OPERATING INSTRUCTIONS FOR Model 9060L Percent Oxygen Analyzer P/N M77713 ECO: 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 9060L Copyright © 2005 Teledyne Instruments/ Analytical Instruments All Rights Reserved.
Percent Oxygen Analyzer Specific Model Information Instrument Serial Number: _______________________ Instrument Range: _______________ Calibrated for: _______________ Background Gas: _______________ Zero Gas: _______________ Span Gas: _______________ Teledyne Analytical Instruments iii
Model 9060L 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 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. Occasionally, some instruments are customized for a particular application or features and/or options added per customer requests.
Model 9060L Table of Contents List of Figures ............................................................................ viii List of Tables ................................................................................ ix Introduction ................................................................................. 11 1.1 Overview 11 1.2 Main Features of the Analyzer 11 1.3 Front Panel Description 12 1.4 Rear Panel Description 13 Operational Theory ....................................................
Percent Oxygen Analyzer 3.4.1 Oxygen Probe Connections 3.5 Installation Checklist 28 29 Operation ..................................................................................... 31 4.1 Introduction 31 4.2 Using the Function and Data Entry Buttons 32 4.3 Setting the Analysis Ranges 32 4.3.1 HI Range 33 4.3.2 LO Range 33 4.4 Setting the Alarm Setpoints 33 4.4.1 Set Alarm 1 (HI alarm) 33 4.4.2 Set Alarm 2 (LO alarm ) 34 4.4.3 Sensor Fail Alarm 34 4.5 Selecting a Fixed Range or Autoranging 34 4.
Model 9060L List of Figures Figure 1-1: Front Panel ................................................................ 12 Figure 1-2 Rear Panel ................................................................... 14 Figure 2-1: Model 9060L Oxygen Probe ....................................... 16 Figure 2-2: Model 9060L Probe..................................................... 17 Figure 2-3: Internal Structure of the Zirconia Sensor and Probe ... 18 Figure 2-3: Signal Processing Block Diagram ................
Percent Oxygen Analyzer List of Tables Table 2-1: Probe Options ..............................................................
Model 9060L 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 Instruments/ Analytical Instruments (TI/AI) Model 9060L 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 9060L are monitoring kilns, boilers, and flue gas at temperature from ambient up to 1400°C (2550°F). 1.
Introduction Model 9060L • Two concentration alarms with adjustable setpoints. • A failure alarm. • Three analog outputs: two for measurement (0–10VDC, and negative ground 4–20 mA DC) and one for range identification (0-10VDC). • Compact and rugged control unit with flush-panel case. Designed for indoor use. 1.3 Front Panel Description All controls and displays except the power switch are accessible from the front panel. See Figure 1-1.
Percent Oxygen Analyzer Introduction • Set Alarm 2 Sets the concentration at which alarm 2 activates upon dropping below the threshold (LO alarm). • Set HI Range Set the high analysis range for the instrument (up to 0-100%). • Set LO Range Set the low analysis range for the instrument (down to 0-1%). • Span Span calibrate the analyzer.
Introduction Model 9060L Figure 1-2 Rear Panel • Power Connection 110 VAC at 50/60 Hz. The connector housing includes the fuse holder and the power switch. (220VAC is optional via setting an internal switch). Fuse Holder: Replacing the fuse is described in Chapter 5, Maintenance. I/O Power Switch: Turns the instrument power ON (1) or OFF (0). • Analog Outputs 0–10 VDC concentration output. 0–10 VDC range ID (or optional overrange) output. 4–20 mA DC concentration output, negative ground.
Percent Oxygen Analyzer Operational Theory Operational Theory 2.1 Introduction The analyzer is composed of two subsystems: 1. Oxygen probe 2. Control unit with signal processing, display and controls The oxygen probe can be heated or unheated. It delivers the sample gas to a state-of-the-art zirconium sensor which translates the amount of oxygen present into a millivolt output.
Operational Theory Model 9060L All Teledyne oxygen probe or sensors are designed and manufactured to exacting standards of performance and reliability and are the result of extensive research and development. Teledyne Analytical Instruments provides worldwide application and after sales support for its oxygen probes, sensors and analyzers. Figure 2-1: Model 9060L Oxygen Probe The probe assembly provides a means of exposing the zirconia sensor to the atmosphere to be measured with sensor.
Percent Oxygen Analyzer Operational Theory Probes of 1000 mm (40”) normally have sufficient length for any installation. Customers requiring probes longer than 1500 mm (59”) are supplied with a flow guide tube that uses the flue velocity to pull flue gas through a filter at the sensing tip and exhaust it near the flue wall. 2.2.1 Probe Configuration The probe can be configured in a variety of ways to suit the analytical environment. Figure 2-1 shows the most common configurable items of the probe.
Operational Theory Model 9060L 2.2.2 The Zirconia Sensor Input to the analyzer is obtained from a solid electrolyte oxygen probe containing a zirconia element and thermocouple. The probe is designed to be inserted into a boiler or furnace exit gas flue or similar process. The 9060LEX sensor is designed to be installed outside of the flue or process. Sampling lines and filters are not required for in-situ probes but they are required for 9060LEX sensors.
Percent Oxygen Analyzer Operational Theory require a heater. When the outside and inside of the sensor are exposed to different oxygen partial pressures, an EMF (E) is developed which obeys the Nernst equation: E(millivolts) = ⎛ (PO2) Inside ⎞ RT ⎟⎟ log e⎜⎜ 4F ⎝ (PO2) Outside ⎠ where T is the temperature (K) at the disc (>650°C (1200°F)), R is the gas constant.
Operational Theory Model 9060L THE PROBE/SENSOR MUST ALWAYS BE CONNECTED TO EARTH. Power to the heater is supplied directly from the main power source, and the temperature is initially controlled above 700°C (1300°F) after power up. 2.3 Applications Not at Atmospheric Pressure For high and low pressure applications where the pressure at the point of measurement is significantly above or below atmospheric pressure, compensation must be applied.
Percent Oxygen Analyzer Operational Theory located on the Main PCB, which is mounted vertically, just behind the front panel of the control unit. 2.5.2 Signal Processing Figure 2-3 is a block diagram of the signal processing electronics described below. Figure 2-3: Signal Processing Block Diagram In the presence of oxygen the sensor generates a millivolt potential which is fed to a voltage amplifier.
Operational Theory Model 9060L 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 and alarm relays. 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. 3. Installing the probe. 4. Making electrical connections. 5. Testing the installation. CAUTION: READ THIS CHAPTER IN ITS ENTIRETY BEFORE INSTALLING THE SYSTEM. FOR INDOOR USE ONLY. 3.1 Unpacking the Analyzer As soon as you receive the instrument, carefully unpack and inspect the control unit, and any included accessories for damage.
Installation Model 9060L Note: Mount the probe as close to the combustion source as possible. This reduces the lag time inherent in the sampling process and results in better control. The probe has a typical response time of less than four seconds, so most of the delay time is associated with the transit time of the gas from the point of combustion to the point of sensing. Probes can be mounted at any angle.
Percent Oxygen Analyzer Installation probe or install a longer probe. This is normally caused by stratification of the flue gas. Figure 3-1: Oxygen Probe Mounting 3.4 Electrical Connections Figure 3-1 shows the Model 9060L rear panel. For detailed pinouts, see the wiring/interconnection drawings in the Drawings section at the rear of this manual. 3.4.1 Primary Input Power The power cord receptacle, fuse block and Power switch are located in the same assembly.
Installation Model 9060L Figure 3-2: Model 9060L Rear panel 3.4.2 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: 0–10V % Range: Voltage rises with increasing oxygen concentration, from 0V at 0 percent oxygen to 10V at full scale percent oxygen. (Full scale = 100% of programmed range.) 0–10V Range ID: 03.33V = Low Range, 06.66V = High Range, 10V = Air Cal Range.
Percent Oxygen Analyzer Installation The alarm relay circuits are designed for failsafe operation, meaning the relays are energized during normal operation. If power fails the relays de-energize (alarms activated). The contact connections are indicated diagrammatically on the rear panel as Normally Closed, Common, and Normally Open. Figure 3-3 explains how these act in failsafe operation. Alarm 1 and Alarm 2 are configured as HI and LO respectively.
Installation Model 9060L 3.4.1 Oxygen Probe Connections The receptacle for the probe cable is located in the lower left-hand corner of the rear panel. The 6-pin polarized connector is keyed to fit only one way into the receptacle. Do not force it in. The other end of the cable connects to the probe assembly. See Figure 3-5. Connect the probe lead as shown in Figure 3-4 . The heater connector is on the right-hand corner of the rear panel.
Percent Oxygen Analyzer Installation Figure 3-5: Connections to Probe 3.5 Installation Checklist Prior to powering up the unit make sure you have: • Installed the unit correctly • Checked the probe and welded probe socket for leaks Once the above checks have been made, you can connect the power source. Wait approximately 30 minutes for warm up, two hours wait is best. After that, the instrument is ready for operation.
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Percent Oxygen Analyzer Operation Operation 4.1 Introduction Once the analyzer has been mounted, the probe installed, 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 9060L 4.2 Using the Function and Data Entry Buttons When no buttons on the analyzer are being pressed, the instrument is in the analyze 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 enters the setup mode or the calibration mode.
Percent Oxygen Analyzer Operation range full scale value, and it switches back to the LO range when the oxygen concentration reaches 85% of the LO range full scale value Note: The HI Range setpoint MUST be set at a higher concentration percentage than the LO Range setpoint. 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.
Operation Model 9060L until the display reads the desired percent concentration. If within 5 seconds no key is pressed, the instrument will return to the sample mode and display oxygen concentration. After setting the value wait for the unit to time out of this mode (approximately 5 seconds) and return to displaying oxygen concentration. 4.4.2 Set Alarm 2 (LO alarm ) Alarm 2 is preset as a low alarm. To configure this alarm to your preferences: 1. Press the SET ALARM 2 function button once. 2.
Percent Oxygen Analyzer Operation 2. Immediately (within 5 seconds) press either the Δ or ∇ button until Auto, Lo, or Hi displays on the LCD, as desired. After about three seconds, the analyzer resumes monitoring in the selected range mode. 4.6 Oxygen Calibration There are two types of calibration one is air calibration, and the other is span which uses some other gas other than air. Since the zirconia sensor uses air as reference, the output is nearly zero millivolts.
Operation Model 9060L for five minutes before timing-out. During this five minute interval, the LED will continue to track gas through the analyzer. 2. Flow span gas of a known oxygen concentration (between 1 and 16% oxygen) into the analyzer. The analyzer will begin to track the span gas. Note: The alarms will not change state during span calibration. 3. When the meter stabilizes, use the UP/DOWN arrows to adjust the analyzer span value to the exact percent O2 concentration in the span gas.
Percent Oxygen Analyzer Operation 4.6.2 Air Calibration To perform air calibration, make sure you have air flowing through the same inlet you use for span calibration at a flow of 1- 5 liters per minute. Wait for readings to stabilize. Press both the SET ALARM 1 and SET ALARM 2 simultaneously. The LED display will show “OFSt” for a few seconds. After that the instrument should read near 20.9%.
Operation Model 9060L Within the time the temperature is being displayed, one can use the UP and DOWN arrow keys to adjust the temperature, thus recalibrating the temperature readout. WARNING: TEMPERATURE READING IS CALIBRATED AT THE FACTORY. DO NOT ATTEMPT RECALIBRATION OF THE PROBE TEMPERATURE. ERROR OF A FEW DEGREES WOULD HAVE LITTLE IMPACT ON THE OXYGEN CALCULATIONS, BUT IF THE PROBE IS GROSSLY MISCALIBRATED IT WILL HAVE AN ADVERSE EFFECT ON THE OXYGEN READOUT.
Percent Oxygen Analyzer Operation output of the sensor higher than the top scale of the ADC. It may also occur if the thermocouple should open. -03- This message is displayed when the input voltage to the ADC has fallen below the lower negative limit of the ADC.
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Percent Oxygen Analyzer Maintenance Maintenance Aside from normal cleaning and checking for leaks at the probe connection, the Model 9060L should not require any maintenance beyond replacement of a blown fuse. Routine maintenance includes occasional recalibration, as described in Chapter 4, Operation. 5.1 Replacing the Fuse CAUTION: REMOVE POWER TO UNIT BEFORE REPLACING THE FUSE. When a fuse blows, check first to determine the cause, then replace the fuse using the following procedure: 1.
Maintenance Model 9060L 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. There are two fuses in use and are visible in the clip. 4. Remove the bad fuse and replace it with a 5x20mm 2A, 250 VAC, IEC time lag (T) fuse (P /N F1296). 5. Replace the fuse holder into its receptacle, pushing in firmly until it clicks.
Percent Oxygen Analyzer Appendix Appendix A.1 Specifications Ranges: 0-3 % and 0-10 % oxygen (Standard Ranges), and 0-25 % (nominal) Calibration Range. User selectable % Ranges can be set between 1% and 100 % oxygen . Signal Output: Voltage: 0–10 VDC, negative ground Current: 4-20 mA, negative ground Range ID: 0-10 VDC. Display: Light emitting diode display. Alarms: Two customer selectable fully adjustable HI and LO alarms. One sensor failure alarm.
Appendix Model 9060L A.2 Probe Specifications Application: Combustion flue below 700°C (1290°F), above 700°C (1290°F) 900°C (1650°F) — no contaminants. With contaminants see notes 1 &2 Temperature Range: 0-900°C 800-1400°C 800-1200°C (32-1650°F) (1470-2550°F) (1470-2190°F) Length: 250-1000 mm 500-1160 mm 457-1219 mm (10” to 40”) (20” to 46”) (18” to 48”) Process Connection: 1 1/2" BSP 3/4" BSP 1" BSP or equivalent NPT Electrical Connection: Weatherproof plug-in connector or optional screw terminals.
Percent Oxygen Analyzer Appendix Notes: 1. Care must be taken to avoid contact with explosive or inflammable gases with 9060L heated probes when hot. 2. Please contact factory for corrosives other than sulphur or zinc. We can provide test materials to try in your atmosphere. A.3 Spare Parts List QTY.
Appendix Model 9060L A.4 Reference Drawing D-77712 Outline Diagram D77713 Control Unit Final Assembly C77925 Interconnection Diagram A.5 Probe or Sensor EMF Tables ZIRCONIA OXYGEN SENSOR OUTPUT (mV) PROBE TYPE 9060L, SENSOR TYPE 9060LEX % OXYGEN mV at 720°C (1320°F) 21.0 0.00 20.5 0.46 20.0 0.99 19.5 1.53 19.0 2.09 18.5 2.66 18.0 3.25 17.5 3.85 17.0 4.47 16.5 5.11 16.0 5.77 15.5 6.45 15.0 7.15 14.5 7.87 14.0 8.62 13.5 9.40 13.0 10.21 12.5 11.05 12.0 11.92 11.
Percent Oxygen Analyzer 11.0 13.78 10.5 14.78 10.0 15.82 9.5 16.92 9.0 18.08 8.5 19.30 8.0 20.60 7.5 21.98 7.0 23.45 6.5 25.04 6.0 26.75 5.5 28.61 5.0 30.65 4.5 32.90 4.0 35.42 3.5 38.28 3.0 41.58 2.5 45.48 2.0 50.25 1.5 56.41 1.0 65.08 0.5 79.91 0.2 99.51 Appendix 'K’ TC mV 29.212 at 720 °C (1320°F) These tables are based on the Nernst equation: Sensor e.m.f. = 0.02154 x T x 1n ( 20.95 / % oxygen), where T = ° K (° C + 273), e.m.f.
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Percent Oxygen Analyzer Index Index accuracy, 43 address, 45 air calibration, 35, 37 air purge, 16 alaram delay, 36 alarm, 43 concentration, 12 HI, 27 LO, 27 sensor fail, 27, 34 sensor failure, 12 setpoint, 33 threshold, 12, 27 Alarm 1, 27 Alarm 2, 27 alarm connection, 26 alarm connections, 14 alarm delay, 37 alarm indicator, 12 alarm relay circuit, 27 alarm setpoint, 13 analog concentration signal, 22 analog to digital converter, 20, 21, 38 analysis range, 32 analyze mode, 32 applications, 11 autoranging
Index Model 9060L input connector, 13 insertion length, 17 instasllation checklist, 29 instrument range, 11 internal power switch, 20, 25 lagging extension, 17 leak check, 29 LED, 13 LED flashing, 35 LO range, 33 main PCB, 21 maintenance, 41 manuals, additional, v Measurement Parameters Readout, 13 membrane switches, 12 Meter Readout, 13 micro-controller, 15, 20, 21 millivolt potential, 21 mounting thread, 17 Nernst equation, 19, 47 NPT socket, 23 OFSt, 37 open thermocouple, 27, 34, 38 operating temperatu
Percent Oxygen Analyzer tables listing, ix technician symbol, iv temperature, 44 temperature controller, 18 temperature maximum, 24 temperature too low, 38 thermal shock, 15, 24 thermocouple, 18 thermocouple type, 44 time out, 34 time-out, 37 t-Lo, 38 Index transit time, 24 U length, 24 Up Arrow, 13 voltage amplifier, 21 warning sign, iv warranty, ii water vapor, 16 website address, v zero oxygen concentration, 38 zirconia element, 18 zirconia sensor.