
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  
2.2.6 Micro-Fuel Cell “Class............................................ 2-5  
2.3 Sample System.............................................................. 2-6  
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  
3.3.3 Remote Probe Connector ...................................... 3-9  
3.4 Installing the Micro-Fuel Cell ......................................... 3-9  
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 Setting the Display................................................. 4-4  
4.3.2 Setting up an Auto-Cal........................................... 4-5  
4.3.3 Password Protection .............................................. 4-5  
4.3.3.1 Entering the Password ................................... 4-6  
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Percent Oxygen Analyzer  
4.3.3.2 Installing or Changing the Password ............. 4-7  
4.3.4 Logout.................................................................... 4-8  
4.3.5 System Self-Diagnostic Test .................................. 4-9  
4.3.6 Version Screen ...................................................... 4-9  
4.4 The Zero and Span Functions ....................................... 4-10  
4.4.1 Cell Failure ............................................................ 4-12  
4.4.2 Span Cal................................................................ 4-11  
4.4.2.1 Auto Mode Spanning ..................................... 4-11  
4.4.2.2 Manual Mode Spanning................................. 4-12  
4.5 The Alarms Function...................................................... 4-12  
4.6 The Range Function ...................................................... 4-15  
4.6.1 Setting the Analog Output Ranges......................... 4-16  
4.6.2 Autoranging Analysis............................................. 4-16  
4.6.3 Fixed Range Analysis............................................ 4-16  
4.7 The Analyze Function.................................................... 4-17  
4.8 Signal Output ................................................................. 4-17  
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 ................................. 5-3  
5.2.4 Installing a New Micro-Fuel Cell.............................. 5-5  
5.2.5 Cell Warranty ........................................................... 5-5  
5.3 Fuse Replacement......................................................... 5-6  
5.4 System Self Diagnostic Test........................................... 5-6  
5.5 Major Internal Components............................................ 5-7  
5.6 Cleaning ........................................................................ 5-8  
5.7 Troubleshooting ............................................................. 5-9  
Appendix  
A-1 Model 3000PA 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 Restrictors, Pressures & Flow...... A-5  
A-6 Zero Functions............................................................... A-8  
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Model 3000PA  
DANGER  
COMBUSTIBLE GAS USAGE WARNING  
This is a general purpose instrument designed for usage in a  
nonhazardous area. It is the customer's responsibility to ensure  
safety especially when combustible gases are being analyzed  
since the potential of gas leaks always exist.  
The customer should ensure that the principles of operating of  
this equipment is well understood by the user. Misuse of this  
product in any manner, tampering with its components, or 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 byTeledyne, its affiliates, and agents  
for damage or injury from misuse or neglect of this equipment is  
implied or assumed.  
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Percent Oxygen Analyzer  
Introduction 1  
Introduction  
1.1 Overview  
TheTeledyneAnalyticalInstruments  
Model 3000PA Percent Oxygen Analyzer is a versatile microprocessor-  
based instrument for detecting the percentage of oxygen in a variety of  
background gases. This manual covers the Model 3000PA General Purpose  
flush-panel and/or rack-mount units only. These units are for indoor use in a  
nonhazardousenvironment.  
1.2 Typical Applications  
A few typical applications of the Model 3000PA are:  
Monitoringinertgasblanketing  
Airseparationandliquefaction  
Chemicalreactionmonitoring  
Semiconductormanufacturing  
Petrochemicalprocesscontrol  
Qualityassurance  
Gasanalysiscertification.  
1.3 Main Features of the Analyzer  
The Model 3000PA Percent 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 from low  
percent levels through 100 %. Large, bright, meter readout.  
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1 Introduction  
Model 3000PA  
Advanced Micro-Fuel Cell, designed for percent oxygen  
analysis. Several options are available.  
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% through 0-100 %)  
allow best match to users process and equipment.  
Air-calibration range for convenient spanning at 20.9 %.  
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.  
Analog outputs for percent-of-range and for range identification.  
01 V dc. (Isolated 420 mA dc optional)  
Convenient and versatile, steel, flush-panel orrack-mountable  
case with slide-out electronics drawer.  
1.4 Model Designations  
3000PA:  
Standardmodel.  
3000PA-C: In addition to all 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 3000PA electronics, to automatically switch between  
gases in synchronization with the analyzers operations.  
3000PA-M: This model has current output signals (4-20 mA) for percent-  
of-range and range ID, in addition to voltage outputs.  
3000PA-S: A Stainless Steel Probe and Probe Holder are used in this  
model, for use where resistance to corrosion is important.  
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Percent Oxygen Analyzer  
Introduction 1  
All of the above options are available in combination. For example, the  
-C and -V options are combined as Model 3000PA-C-V.  
Figure 1-1: Model 3000PA Front Panel  
1.5 Front Panel (Operator Interface)  
The standard 3000PA 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 alphanu-  
meric display, and a window for viewing the sample flowmeter.  
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1 Introduction  
Model 3000PA  
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 Performsystem-relatedtasks(describedindetailin  
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  
Selectbetweenfunctionscurrently  
displayed on theVFD 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 LED device that  
produces large, bright, 7-segment numbers that are legible in any lighting  
environment. It produces a continuous readout from 0-100 %. It is accurate  
across all ranges without the discontinuity of 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).  
Standby Button: The  
Sta ndby 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.  
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Percent Oxygen Analyzer  
Introduction 1  
Access Door: To provide access to the Micro-Fuel Cell, the front panel  
swings open when the 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 the rear panel screws and sliding the unit out of the  
case.  
1.6 Recognizing Difference Between LCD &  
VFD  
LCD has GREEN background with BLACK characters. VFD has  
DARK background with GREEN characters. In the case of VFD - NO  
CONTRAST ADJUSTMENT IS NEEDED.  
1.7 Rear Panel (Equipment Interface)  
The rear panel, shown in Figure 1-2, contains the gas and electrical  
connectors for external inlets and outlets. The Zero and Span gas connectors,  
and the Current signal outputs are optional and may not appear on your  
instrument. The connectors are described briefly here and in detail in the  
Installationchapterofthismanual.  
Figure 1-2: Model 3000PA Rear Panel  
Power Connection  
Universal AC power source.  
Gas Inlet and Outlet One inlet (must be externally valved)  
and one exhaust out.  
Analog Outputs  
0-1 V dc concentration output, plus  
0-1 V dc range ID.  
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1 Introduction  
Model 3000PA  
Alarm Connections  
2 concentration alarms and 1 system  
alarm.  
RS-232 Port  
Serialdigitalconcentrationsignaloutput  
and control input.  
Remote Probe  
Remote Span/Zero  
Used in the 3000PA for controlling  
external solenoid valves only.  
Digital inputs allow external control of  
analyzer calibration. (See Note, below.)  
Calibration Contact To notify external equipment that  
instrument is being calibrated and  
readings are not monitoring sample.  
Range ID Contacts  
Network  
Four separate, dedicated, range relay  
contacts. Low, Medium, High, Cal.  
For future expansion. Not implemented  
atthisprinting.  
Optional:  
Calibration Gas Ports  
Separate fittings for zero, span and  
sample gas input, and internal valves  
forautomaticallyswitchingthegases.  
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 3000PA is accurate to 2-3 %. Accordingly, internally  
scheduled calibrations can vary 2-3 % per day.  
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Percent Oxygen Analyzer  
Operational Theory 2  
Operational Theory  
2.1 Introduction  
The analyzer is composed of three subsystems:  
1. Micro-FuelCellSensor  
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 3000P series is a Micro-Fuel Cell  
designed and manufactured by Analytical Instruments. It is a sealed plastic  
disposableelectrochemicaltransducer.  
The active components of the Micro-Fuel Cell are a cathode, an anode,  
and the 15% 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)  
comes from outside the device as a constituent of the sample gas being  
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2 Operational Theory  
Model 3000PA  
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 1  
inch thick. It is made of extremely inert plastic, which can be placed confi-  
dently 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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Percent Oxygen Analyzer  
Operational Theory 2  
the oxygen sensing elementthe cathodewith 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 + 4e4OH–  
(cathode)  
(Four electrons combine with one oxygen moleculein the presence of  
water from the electrolyteto 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 + 2OHPb+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 3000PA  
(These reactions will hold as long as no gaseous components capable of  
oxidizing leadsuch as iodine, bromine, chlorine and fluorineare present  
in the sample.)  
The output of the fuel cell is limited by (1) the amount of oxygen in the  
cell at the time and (2) the amount of stored anode material.  
In the absence of oxygen, no current is generated.  
2.2.4 The Effect of Pressure  
In order to state the amount of oxygen present in the sample as a per-  
centage 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 constant  
betweencalibrations.  
2.2.5 Calibration Characteristics  
Given that the total pressure of the sample gas at 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 oxygen, the charac-  
teristic curve has close to an absolute zero. In the percent ranges, the cell  
itself does not need to be zeroed. In practical application zeroing is still used  
to compensate for zero offsets in the electronics. (The electronics is zeroed  
automatically when the instrument power is turned on.)  
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Percent Oxygen Analyzer  
Operational Theory 2  
Figure 2-3. Characteristic Input/Output Curve for a Micro-Fuel Cell  
2.2.6 Micro-Fuel Cell Class”  
TBE manufactures Micro-Fuel Cells with a variety of characteristics to  
give the best possible performance for any given sample conditions. A few  
typical Micro-Fuel Cells are listed below with their typical use and electrical  
specifications.  
2.2.6.1 Class A-3 Cell  
The class A-3 cell is for use in applications where it is exposed continu-  
ously to carbon dioxide concentrations between 1 % and 100 % in the  
samplegas.  
Nominal output in air is 0.20 mA, and 90 % response time is 45 s.  
Expected life in flue gas is 8 months.  
2.2.6.2 Class A-5 Cell  
The class A-5 cell is for use in applications where it is exposed intermit-  
tently to carbon dioxide concentrations up to 100 % in the sample gas.  
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2 Operational Theory  
Model 3000PA  
Nominal output in air is 0.19 mA, and 90 % response time is 45 s.  
Expected life in flue gas is 8 months.  
2.2.6.3 Class B-1 Cell  
The class B-1 cell is for use in applications where it is exposed to less  
than 0.1 % of carbon dioxide, and where fast response is important.  
Nominal output in air is 0.50 mA, and 90 % response time is 7 s.  
Expected life in air is 8 months.  
2.2.6.4 Class B-3 Cell  
The class B-3 cell is for use in applications where a slightly longer  
response time is acceptable in order to have a longer cell life.  
Nominal output in air is 0.30 mA, and 90 % response time is 13 s.  
Expected life in air is 12 months.  
2.2.6.5 Class C-3 Cell  
The class B-1 cell is for use in applications where it is exposed to less  
than 0.1 % of carbon dioxide, and where a longer response time is accept-  
able in order to have a longer cell life.  
Nominal output in air is 0.20 mA, and 90 % response time is 30 s.  
Expected life in air is 18 months.  
2.2.6.6 Hydrogenand/orHeliumService  
If the sample gas contains 10 % or more hydrogen and/or helium,  
clampcells are used. These Micro-Fuel cells are identified by the suffix -C  
added to the cell class number.  
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 3000P 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 encounters almost no dead space. This mini-  
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Percent Oxygen Analyzer  
Operational Theory 2  
mizes residual gas pockets that can interfere with very low level oxygen  
analysis.  
The sample system for the standard instrument incorporates ¼ inch tube  
fittings for sample inlet and outlet connections at the rear panel. For metric  
system installations, 6 mm adapters are supplied with each instrument. The  
sample or calibration gas flow through the system is monitored by a flow-  
meter downstream from the cell. Figure 2-4 shows the piping layout for the  
standardmodel.  
Figure 2-4: Piping Layout and Flow Diagram for Standard Model  
Figure 2-5 is the flow diagram for the sampling system. In the standard  
instrument, calibration gases (zero and span) can be connected directly to the  
Sample In port by teeing to the port with appropriate valves. The shaded  
portion of the diagram shows the components added when the C option is  
ordered. The valving is installed inside the 3000PA-C enclosure and is  
regulated by the instrument's internal electronics.  
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Model 3000PA  
Components in the shaded area are in  
Span In  
Zero In  
the -C option (internal control valves)  
only and are not shown in the piping  
diagram above.  
Cell  
Sample In  
Solenoid  
Valves  
In vacuum service the  
Flowmeter  
restrictor should be  
placed here .  
In normal service the  
restrictor should be  
placed here .  
Exhaust Out  
Restrictor  
Figure 2-5: Flow Diagram  
2.4 Electronics and Signal Processing  
The Model 3000P Percent Oxygen Analyzer uses an 8031 microcon-  
troller with 32 kB of RAM and 128 kB of ROM to control all signal pro-  
cessing, 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.  
Figure 2-6: Location of Electronic Components  
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Percent Oxygen Analyzer  
Operational Theory 2  
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 2-7: Block Diagram of the Model 3000P Electronics  
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2 Operational Theory  
Model 3000PA  
In the presence of oxygen the cell generates a current. A current to  
voltage amplifier converts this current to a voltage, and then the voltage is  
amplified in the second stage amplifier.  
The second stage amplifier also supplies temperature compensation for  
the oxygen sensor output. This amplifier circuit incorporates a thermistor,  
which is physically located in the cell block. The thermistor is a temperature  
dependent resistance 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 due to the same temperature changes. The  
result is a signal that is temperature independent. The output from the second  
stage amplifier is sent to an 18 bit analog to digital converter controlled by  
themicroprocessor.  
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 0-1 V dc analog percent-of-range signal output and the analog range ID  
output. Models with the MA option also have a 4-20 mA dc percent-of-  
range signal output and analog range ID output.  
Signals from the power supply are also monitored by the microproces-  
sor, and the system failure alarm is activated if a malfunction is detected.  
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Percent Oxygen Analyzer  
Installation 3  
Installation  
Installation of the Model 3000PA 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 3000PA is for indoor use in a general purpose area. It is  
NOT for use in hazardous environments of any type.  
The standard model is designed for flush panel mounting. Figure 3-1 is  
an illustration of the 3000PA standard front panel and mounting bezel. There  
are four mounting holesone in each corner of the rigid frame. Drawing  
number D-62928, in the Drawings section in the rear of this manual, con-  
tains a panel cutout diagram.  
On special order, a 19" rack-mounting panel can be provided. For rack  
mounting, one or two 3000 series analyzers are flush-panel mounted on the  
rack panel. See Appendix for dimensions of the mounting panel.  
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3 Installation  
Model 3000PA  
6.7”  
10”  
Figure 3-1: Front Panel of the Model 3000PA  
All operator controls 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 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),  
such as a small hex wrench or screwdriver 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 3000PA rear panel. It contains all of the  
gas and electrical inputs and outputs. Some ports are optional equipment.  
Refer to page iii in the front of this manual for options included in your  
instrument. Be sure to note the instrument serial number.  
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Percent Oxygen Analyzer  
Installation 3  
Figure 3-3: Rear Panel of the Model 3000PA  
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 applica-  
tions. Inspect the restrictor kit that came with the unit. The kit consist of two  
restrictors and a union for 1/4diameter tubing. Notice that the two 1 3/4”  
long, 1/4diameter tubing are restrictors. It has an open end and a closed  
end with a small circular orifice. The restrictor without the blue sticker is for  
;ow pressure and vacuum service. For high pressure (5 to 50 psig) applica-  
tions, use the restrictor that has a blue sticker on the body.  
For pressurized service, use the restrictor without the blue dot and union  
from the restrictor kit and attach it to the Sample In port. The small circular  
orifice should face away from the back of the unit (against the direction of  
gas flow). Use the restrictor without the blue dot sticker in the same manner  
for low pressure applications (less than 5 psig).  
For vacuum service (5-10 in Hg), use the restrictor without the blue dot  
sticker and union but attach it to the Exhaust Out port. The small circular  
orifice should face toward the back of the unit (against the direction of gas  
flow).  
Remove the blue sticker from the restrictor before using.  
WARNING:  
Operating the unit without restrictors can cause damage to t  
the micro-fuel cell.  
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3 Installation  
Model 3000PA  
The unit is manufactured with 1/4 inch tube fittings. Six millimeter  
adapters are supplied for metric system installations. For a safe connection:  
1. Insert the tube into the tube 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, and with  
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.  
Ensure that the gas pressure is reasonably regulated. Pressures between  
3 and 40 psig are acceptable as long as the pressure, once established, will  
keep the front panel flowmeter reading in an acceptable range (0.1 to 2.4  
SLPM). Exact figures will depend on your process.  
If greater flow is required for improved response time, install a bypass  
in the sampling system upstream of the analyzer input.  
Note: If the unit is for vacuum service, the above numbers apply  
instead to the vacuum at the EXHAUST OUT connector, de-  
scribed below, with minus signs before the pressure readings.  
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.  
Note: If the unit is for vacuum service, see Sample In, above, for gas  
pressure/flow considerations.  
ZERO IN and SPAN IN (Optional): These are additional input ports  
for span gas and zero gas. There are electrically operated valves inside for  
automatic switching between sample and calibration gases. These valves are  
under control of the 3000P Electronics. They can be externally controlled  
only indirectly through the Remote Cal Inputs, described below.  
Pressure, flow, and safety considerations are the same as prescribed for  
the SAMPLE IN inlet, above.  
3.3.2 Electrical Connections  
For safe connections, ensure that no uninsulated wire extends outside of  
the connectors they are attached to. Stripped wire ends must insert com-  
pletely into terminal blocks. No uninsulated wiring should be able to come in  
contact with fingers, tools or clothing during normal operation.  
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Percent Oxygen Analyzer  
Installation 3  
Primary Input Power: The power cord receptacle and fuse block are  
located in the same assembly. Insert the female plug end of 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 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 85250 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. The 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.)  
Analog Outputs: There are four DC output signal connectors with  
spring terminals on the panel. (Two of them are optional, as explained  
below.) There are two wires per output with the polarity noted. See Figure 3-  
4. The outputs are:  
0-1 V dc % Range:  
Voltage rises linearly with increasing oxygen con-  
centration, from 0 V at 0 percent to 1 V at full scale.  
(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: –M option only. Current increases linearly with  
increasing oxygen concentration, from 4 mA at 0  
percent to 20 mA at full scale. (Full scale = 100% of  
programmablerange.)  
4-20 mA dc Range ID: –M option only. 8 mA = Low Range, 12 mA =  
Medium Range, 16 mA = High Range, 20 mA = Air  
Cal Range.  
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3 Installation  
Model 3000PA  
Figure 3-4: Analog Output Connections  
Alarm Relays: The three alarm-circuit connectors are spring terminals  
for making connections to internal alarm relay contacts. Each provides a set  
of Form C contacts for each type of alarm. Each has both normally open and  
normally closed contact connections. The contact connections are indicated  
by diagrams on the rear panel. They are capable of switching up to 3 am-  
peres at 250 V ac into a resistive load. See Figure 3-5. The connectors are:  
Threshold Alarm 1: 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).  
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.  
Figure 3-5: Types of Relay Contacts  
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Percent Oxygen Analyzer  
Installation 3  
Digital Remote Cal Inputs: Accept 0 V (off) or 24 V dc (on) inputs  
for remote control of calibration. (See Remote Calibration Protocol below.)  
Zero:  
Floating input. A 5 to 24 V pulse input across the + and –  
terminals puts the analyzer into the Zero mode. Either side  
may be grounded at the source of the signal. A synchronous  
signal must open and close the external zero valve appropri-  
ately. See 3.3.3 Remote Probe Connector. (The C option  
internalvalvesoperateautomatically.)  
Span:  
Floating input. A 5 to 24 V pulse input across the + and –  
terminals puts the analyzer into the Span mode. Either side  
may be grounded at the source of the signal. A synchronous  
signal must open and close external span valve appropriately.  
See 3.3.3 Remote Probe Connector. (The C option internal  
valvesoperateautomatically.)  
Cal Contact: This relay contact is closed while analyzer is spanning  
and/or zeroing. (See Remote Calibration Protocol below.)  
Remote Calibration Protocol: To properly time the Digital Remote  
Cal Inputs to the Model 3000PA 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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3 Installation  
Model 3000PA  
Note: The Remote Probe connector (paragraph 3.3.3) provides  
signals to ensure that the zero and span gas valves will be  
controlled synchronously. If you have the C Internal valve  
optionwhich includes additional zero and span gas inputs—  
the 3000P 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 orderLow 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%).  
Network I/O: A serial digital input/output for local network protocol.  
At this printing, this port is not yet functional.  
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 percent  
The range in use (HI, MED, LO)  
The span of the range (0-10 %, etc)  
Which alarmsif anyare disabled (ALx DISABLED)  
Which alarmsif anyare tripped (ALx ON).  
Each status output is followed by a carriage return and line feed.  
Four input functions using RS-232 have been implemented to date.  
They are described in Table 3-1.  
Table 3-1: Commands via RS-232 Input  
Command  
as<enter>  
az<enter>  
co<enter>  
Description  
Immediatelystartsanautospan.  
Immediatelystartsanautozero.  
Reports "Raw Cell Output" (current output of the sensor  
itself) in µA. For example—  
RawCellOutput: 99 µA.  
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Percent Oxygen Analyzer  
Installation 3  
st<enter>  
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 3-2 lists certain RS-232 values that are required by the 3000PA  
implementation.  
Table 3-2: Required RS-232 Options  
Parameter  
Setting  
Baud 2400  
Byte 8 bits  
Parity none  
Stop Bits  
MessageInterval  
1
2 seconds  
3.3.3 Remote Probe Connector  
The 3000PA is a single-chassis instrument, which has no Remote Probe  
Unit. Instead, the Remote Probe connector is used as another method for  
controlling external sample/zero/span gas valves. See Figure 3-6.  
Figure 3-6: Remote Probe Connector Pinouts  
Due to power supply limits, 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 could limit the obtainable  
voltage, depending on the load impedance applied. See Figure 3-7.  
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3 Installation  
Model 3000PA  
Figure 3-7: FET Series Resistance  
3.4 Installing the Micro-Fuel Cell  
The Micro-Fuel Cell is not installed in the cell block when the  
instrument is shipped. It must be installed before the analyzer is placed in  
service.  
Once it is expended, or if the cell is exposed to air for too long, the  
Micro-Fuel Cell will need to be replaced. The cell could also require replace-  
ment if the instrument has been idle for too long.  
When the micro-Fuel Cell needs to be installed or replaced, follow the  
procedures in chapter 5, Maintenance, for removing and installing cells.  
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 sample pressure is between 3 and 40 psig, according  
to the requirements of your process.  
Power up the system, and test it by performing the following  
operations:  
1. Repeat the Self-Diagnostic Test as described in chapter 4, section  
4.3.5.  
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Percent Oxygen Analyzer  
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 3000PA these default values are in effect:  
Ranges: LO = 1 %, MED = 5 %, HI = 10 %  
Auto Ranging: ON  
Alarm Relays: Defeated, 10 %, HI, Not failsafe, Not latching  
Zero: Auto, every 0 days at 0 hours  
Span: Auto, at 20.9 %, 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 Operation  
Model 3000PA  
4.2 Using the Data Entry and Function  
Buttons  
Data Entry Buttons: The < > arrow buttons select options from the  
menu currently displayed on the VFD screen. The selected option blinks.  
When the selected option includes a modifiable item, the 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:  
Set LCD screen contrast  
Setup Auto-Cal  
Contrast Function is DISABLED  
(Refer to Section 1.6)  
Assign Password  
InitiateSelf-Test  
Check software version  
View sensor output  
Log out.  
Zero. Usedtosetupazerocalibration.  
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-  
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Percent Oxygen Analyzer  
Operation 4  
Contrast Function is DISABLED  
(Refer to Section 1.6)  
Figure 4-1: Hierarchy of Functions and Subfunctions  
duced, at the appropriate point in the procedure, in a Monospaced type  
style. Pushbutton names are printed in Oblique type.  
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 a 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  
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4 Operation  
Model 3000PA  
operation, such as setting the instrument span or zero setting,  
adjusting the alarm setpoints, or defining analysis ranges.  
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 TBEAI by default. This allows  
access to anyone. After a unique password is assigned, to defeat  
the security, the password must be changed back to TBEAI.  
Logout: Logging out prevents an unauthorized tampering with  
analyzersettings.  
More: Select and enter More to get a new screen with additional  
subfunctionslisted.  
SelfTest: 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.  
4.3.1 Setting the Display  
Contrast Function is DISABLED  
(Refer to Section 1.6)  
Ifyoucannotreadanythingonthedisplayafterfirstpoweringup:  
1. ObserveLEDreadout.  
a. If LED meter reads all eights and periods, go to step 3.  
b. If LED meter displays anything else, go to step 2.  
2. Press  
button twice to turn Analyzer OFF and ON again.  
LED meter should now read all eights and periods. Go to step 3.  
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Percent Oxygen Analyzer  
Operation 4  
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-  
cally zero and span the instrument.  
Note: If you require highly accurate Auto-Cal timing, use external  
Auto-Cal control where possible. The internal clock in the  
Model 3000PA is accurate to 2-3 %. Accordingly, internally  
scheduled calibrations can vary 2-3 % per day.  
To setup an AutoCal cycle:  
Choose System from the Function buttons. The VFD will display five  
subfunctions.  
Contrast AutoCal  
Contrast Function is DISABLED  
(Refer to Section 1.6)  
PSWD Logout More  
Use < > arrows to blink AutoCal, and press Enter. A new screen for  
Span/Zerosetappears.  
Span OFF Nxt: 0d 0h  
Zero OFF Nxt: 0d 0h  
Press < > arrows to blink Span (or Zero), then press Enter again. (You  
wont be able to set OFF to ON if a zero interval is entered.) A Span  
Every ... (or Zero Every...) screen appears.  
Span Every 0 d  
Start 0 h from now  
Use arrows to set an interval value, then use < > arrows to move to  
the start-time value. Use arrows to set a start-time value.  
To turn ON the Span and/or Zero cycles (to activate Auto-Cal): Press  
System again, choose AutoCal, and press Enter again. When the Span/  
Zero screen appears, use the < > arrows to blink the Span (or Zero) OFF/  
ON field. Use arrows to set the OFF/ON field to ON. You can now turn  
these fields ON because 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.  
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4 Operation  
Model 3000PA  
If you have decided not to employ password security, use the default  
password TBEAI. This password will be displayed automatically by the  
microprocessor. The operator just presses the Enter key to be allowed total  
accesstotheinstrumentsfeatures.  
NOTE: If you use password security, it is advisable to keep a copy of  
the password in a separate, safe location.  
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 TBEAI  
password for you.  
Press System to enter the System mode.  
Contrast AutoCal  
PSWD Logout More  
Contrast Function is DISABLED  
(Refer to Section 1.6)  
Use the < > arrow keys to scroll the blinking over to PSWD, and press  
Enter to select the password function. Either the default TBEAI password or  
AAAAA place holders for an existing password will appear on screen  
depending on whether or not a password has been previously installed.  
T B E A I  
Enter PWD  
or  
A A A A A  
Enter PWD  
The screen prompts you to enter the current password. If you are not  
using password protection, press Enter to accept TBEAI 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 ∇  
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.  
PSWD Restrictions  
Removed  
In a few seconds, you will be given the opportunity to change this  
password or keep it and go on.  
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Operation 4  
Change Password?  
<ENT>=Yes <ESC>=No  
Press Escape to move on, or proceed as in Changing the Password,  
below.  
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:  
Change Password?  
<ENT>=Yes <ESC>=No  
Press Enter to change the password (either the default TBEAI 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.  
T B E A I  
<ENT> To Proceed  
or  
A A A A A  
<ENT> To Proceed  
Enter the password using the < > arrow keys to move back and forth  
between the existing password letters, and the 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
}
)
B
L
V
`
j
t
*
4
>
C
M
W
a
k
u
!
+
5
?
D
N
X
b
l
v
"
'
E
O
Y
c
m
w
#
F
P
Z
d
n
x
$
.
G
Q
[
e
o
y
%
/
9
H
R
¥
f
p
z
&
0
:
I
S
]
g
q
{
'
1
;
J
T
^
h
r
|
(
2
<
-
7
3
=
6
@
8
When you have finished typing the new password, press Enter. A  
verification screen appears. The screen will prompt you to retype your  
passwordforverification.  
\
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4 Operation  
Model 3000PA  
A A A A A  
Retype PWD To Verify  
Wait a moment for the entry screen. You will be given clearance to  
proceed.  
A A A A A  
<ENT> TO Proceed  
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  
% Anlz  
Range: 0 10  
If an alarm is tripped, the second line will change to show which alarm  
itis:  
0.0  
% Anlz  
AL1  
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.  
Contrast Function is DISABLED  
Contrast AutoCal  
PSWD Logout More  
(Refer to Section 1.6)  
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:  
Protected Until  
Password Reentered  
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Percent Oxygen Analyzer  
Operation 4  
4.3.5 System Self-Diagnostic Test  
The Model 3000PA 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  
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.  
Contrast Function is DISABLED Contrast AutoCal  
(Refer to Section 1.6)  
PSWD Logout More  
Use the < > arrow keys to blink More, then press Enter.  
Version SelfTest  
Cell Output: ### µA  
Use the < > arrow keys again to move the blinking to the SelfTest  
function. The screen will follow the running of the diagnostic.  
RUNNING DIAGNOSTIC  
Testing Preamp 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:  
Press Any Key  
To Continue...  
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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4 Operation  
Model 3000PA  
4.4 The Span Functions  
The analyzer is calibrated using span gas.  
NOTE: Zero is not necessary for Percent (%) level measurements.  
Additional information on Zero functions is provided in the  
Appendix A-6 of this manual.  
Although the instrument can be spanned using air, a span gas with a  
known oxygen concentration in the range of 7090% of full scale of the  
range of interest is recommended. Since the oxygen concentration in air is  
20.9 %, the cell can take longer to recover if the instrument is used for less  
than 1 % oxygen analysis immediately following calibration in air.  
Connect the calibration gases to the analyzer according to the instruc-  
tions given in Section 3.4.1, Gas Connections, observing all the prescribed  
precautions.  
Shut off the gas pressure before connecting it to the analyzer, and  
be sure to limit the pressure to 40 psig or less when turning it back on.  
Readjust the gas pressure into the analyzer until the flowrate (as read on  
the analyzers SLPM flowmeter) settles between 0.5 and 2.4 SLPM (ap-  
proximately1-5scfh).  
If you are using password protection, you will need to enter your  
password to gain access to either of these functions. Follow the instructions  
in section 4.3.3 to enter your password. Once you have gained clearance to  
proceed, you can enter the Zero or Span function.  
4.4.1.  
CellFailure  
When the sensor in the 3000PA begins to fail, the analyzer will usually  
require more and more frequent calibration. If the 3000PA analysis readings  
driftdownwarduncharacteristically,tryrecalibration.Ifrecalibrationraises  
the readings temporarily, the cell may be failing.  
You can check the output of the cell itself by going to the System  
function, selecting More, and pressing Enter. The cell output reading will be  
on the second line of the display.  
Version SelfTest  
Cell Output: ### µA  
The goodreading depends on the class of cell your analyzer is using.  
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Percent Oxygen Analyzer  
Operation 4  
Although the B-1 cell is standard in the 3000PA, check Specific Model  
Information in the Front Matter in this manual for the class of cell you  
purchased. Then check Cell Replacement in chapter 5 Maintenance, and do  
theprescribedcalculations.  
If a weak cell is indicated, replace the cell as described there in chapter  
5.  
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 manual mode, where the operator determines  
when the span concentration reading is acceptable and then 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 arrow keys to toggle between AUTO and MAN span  
settling. Stop when AUTO appears, blinking, on the display.  
Span: Settling: AUTO  
<ENT> For Next  
Press Enter to move to the next screen.  
Span Val: 20.90  
<ENT>Span <UP>Mod #  
Use the arrow keys to enter the oxygen-concentration mode. Use  
the < > arrow keys to blink the digit you are going to modify. Use the ∇  
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 (20.90 if  
youareusingair), press EntertobegintheSpancalibration.  
####  
Slope=####  
%
Span  
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 slope is less than 1/50  
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4 Operation  
Model 3000PA  
of the displayed value of the oxygen concentration (in ppm) for three min-  
utes. Then the instrument automatically returns to the analyze mode.  
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> For Next  
Use the 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.  
Span Val: 20.90  
<ENT>Span <UP>Mod #  
Press (<UP>) to permit modification (Mod #) of span value.  
Use the arrow keys to enter the oxygen concentration of the span gas  
you are using (20.90 if you are using air). The < > arrows chose the digit,  
and the 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 Slope on the screen. It takes several seconds  
for the first Slope value to display. Slope indicates rate of change of the  
Span reading. It is a sensitive indicator of stability.  
####  
% Span  
Slope=#### ppm/s  
When the Span value displayed on the screen is sufficiently stable,  
press Enter. (Generally, when the Span reading changes by 1 % or less of  
the full scale of the range being calibrated for a period of five minutes it is  
sufficiently stable.) Once Enter is pressed, the Span reading changes to the  
correct value. The instrument then automatically enters the Analyze func-  
tion.  
4.5 The Alarms Function  
The Model 3000PA is equipped with 2 fully adjustable concentration  
alarms and a system failure alarm. Each alarm has a relay with a set of form  
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Percent Oxygen Analyzer  
Operation 4  
C" contacts rated for 3 amperes resistive load at 250 V ac. See Figure 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 described in chapter  
3Installation.  
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:  
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.  
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4 Operation  
Model 3000PA  
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 AL1 is blinking.  
AL1  
AL2  
Choose Alarm  
Set up alarm 1 by moving the blinking over to AL1 using the < >  
arrow keys. Then press Enter to move to the next screen.  
AL1 1.00 % HI  
DftN FsN LtchN  
Five parameters can be changed on this screen:  
Value of the alarm setpoint, AL1 #### % (oxygen)  
Out-of-range direction, HI or LO  
Defeated? DftY/N (Yes/No)  
Failsafe? FsY/N (Yes/No)  
Latching? LtchY/N (Yes/No).  
To define the setpoint, use the < > arrow keys to move the  
blinking over to AL1 ####. Then use the arrow keys to  
change the number. Holding down the key speeds up the  
incrementing or decrementing. (Remember, the setpoint units are  
percent-of-oxygen.)  
To set the other parameters use the < > arrow keys to move the  
blinking over to the desired parameter. Then use the 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 (AL2).  
To reset a latched alarm, go to Dftand then press either two  
times or two times. (Toggle it to Y and then back to N.)  
OR –  
Go to Ltchand then press either two times or two times.  
(Toggle it to N and back to Y.)  
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Percent Oxygen Analyzer  
Operation 4  
4.6 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 custom ranges  
are defined by the user, the instrument defaults to:  
Low = 01.00 %  
Med = 05.00 %  
High = 010.00 %.  
The Model 3000PA is set at the factory to default to autoranging. In this  
mode, themicroprocessorautomaticallyrespondstoconcentrationchanges  
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 slightly below 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  
concentration exceeds the upper limit of the range, the DC output will  
saturate at 1 V dc.  
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.  
4.6.1 Setting the Analog Output Ranges  
To set the ranges, enter the range function mode by pressing the  
Range button on the front panel.  
L1.00 M5.00  
H10.00 ModeAUTO  
Use the < > arrow keys to blink the range to be set: low (L), medium  
(M), or high (H).  
Use the arrow keys to enter the upper value of the range (all ranges  
begin at 0 %). 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 01 % and range 2 is set as 010 %, range 3  
cannot be set as 05 % since it is lower than range 2.  
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4 Operation  
Model 3000PA  
4.6.2 Autoranging Analysis  
Set your analysis ranges as in 4.6.1, above. Leave Mode in Auto, or  
use the arrow buttons to change back to Auto.  
When operating in autoranging, if the oxygen concentration in your  
sample goes ABOVE your HIGHEST range setting, the analyzer will go  
into the special 25 % cal range.  
However, if one of your range settings is below 0-25 % and another is  
set above 0-25 %, the special 0-25 % Air Cal range will NOT activate as the  
oxygen level goes through 25 %. Nevertheless, if the oxygen concentration  
in your sample goes ABOVE your HIGHEST range setting, the analyzer  
will THEN drop back down into the special 25 % cal range.  
Once the oxygen concentration drops back down into your highest  
range setting, the analyzer will automatically switch back to that range.  
CAUTION: While the analyzer is in the Air Cal range, the oxygen  
reading cannot go over 25 %, even if the oxygen  
concentration is higher than 25 %.  
4.6.3 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 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).  
L1.00 M5.00  
H10.00 ModeFX/LO  
or  
L1.00 M5.00  
H10.00 ModeFX/MED  
or  
L1.00 M5.00  
H10.00 ModeFX/HI  
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Percent Oxygen Analyzer  
Operation 4  
Press Escape to re-enter the Analyze mode using the fixed range.  
NOTE:When performing analysis on a fixed range, if the oxygen  
concentration rises above the upper limit (or default value) as  
established by the operator for that particular range, the  
output saturates at 1 V dc. However, the digital readout and  
the RS-232 output continue to read the true value of the oxy-  
gen concentration regardless of the analog output range.  
4.7 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.  
4.8 Signal Output  
The standard Model 3000PA Percent Oxygen Analyzer is equipped  
with two 01 V dc analog output terminals accessible on the back panel (one  
concentration and one range ID). The MA option also has 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 010 % O2, then the output would be:  
Voltage Signal Current Signal  
% O2  
Output (V dc)  
Output (mA dc)  
0
1
2
3
4
5
6
7
8
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  
9
10  
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4 Operation  
Model 3000PA  
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 if you  
have 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%)  
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Percent 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 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 discarded  
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 4-5 months after commissioning  
the 3000PA, or shortly before the end of the cell 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.  
WARNING: THE SENSOR USED IN THE MODEL 3000PA PER-  
CENT OXYGEN ANALYZER USES ELECTROLYTES  
WHICH CONTAIN TOXIC SUBSTANCES, MAINLY  
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5 Maintenance  
Model 3000P  
LEAD AND POTASSIUM HYDROXIDE, THAT CAN BE  
HARMFUL IF TOUCHED, SWALLOWED, OR IN-  
HALED. AVOID CONTACT WITH ANY FLUID OR  
POWDER IN OR AROUND THE UNIT. WHAT MAY  
APPEAR TO BE PLAIN WATER COULD CONTAIN  
THESE TOXIC SUBSTANCES. IN CASE OF EYE  
CONTACT, IMMEDIATELY FLUSH EYES WITH WA-  
TER 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 a longer time to reach zero after  
installation.  
5.2.2 When to Replace a Cell  
When the sensor in the 3000PA begins to fail, the analyzer usually  
requires more frequent calibration. If the 3000PA analysis readings drift  
downward uncharacteristically, try recalibration. If recalibration raises the  
readings temporarily, suspect the cell, but first check for leaks downstream  
from the cell where gases may be leaking into the system.  
You can check the output of the cell itself by going to the System  
function, selecting More , and pressing Enter. The cell output reading will  
be on the second line of the display.  
Version  
SelfTest  
Cell Output: ### µA  
The goodcell output range depends on the class of cell your ana-  
lyzer is using. The B-1 cell is standard in the 3000PA, but others can be  
specified.  
Check Specific Model Information in the Front Matter in this  
manual for the class of cell you purchased. Then check Table 5-1, the  
cell index table below, and do the simple calculation. If the resulting value  
isbelowtheCe llOutputreading,replacethecell.  
To find out if your cell is too weak:  
1. Flow span gas through the analyzer, and allow time to purge.  
2. With span gas flowing, read the raw output of the cell from the  
System function display.  
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Percent Oxygen Analyzer  
Maintenance 5  
3. Divide the raw output reading by the percent oxygen  
concentration of your span gas.  
If the quotient is less than the Index value for the cell class you are  
using, replace the cell.  
Table 5-1: Cell Indices  
Cell Class  
A-3  
Index  
1.818  
1.818  
4.545  
3.716  
1.244  
1.515  
2.488  
0.606  
A-5  
B-1  
B-3  
B-5  
B-7  
C-3  
C-5  
5.2.3 Removing the Micro-Fuel Cell  
The Micro-Fuel cell is located inside the nylon Probe behind the front  
panel. (See Figure 5-1.) To remove an existing 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 and releasing it.  
3. Pull up on the nylon Probe, with a slight rocking motion, to  
release it from the Probe Receptacle.  
4. Do Not remove the O-rings unless they are worn and no longer  
hold the Probe tightly. (If worn, replace them.)  
5. When it is free, unscrew the Cap from the nylon Probe. Hold  
the Probe vertically to prevent dropping the cell out of the  
probe.  
6. Remove the Cell from the Probe, and dispose of it in an  
environmentally safe manner.  
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5 Maintenance  
Model 3000P  
Figure 5-1: Removing or Installing a Micro-Fuel Cell  
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Percent Oxygen Analyzer  
Maintenance 5  
5.2.4 Installing a New Micro-Fuel Cell  
CAUTION: Do not touch the sensing surface of the cell. It is  
covered with a delicate Teflon membrane that can  
leak if punctured. The sensor must be replaced if  
the membrane is damaged.  
1. Place the Cell in the Probe with the sensing surface facing  
outward (toward the screen in the Cap).  
2. Screw the Probe Cap onto the Probe until it stops.  
3. With the O-rings in place, push the assembled Probe down into  
the Cell HolderCap Downwith a slight rocking motion  
until it is seated on the bottom of the holder. This forces the  
holder into position and forms a gas-tight seal.  
5.2.5 Cell Warranty  
The Class B-1 Micro-Fuel cell is standard in the Model 3000PA. This  
cell is warranted for 6 months from the date of shipment. Check the Spe-  
cific Model Information, and note any Addendum that might be attached to  
the front of this manual for special information applying to the Cell in your  
instrument.  
The warranty period for spare cells begins on the date of shipment.  
Do not purchase more than one spare cell per instrument. Do not stockpile  
spare cells.  
The B-1 cell is not designed for applications where CO2 is a major  
component in the sample, however slight amounts will not adversely  
effect the cell performance. Consult TAI for available options for either  
intermittent or continuous CO2 exposure.  
If a cell was working satisfactorily, but ceases to function before the  
warranty period expires, the customer will receive credit toward the pur-  
chase of a new cell.  
If you have a warranty claim, you must return the cell in question to  
the factory for evaluation. If it is determined that failure is due to faulty  
workmanship or material, the cell will be replaced at no cost to you.  
NOTE:Evidence of damage due to tampering or mishandling will  
render the cell warranty null and void.  
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5 Maintenance  
Model 3000P  
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  
replace screw.  
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  
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 Se lf-Te st, and press Enter.  
The following failure codes apply:  
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Percent Oxygen Analyzer  
Maintenance 5  
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 (01 V Concentration)  
DAC B (01 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.  
WARNINGS:See warnings on the title page of this manual.  
The 3000PA contains the following major components:  
Analysis Section  
Micro Fuel Cell (B-1 standardothers available)  
Nylon Probe and Holder  
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.  
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5 Maintenance  
Model 3000P  
X
X
X
X
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  
controlling your process.  
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Percent Oxygen Analyzer  
Maintenance 5  
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 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 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 of mini-  
mize 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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5 Maintenance  
Model 3000P  
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Percent Oxygen Analyzer  
Appendix  
Appendix  
A-1 Model 3000PA Specifications  
Packaging: General Purpose  
Flush panel mount (Standard).  
Rack mount Relay rack mounted to  
contain either one or two instruments in one  
19" relay rack mountable plate (Optional).  
Sensor: Class B-1 Micro-Fuel Cell (standard). Others  
available.  
Cell Block: Nylon.  
90 % Response Time: 10 seconds at 25 °C (77 °F).  
Ranges: Three user definable ranges from 0-1 % to  
0-100 %, plus air calibration range of 0-25 %.  
Alarms: One system-failure alarm contact to detect  
powerfailure.  
Twoadjustableconcentrationthresholdalarms  
withfullyprogrammablesetpoints.  
Displays: 2 line by 20 character, alphanumeric, VFD  
screen.  
One 5 digit LED display.  
DigitalInterface: Full duplex RS-232 communications port.  
Power: Universal power supply 85-250 V ac, at  
47-63 Hz.  
OperatingTemperature: 0-50 °C (32-122 °F).  
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Appendix  
Model 3000PA  
Accuracy: ±2% of full scale at constant temperature.  
±5% of full scale over operating temperature  
range, on factory default analysis ranges, once  
thermal equilibrium has been reached.  
Analog outputs: 0-1 V dcpercent-of-range(Standard)  
0-1 V dc range ID (Standard)  
4-20 mA dcisolatedpercent-of-range  
(Optional)  
4-20 mA dcisolatedrange ID (Optional)  
Dimensions: 19 cm high × 24.9 cm wide × 31 cm deep  
(5.96″ × 8.7″ × 12.2).  
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Percent Oxygen Analyzer  
Appendix  
A-2 Recommended 2-Year Spare Parts List  
Qty PartNumber Description  
1
C62374  
C62371-B  
C62368-B  
C62365-C  
C62365-A  
F9  
Back Panel Board  
1
Front Panel Board  
1
PercentPreamplifierBoard  
1*  
1*  
3
Main Computer Board (std)  
Main Computer Board (4-20 mA)  
Fuse, 1 A, 250 V, 3 AG, Slow Blow  
Fuse, 1 A, 250 V, 5 × 20 mm, Slow Blow  
Molex Connector for Remote Probe  
3
F1275  
1
R1460  
1
T976  
Molex Crimp Terminals for Remote Probe Connector  
O-ring  
2
O38  
1** C6689-B1  
Micro-FuelCell(foroptionssee**)  
__________________  
* Order -B or -C, not both.  
** Check Specific Model Information for cell in your instrument.  
A minimum charge of $20.00 US dollars 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 3000PA  
A-3 Drawing List  
D-64573 FinalAssembly/OutlineDrawing  
A-4 19-inch Relay Rack Panel Mount  
Figure A-1: Single and Dual 19" Rack Mounts  
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Percent Oxygen Analyzer  
Appendix  
3000 SERIES ANALYZERS  
APPLICATIONNOTESONRESTRICTORS,  
A-5  
PRESSURES, AND FLOW RECOMMENDATIONS  
3000seriesanalyzersrequirereasonablyregulatedsamplepressures.  
Whilethe3000analyzersarenotsensitivetovariationsofincomingpressure  
(providedtheyareproperlyventedtoatmosphericpressure)Thepressuremust  
bemaintainedastoprovideauseableflowratetroughtheanalyzer.Anyline  
attachedtosampleventshouldbe1/4orlarger indiameter.  
FLOWRATERECOMMENDATIONS:  
Ausableflowratefora3000seriesanalyzerisonewhichcanbe  
measuredontheflowmeter.Thisisbasically .2-2.4SLPM.Theoptimumflow  
rateis1SLPM (midscale). Note:responsetimeisdependentonflowrate, a  
lowflowratewillresultinslowresponsetoO2changesinthesamplestream.  
Thespanflowrateshouldbetheapproximatelysameasthesampleflowrate.  
CELLPRESSURECONCERNS:  
Thesensorsusedin3000seriesanalyzersareoptimized tofunctionat  
atmosphericpressure.Atpressuresotherthanatmosphericthediffusionrateof  
O2willbedifferentthanoptimumvalue.HigherpressureswillproducefasterO2  
diffusionrates resultinginhigherO2reading andshortercelllife.Tousea3000  
seriesanalyzeratacellpressureotherthanatmospheric,theanalyzermustbe  
calibratedwithaknowncalibrationgasatthenewcellpressuretoadjustforthe  
differentdiffusionrate.Cellpressuresbelow2/3atmosphericarenot  
recommendedbecauseastheytendtocauseexcessiveinternalexpansionwhich  
mayresultinsealfailure.  
Foroperationatcellpressuresotherthanatmosphericcaremustbe  
takennottochangethesamplepressurerapidlyorcelldamagemayoccur.For  
cellpressuresaboveatmospheric,cautionmustbeexercisedtoavoidover  
pressuringthecellholder.(percentanalyzerswillrequiresometypeofcell  
retainertopreventthecellfrombeingpushedoutbythepressure.) For  
operationatpressuresbelowatmosphericpressureasuffixC(clamped)cellis  
required.  
RESTRICTIONDEVICES:  
Forproperoperation,all3000seriesanalyzersrequireaflowrestriction  
device.Thisdeviceistypicallyarestrictororavalve.Thisrestrictiondevice  
servestwofunctionsinthesamplepath.Thefirstfunctionistolimittheflowrate  
ofthesamplethroughtheanalyzer.Arestrictorischosentooperateoverarange  
ofpressuresandprovideauseableflowrateoverthatrange.  
Thesecond functionthattherestrictiondeviceprovidesisapressure  
drop.Thisdeviceisselectedtoprovidetheonlysignificant pressuredropinthe  
samplepath.  
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Appendix  
Model 3000PA  
RESTRICTORKIT  
Thecurrentrevisionofthe3000seriesanalyzersaresuppliedwithakit  
containingtworestrictorsandaunionwhichareuserinstalled.Theseparts  
suppliedtogivetheendusermoreflexibilitywheninstallingtheanalyzer.The  
restrictorkitissuitableforhighandlowpositivepressureapplicationsaswellas  
vacuumservice(atmosphericpressuresample)applications(seemanualfor  
installationinstructions).Thestandardrestrictor(BLUEDOT)isrecommended  
for pressures between 5 PSIG and 50 PSIG. For positive low pressure  
application ( 5 psig or less ) the un-marked restrictor is better suited . For  
nonepressurizedsampleapplicationsthemarkedrestrictorshouldbeusedand  
configuredforvacuumservice.Note:forextremelylowpositivepressure  
applications(lessthen2psig)thevacuumserviceconfigurationshouldprovide  
higherperformance(higherflowrates). Forvacuumservicetheendusermust  
supplyavacuumpumpandaby-passvalveforthepump.Avacuumlevelof 5-  
10inchesofmercuryshould providetheoptimumflowrate.CAUTION:flow  
restrictors have very small orifices and may be plugged by small  
particles ( .005dia or larger) A sample filter must be included in the  
samplelinepriortotherestrictor!(a60micronfilterisrecommended)  
3000PAEXAMPLES:  
Example1,withaincoming pressureof10psigthestdrestrictor(blue  
dot) willprovideaflowrateof.76SLPM.Up-streamoftherestrictorthe  
samplelinepressurewillbe10psig, whiledownstream(includingthecell)the  
pressurewillbeatatmosphericpressure.(analyzerventedtoatmospheric  
pressure) Note,allotherpressuredropsinthesamplepathareinsignificantat  
theseflowrates.Thisinsuresthatthecelloperatesatatmosphericpressure.At  
veryhighflowrates(offscaleofflow-meter),pressuredropsotherthanthe  
restrictiondevicecouldbecomesignificant,andresultin pressurizingthecell.  
Example2, A3000PAisconfiguredforvacuumserviceasfollows.The  
un-markedrestrictorisplacedinthesampleventport.Thedownstreamendof  
therestrictoristhenconnectedtoavacuumpumpandby-passvalve.Theby-  
passvalveisadjustedtoprovideaflowrateof1SLPM.Thesamplepressure  
betweenthepumpandtherestrictorwillbeapproximately -7inchesofmercury,  
whilethepressureinthebalanceofthesamplesystemincludingthecellwillbe  
approximatelyatatmosphericpressure.(providedthesampleflowintothe  
analyzerisnotblocked.)  
BY-PASS:  
Toimprovethesystemresponse, aby-passcanbeaddedtoincrease  
thesampleflowratetotheanalyzerbyafactoroften.Aby-passprovidesa  
sampleflowpatharoundtheanalyzerof 2-18SCFH.typically.  
CALIBRATION GAS:  
3000seriesanalyzerrequirementsforunitswithAuto-Caloptions.The  
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Percent Oxygen Analyzer  
Appendix  
customermustsupplyacontrolvalves(orrestrictors) foranySPANor ZEROgas  
sourcewhichisattachedtotheAuto-Calports.Thevalveshouldbeadjustedtothe  
sameflowrateasthesamplegas.Whenrestrictorsareused,thegaspressuremust  
beadjustedtoachievetheproperflowrate.  
OPERATIONWITHOUT ARESTRICTORDEVICE:  
Operationwithoutarestrictordeviceisnotrecommendasmentioned  
above. A3000PA withoutanyflowrestrictordevicewastestedon11-19-97.  
This results in a flow rate of 2.4 SLPM @ 1 PSIG. This is a cv of 0.023 for the  
standardsamplesys.  
REFERENCE: FLOW_1.XLS & FLOW_2.XLS forinformationonflowrates  
atvariouspressures.  
TAI PART NUMBERS  
RESTRICTORKIT:  
UNION (SS)  
LP.RESTRICTOR  
STD..RESTRICTOR  
NUT  
A68729  
U11  
R2323 ( LOW PRESSURE / VAC. SERVICE )  
R2324  
N73  
F73  
BLUEDOT  
FERRULE  
FERRULE  
F74  
BOTHFERRULESARE  
REQUIRED  
CONVERSIONS:  
1 PSI  
1 SCFH  
=
=
2.04 INCHES OF MERCURY (in. Hg.)  
0.476 SLPM  
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Appendix  
Model 3000PA  
A-6  
Zero Cal  
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 zeroing is becoming more and more dificult,  
skip to section 4.4.1.3 Cell Failure.  
Auto Mode Zeroing  
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 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.  
#### % 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 Le ft, 4 Le ft, 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.  
#### % 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.  
Manual Mode Zeroing  
Press Zero to enter the Zero function. The screen that appears allows  
you to select between automatic or manual zero calibration. Use the keys  
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Percent Oxygen Analyzer  
Appendix  
to toggle between AUTO and MAN zero settling. Stop when MAN appears,  
blinking, on the display.  
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).  
#### % 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 span settling completes, the information is stored in the  
microprocessor, and the instrument automatically returns to the Analyze  
mode.  
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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