Trace Oxygen Analyzer OPERATING INSTRUCTIONS FOR Model 3190Z Trace Oxygen Analyzer P/N M3190Z 6/09/09 DANGER Toxic gases and or flammable liquids may be present in this monitoring system. Personal protective equipment may be required when servicing this instrument. Hazardous voltages exist on certain components internally which may persist for a time even after the power is turned off and disconnected. Only authorized personnel should conduct maintenance and/or servicing.
Model 3190Z Copyright © 2009 Teledyne Instruments/ Analytical Instruments All Rights Reserved.
Trace Oxygen Analyzer Safety Messages Your safety and the safety of others is very important. We have provided many important safety messages in this manual. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is associated with a safety alert symbol. These symbols are found in the manual and inside the instrument.
Model 3190Z CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL. IF YOU USE THE ANALYZER IN A MANNER OTHER THAN THAT FOR WHICH IT WAS INTENDED, UNPREDICTABLE BEHAVIOR COULD RESULT POSSIBLY ACCOMPANIED WITH HAZARDOUS CONSEQUENCES. This manual provides information designed to guide you through the installation, calibration operation and maintenance of your new analyzer. Please read this manual and keep it available.
Trace Oxygen Analyzer Table of Contents Safety Messages .......................................................................... iii Introduction ................................................................................... 1 1.1 Overview 1 1.2 Main Features of the Analyzer 1 1.3 Front Panel Description 2 1.4 Rear Panel Description 3 Operational Theory ....................................................................... 7 2.1 Introduction 7 2.2 Zirconium Oxide Sensors 7 2.2.
Model 3190Z 4.3.2 LO Range 4.4 Setting the Alarm Setpoints 4.4.1 HI Alarm 4.4.2 LO Alarm 4.4.3 Sensor Fail Alarm 4.5 Selecting a Fixed Range or Autoranging 4.6 Calibration 4.7 LED Display on StartUp 19 19 19 19 20 20 20 21 Maintenance ................................................................................ 23 5.1 Replacing the Fuse 23 5.1.1 AC Powered Units 23 5.1.2 DC Powered Units 24 5.2 Sensor Installation or Replacement 24 5.2.1 When to Replace a Sensor 24 A.1 Specifications 25 A.
Trace Oxygen Analyzer DANGER COMBUSTIBLE GAS USAGE WARNING This is a general purpose instrument designed for use in a non-hazardous area. It is the customer's responsibility to ensure safety especially when combustible gases are being analyzed since the potential of gas leaks always exist. The customer should ensure that the principles of operating this equipment are well understood by the user.
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Trace Oxygen Analyzer Introduction Introduction 1.1 Overview The Teledyne Electronic Technologies Analytical Instruments (TETAI) Model 3190Z is a microprocessor-based trace oxygen analyzer for real-time measurement of trace amounts of oxygen in inert gases, or in a wide variety of gas mixtures. It features simple operation, fast response, and a compact, rugged construction. 1.
Introduction Model 3190Z • Compact and rugged control unit with flush-panel case. Designed for indoor use. Front panel NEMA-4 rated. • External probe 1.3 Front Panel Description All controls and displays except the power switch are accessible from the front panel. See Figure 1-1. The front panel has seven pushbutton membrane switches, a digital meter, and an alarm indicator LED for operating the analyzer. These features are described briefly here and in greater detail in Chapter 4 - Operation.
Trace Oxygen Analyzer Introduction Data Entry Keys: Two pushbutton membrane switches are used to manually change measurement parameters of the instrument as they are displayed on the LED meter readout: Up Arrow • Down Arrow Increment values of parameters downwards as they are displayed on the LED readout. Increment values of parameters upwards as they are displayed on the LED readout.
Introduction Model 3190Z Figure 1-2 Rear Panel (AC and DC versions) Power Connection AC version: 100–240 VAC, 50/60 Hz. The connector housing includes the fuse holder and the power switch. DC version: Requires 10 - 36 VDC. Fuse Holder: Replacing the fuse is described in Chapter 5 - Maintenance.
Trace Oxygen Analyzer Introduction I/O Power Switch: Turns the instrument power ON (I) or OFF (O). • Analog Outputs 0–10 VDC concentration output. 0–10 VDC Range ID (or optional over-range) output. 4–20 mADC concentration output, negative ground. • Alarm Connections HI Alarm, LO Alarm, and Sensor Failure Alarm connections. • RS-232 Port • External Probe Connects to the remote probe or remote analysis unit. Serial digital output of concentration and range signals.
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Trace Oxygen Analyzer Operational Theory Operational Theory 2.1 Introduction The analyzer is composed of three subsystems: 1. Analysis unit with zirconium oxide sensor(s) 2. Control unit with signal processing, display and controls 3. Interface unit, supplying signals between 1 and 2. The analysis unit is designed to accept the sample gas and direct it to the sensitive surface of the zirconium oxide sensor.
Operational Theory Model 3190Z The sensor is designed for long term stability with an operating life of 5 years. This unit features one or two sensors, and can be custom-designed for a specific range of oxygen analysis. 2.2.2 The Effect of Pressure In order to state the amount of oxygen present in the sample as a specific portion of the gas mixture, it is necessary that the sample diffuse into the sensors under constant pressure.
Trace Oxygen Analyzer Operational Theory 2.3.2 Signal Processing Figure 2-4 is a block diagram of the signal processing electronics described below. Figure 2-4: Block Diagram of the Signal Processing Electronics In the presence of oxygen, the sensor(s) produce a current. A current to voltage amplifier (I–E AMPL) converts this current to a voltage.
Operational Theory Model 3190Z RS-232 (optional) output. The same digital information is also sent to a 8-bit digital to analog converter (DAC) that produces the 0-10 VDC analog concentration signal and the 0-10 VDC analog range ID output. A current to voltage converter (E–I CONV) produces the 4-20 mADC analog concentration signal.
Trace Oxygen Analyzer Installation Installation Installation of the analyzer includes: 1. Unpacking the system. 2. Mounting the control unit and external sample block. 3. Making the electrical connections. 4. Making the gas connections. 5. Testing the installation. CAUTION: READ THIS CHAPTER IN ITS ENTIRETY BEFORE INSTALLING THE UNITS. THE MODEL 3190Z IS FOR INDOOR USE ONLY. THE SAMPLE MUST BE FREE OF ENTRAINED SOLIDS, WATER, OR COMBUSTIBLE COMPOUNDS. 3.
Installation Model 3190Z 3.2 Location and Mounting 3.2.1 Control Unit Installation The 3190Z control unit is designed to be panel-mounted in a general purpose, indoor area, away from moisture and the elements. The unit should be installed at viewing level in a sheltered area. CAUTION: FOR THE DC POWERED VERSION, THE CONTROL UNIT CHASSIS MUST BE ISOLATED FROM THE INPUT POWER GROUND. Refer to the Outline Diagram for the physical dimensions of the analyzer, which can be found at the back of the manual. 3.
Trace Oxygen Analyzer Installation standard AC power cord is supplied with the control unit. Insert the female plug end of the power cord into the power cord receptacle. The universal power supply allows direct connection to any 100240VAC, 50/60 Hz power source. The fuse block, to the right of the power cord receptacle, accepts a 5 × 20 mm, 0.5A time-delay fuse (see Fuse Replacement in Chapter 5 - Maintenance).
Installation Model 3190Z Figure 3-2 Rear Panel Electrical Connectors for AC and DC Units Analog Outputs: There are three DC output signal connectors with screw terminals on the panel. There are two wires per output with the polarity noted. See Figure 3-3. The outputs are: 0–10 V Concentration: Voltage is proportional to oxygen reading, from 0 V at 0 ppm oxygen to 10 V at full scale ppm oxygen. (Full scale = 100% of programmed range). 0–10 V Range ID: 3.33 V = Low Range, 6.
Trace Oxygen Analyzer Installation Alarm Relays: The three alarm circuit connectors are screw terminals for making connections to internal alarm relay contacts. There is one set of contacts for each type of alarm. Contacts are Form C, with normally open and normally closed contact connections capable of switching up to 0.5A at 125 VAC into a resistive load. The alarm relay circuits are designed for failsafe operation, meaning the relays are energized during normal operation.
Installation Model 3190Z External Probe: The receptacle for the analysis unit cable is located in the lower left-hand corner of the rear panel. The 6-pin Minifit ™ connector is keyed to fit only one way into the receptacle; do not force it. The other end of the cable consists of four separate wires. These should be connected to the terminal strip on the analysis unit as follows: Red: Black: #1 #2 White: Green: #3 #4 Refer to the Final Assembly, located at the back of the manual. 3.
Trace Oxygen Analyzer Operation Operation 4.1 Introduction Once the analyzer has been mounted, the gas lines connected, and the electrical connections made, the analyzer can be configured for your application. This involves setting the system parameters as follows: • Defining the user-selectable analysis ranges • Setting alarm set-points. • Calibrating the instrument All of these functions are performed via the front panel controls, shown in Figure 4-1.
Operation Model 3190Z 4.2 Using the Function and Data Entry Buttons When one of the function buttons is being pressed, the analyzer is in the Setup mode or the Calibration mode. The four setup function buttons on the analyzer are: • SET HI ALARM • SET LO ALARM • SET HI RANGE • SET LO RANGE The Calibration mode button is: • SPAN The data entry buttons (Δ and ∇) adjust the value displayed on the TRACE OXYGEN meter while one of the function buttons is being held down.
Trace Oxygen Analyzer Operation 4.3.1 HI Range Setting the HI Range full-scale value defines the LEAST sensitive analysis range to be used. To set the HI Range: 1. Press the SET HI RANGE function button once. 2. Immediately (within 5 seconds) press either the Δ or ∇ button to raise or lower the displayed value as required, until the display reads the desired full-scale concentration. 4.3.2 LO Range Setting the LO Range full-scale value defines the MOST sensitive range to be used. To set the LO Range: 1.
Operation Model 3190Z 1. Press the SET LO ALARM function button once. 2. Within 5 seconds press either the Δ or ∇ button to raise or lower the displayed value as required, until the display reads the desired concentration. 4.4.3 Sensor Fail Alarm Not active in this product. 4.5 Selecting a Fixed Range or Autoranging The Model 3290 can operate in fixed high, fixed low, or autoranging mode. To change modes: 1. Press and then release the SET HI RANGE and the SET LO RANGE buttons simultaneously. 2.
Trace Oxygen Analyzer Operation 3. Immediately (within 5 seconds) press either the Δ or ∇ button until the display is stable and displays the oxygen concentration of the applied calibration gas. Once set, the unit will enter Analyze Mode after approximately three seconds. The unit is now calibrated.
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Trace Oxygen Analyzer Maintenance Maintenance Aside from normal cleaning and checking for leaks at the gas connections, the Model 3190Z should not require any maintenance beyond replacement of zirconium oxide sensors, and perhaps a blown fuse. Routine maintenance includes occasional recalibration, as described in Chapter 4 - Operation. 5.1 Replacing the Fuse 5.1.1 AC Powered Units When a fuse blows, check first to determine the cause, then replace the fuse using the following procedure: 1.
Maintenance Model 3190Z 3. Insert a small flat-blade screwdriver into the slot in the receptacle wall nearest the fuse and gently pry open the fuse receptacle. The fuse holder will slide out. The fuse in use is visible in the clip. To open the spare fuse compartment, push on one end until it slides out. 4. Remove the bad fuse and replace it with a 5×20 mm 0.5 A, 250 VAC, IEC, time lag (T) fuse (P/N F1128) for AC units. 5. Replace the fuse holder into its receptacle, pushing in firmly until it clicks. 5.1.
Trace Oxygen Analyzer Appendix Appendix A.1 Specifications Ranges: Two user selectable ranges can be set between 0-10 ppm and 0-1,000 ppm oxygen. Default ranges are 0-100 ppm and 0-1,000 ppm oxygen Signal Output: Voltage: 0–10 VDC, negative ground Current: 4-20 mA, negative ground Range ID: 0-10 VDC Display: Light-emitting diode (LED) display Alarms: One high alarm relay, adjustable; one low alarm relay, adjustable; one sensor failure relay. All alarms failsafe.
Appendix Model 3190Z A.2 Spare Parts List 1* C-64586A PC Board, Power Supply (AC-version) 1* C-64586B PC Board, Power Supply (DC-version) 1 C-76491C PCB Board, Main 1 C-76490C Interface Unit 2* F-1130 Fuse (AC), ½A, 250 VAC IEC Type T, 5x20mm 1* F-51 Fuse (DC), ½A, 125 VDC Micro-fuse 1 S-1439 Sensor, 0-1,000 ppm, zirconium oxide * - configuration-dependent A minimum charge of US $150.00 is applicable to spare parts orders.
Trace Oxygen Analyzer Appendix A.3 Drawing List D-76533 Outline/Interconnection Diagram A.4 Miscellaneous The symbol: ~ is used on the rear panel of the model 3190Z to signify volts alternating current (VAC).