Teledyne Respiratory Product 3020T User Manual

OPERATING INSTRUCTIONS FOR  
Model 3020T  
Trace Oxygen Analyzer  
DANGER  
HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS  
MONITORING SYSTEM.  
PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.  
HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PER-  
SIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.  
P/N M65908  
11/22/99  
ECO # 99-0459  
ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING.  
BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED  
SUPERVISOR/MANAGER.  
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Trace Oxygen Analyzer  
SpecificModelInformation  
Theinstrumentforwhichthismanualwassuppliedmayincorporateoneor  
moreoptionsnotsuppliedinthestandardinstrument.Commonlyavailable  
optionsarelistedbelow,withcheckboxes.Anythatareincorporatedinthe  
instrumentforwhichthismanualwassuppliedareindicatedbyacheckmarkin  
thebox.  
InstrumentSerialNumber:__________________________  
Theinstrumentwiththeaboveserialnumberhasthefollowing  
Options:  
3020T-C  
Threegasinputs,forsample,zeroandspangases,with  
threesolenoid-actuatedgas-flowcontrolvalvesbuiltin.  
Valvesareautomaticallysynchronizedtotheanalyzer's  
electroniccontrolsequences.  
3020T–F  
Built-in flame arresters for Groups C and D service.  
3020T–G  
Built-in flame arresters for Groups C and D service, plus  
gas-control valves as in –C option, above.  
3020T–H  
Built-in flame arresters for Group B (hydrogen) service.  
3020T–I  
Built-in flame arresters for Group B (hydrogen) service,  
plus gas-control valves as in –C option, above.  
19" Rack Mount  
The 19" Relay Rack Mount units are available with  
either one or two series 3000 analyzer Control Units  
installed in a standard 19" panel and ready to mount in a  
standard rack. See Appendix for details.  
Cell Class* ____________________(L-2C standard).  
Enter Class Designation  
* See Part II, Chapter 2 and/or any addendum that may be  
attached to this manual for cell specifications.  
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Model 3020T  
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 Operator Interface .......................................................... 1-3  
1.5.1 UP/DOWN Switch.................................................. 1-4  
1.5.2 ESCAPE/ENTER Switch....................................... 1-4  
1.5.3 Displays ................................................................. 1-5  
1.6 Recognizing Difference Between LCD & VFD............... 1-5  
1.7 Rear Panel Equipment Interface .................................... 1-5  
1.7.1 Electrical Connector Panel .................................... 1-5  
1.7.2 Gas Connector Panel............................................. 1-7  
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  
2.3 Sample System.............................................................. 2-5  
2.4 Electronics and Signal Processing ................................ 2-6  
2.5 Temperature Control ...................................................... 2-8  
3 Installation  
3.1 Unpacking the Analyzer................................................. 3-1  
3.2 Mounting the Analyzer ................................................... 3-1  
3.3 Electrical Connections ................................................... 3-3  
3.3.1 Primary Input Power............................................... 3-4  
3.3.2 Fuse Installation..................................................... 3-4  
3.3.3 Analog Outputs ...................................................... 3-4  
3.3.4 Alarm Relays ......................................................... 3-6  
3.3.5 Digital Remote Cal Inputs ...................................... 3-7  
3.3.6 Range ID Relays ................................................... 3-9  
3.3.7 Network I/O ............................................................ 3-9  
3.3.8 RS-232 Port ........................................................... 3-9  
3.3.9 Remote Sensor and Solenoid Valves ....................3-10  
3.4 Installing the Micro-Fuel Cell ........................................ 3-11  
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3.5 Gas Connections .......................................................... 3-12  
3.6 Testing the System........................................................ 3-14  
4 Operation  
4.1 Introduction .................................................................... 4-1  
4.2 Using the Controls ......................................................... 4-1  
4.2.1 Mode/Function Selection ....................................... 4-2  
4.2.1.1 Analysis Mode ............................................... 4-2  
4.2.1.2 Setup Mode ................................................... 4-2  
4.2.2 Data Entry .............................................................. 4-4  
4.2.2.1 ENTER .......................................................... 4-4  
4.2.2.2 ESCAPE........................................................ 4-4  
4.3 The AUTO-CAL Function ............................................... 4-5  
4.4 The PWD Function ........................................................ 4-5  
4.4.1 Entering the Password ........................................... 4-6  
4.4.2 Installing or Changing the Password ..................... 4-7  
4.5 The LOGOUT Function .................................................. 4-8  
4.6 The VERSION Screen ................................................... 4-8  
4.7 The SELF TEST Function.............................................. 4-9  
4.8 The ZERO and SPAN Functions ................................... 4-9  
4.8.1 Zero Cal ................................................................. 4-10  
4.8.1.1 Auto Mode Zeroing ........................................ 4-10  
4.8.1.2 Manual Mode Zeroing.................................... 4-11  
4.8.1.3 Cell Failure .................................................... 4-11  
4.8.2 Span Cal................................................................ 4-12  
4.8.2.1 Auto Mode Spanning ..................................... 4-12  
4.8.2.2 Manual Mode Spanning................................. 4-13  
4.9 The ALARMS Function .................................................. 4-14  
4.10 The RANGE Function .................................................... 4-16  
4.10.1 Setting the Analog Output Ranges......................... 4-16  
4.10.2 Fixed Range Analysis............................................ 4-17  
4.11 The CONTRAST Function............................................. 4-18  
4.12 The STANDBY Function ................................................ 4-18  
4.13 The Analysis Mode ........................................................ 4-19  
Maintenance  
5.1 Routine Maintenance..................................................... 5-1  
5.2 Major Internal Components............................................ 5-1  
5.3 Cell Replacement .......................................................... 5-2  
5.3.1 Storing and Handling Replacement Cells ............... 5-3  
5.3.2 When to Replace a Cell ........................................... 5-3  
5.3.3 Removing the Micro-Fuel Cell ................................. 5-4  
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5.3.4 Installing a New Micro-Fuel Cell.............................. 5-6  
5.2.5 Cell Warranty ........................................................... 5-6  
5.4 Fuse Replacement......................................................... 5-7  
5.5 System Self Diagnostic Test........................................... 5-7  
Appendix  
A-1 Specifications ................................................................ A-1  
A-2 Recommended 2-Year Spare Parts List ......................... A-3  
A-3 Drawing List ................................................................... A-4  
A-4 Application Notes on Restrictors, Pressures & Flow...... A-4  
A-5 Material Safety Data Sheet ............................................ A-5  
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Trace Oxygen Analyzer  
Introduction 1  
Introduction  
1.1 Overview  
The Teledyne Analytical Instruments Model 3020T Trace Oxygen  
Analyzer is a versatile microprocessor-based instrument for detecting oxygen  
at the parts-per-million (ppm) level in a variety of gases. This manual covers  
the Model 3020T, trace oxygen, explosion-proof, bulkhead-mount units  
only.  
1.2 Typical Applications  
A few typical applications of the Model 3020T are:  
Monitoringinertgasblanketing  
Airseparationandliquefaction  
Chemicalreactionmonitoring  
Semiconductormanufacturing  
Petrochemicalprocesscontrol  
Qualityassurance  
Gasanalysiscertification.  
1.3 Main Features of the Analyzer  
The Model 3020T Trace Oxygen Analyzer is sophisticated yet simple  
to use. The main features of the analyzer include:  
A 2-line alphanumeric display screen, driven by microprocessor  
electronics, that continuously prompts and informs the operator.  
High resolution, accurate readings of oxygen content from low  
ppm levels through 25%. Large, bright, meter readout.  
Stainlesssteelcellblock.  
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1 Introduction  
Model 3020T  
Advanced Micro-Fuel Cell, redesigned for trace analysis, has an  
expected life of one year.  
Versatile analysis over a wide range of applications.  
Microprocessorbasedelectronics:8-bitCMOSmicroprocessor  
with 32 kB RAM and 128 kB ROM.  
Three user definable output ranges (from 0-10 ppm through 0-  
250,000 ppm) 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.  
RS-232 serial digital port for use with a computer or other digital  
communicationdevice.  
Four analog outputs: two for measurement (0–1 V dc and  
Isolated 4–20 mA dc) and two for range identification.  
1.4 Model Designations  
3020T:  
Standardmodel.  
3020T-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 3020T electronics, to automatically switch between gases  
in synchronization with the analyzer’s operations  
3020T-F:  
3020T-G:  
3020T-H:  
3020T-I:  
Flame arrestors for Groups C and D installed.  
Flame arrestors for Groups C and D, & -C option, installed.  
Flame arrestors for Group B (hydrogen) installed.  
Flame arrestors for Group B, & -C option, installed.  
All of the above options are available in combination.  
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Trace Oxygen Analyzer  
Introduction 1  
1.5 Operator Interface  
All controls and displays on the standard 3020T are accessible from  
outside the housing. The instrument has two simple operator controls. A  
digital meter, an alphanumeric display, and a sample flowmeter give the  
operator constant feedback from the instrument. See Figure 1-1. The controls  
are described briefly here and in greater detail in chapter 4.  
Figure 1-1: Model 3020T Controls, Indicators, and Connectors  
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1 Introduction  
Model 3020T  
1.5.1 UP/DOWN Switch  
Functions: The UP/DOWN switch is used to select the function to be  
performed. Choose UP or DOWN to scroll through the following list of  
elevenfunctions:  
Auto-Cal Set up an automatic calibration sequence.  
PWD Installapasswordtoprotectyouranalyzersetup.  
Logout Locks Setup Mode.  
Version Displays model and version of analyzer.  
Self-Test Runsinternaldiagnosticprogram, displaysresults.  
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.  
Contrast Allows adjustment of LCD contrast.  
Contrast Function is DISABLED  
(Refer to Section 1.6)  
Standby Leaves analyzer powered, but no outputs or displays.  
WARNING: THE POWER CABLE MUST BE DISCONNECTED TO  
FULLY REMOVE POWER FROM THE INSTRUMENT.  
Subfunctions: Once a Function is entered, the UP/DOWN switch is  
used to select between any subfunctions displayed on the VFD screen.  
Parameter values: When modifiable values are displayed on the  
VFD, the UP/DOWN switch can be used to increment or decrement the  
values.  
1.5.2 ESCAPE/ENTER Switch  
Data Entry: The ESCAPE/ENTER switch is used to input data, from  
the alphanumeric VFD screen into the instrument:  
Escape Moves VFD display back to the previous screen in a  
series. If none remains, returns to the Analyze screen.  
Enter With a Subfunction Selected: Moves VFD display on to  
the next screen in a series. If none remains, returns to  
the Analyze screen.  
With a Value Selected: Enters the value into the  
analyzer as data. AdvancesVFD to next operation.  
(See Chapter 4 for details.)  
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Trace Oxygen Analyzer  
Introduction 1  
1.5.3 Displays  
Digital Meter Display: The meter display is a LED device that  
produces large, bright, 7-segment numbers that are legible in any lighting. It  
produces a continuous readout from 0-10,000 ppm and then switches to a  
continuous percent readout from 1-25%. It is accurate across all analysis  
ranges without the discontinuity inherent in analog range switching.  
Alphanumeric Interface Screen: The VFD screen is an easy-to-use  
interface from operator to analyzer. It displays values, options, and messages  
that give the operator immediate feedback.  
Flowmeter: Monitors the flow of gas past the sensor. Readout is 0.2 to  
2.4 standard liters per minute (SLPM).  
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 Equipment Interface  
1.7.1 Electrical Connector Panel  
The electrical connector panel, shown in Figure 1-2, contains the  
electrical connections for external inlets and outlets. The connectors are  
described briefly here and in detail in the Installation chapter of this manual.  
CAUTION: The power cable must be disconnected to fully  
remove power from the instrument.  
Access: To access the electrical connector panel, or the sensor block,  
the control panel doubles as a door that can be unbolted and swung open.  
Electrical Connections: The electrical connections on the electrical  
connector panel are described briefly here, and in more detail in chapter 3  
Installation.  
Power Connection  
Analog Outputs  
115 or 230 V dc, 50 or 60 Hz.  
0-1 V dc concentration plus 0-1 V dc  
range ID, and isolated 4-20 mA dc plus  
4-20 mA dc range ID.  
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1 Introduction  
Model 3020T  
Alarm Connections 2 concentration alarms and 1 system  
alarm.  
RS-232 Port  
Serialdigitalconcentrationsignaloutput  
and control input.  
Remote Valves  
Used for controlling external solenoid  
valves, if desired.  
Figure 1-2: Electrical Connector Panel  
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Trace Oxygen Analyzer  
Introduction 1  
Remote Sensor  
Remote Span/Zero  
Used for external sensor and  
thermocouple,ifdesired.  
Digital inputs allow external control of  
analyzercalibration.  
Calibration Contact To notify external equipment that  
instrument is being calibrated and  
readings are not monitoring sample.  
Range ID Contacts  
Network I/O  
Four separate, dedicated, range relay  
contacts. Low, Medium, High, Cal.  
Serialdigitalcommunicationsforlocal  
network access. For future expansion.  
Not implemented at this printing.  
1.7.2 Gas Connector Panel  
The gas connector panel, shown in Figure 1-3, contains the gas con-  
nections for external inlets and outlets. Those that are optional are shown  
shaded in the figure. The connectors are described briefly here and in detail  
in the Installation chapter of this manual.  
Figure 1-3: Model 3020T Gas Connector Panel  
Gas Inlet and Outlet One inlet (must be externally valved)  
and one exhaust out.  
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1 Introduction  
Model 3020T  
Optional:  
Calibration Gas Ports Separate fittings for zero, span and  
sample gas input, plus internal valves for  
automatically switching the gases in  
sync with the 3020 electronics.  
Note: If you require highly accurate Auto-Cal timing, use external  
Auto-Cal control where possible. The internal clock in the  
Model 3020T is accurate to 2-3 %. Accordingly, internally  
scheduled calibrations can vary 2-3 % per day.  
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Operational Theory 2  
Operational Theory  
2.1 Introduction  
The analyzer is composed of three subsystems:  
1. Micro-Fuel Cell Sensor  
2. SampleSystem  
3. Electronic Signal Processing, Display and Control  
The sample system is designed to accept the sample gas and transport it  
through the analyzer without contaminating or altering the sample prior to  
analysis. The Micro-Fuel Cell is an electrochemical galvanic device that  
translates the amount of oxygen present in the sample into an electrical  
current. The electronic signal processing, display and control subsystem  
simplifies operation of the analyzer and accurately processes the sampled  
data. The microprocessor controls all signal processing, input/output and  
display functions for the analyzer.  
2.2 Micro-Fuel Cell Sensor  
2.2.1 Principles of Operation  
The oxygen sensor used in the Model 3020T 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 3020T  
analyzed. The Micro-Fuel Cell is therefore a hybrid between a battery and a  
true fuel cell. (All of the reactants are stored externally in a true fuel cell.)  
2.2.2 Anatomy of a Micro-Fuel Cell  
The Micro-Fuel Cell is a cylinder only 1¼ inches in diameter and 1¼  
inches thick. It is made of an extremely inert plastic, which can be placed  
confidently in practically any environment or sample stream. It is effectively  
sealed, although one end is permeable to oxygen in the sample gas. The  
other end of the cell is a contact plate consisting of two concentric foil rings.  
The rings mate with spring-loaded contacts in the sensor block assembly and  
provide the electrical connection to the rest of the analyzer. Figure 2-1  
illustratestheexternalfeatures.  
Figure 2-1: Micro-Fuel Cell  
Refer to Figure 2-2, Cross Section of a Micro-Fuel Cell, which illus-  
tratesthefollowinginternaldescription.  
Figure 2-2. Cross Section of a Micro-Fuel Cell (not to scale)  
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Trace Oxygen Analyzer  
Operational Theory 2  
At the top end of the cell is a diffusion membrane of Teflon, whose  
thickness is very accurately controlled. Beneath the diffusion membrane lies  
the oxygen sensing element—the cathode—with a surface area almost 4 cm2.  
The cathode has many perforations to ensure sufficient wetting of the upper  
surface with electrolyte, and it is plated with an inert metal.  
The anode structure is below the cathode. It is made of lead and has a  
proprietary design which is meant to maximize the amount of metal available  
forchemicalreaction.  
At the rear of the cell, just below the anode structure, is a flexible  
membrane designed to accommodate the internal volume changes that occur  
throughout the life of the cell. This flexibility assures that the sensing mem-  
brane remains in its proper position, keeping the electrical output constant.  
The entire space between the diffusion membrane, above the cathode,  
and the flexible rear membrane, beneath the anode, is filled with electrolyte.  
Cathode and anode are submerged in this common pool. They each have a  
conductor connecting them to one of the external contact rings on the contact  
plate, which is on the bottom of the cell.  
2.2.3 Electrochemical Reactions  
The sample gas diffuses through the Teflon membrane. Any oxygen in  
the sample gas is reduced on the surface of the cathode by the following  
HALF REACTION:  
O2 + 2H2O + 4e4OH–  
(cathode)  
(Four electrons combine with one oxygen molecule—in the presence of  
water from the electrolyte—to produce four hydroxyl ions.)  
When the oxygen is reduced at the cathode, lead is simultaneously  
oxidized at the anode by the following HALF REACTION:  
Pb + 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.  
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2 Operational Theory  
Model 3020T  
The overall reaction for the fuel cell is the SUM of the half reactions  
above, or:  
2Pb + O2 2PbO  
(These reactions will hold as long as no gaseous components capable of  
oxidizing lead—such as iodine, bromine, chlorine and fluorine—are 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 in parts-  
per-million or a percentage of the gas mixture, it is necessary that the sample  
diffuse into the cell under constant pressure.  
If the total pressure increases, the rate that oxygen reaches the cathode  
through the diffusing membrane will also increase. The electron transfer, and  
therefore the external current, will increase, even though the oxygen concen-  
tration of the sample has not changed. It is therefore important that the  
sample pressure at the fuel cell (usually vent pressure) remain relatively  
constantbetweencalibrations.  
2.2.5 Calibration Characteristics  
Given that the total pressure of the sample gas on the surface of the  
Micro-Fuel Cell input is constant, a convenient characteristic of the cell is  
that the current produced in an external circuit is directly proportional to the  
rate at which oxygen molecules reach the cathode, and this rate is directly  
proportional to the concentration of oxygen in the gaseous mixture. In other  
words it has a linear characteristic curve, as shown in Figure 2-3. Measuring  
circuits do not have to compensate for nonlinearities.  
In addition, since there is zero output in the absence oxygen, the charac-  
teristic curve has close to an absolute zero (within ± 1 ppm oxygen). In  
practical application, zeroing may still used to compensate for the combined  
zero offsets of the cell and the electronics. (The electronics is zeroed auto-  
matically when the instrument power is turned on.)  
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Trace Oxygen Analyzer  
Operational Theory 2  
Figure 2-3. Characteristic Input/Output Curve for a Micro-Fuel Cell  
2.3 Sample System  
The sample system delivers gases to the Micro-Fuel Cell sensor from  
the analyzer gas panel inlets. Depending on the mode of operation either  
sample or calibration gas is delivered.  
The Model 3020T 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-  
mizes residual gas pockets that can interfere with trace 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 to be  
used if needed. The sample or calibration gas flowing through the system is  
monitored by a flowmeter downstream from the cell.  
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2 Operational Theory  
Model 3020T  
Figure 2-4 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 and/or F  
options are ordered. The valves, when supplied, are installed inside the  
3020T enclosure and are regulated by the instruments internal electronics.  
The flame arrestors, when supplied, are installed in the Gas Connector Panel.  
Components in the s  
the -C option (interna  
only and are not sho  
Span In  
diagram abov e  
Zero In  
Cell  
Sample In  
Solenoid  
Valves  
In vacuum service the  
restrictor should b  
placed here.  
In normal service the  
restrictor should b  
placed here.  
Exhaust  
O
u
Restrictor  
Figure 2-4: Flow Diagram  
2.4 Electronics and Signal Processing  
The Model 3020T Trace Oxygen Analyzer uses an 8031 microcontrol-  
ler with 32 kB of RAM and 128 kB of ROM to control all signal processing,  
input/output, and display functions for the analyzer. System power is sup-  
plied from a universal power supply module designed to be compatible with  
most international power sources. See chapter 5 Maintenance for the location  
of the power supply and the main electronic PC boards.  
The signal processing electronics including the microprocessor, analog  
to digital, and digital to analog converters are located on the motherboard at  
the bottom of the case. The preamplifier board is mounted on top of the  
motherboard as shown in the figure. These boards are accessible after re-  
moving the access panel. Figure 2-5 is a block diagram of the Analyzer  
electronics.  
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Trace Oxygen Analyzer  
Operational Theory 2  
Figure 2-5: Block Diagram of the Model 3020T Electronics  
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2 Operational Theory  
Model 3020T  
In the presence of oxygen the cell generates a current. A current to  
voltage amplifier converts this current to a voltage, which is amplified in the  
secondstageamplifier.  
The second stage amplifier also supplies temperature compensation for  
the oxygen sensor output. This amplifier circuit incorporates a thermistor,  
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 4-20 mA dc and the 0-1 V dc analog concentration signal outputs, and  
the analog range ID outputs.  
Signals from the power supply are also monitored, and through the  
microprocessor, the system failure alarm is activated if a malfunction is  
detected.  
2.5 Temperature Control  
For accurate analysis this instrument is temperature controlled not to fall  
beneath a certain temperature. This temperature is 22oF. This is to prevent  
the sensor from freezing in cold environments.  
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Installation  
Installation of the Model 3020T 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 3020T is designed for bulkhead mounting in hazardous  
environments. There are four mounting lugs—one in each corner of the  
enclosure, as shown in Figure 3-1. The outline drawing, at the back of this  
manual, gives the mounting hole size and spacing. The drawing also con-  
tains the overall dimensions. Do not forget to allow an extra 13/8" for the  
hinges.  
Be sure to allow enough space in front of the enclosure to swing the  
door open—a 16 1/4" radius, as shown in Figure 3-2.  
All electrical connections are made via cables which enter the explo-  
sion-proof housing through ports in its side. No conduit fittings are supplied.  
The installer must provide two 3/4" NPT and two 1" NPT adapters and the  
appropriatesealingconduit.  
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Figure 3-1: Front View of the Model 3020T (Simplified)  
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Figure 3-2: Required Front Door Clearance  
3.3 Electrical Connections  
Figure 3-3 shows the Model 3020T Electrical Connector Panel. There  
are terminal blocks for connecting power, communications, and both digital  
and analog concentration outputs.  
Figure 3-3: Electrical Connector Panel  
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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.  
3.3.1 Primary Input Power  
The universal power supply requires a 115 or 230 V ac, 50 or 60 Hz  
power source. The actual input voltage used must show in the window of the  
VOLTAGE SELECTOR switch before the power source is connected. See  
Figure 3-4 for detailed connections.  
DANGER: Power is applied to the instrument's circuitry as  
long as the instrument is connected to the power  
source. The Standby function switches power on or  
off to the displays and outputs only.  
Figure 3-4: Primary Input Power Connections  
3.3.2 Fuse Installation  
The fuse holders accept 5 x 20 mm, 1.6 A, T type (slow blow) fuses.  
Fuses are not installed at the factory. Be sure to install the proper fuse as part  
of installation. (See Fuse Replacement in chapter 5, maintenance.)  
3.3.3 Analog Outputs  
There are eight DC output signal connectors on the ANALOG OUT-  
PUTS connector block. There are two connectors per output with the polar-  
ity noted. See Figure 3-5.  
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Figure 3-5: Analog Output Connections  
The outputs are:  
0–1 V dc % of Range: Voltage rises linearly with increasing oxygen, from  
0 V at 0 ppm to 1 V at full scale ppm. (Full scale =  
100% of programmable range.)  
0–1 V dc Range ID:  
0.25 V = Low Range, 0.5 V = Medium Range,  
0.75 V = High Range, 1 V = Air Cal Range.  
4–20 mA dc % Range: Current increases linearly with increasing oxygen,  
from 4 mA at 0 ppm to 20 mA at full scale ppm.  
(Full scale = 100% of programmable range.)  
4–20 mA dc Range ID: 8 mA = Low Range, 12 mA = Medium Range, 16  
mA = High Range, 20 mA = Air Cal Range.  
Examples:  
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.  
The signal output for concentration is linear over the currently selected  
analysis range. For example, if the analyzer is set on a range that was defined  
as 0–100 ppm O2, then the output would be as shown in Table 3-1.  
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Table 3-1: Analog Concentration Output—Example  
Voltage Signal Current Signal  
ppm O2  
Output (V dc)  
Output (mA dc)  
0
10  
20  
30  
40  
50  
60  
70  
80  
90  
100  
0.0  
0.1  
0.2  
0.3  
0.4  
0.5  
0.6  
0.7  
0.8  
0.9  
1.0  
4.0  
5.6  
7.2  
8.8  
10.4  
12.0  
13.6  
15.2  
16.8  
18.4  
20.0  
To provide an indication of the range, a second pair of analog output  
terminals are used. They generate a steady preset voltage (or current when  
using the current outputs) to represent a particular range. Table 3-2 gives the  
range ID output for each analysis range.  
Table 3-2: Analog Range ID Output—Example  
Range  
Voltage (V)  
Current (mA)  
LO  
0.25  
8
MED  
0.50  
0.75  
1.00  
12  
16  
20  
HI  
CAL (0-25%)  
3.3.4 Alarm Relays  
There are three alarm-circuit connectors on the alarm relays block  
(under RELAY OUTPUTS) 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 connector panel. They  
are capable of switching up to 3 amperes at 250 V ac into a resistive load.  
See Figure 3-6.  
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Figure 3-6: Types of Relay Contacts  
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.  
To reset a System Alarm during installation, discon-  
nect power to the instrument and then reconnect it.  
Further detail can be found in chapter 4, section 4-5.  
3.3.5 Digital Remote Cal Inputs  
Remote Zero and Span Inputs: The REMOTE SPAN and RE-  
MOTE ZERO inputs are on the DIGITAL INPUT terminal block. They  
accept 0 V (OFF) or 24 V dc (ON) for remote control of calibration. (See  
Remote Calibration Protocol below.)  
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ZERO:  
Floating input. 5 to 24 V input across the + and – terminals  
puts the analyzer into the Zero mode. Either side may be  
grounded at the source of the signal. 0 to 1 volt across the  
terminals allows Zero mode to terminate when done. A  
synchronous signal must open and close the external zero  
valve appropriately. See 3.3.9 Remote Sensor and Solenoid  
Valves. (With the –C option, the internal valves automatically  
operatesynchronously.)  
SPAN:  
Floating input. 5 to 24 V input across the + and – terminals  
puts the analyzer into the Span mode. Either side may be  
grounded at the source of the signal. 0 to 1 volt across the  
terminals allows Span mode to terminate when done. A  
synchronous signal must open and close the external span  
valve appropriately. See 3.3.9 Remote Sensor and Solenoid  
Valves. (With the –C option, the internal valves automatically  
operatesynchronously.)  
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 3020T Analyzer, the customer's controller must  
monitor the CAL CONTACT relay.  
When the contact is OPEN, the analyzer is analyzing, the Remote Cal  
Inputs are being polled, and a zero or span command can be sent.  
When the contact is CLOSED, the analyzer is already calibrating. It  
will ignore your request to calibrate, and it will not remember that request.  
Once a zero or span command is sent, and acknowledged (contact  
closes), release it. If the command is continued until after the zero or span is  
complete, the calibration will repeat and the Cal Relay Contact (CRC) will  
closeagain.  
Forexample:  
1) Test the CRC. When the CRC is open, Send a zero command  
until the CRC closes (The CRC will quickly close.)  
2) When the CRC closes, remove the zero command.  
3) When CRC opens again, send a span command until the CRC  
closes. (The CRC will quickly close.)  
4) When the CRC closes, remove the span command.  
When CRC opens again, zero and span are done, and the sample is  
being analyzed.  
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Note: The remote probe connections (paragraph 3.3.9) provide  
signals to ensure that the zero and span gas valves will be  
controlled synchronously. If you have the –C Internal valve  
option—which includes additional zero and span gas inputs—  
the 3020T automatically regulates the zero, span and sample  
gas flow.  
3.3.6 Range ID Relays  
There are four dedicated RANGE ID CONTACT relays. The first  
three ranges are assigned to relays in ascending order—Low range is as-  
signed to RANGE 1 ID, Medium range is assigned to RANGE 2 ID, and  
High range is assigned to RANGE 3 ID. RANGE 4 ID is reserved for the  
Air Cal Range (25%).  
3.3.7 NetworkI/O  
A serial digital input/output for local network protocol. At this printing,  
this port is not yet functional. It is to be used in future versions of the instru-  
ment.  
3.3.8 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. The pinouts are listed in Table 3-3.  
Table 3-3: RS-232 Signals  
RS-232 Sig RS-232 Pin Purpose  
DCD  
RD  
TD  
DTR  
COM  
DSR  
RTS  
CTS  
RI  
1
2
3
4
5
6
7
8
9
Data Carrier Detect  
Received Data  
TransmittedData  
Data Terminal Ready  
Common  
Data Set Ready  
Request to Send  
Clear to Send  
RingIndicator  
The data sent is status information, in digital form, updated every two  
seconds. Status is reported in the following order:  
The concentration in ppm or percent  
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The range in use (HI, MED, LO)  
The span of the range (0-100 ppm, etc)  
Which alarms—if any—are disabled (AL–x DISABLED)  
Which alarms—if any—are tripped (AL–x ON).  
Each status output is followed by a carriage return and line feed.  
Three input functions using RS-232 have been implemented to date.  
They are described in Table 3-4.  
Table 3-4: Commands via RS-232 Input  
Command  
as<enter>  
az<enter>  
st<enter>  
Description  
Immediatelystartsanautospan.  
Immediatelystartsanautozero.  
Toggling input. Stops/Starts any status message output from  
the RS-232, until st<enter> is sent again.  
The RS-232 protocol allows some flexibility in its implementation.  
Table 3-5 lists certain RS-232 values that are required by the 3020T imple-  
mentation.  
Table 3-5: Required RS-232 Options  
Parameter  
Baud  
Setting  
2400  
Byte  
Parity  
8 bits  
none  
Stop Bits  
MessageInterval  
1
2 seconds  
3.3.9 Remote Sensor and Solenoid Valves  
The 3020T is a single-chassis instrument, which has its own sensor and,  
in the –C option, its own gas-control solenoid valves. The REMOTE SEN-  
SOR connector is not used, and the SOLENOID RETURN connectors are  
used (without the –C option) to synchronize external gas control valves, if  
desired. See Figure 3-7.  
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Figure 3-7: Remote Solenoid Return Connector Pinouts  
The voltage from these outputs is nominally 0 V for the OFF and  
15 V dc for the ON conditions. The maximum combined current that can be  
pulled from these output lines is 100 mA. (If two lines are ON at the same  
time, each must be limited to 50 mA, etc.) If more current and/or a different  
voltage is required, use a relay, power amplifier, or other matching circuitry  
to provide the actual driving current.  
In addition, each individual line has a series FET with a nominal ON  
resistance of 5 ohms (9 ohms worst case). This could limit the obtainable  
voltage, depending on the load impedance applied. See Figure 3-8.  
Figure 3-8: 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.  
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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 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 1/4” diameter tubing. Notice that the two 1 3/4”  
long, 1/4” diameter 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 (2 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.  
Figure 3-9 is an illustration of the Gas Connector Panel. Optional gas  
connections are shown in a shaded block.  
The unit is manufactured with 1/4 inch tube fittings only. Adapters must  
be used for metric tubing. (At least 6 mm is recommended.)  
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 11/4 turns.  
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Figure 3-9: Gas Connector Panel  
SAMPLE IN: In the standard model, gas connections are made at the  
SAMPLE IN and EXHAUST OUT connections. Calibration gases must be  
Tee'd into the Sample inlet with appropriate valves.  
The gas pressure in should be 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.  
ZERO IN and SPAN IN: These are additional ports for inputting span  
gas and zero gas. There are electrically operated valves inside for automatic  
switching between sample and calibration gases. These valves are com-  
pletely under control of the 3020T 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.  
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.  
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Note: If the unit is for vacuum service, see Sample In, above, for gas  
pressure/flow considerations.  
3.6 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.  
Check that the voltage selector switch on the Electrical  
Connector Panel is in the appropriate position for your power  
source.  
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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Operation 4  
Operation  
4.1 Introduction  
Once the analyzer has been installed, it can be configured for your  
application. To do this you will:  
Establish and start an automatic calibration cycle, if desired.  
(Electricallyoperatedvalvesrequired.)  
Define the three user selectable analysis ranges. Then choose  
autoranging or select a fixed range of analysis, as required.  
Calibratetheinstrument.  
Set alarm setpoints, and modes of alarm operation (latching,  
failsafe,etc).  
Establish a security password, if desired, requiring Operator to  
log in.  
Before you configure your 3020T these default values are in effect:  
Ranges: LO = 100 ppm, MED = 1000 ppm, HI = 10,000 ppm.  
Auto Ranging: ON  
Alarm Relays: Defeated, 1000 ppm, HI, Not failsafe, Not latching.  
Zero: Auto, every 0 days at 0 hours.  
Span: Auto, at 209,000 ppm, every 0 days at 0 hours.  
If you choose not to use password protection, the default password is  
displayed on the VFD screen only if you have entered the logout or pass-  
word function, as explained later. Then, you must enter the default password  
foraccess.  
4.2 Using the Controls  
To get the proper response from these controls, turn the control toward  
the desired action (ESCAPE or ENTER—DOWN or UP), and then release it.  
Turn-and-release once for each action. For example, turn-and-release twice  
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toward UP to move the VFD screen two selections upwards on the list of  
options(menu).  
The item that is between arrows on the screen is the item that is cur-  
rentlyselectablebychoosingENTER(turn-and-releasetowardENTER with  
theESCAPE/ENTERcontrol).  
In these instructions, to ENTER means to turn-and-release toward  
ENTER, and To ESCAPE means to turn-and-release towards ESCAPE. To  
scroll UP (or scroll DOWN) means to turn-and-release toward UP (or  
DOWN) as many times as necessary to reach the required menu item.  
4.2.1 Mode/Function Selection  
When the analyzer is first powered up, and has completed its initializa-  
tion and self diagnostics, ESCAPE toggles the instrument between the  
ANALYZE screen (Analysis Mode) and the MAIN MENU screen (Setup  
Mode). The ANALYZE screen is the only screen of the Analysis Mode.  
The MAIN MENU screen is the top level in a series of screens used in  
the Setup Mode to configure the analyzer for the specific application. The  
DOWN/UP commands scroll through the options displayed on the VFD  
screen. The selectable option appears between arrows. When you reach the  
desired option by scrolling, ENTER the selection as described below.  
ESCAPE takes you back up the hierarchy of screens until you reach the  
MAIN MENU again. ESCAPING any further just toggles between the  
MAIN MENU and the ANALYZE screen.  
4.2.1.1 Analysis Mode  
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. Either control switches you to Setup Mode. Setup Mode  
switches back to Analyze Mode if no controls are used for more than 5 s.  
4.2.1.2 Setup Mode  
The MAIN MENU consists of 11 functions you can use to customize  
the operations of the analyzer. Figure 4-1 shows the functions available with  
the Model 3020T. They are listed here with brief descriptions:  
1 AUTO-CAL: Used to define and/or start an automatic calibration  
sequence.  
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Contrast Function is DISABLED  
(Refer to Section 1.6)  
Figure 4-1: Modes and Functions  
2 PWD: Used to establish password protection or change the  
existingpassword.  
3 LOGOUT: Logging out prevents unauthorized tampering with  
theanalyzersettings.  
4 VERSION: Displays Manufacturer, Model, and Software version  
oftheinstrument.  
5 SELF-TEST: The instrument performs a self-diagnostic routine  
to check the integrity of the power supply, output boards and  
amplifiers.  
6 SPAN: Set up and/or start a span calibration.  
7 ZERO:startazerocalibration.  
8 ALARMS: Used to set the alarm setpoints and determine  
whether each alarm will be active or defeated, HI or LO acting,  
latching or not, and failsafe or not.  
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9 RANGE: Used to set up three analysis ranges that can be  
switched automatically with auto-ranging or used as individual  
fixedranges.  
10 STANDBY: Remove power to outputs and displays, but  
maintainpowertointernalcircuitry.  
Any function can be selected at any time. Just scroll through the MAIN  
MENU with the DOWN/UP control to the appropriate function, and ENTER  
it. The analyzer will immediately start that function, unless password  
restrictions have been assigned. (Password assignment is explained further  
on.)  
All of these functions are described in greater detail in the procedures  
starting in section 4.3. The VFD screen texts used to illustrate the procedures  
are reproduced in a Monospaced type style.  
4.2.2 Data Entry  
4.2.2.1 ENTER  
When the item you want from the VFD screen appears between the  
arrows on the VFD screen, ENTER it using the ESCAPE/ENTER control.  
When the selected option is a function or subfunction, ENTER moves  
to the VFD screen for that function or subfunction.  
When the selected option is a modifiable item, the DOWN/UP control  
can be used to increment or decrement that modifiable item to the value or  
action you want. Then you ENTER the item.  
ENTER then puts you into the next field to continue programming. If  
the screen is completed, ENTER takes you to the next screen in the process,  
or if the process is completed, ENTER takes you back to the ANALYZE  
screen.  
4.2.2.2 ESCAPE  
If you do not wish to continue a function, you can abort the session  
with a turn-and-release toward ESCAPE. Escaping a function takes the  
analyzer back to the previous screen, or to the ANALYZE Function, depend-  
ing on the function escaped.  
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4.3 The AUTO-CAL Function  
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 3020T is accurate to 2-3 %. Accordingly, internally  
scheduled calibrations can vary 2-3 % per day.  
To setup an AUTO-CAL cycle:  
Scroll to AUTO-CAL, and ENTER. A new screen for Span/Zero set  
appears.  
Span OFF Nxt: 0d 0h  
Zero OFF Nxt: 0d 0h  
If SPAN (or ZERO) is not between the arrows, scroll with DOWN/UP  
control to SPAN (or ZERO), then ENTER. (You won’t be able to set OFF to  
ON if a zero interval is entered.) A Span Every ... (or Zero Every ...)  
screenappears.  
Span Every 0 d  
Start 0 h from now  
Use DOWN/UP control to set an interval value, and ENTER. Then use  
DOWN/UP to set a start-time value, and ENTER.  
To turn ON the Span and/or Zero cycles (to activate AUTO-CAL):  
Scroll to Auto—Cal, and ENTER it again.  
Span OFF Nxt: 0d 0h  
Zero OFF Nxt: 0d 0h  
When the Span/Zero values screen appears, use the scroll DOWN to  
blink the OFF/ON field of the SPAN (or ZERO) function. Use DOWN/UP  
to set the OFF/ON field to ON. You can now turn these fields ON because  
there is a nonzero span interval defined.  
4.4 The PWD (Password) Function  
Security can be established by choosing a 5 digit password from the  
standard ASCII character set. If you decide NOT to employ password  
security, use the default password TETAI. This password will be displayed  
automatically by the microprocessor. The operator just ENTERs it to be  
allowed total access to the instrument’s features.  
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4 Operation  
Model 3020T  
Once a unique password is assigned and activated, the operator MUST  
enter the UNIQUE password to gain access to any of the set-up functions  
(except to enter the password). However, the instrument will continue to  
analyze sample gas and report on alarm conditions without entering the  
password.  
Only one password can be defined.  
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.  
To defeat the security after a unique password is activated, the  
password must be changed back to TETAI.  
NOTE: If you use password security, it is advisable to keep a copy of  
the password in a separate, safe location.  
4.4.1 Entering the Password  
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, issuing the ENTER command will enter the default TETAI pass-  
word for you.  
Scroll to PWD, and ENTER to select the password function. Either the  
TETAI default password or AAAAA place-holder password for an existing  
password will appear on screen depending on whether or not a password has  
beenpreviouslyinstalled.  
T E T 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, ENTER to accept TETAI as the default password.  
If a password has been previously installed, enter the password using EN-  
TER to scroll through the letters, and the DOWN/UP keys to change the  
letters to the proper password. The last ENTER enters the password.  
If the password is accepted, the screen will indicate that the password  
restrictions have been removed and you have clearance to proceed.  
PWD Restrictions  
Removed  
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Operation 4  
In a few seconds, if you do not ESCAPE, you will be given the oppor-  
tunity to change this password or keep it and go on.  
Change Password?  
<ENT>=Yes <ESC>=No  
ESCAPE to move on, or proceed as in Changing the Password, below.  
4.4.2 Installing or Changing the Password  
If you want to install a password, or change an existing password:  
Proceed as above in Entering the Password, until you are given the opportu-  
nity to change the password:  
Change Password?  
<ENT>=Yes <ESC>=No  
ENTER to change the password (to change either the default TETAI or  
the previously assigned password), or ESCAPE to keep the existing pass-  
word and move on.  
If you choose ENTER to change the password, the password assign-  
ment screen appears.  
T E T A I  
<ENT> To Proceed  
or  
A A A A A  
<ENT> To Proceed  
Enter the password using ENTER to scroll through the existing pass-  
word letters, and DOWN/UP to change the letters to the new password. The  
full set of 94 characters available for password use are shown in the table  
below.  
Characters Available for Password Definition:  
A
K
U
_
i
s
}
)
3
=
B
L
V
`
j
t
*
4
>
C
M
W
a
k
u
!
+
5
?
D
N
X
b
l
v
"
'
6
@
E
O
Y
c
m
w
#
-
7
F
P
Z
d
n
x
$
.
8
G
Q
[
e
o
y
%
/
9
H
R
¥
f
p
z
&
0
:
I
S
]
g
q
{
'
1
;
J
T
^
h
r
|
(
2
<
When you have finished typing the new password, the last ENTER  
enters it. A verification screen appears. The screen will prompt you to retype  
your password for verification.  
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4 Operation  
Model 3020T  
A A A A A  
Retype PWD To Verify  
Wait a moment for the entry (<ENT>) screen. You will be given  
clearance to proceed.  
A A A A A  
<ENT> TO Proceed  
ENTER the letters of your new password. Your password will be stored  
in the microprocessor and the system will immediately switch to the ANA-  
LYZE screen, and you now have access to all instrument functions.  
If all alarms are defeated, the ANALYZE screen appears as:  
0.0  
ppm Anlz  
Range: 0 — 100  
If an alarm is tripped, the second line will change to show which alarm  
itis:  
0.0  
ppm Anlz  
AL—1  
NOTE:If you log off the system using the LOGOUT function in the  
MAIN MENU, you will now be required to re-enter the pass-  
word to gain access to SPAN, ZERO, ALARM, and RANGE  
functions.  
4.5 The LOGOUT Function  
By entering LOGOUT, you effectively log off the instrument, leaving  
the system protected against tampering until the password is reentered. To  
log out, scroll to place the LOGOUT function between the arrows, and  
ENTER to log out. The screen will display the message:  
Protected Until  
Password Reentered  
4.6 The VERSION Screen  
Scroll through the MAIN MENU to VERSION, and ENTER. The  
screen displays the manufacturer, model, and software version information.  
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Trace Oxygen Analyzer  
Operation 4  
4.7 The SELF-TEST Function  
The Model 3020T has a built-in self-testing diagnostic routine. Prepro-  
grammed 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 SELF-TEST during operation:  
Use the DOWN/UP control to scroll through the MAIN MENU to SELF-  
TEST. 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 for number-code information. The results screen alternates for a  
timewith:  
Press Any Key  
To Continue...  
Then the analyzer returns to the ANALYZE screen.  
4.8 The ZERO and SPAN Functions  
Zeroing is not required in order to achieve the published  
accuracy specification of this unit.  
Zeroingwilleliminateoffseterrorcontributedbysensor, elec-  
tronics, and internal and external sampling system and im-  
prove performance beyond published specification limits.  
The analyzer is calibrated using zero and span gases.  
Any suitable oxygen-free gas can be used for zero gas as long as it is  
known to be oxygen free and does not react adversely with the sample system.  
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4 Operation  
Model 3020T  
Although the instrument can be spanned using air, a span gas with a  
known oxygen concentration in the range of 70–90% of full scale of the  
range of interest is recommended. Since the oxygen concentration in air is  
209,000 ppm, the cell can take a long time to recover if the instrument is  
used for trace oxygen analysis immediately following calibration in air.  
Connect the calibration gases to the analyzer according to the instruc-  
tions given in section 3.5, 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 analyzer’s 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 4.4 to enter your password. Once you have gained clearance to  
proceed, you can ENTER the ZERO or SPAN function.  
4.8.1 Zero Cal  
The ZERO function on the MAIN MENU is used to enter the zero  
calibration function. Zero calibration can be performed in either the auto-  
matic or manual mode. In the automatic mode, an internal algorithm com-  
pares consecutive readings from the sensor to determine when the output is  
within the acceptable range for zero. In the manual mode, the operator  
determines when the reading is within the acceptable range for zero.  
Make sure the zero gas is connected to the instrument.  
If you get a CELL FAILURE message skip to section 4.8.1.3.  
4.8.1.1  
AutoModeZeroing  
Select ZERO to enter the ZERO function. The ZERO screen allows  
you to select whether the zero calibration is to be performed automatically or  
manually. Use the DOWN/UP control to toggle between AUTO and MAN  
zero settling. Stop when AUTO appears on the display.  
Zero: Settling: AUTO  
<ENT> To Begin  
ENTER to begin zeroing.  
####  
Slope=####  
PPM Zero  
ppm/s  
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Operation 4  
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: 1 Left, 0 Left, and so fourth.  
These are two steps in the zeroing process that the system must complete,  
AFTER settling, before it can go back to ANALYZE.  
####  
1 Left=###  
PPM Zero  
ppm/s  
The zeroing process will automatically conclude when the output is  
within the acceptable range for a good zero. Then the analyzer automatically  
returnstotheANALYZEscreen.  
4.8.1.2  
ManualModeZeroing  
ENTER the ZERO function. The screen that appears allows you to  
select between automatic or manual zero calibration. Use DOWN/UP to  
toggle between AUTO and MAN zero settling. Stop when MAN appears on  
thedisplay.  
Zero: Settling: Man  
<ENT> To Begin  
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 predeter-  
mined 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).  
####  
Slope=####  
ppm Zero  
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 using 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, ENTER it. In a  
few seconds, the screen will update.  
Once zero settling completes, the information is stored in the  
microprocessor,andtheinstrumentautomaticallyreturnstotheANALYZE  
screen.  
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4 Operation  
Model 3020T  
4.8.1.3  
CellFailure  
Cell failure in the 3020T is usually associated with inability to zero the  
instrument down to a satisfactorily low ppm reading. When this occurs, the  
3020T system alarm trips, and the VFD displays a failure message.  
#.#  
ppm Anlz  
CELL FAIL/ ZERO HIGH  
Before replacing the cell:  
a. Check for leaks downstream from the cell, where oxygen may be  
leaking into the system.  
b. Check your span gas to make sure it is within specifications.  
c. If there are no leaks and the span gas is OK, replace the cell as  
described in chapter 5, Maintenance.  
d. After correcting the condition, reset the Cell Fail Alarm by taking  
the analyzer into, and then back out of, STANDBY.  
4.8.2 Span Cal  
SPAN is used to span calibrate the analyzer. 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 calibration can also be performed in  
manual mode, where the operator determines when the span concentration  
reading is acceptable and manually exits the function.  
4.8.2.1  
AutoModeSpanning  
Scroll to SPAN, and 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 DOWN/UP control to toggle between  
AUTO and MAN span settling. Stop when AUTO appears on the display.  
Span: Settling: AUTO  
<ENT> For Next  
Use ENTER to move to the next screen.  
Span Val: 209000.00  
<ENT>Span <UP>Mod #  
Use DOWN/UP to start changing the oxygen-concentration. Use  
ESCAPE/ENTER to blink the digit you are going to modify. Use DOWN/UP  
again to change the value of the selected digit. When you have finished  
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Operation 4  
typing in the concentration of the span gas you are using, repeatedly select  
ENTERuntiltherightmostdigitisreached,then,thenextENTERwillexitthe  
Span Val field. One more ENTER will enter the new span value, bring up the  
next screen, and start the span calibration.  
####  
Slope=####  
ppm  
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 span output corre-  
sponds, within tolerance, to the value of the span gas concentration. Then the  
instrumentautomaticallyreturnstotheANALYZEmode.  
4.8.2.2  
ManualModeSpanning  
ENTER SPAN from the MAIN MENU 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 DOWN/UP to toggle between AUTO and MAN span settling. Stop  
when MAN appears on the display. Use ENTER to move to the next screen.  
Span Val: 209000.00  
<ENT>Span <UP>Mod #  
Use UP to permit modification (Mod #) of span value.  
Use ESCAPE/ENTER to choose the digit, and use DOWN/UP to  
choose the value of the digit.  
When you have finished typing in the concentration of the span gas you  
areusing,repeatedlyselectENTERuntiltherightmostdigitisreached,then,the  
nextENTERwillexittheSpanValfield.OnemoreENTERwillenterthenew  
span value, bring up the next screen, and start 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.  
####  
Slope=####  
% Span  
ppm/s  
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4 Operation  
Model 3020T  
When the Span value displayed on the screen is sufficiently stable,  
ENTER it. (Generally, when the Span reading changes by 1 % or less of the  
full scale of the range being calibrated for a period of ten minutes it is suffi-  
ciently stable.) Once you ENTER it, the Span reading changes to the correct  
value. The instrument thenautomaticallyenterstheANALYZEfunction.  
4.9 The ALARMS Function  
The Model 3020T is equipped with 2 fully adjustable concentration  
alarms and a system failure alarm. Each alarm has a relay with a set of form  
“C" contacts rated for 3 amperes resistive load at 250 V ac. See Figure 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  
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Trace Oxygen Analyzer  
Operation 4  
to non-alarm conditions. This mode requires an alarm to be  
recognized before it can be reset. In the non-latching mode, the  
alarm status will terminate when process conditions revert to non-  
alarmconditions.  
4. Are either of the alarms to be defeated?  
The defeat alarm mode is incorporated into the alarm circuit so  
that maintenance can be performed under conditions which  
would normally activate the alarms.  
The defeat function can also be used to reset a latched alarm.  
(See procedures, below.)  
If you are using password protection, you will need to enter your  
password to access the alarm functions. Follow the instructions in section 4.4  
to enter your password. Once you have clearance to proceed, ENTER the  
ALARM function.  
AL—1  
AL—2  
Choose Alarm  
Use the DOWN/UP control to blink your choice of alarm, AL-1 or  
AL-2. Then ENTER to move to the next screen.  
AL—1 1000 ppm HI  
Dft—N Fs—N Ltch—N  
Five parameters can be changed on this screen.  
Value of the alarm setpoint: AL–1 #### ppm (oxygen)  
Out-of-range direction: HI or LO  
Defeated? (Yes/No): Dft–Y/N  
Failsafe? (Yes/No): Fs–Y/N  
Latching? (Yes/No): Ltch–Y/N.  
To define the setpoint, use ENTER to blink AL–1 ####. Then  
use the DOWN/UP control to change the number. Holding the  
control on the DOWN or UP position, while the number changes,  
speeds up the incrementing or decrementing. (Remember, the  
setpoint units are always ppm O2.)  
To set the other parameters use ENTER to blink the desired  
parameter. Then use DOWN/UP to change the parameter.  
Once the parameters for the alarm have been set, ENTER the  
ALARM function again, and repeat this procedure for next alarm.  
To reset a latched alarm, go to Dft– and then assert either DOWN  
two times or UP two times. (Toggle it to Y and then back to N.)  
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4 Operation  
Model 3020T  
–OR –  
Go to Ltch– and then assert either DOWN two times or UP two  
times. (Toggle it to N and back to Y.)  
4.10 The RANGE Function  
The RANGE function allows the operator to program up to three  
concentration ranges to correlate with the DC analog outputs. If no ranges  
are defined by the user, the instrument defaults to:  
Low = 0–100 ppm  
Med = 0–1,000 ppm  
High = 0–10,000 ppm.  
The Model 3020T 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 to below 85% of full scale of the next lower  
range, the instrument will switch to that range. A corresponding shift in the  
DC percent-of-range output, and in the range ID outputs, will be noticed.  
The autoranging feature can be overridden so that analog output stays  
on a fixed range regardless of the oxygen concentration detected. If the  
concentration exceeds the upper limit of the range, the DC output will  
saturate at 1 V dc (20 mA at the current output).  
However, the digital readout and the RS-232 output of the concentra-  
tion are unaffected by the fixed range. They continue to read accurately with  
full precision. See Front Panel description in Chapter 1.  
The automatic air calibration range is always 0-25 % and is not pro-  
grammable.  
4.10.1 Setting the Analog Output Ranges  
To set the ranges, ENTER the RANGE function mode by selecting  
RANGE from the MAIN MENU. The RANGE screen appears.  
L—100  
M—1000  
H—10000 Mode—AUTO  
Use the DOWN/UP control to the range to be set: low (L), medium (M),  
or high (H).  
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Operation 4  
Use the DOWN/UP control to enter the upper value of the range (all  
ranges begin at 0 ppm). Repeat for each range you want to set. ENTER to  
accept the values and return to the Analysis Mode. (See note below.)  
Note: The ranges must be increasing from low to high, for example,  
if range 1 is set as 0–100 ppm and range 2 is set as 0–1,000  
ppm, range 3 cannot be set as 0–500 ppm since it is lower than  
range 2.  
Ranges, alarms, and spans are always set in ppm units (over the entire  
0-250,000 ppm range), even though all concentration-data outputs change  
from ppm units to percent when the concentration is above 10,000 ppm.  
After defining your analysis ranges, set Mode– to either AUTO or one  
of the fixed ranges, as described below.  
4.10.2 Fixed Range Analysis  
The autoranging mode of the instrument can be overridden, forcing the  
analyzer DC outputs to stay in a single predetermined range.  
To switch from autoranging to fixed range analysis, ENTER the  
RANGE function by selecting RANGE from the MAIN MENU.  
Use the DOWN/UP control to move AUTO between the arrows.  
Use the DOWN/UP control 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).  
L—100  
M—1000  
H—10000 Mode—FX/LO  
or  
L—100  
M—1000  
H—10000 Mode—FX/MED  
or  
L—100  
M—1000  
H—10000 Mode—FX/HI  
ESCAPE to re-enter the ANALYZE screen using the fixed range.  
NOTE:When performing analysis on a fixed range, if the oxygen  
concentration rises above the upper limit, as established by  
the setup, for that particular range, the output saturates at 1  
V dc (or 20 mA). However, the digital readout and the RS-232  
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4 Operation  
Model 3020T  
output continue to read the true value of the oxygen concen-  
tration regardless of the analog output range.  
4.11 The CONTRAST Function  
Contrast Function is DISABLED  
(Refer to Section 1.6)  
If you cannot read anything on the display after first powering up:  
1. Observe LED readout.  
a. If LED meter reads all eights and dots, go to step 3.  
b. If LED meter displays anything else, go to step 2.  
2. Disconnect power to the Analyzer and reconnect again. LED  
meter should now read all eights and dots.  
4.12 The STANDBY Function  
In STANDBY, the analyzer’s internal circuits are powered, but there  
are no displays or outputs from the analyzer.  
WARNING: THE POWER CABLE MUST BE UNPLUGGED TO  
FULLY DISCONNECT POWER FROM THE INSTRU-  
MENT. WHEN THE ACCESS DOOR IS OPEN AND  
THE POWER CABLE IS CONNECTED, EXTRA  
CARE IS REQUIRED TO AVOID CONTACT WITH  
LIVE ELECTRICAL CIRCUITS.  
CAUTION: If you disconnect the primary power source from  
the analyzer, then on re-energizing, you will be  
required to choose to keep the configuration you  
previously programmed into your instrument in the  
Setup Mode, or it will reset to factory defaults.  
Use this function whenever you want to power down without loosing  
all of the configuration you programmed into your instrument in the Setup  
Mode.  
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Trace Oxygen Analyzer  
Operation 4  
4.13 The Analysis Mode  
This is the normal operating mode of the analyzer. In this mode the  
analyzer is monitoring the sample, measuring and displaying the amount of  
oxygen, and reporting alarm conditions.  
Normally, all of the functions automatically switch back to the Analysis  
Mode ANALYZE screen when they have completed their assigned opera-  
tions. After four or five minutes in the MAIN MENU without any action by  
the operator, the analyzer automatically switches itself back to the ANA-  
LYZE screen. ESCAPE, asserted one or more times, depending on the  
starting point, also switches the analyzer back to the ANALYZE screen.  
IMPORTANT:In the event of loss of flow through the analyzer, if the  
vent is vented to a location of high oxygen content,  
oxygen will back diffuse through the vent line and in  
most cases quickly saturate the cell with oxygen which  
can then require a quite long purge down time for the  
sensor when then exposed to low oxygen concentra-  
tions. In the event that flow is to be interrupted into the  
analyzer, it is suggested that the user do one of the  
following:  
1.  
2.  
Bag the sensor in nitrogen during this time  
Install a shut off valve on the vent port of the ana-  
lyzer or somewhere within the users sample system.  
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4 Operation  
Model 3020T  
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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 The Zero and Span  
Functions.  
WARNING: SEE WARNINGS ON TITLE PAGE OF THIS MANUAL.  
5.2 Major Internal Components  
All internal components are accessed by unbolting and swinging open  
the front cover, as described earlier. The major internal component locations  
are shown in Figure 3-1, the cell block is illustrated in Figure 3-2, and the  
fuse receptacle is shown in Figure 3-3  
The 3020T contains the following major internal components:  
Micro-Fuel Cell (L-2C)  
Stainlesssteelcellblock  
Customer Interface PCB (Power Supply on bottom surface)  
Preamp PCB (Contains Microprocessor)  
Front Panel PCB (Contains Displays)  
5 digit LED meter  
2 line, 20 character, alphanumeric, VFD display  
Solenoid Operated Gas Control Valves (–C option only).  
See the drawings in the Drawings section in back of this manual  
fordetails.  
5-1  
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5 Maintenance  
Model 3020T  
Figure 5-1: Major Internal Components  
To swing open the cover panel, remove all screws.  
5.3 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 in accor-  
dance with to all applicable safety and environmental regulations. This  
section describes fuel cell care as well as when and how to replace it.  
The Class L-2C Micro-Fuel Cell is used in the standard Model 3020T.  
If any other cell is supplied with your instrument, check the front of this  
manual for any addenda applying to your special model.  
5-2  
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Maintenance 5  
5.3.1 Storing and Handling Replacement Cells  
To have a replacement cell available when it is needed, it is recom-  
mended that one spare cell be purchased 9-10 months after commissioning  
the 3020T, or shortly before the end of the cell's one year warranty period.  
CAUTION: Do not stockpile cells. The warranty period starts on  
the day of shipment.  
The spare cell should be carefully stored in an area that is not subject to  
large variations in ambient temperature (75 °F nominal) or to rough handling.  
WARNING: THE SENSOR USED IN THE MODEL 3020T TRACE  
OXYGEN ANALYZER USES ELECTROLYTES  
WHICH CONTAIN TOXIC SUBSTANCES, MAINLY  
LEAD AND POTASSIUM HYDROXIDE, THAT CAN  
BE HARMFUL IF TOUCHED, SWALLOWED, OR  
INHALED. AVOID CONTACT WITH ANY FLUID OR  
POWDER IN OR AROUND THE UNIT. WHAT MAY  
APPEAR TO BE PLAIN WATER COULD CONTAIN  
ONE OF THESE TOXIC SUBSTANCES. IN CASE OF  
EYE CONTACT, IMMEDIATELY FLUSH EYES WITH  
WATER FOR AT LEAST 15 MINUTES. CALL PHYSI-  
CIAN. (SEE APPENDIX, MATERIAL SAFETY DATA  
SHEET.)  
CAUTION: Do not disturb the integrity of the cell package until  
the cell is to actually be used. If the cell package is  
punctured and air is permitted to enter, the cell will  
require an excessively long time to reach zero after  
installation(1-2weeks!).  
5.3.2 When to Replace a Cell  
The characteristics of the Micro-Fuel Cell show an almost constant  
output throughout its useful life and then fall off sharply towards zero at the  
end. Cell failure in the 3020T is usually characterized inability to zero the  
instrument down to a satisfactorily low ppm reading. When this occurs, the  
3020T system alarm trips, and the screen displays a failure message.  
#.# ppm Anlz  
CELL FAIL/ ZERO HIGH  
5-3  
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5 Maintenance  
Model 3020T  
Before replacing the cell:  
a. Check your span gas to make sure it is within specifications.  
b. Check for leaks downstream from the cell, where oxygen may be  
leaking into the system.  
If there are no leaks and the span gas is OK, replace the cell.  
5.3.3 Removing the Micro-Fuel Cell  
The Micro-Fuel Cell is located inside the stainless steel cell block  
behind the front panel (see Figure 5-1). To remove an existing cell:  
1. Remove power to the instrument by unplugging the power cord  
at the power source.  
2. Open the front panel door by unbolting it and swinging it open  
on its hinges.  
3. Leave the cell block installed. Place one hand underneath the cell  
block, ready to catch the cell holder and Micro-Fuel Cell.  
4. Lift up on the stainless steel gate in front of the cell block. This  
releases the cell and cell holder from the block. The cell and  
holder will fall out in your hand.  
5-4  
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Maintenance 5  
Lift Up  
Gate  
Figure 5-2: Exploded View of Cell Block and Micro-Fuel Cell  
5-5  
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5 Maintenance  
Model 3020T  
5.3.4 Installing a New Micro-Fuel Cell  
It is important to minimize the amount of time that a Teledyne Trace  
Oxygen Sensor is exposed to air during the installation process. The quicker the  
sensor can be installed into the unit, the faster your TAI O2 sensor will recover  
to low O2 measurement. levels.  
CAUTION: Do not touch the sensing surface of the cell. It is cov-  
ered with a delicate Teflon membrane that can leak  
when punctured. The sensor must be replaced if the  
membrane is damaged.  
Before installing a new cell, check the O-ring in the base of the cell holder.  
Replace if worn or damaged.  
Place the cell on the holder with the screen side facing down.  
Note: There is a small location hole drilled in the holder. This hole  
mates with a guide pin on the bottom rear of the cell block. The  
hole in the cell block holder must align with the guide pin on the  
cell block.  
Step 1. Remove power from instrument.  
Step 2. Remove the old sensor (if installed) from the analyzer.  
Step 3. Purge the analyzer at approximately 1 SCFH flow rate with  
N2 (or applicable sample gas with the sensor holder re-  
moved).  
Step 4. Remove sensor from double bag storage.  
Step 5. Remove sensor shorting button.  
Step 6. Place sensor on sensor holder so that the gold contact plate of  
the sensor is facing up towards the sky.  
Step 7. Install sensor and sensor holder into cell block.  
Step 8. With O-ring in place, align the guide pin with the hole on the  
cell holder. Then, with the holder, lift cell into the cell block.  
Step 9. Push the gate on the cell block down so that the slots on the  
side of the gate engage the locating screws on the side of the  
block. This forces the holder into position and forms a gas-  
tightseal.  
Step 10. Purge system with sample or zero gas.  
Step 11. Power-up.  
If steps 4 through 10 are accomplished quickly (elapsed time less  
than 15 seconds), recovery to less than 1ppm level should occur in  
less than 8 hours.  
5-6  
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Maintenance 5  
5.3.5 Cell Warranty  
The Class L-2C Micro-Fuel cell is used in the Model 3020T. This cell  
is a long life cell and is warranted for 1 year from the date of shipment. If  
any other cell is supplied with your instrument, check the front of this  
manual for any special information applying to your cell.  
With regard to spare cells, warranty period begins on the date of ship-  
ment. The customer should purchase only one spare cell (per section 5.3.1).  
Do not attempt to stockpile spare cells.  
The L-2C cell is not designed for applications where CO2 is a  
major component in the sample, however concentrations of 1,000 ppm or  
less will not adversely effect the cell performance. Consult Analytic Instru-  
ments for available options for either intermittent or continuous CO2 expo-  
sure.  
If a cell was working satisfactorily, but ceases to function before the  
warranty period expires, the customer will receive credit toward the purchase  
of a new cell.  
If you have a warranty claim, you must return the cell in question to the  
factory for evaluation. If it is determined that failure is due to faulty work-  
manship or material, the cell will be replaced at no cost to you.  
Note: Evidence of damage due to tampering or mishandling will  
render the cell warranty null and void.  
5.4 Fuse Replacement  
The 3020T requires two 5 x 20 mm, 4 A, T type (Slow Blow) fuses.  
The fuses are located inside the explosion proof housing on the Electrical  
Connector Panel, as shown in Figure 5-2. To replace a fuse:  
1. Disconnect the Unit from its power source.  
2. Place a small screwdriver in the notch in the fuse holder cap,  
push in, and rotate 1/4 turn. The cap will pop out a few  
millimeters. Pull out the fuse holder cap and fuse, as shown in  
Figure 5-3.  
5-7  
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5 Maintenance  
Model 3020T  
Figure 5-3: Removing Fuse Cap and Fuse from Holder  
2. Replace fuse by reversing process in step 1.  
5.5 System Self Diagnostic Test  
Use the DOWN/UP control to scroll through the MAIN MENU to  
SELF-TEST. The screen will follow the running of the diagnostic.  
RUNNING DIAGNOSTIC  
TestingPreamp83  
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 Table 5-1  
for number-code information. The results screen alternates for a time with:  
PressAnyKey  
ToContinue...  
The following failure codes apply:  
5-8  
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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 (0–1 V Concentration)  
DAC B (0–1 V Range ID)  
Both Failed  
Preamp  
0
1
2
3
OK  
Zero too high  
Amplifier output doesn't match test input  
Both Failed  
5-9  
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5 Maintenance  
Model 3020T  
5-10  
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Appendix  
Appendix  
A-1 Specifications  
Packaging: Explosion-proof. Bulkheadmount.  
Sensor: L-2C trace analysis Micro-Fuel Cell.  
Cell Block: 316stainlesssteel.  
Ranges: Three user definable ranges from 0–10 ppm to  
0–250,000 ppm, plus air calibration range of 0-  
250,000 ppm (25 %).  
Autoranging with range ID output.  
SampleSystem: Flow indicator visible from front of unit.  
Positivepressureservice.  
Vacuumservice(optional).  
Auto Cal / Auto Zero. (Available with op-  
tional,electricallyoperatedvalves.)  
Alarms: One system-failure alarm contact to detect  
powerfailure.  
Twoadjustableconcentrationthresholdalarms  
withfullyprogrammablesetpoints.  
Diagnostics: Start-up or on-demand, comprehensive, self  
testing function initiated by keyboard or  
remotecommand.  
Displays: 2 line by 20 alphanumeric, VFD screen, and  
one 5 digit LED display.  
DigitalInterface: Full duplex RS-232 communications port.  
Power: Universal power supply 115 or 230 V ac, at  
50 or 60 Hz.  
A-1  
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Appendix  
Model 3020T  
OperatingTemperature: 0-50 °C  
Accuracy:  
temperature.  
±2% of full scale at constant  
±5% of full scale over operating temperature  
range, on factory default analysis ranges, once  
thermal equilibrium has been achieved.  
Analog outputs: 0-1 V dcpercent-of-range  
0-1 V dc range ID.  
4-20 mA dcpercent-of-range  
4-20 mA dc range ID.  
Password Access: Can be user-configured for password  
protection.  
A-2  
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Appendix  
A-2 Recommended 2-Year Spare Parts List  
Qty  
PartNumber  
Description  
1
1
1
1
3
C62371B  
D65295A  
C62368-A  
C62365-A  
F1295  
Display PCB  
CustomerInterfacePCB  
TracePreamplifierBoard  
Main PCB  
Fuse, 4A, 250V, 5x20 mm, T (Slow  
Blow)  
1
1
O165  
O-ring  
C6689-L2C  
Micro-FuelCell  
A minimum charge is applicable to spare parts orders.  
Note: Orders for replacement parts should include the part number  
(if available) and the model and serial number of the instru-  
ment for which the parts are intended.  
Orders should be sent to:  
TeledyneAnalyticalInstruments  
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.  
A-3  
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Appendix  
Model 3020T  
A-3 Drawing List  
D65908 Final Assembly Drawing  
D65909 Outline Drawing  
D65911 WiringDiagram  
A-4  
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A-4  
Appendix  
3000 SERIES ANALYZERS  
APPLICATIONNOTESONRESTRICTORS,  
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.Cellpressuresbelow2/3atmosphericarenotrecom-  
mendedbecauseastheytendtocauseexcessiveinternalexpansionwhichmay  
resultinsealfailure.  
Foroperationatcellpressuresotherthanatmosphericcaremustbe  
takennottochangethesamplepressurerapidlyorcelldamagemayoccur.For  
cellpressuresaboveatmospheric,cautionmustbeexercisedtoavoidover  
pressuringthecellholder.(percentanalyzerswillrequiresometypeofcell  
retainertopreventthecellfrombeingpushedoutbythepressure.) Foropera-  
tionatpressuresbelowatmosphericpressureasuffixC(clamped)cellis  
required.  
RESTRICTIONDEVICES:  
Forproperoperation,all3000seriesanalyzersrequireaflowrestriction  
device.Thisdeviceistypicallyarestrictororavalve.Thisrestrictiondevice  
servestwofunctionsinthesamplepath.Thefirstfunctionistolimittheflowrate  
ofthesamplethroughtheanalyzer.Arestrictorischosentooperateoverarange  
ofpressuresandprovideauseableflowrateoverthatrange.  
A-5  
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Appendix  
Model 3020T  
Thesecond functionthattherestrictiondeviceprovidesisapressure  
drop.Thisdeviceisselectedtoprovidetheonlysignificant pressuredropinthe  
samplepath.  
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 appli-  
cation ( 5 psig or less ) the un-marked restrictor is better suited . For none  
pressurizedsampleapplicationsthemarkedrestrictorshouldbeusedand  
configuredforvacuumservice.Note:forextremelylowpositivepressureappli-  
cations(lessthen2psig)thevacuumserviceconfigurationshouldprovidehigher  
performance(higherflowrates). Forvacuumservicetheendusermustsupply  
avacuumpumpandaby-passvalveforthepump. Avacuumlevelof 5-10  
inchesofmercuryshould providetheoptimumflowrate.CAUTION:flow  
restrictors have very small orifices and may be plugged by small par-  
ticles ( .005” dia or larger) A sample filter must be included in the sample  
linepriortotherestrictor!(a60micronfilterisrecommended)  
3020TEXAMPLES:  
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, A3020Tisconfiguredforvacuumserviceasfollows.The  
un-markedrestrictorisplacedinthesampleventport.Thedownstreamendof  
therestrictoristhenconnectedtoavacuumpumpandby-passvalve.Theby-  
passvalveisadjustedtoprovideaflowrateof1SLPM.Thesamplepressure  
betweenthepumpandtherestrictorwillbeapproximately -7inchesofmercury,  
whilethepressureinthebalanceofthesamplesystemincludingthecellwillbe  
approximatelyatatmosphericpressure.(providedthesampleflowintothe  
analyzerisnotblocked.)  
A-6  
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Appendix  
BY-PASS:  
Toimprovethesystemresponse,aby-passcanbeaddedtoincreasethesampleflow  
ratetotheanalyzerbyafactoroften.Aby-passprovidesasampleflowpatharoundthe  
analyzerof 2-18SCFH.typically.  
CALIBRATION GAS:  
3000seriesanalyzerrequirementsforunitswithAuto-Caloptions.Thecustomermust  
supplyacontrolvalves(orrestrictors) foranySPANor ZEROgassourcewhichisattached  
totheAuto-Calports. Thevalveshouldbeadjustedtothesameflowrateasthesamplegas.  
Whenrestrictorsareused,thegaspressuremustbeadjustedtoachievetheproperflowrate.  
OPERATIONWITHOUT ARESTRICTORDEVICE:  
Operationwithoutarestrictordeviceisnotrecommendasmentionedabove. A  
3020T withoutanyflowrestrictordevicewastestedon11-19-97.Thisresultsina flowrate  
of 2.4 SLPM @ 1 PSIG. This is a cv of 0.023 for the standard sample sys.  
REFERENCE: FLOW_1.XLS & FLOW_2.XLS forinformationonflowratesat  
variouspressures.  
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  
=
2.04 INCHES OF MERCURY (in. Hg.)  
1 SCFH =  
0.476 SLPM  
A-7  
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