OPERATING INSTRUCTIONS FOR Model 3290 Percent Oxygen Analyzer P/N M64643 8/10/11 DANGER Depending upon your application, toxic gases 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 3290 Copyright © 2011 Teledyne Instruments/ Analytical Instruments All Rights Reserved.
Percent Oxygen Analyzer Specific Model Information Instrument Serial Number: _______________________ Instrument Range: _______________ Background Gas: _______________ Span Gas: _______________ Teledyne Analytical Instruments iii
Model 3290 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.
Percent Oxygen Analyzer 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. Occasionally, some instruments are customized for a particular application or features and/or options added per customer requests.
Model 3290 Table of Contents List of Figures ............................................................................ viii List of Tables ................................................................................ ix 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 4 Operational Theory ........................................................
Percent Oxygen Analyzer 3.5 Installation Checklist 22 Operation ..................................................................................... 23 4.1 Introduction 23 4.2 Using the Function and Data Entry Buttons 24 4.3 Setting the Analysis Ranges 24 4.3.1 HI Range 25 4.3.2 LO Range 25 4.4 Setting the Alarm Setpoints 25 4.4.1 HI Alarm 25 4.4.2 LO Alarm 26 4.4.3 Sensor Fail Alarm 26 4.5 Selecting a Fixed Range or Autoranging 26 4.6 Calibration 26 Maintenance..........................................
Model 3290 List of Figures Figure 1-1: Front Panel ................................................................... 2 Figure 1-2: Rear Panel (AC and DC versions) ................................ 4 Figure 2-1: Basic Elements of the Oxygen Sensor (not to scale) .... 8 Figure 2-2: Input/Output Curve for a Typical Oxygen Sensor........ 11 Figure 2-3: Block Diagram of the Signal Processing Electronics... 13 Figure 3-1: Rear Panel Electrical Connectors for AC & DC Units .
Percent Oxygen Analyzer List of Tables Table 3-1: Required RS-232 Data Format .....................................
Model 3290 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.
Percent Oxygen Analyzer Introduction Introduction 1.1 Overview The Teledyne Analytical Instruments (TAI) Model 3290 is a microprocessor-based percent oxygen analyzer for real-time measurement of the percent of oxygen in inert gases, or in a wide variety of gas mixtures. It features simple operation, fast response, and a compact, rugged construction. Typical applications of the Model 3290 are monitoring nitrogen generators and inert gas blanketing applications. 1.
Introduction Model 3290 User selectable autoranging feature, which allows the analyzer to automatically select the proper preset range for a given measurement. The analyzer can also be manually locked on a fixed analysis range. Two concentration alarms with adjustable setpoints. Sensor failure alarm. Optional RS-232 serial digital port for output of concentration and range data to a computer, terminal, or other digital device.
Percent Oxygen Analyzer Introduction Function Keys: Five pushbutton membrane switches are used to select the function performed by the analyzer: Set HI Alarm Set the concentration ABOVE which an alarm activates. Set LO Alarm Set the concentration BELOW which an alarm activates. Set HI Range Set the high analysis range for the instrument (up to 0-25 %). Set LO Range Set the low analysis range for the instrument (down to 0-1 %). Span Span calibrate the analyzer.
Introduction Model 3290 1.4 Rear Panel Description The rear panel contains the electrical input and output connectors. Separate rear panel illustrations are shown in Figure 1-2 for the AC and DC powered versions of the instrument. The connectors are described briefly here and in detail in Chapter 3 Installation of this manual.
Percent Oxygen Analyzer Introduction Power Connection AC version: 100–240 VAC, at 50/60 Hz. The connector housing includes the fuse holder and the power switch. DC version: Requires between 10 and 36 VDC. Fuse Holder: Replacing the fuse is described in Chapter 5, Maintenance. 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 overrange) output. 4–20 mA DC concentration output, negative ground.
Introduction Model 3290 Teledyne Analytical Instruments 6
Percent Oxygen Analyzer Operational Theory Operational Theory 2.1 Introduction The analyzer is composed of two subsystems: 1. Analysis Unit with Oxygen Sensor 2. Control Unit with Signal Processing, Display and Controls The Analysis Unit is designed to accept the sample gas and direct it to the sensitive surface of the oxygen sensor. The oxygen sensor is an electrochemical galvanic device that translates the amount of oxygen present in the sample into an electrical current.
Operational Theory Model 3290 therefore a hybrid between a battery and a true fuel cell; where in a true fuel cell all of the reactants are stored externally. 2.2.2 Anatomy of the Oxygen Sensor The oxygen sensor is made of extremely inert plastic (which can be placed confidently in practically any environment or sample stream). It is effectively sealed, though one end is permeable to oxygen in the sample gas.
Percent Oxygen Analyzer Operational Theory The anode structure is larger than the cathode. It is made of lead and is designed to maximize the amount of metal available for chemical reaction. The space between the active elements is filled by a structure saturated with electrolyte. Cathode and anode are wet by this common pool. They each have a conductor connecting them, through some electrical circuitry, to one of the external contacts in the connector receptacle, which is on the top of the cell. 2.2.
Operational Theory Model 3290 2.2.4 The Effect of Pressure In order to state the amount of oxygen present in the sample as a percentage of the gas mixture, it is necessary that the sample diffuse into the cell under constant pressure. The sensing technology deployed in the Model 3290 is an electrochemical oxygen sensor which is a partial pressure device. Any changes in the vent pressure of the unit will affect the pressure of the sample the sensor sees.
Percent Oxygen Analyzer Operational Theory 2.2.5 Calibration Characteristics Given that the total pressure of the sample gas at the surface of the oxygen sensor input is constant, a convenient characteristic of the cell is that the current produced in an external circuit of constant impedance 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.
Operational Theory Model 3290 2.3 Electronics 2.3.1 General The signal processing uses an Intel micro-controller with on-board RAM and ROM to control all signal processing, input/output, and display functions for the analyzer. System power is supplied from a universal power supply module designed to be compatible with most international power sources. The power supply circuitry is on the Power Supply PCB, which is mounted vertically, just behind the rear panel of the Control Unit.
Percent Oxygen Analyzer Operational Theory Figure 2-3: Block Diagram of the Signal Processing Electronics In the presence of oxygen the cell generates a current. A current to voltage amplifier (I–E AMPL) converts this current to a voltage. The second stage amplifier (TEMP COMP) supplies temperature compensation for the oxygen sensor output. The temperature compensation amplifier incorporates a thermistor (THERM) that is physically located in the cell block for the typical oxygen sensor.
Operational Theory Model 3290 The digital concentration signal along with input from the front panel buttons (KEYBOARD) is processed by the micro-controller, and appropriate output signals are directed to the display, alarm relays, and the optional RS-232 output. The same digital information is also sent to a 12-bit digital to analog converter (DAC) that produces the 0-10 VDC analog concentration signal and the 0-10 VDC analog range ID output.
Percent Oxygen Analyzer Installation Installation Installation of the analyzer includes: 1. Unpacking the system. 2. Mounting the Control Unit, external sample block, and oxygen sensor. 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. FOR INDOOR USE ONLY. THE SAMPLE MUST BE FREE OF ENTRAINED SOLIDS OR WATER. THE SENSOR ELECTROLYTE IS CAUSTIC. DO NOT ATTEMPT TO OPEN IT.
Installation Model 3290 3.1 Unpacking the Analyzer As soon as you receive the instrument, carefully unpack and inspect Control Unit, External Probe, and any included accessories for damage. Immediately report any damage to the shipping agent. The analyzer is shipped with all the materials you need to install and prepare the system for operation. CAUTION: DO NOT DISTURB THE INTEGRITY OF THE CELL PACKAGE UNTIL THE CELL IS TO ACTUALLY BE USED.
Percent Oxygen Analyzer Installation For special applications, the type of External Probe unit supplied may vary depending on the specific process. With these systems, specific installation and interconnect information is given in a separate probe manual or in an addendum to this manual depending on the model External Probe used. The addendum will reference the specific Outline and Interconnection Drawings in the Drawings section of this manual, and provides any other appropriate information.
Installation Model 3290 power cord receptacle, accepts a 5 x 20 mm, 0.5 A, time-lag (T) fuse. (See Fuse Replacement in Chapter 5, Maintenance.) The power switch is located at the right within the power source input receptacle assembly. Figure 3-1: Rear Panel Electrical Connectors for AC & DC Units Primary Input Power (DC version): The 10–36 VDC power is connected via the + and terminals in the upper left corner of the panel. The fuse receptacle, to the right of the power terminal strip, holds a 0.
Percent Oxygen Analyzer Installation CAUTION: INSERT THE STRIPPED TIPS OF WIRES ENTIRELY INTO THE TERMINAL BLOCKS. DO NOT LEAVE EXPOSED WIRE OUTSIDE OF THE HOLES IN THE BLOCKS. CAUTION: THE CONTROL UNIT CHASSIS MUST BE ISOLATED FROM THE GROUNDING SYSTEM OF THE DC INPUT POWER. 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 3-1.
Installation Model 3290 The specific descriptions for each type of alarm are as follows: HI Alarm Configured as high alarm (actuates when concentration is above threshold). Can be set anywhere between 1 and 25 %, but must be set ABOVE the threshold set for the LO Alarm. LO Alarm Configured as low alarm (actuates when concentration is below threshold). Can be set anywhere from 1 to 25 %, but must be set BELOW the threshold set for the HI Alarm.
Percent Oxygen Analyzer Installation Table 3-1: Required RS-232 Data Format Parameter Setting Baud 2400 Byte 8 bits Parity none Stop Bits Message Rate 1 2 per second 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 in. The other end of the cable is made of four separate wires.
Installation Model 3290 3.5 Installation Checklist Before connecting the instrument to the power source and turning it on, make sure you have: Correctly installed the Sample and Exhaust gas lines Opened the isolation valves Checked for leaks Set the sample pressure to achieve a 2 SCFH flowrate. Once the above checks have been made, you can connect to the power source. The instrument is now ready for operation.
Percent 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: Defining the user selectable analysis ranges. Setting alarm setpoints. Calibrating the instrument. All of these functions are performed via the front panel controls, shown in Figure 4-1.
Operation Model 3290 4.2 Using the Function and Data Entry Buttons When no buttons on the Analyzer are being pressed, the instrument is in the Analysis mode. It is monitoring the percent of oxygen in the sample gas that is flowing through the remote probe. When one of the function buttons is being pressed, the Analyzer is in the Setup mode or the Calibration mode.
Percent Oxygen Analyzer Operation Note: The HI Range value MUST be set at a higher value than the LO Range value. 4.3.1 HI Range Setting the HI Range fullscale 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 or button to raise or lower the displayed value, as required, until the display reads the desired fullscale percent value. 4.3.
Operation Model 3290 4.4.2 LO Alarm Setting the LO Alarm sets the concentration BELOW which the LO alarm will activate. To set the LO Alarm: 1. Press the SET LO ALARM function button once. 2. Immediately press either the or button to raise or lower the displayed value, as required, until the display reads the desired percent concentration. 4.4.3 Sensor Fail Alarm The SENSOR FAIL alarm is factory preset in the instrument software at 0.05%. It cannot be changed by the user.
Percent Oxygen Analyzer Operation Procedure: 1. Expose the sensor to ambient air or instrument grade air (20.9% oxygen). Allow time for the sampling system to purge and the analyzer to achieve equilibrium. Note: Teledyne recommends not to use breathing air cylinders as a calibration source since the oxygen concentration has been found to vary between 19.5-23.5% oxygen. Always refer to the analysis certificate supplied with the gas cylinder and use the analyzed concentration for the calibration value.
Operation Model 3290 Teledyne Analytical Instruments 28
Percent Oxygen Analyzer Maintenance Maintenance Aside from normal cleaning and checking for leaks at the gas connections, the Model 3290 should not require any maintenance beyond replacement of expended 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 3290 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 520 mm 0.5 A, 250 VAC, time lag (T) fuse (P/N F1128) for AC units. 5. Replace the fuse holder into its receptacle, pushing in firmly until it clicks. 6.
Percent Oxygen Analyzer Maintenance instrument, or calibration cannot be achieved within the range of the buttons, the cell may need replacing. Read the section Cell Warranty Conditions, below, before replacing the cell. In addition, if the front panel Percent Oxygen Meter displays “0.00” when the unit is plugged in, and the power switch is in the ON position, the sensor needs to be replaced. IMPORTANT: After replacing the oxygen sensor, the analyzer must be recalibrated. See Calibration in Chapter 4.
Maintenance Model 3290 5.2.3 Removing the Oxygen Sensor No tools are required to replace the cell in the instrument for either the standard E-2 sensor or the optional C-5 or C-5F sensors. To remove a spent or damaged E-2 oxygen sensor: 1. Disconnect the Power Source from the Unit. 2. Unplug the connector from the spent cell. 3. Remove the spent cell by unscrewing it, counterclockwise, from the cell block. 4. Dispose of the cell in a safe manner, and in accordance with local laws.
Percent Oxygen Analyzer Maintenance 4. Insert the cell block electrical connector plug into the socket in the sensor is such a way that that the sensing membrane is facing down to facilitate water evaporation away from the sensing membrane and that any bubbles that form will migrate away from the sensing cathode due to gravity effects. 5. Reconnect power to the instrument. To install a new C-5 or C-5F sensor: 1. Disconnect power to the analyzer. 2.
Maintenance Model 3290 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. With any warranty claim, the customer must return the cell in question to the factory for evaluation. If it is determined that failure is due to faulty workmanship or material, the cell will be replaced at no cost to the customer.
Percent Oxygen Analyzer Maintenance Appendix A.1 Specifications Ranges: Two user selectable % ranges can be set between 1% and 25 % O2 plus fixed 0-25% cal range. (Optional 0-100% range is available. Consult factory.) Standard ranges configured as 0-3% and 010%. Sensor: E-2 Oxygen Sensor (standard) C-5, C-5F Oxygen Sensor (optional) Signal Output: Voltage: 0–10 VDC, negative ground Current: 4-20 mA, negative ground Range ID: 0-10 VDC Display: Light emitting diode.
Maintenance Model 3290 System Enclosure: Panel Mount: 2.81" H × 6.0" W × 2.87" D (71.4 mm × 152.4 mm × 72.9 mm) Face Plate: 3.75" H × 7.0" W (95.3 mm H × 177.8 mm W) Sensor Type: E-2 (typical) C-5, C-5F (optional) Analysis Unit: 4.0" H × 6.0" W × 2.5" D (101.6 mm × 152.4 mm × 63.5 mm) A.2 Spare Parts List (Standard Version) QTY.
Percent Oxygen Analyzer Maintenance A.3 Drawing List (Standard Version) C-64771 Outline Diagram C-64643 Final Assembly (and interconnection diagram) C-64773 Control Unit Assembly C-65946 Analysis Unit Assembly A.4 Miscellaneous The symbol: ~ is used on the rear panel of the Model 3290 to signify volts alternating current (VAC).
