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OPERATING INSTRUCTIONS FOR
Model 3160
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 PERSIST FOR A
TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.
ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING. BEFORE
CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH
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Copyright © 1999 Teledyne Analytical Instruments All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any other language or computer language in whole or in part, in any form or by any means, whether it be electronic, mechanical, magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-1580. Warranty This equi
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TELEDYNE ANALYTICAL INSTRUMENTS iii
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T T Tab ab able of Contents le of Contents le of Contents T Tab able of Contents le of Contents 1 Introduction 1.1 Features ....................................................................................... 1-1 1.1.1 Fixed Features .............................................................. 1-1 1.1.2 Variable Features ......................................................... 1-1 1.2 Components ................................................................................. 1-3 1.3 Opt
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T T Tab ab able of Contents (contin le of Contents (contin le of Contents (continued) ued) ued) T Tab able of Contents (contin le of Contents (continued) ued) Calibration Zeroing ........................................................... 4-6 Calibration Using Span Gas .............................................. 4-8 Select Active Sensor (Two Cells Only) ............................. 4-11 Install Sensor and Test Alternate Sensor .... (Two Cells Only) .. 4-12 O Range Set-Up ....................
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TELEDYNE ANALYTICAL INSTRUMENTS vi
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Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1.1 Features 1.1.1 Fixed Features The Model 3160 is a microprocessor-based trace oxygen monitoring system that provides on-line monitoring of trace oxygen at parts-per-million (PPM) levels and can directly measure the level of purity in high-grade gases. ® The 3160 computer uses an Intel 80188 microprocessor combined with 32 kilobytes of random access memory (RAM) and 128 kilobytes of read-only memory (R
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1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction The 3160 features six full-scale linear ranges of analysis: 0–1 PPM 0–10 PPM 0–100 PPM 0–1000 PPM 0–1% 0–25% An AutoRanging feature automatically selects the range that is appropriate for a given reading. For example, if the O level exceeds 100% of the current range, the 2 analyzer switches to the next higher range. When desired, a manual override feature allows a particular range of interest to be locked
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Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 1.2 Components The analyzer is designed to mount in a standard 19-inch rack. All of the opera- tional controls are easily accessed through the front panel. The analyzer contains each of the following: Analysis Section Single or Dual Electrochemical Micro-Fuel Cell Sample System Power Supply Microcontroller Module LED Display The front panel consists of: LED Display LCD Display with Touch Panel Micr
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1 Introduction 1 Introduction 1 Introduction 1 Introduction 1 Introduction 1.4 Applications The analyzer is an invaluable tool in the following applications and industries: Inert and gaseous hydrocarbon stream monitoring. Measuring the purity of various gases in air separation plants. Prevention of oxidation by measuring the purity of blanketing gases in fiber and glass industries. Monitoring and controlling gas atmospheres in the heat treatment of metals in steel and other metal in
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Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2.1 Principles of Operation The sub-systems that make up the analyzer are: 1. Micro-Fuel Cell Sensor 2. Sample System 3. Electronic Signal Processing The Micro-Fuel Cell sensor is an electrochemical galvanic device that translates the amount of oxygen present in the sample into an electrical current. The sample system delivers the sample gas in a form that is as unalte
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2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory I O Figure 2-1. Major Components. TELEDYNE ANALYTICAL INSTRUMENTS 2-2
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Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 2.1.1 Micro-Fuel Cell Sensor The Micro-Fuel Cell is a sealed plastic disposable oxygen transducer that mea- sures 1¼ inches in diameter and is ¾ inch thick. Inside of the cell are a cathode and anode immersed in 15% aqueous KOH electrolyte. At one end of the sensor is a Teflon diffusion membrane; the other end is sealed with a polyethylene membrane. At the rear of the cell is a contact p
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2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory Electropolished 316L-type stainless steel components. To eliminate oxygen absorption and desorption from the internal wetted surfaces of the sample system components, the sample system is fabricated from electropolished 316L-type stainless steel. Welding/Metal Gasket-Type Fittings. All of the joints upstream of the Micro-Fuel Cell oxygen sensor are orbitally welded. Orbital welding i
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Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 to be used to zero the analyzer, eliminating the need to switch external tanks. Overall Design. The design of the sample system minimizes the volume of dead space, which can retain residual gas from another route or previous mode of analysis. Figure 2-2: Model 3160 flow schematic. 2.1.3 Electronics and Signal Processing The Model 3160 analyzer has an embedded microcomputer, which cont
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2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory Electronics in the analyzer are grouped according to function: 1. Analog in 2. Analog out 3. Digital circuit 4. Power supply Analog signal processing is accomplished in two plug-in circuit cards operating under control of the microcomputer. All analog signals are converted to digital early in the processing cycle to minimize analog processing and assure maximum system accuracy, since dig
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Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 The analog output printed circuit board (PCB) generates the two 0–1 volt and the two 4–20 mA analog signal outputs available on the rear panel of the analyzer. These signals, generated in digital format by the microcomputer, are converted into analog signals by the circuitry on this PCB. The output signals represent the following: 0–1V Signal (Oxygen Measurement): This output goes from
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2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory 2 Operational Theory The digital printed circuit board (PCB) is a general purpose microcomputer used to control all functions of the analyzer. The analog input PCB and the analog output PCB plug directly into connectors located on the digital PCB. In addition to control- ling these analog PCBs, the digital board performs the following functions: 1. Processes input from the control panel pushbuttons. 2. Provi
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Installation 3 Installation 3 Installation 3 Installation 3 Installation 3 Installation Installation of the analyzer includes: 1. Unpacking the system. 2. Recognizing the necessary precautions when installing the system. 3. Hooking up the sample/span gas and air supply to appropriate connections. 4. Installing the Micro-Fuel Cell sensor(s). 5. Hooking up electrical connections. 6. Testing the system. 3.1 Unpacking the Analyzer The analyzer is shipped with all the materials and special items
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3 Installation 3 Installation 3 Installation 3 Installation 3 Installation 3. Parts Per Million (PPM) and Percent Oxygen indicators: the PPM light will light while the instrument is measuring O in units of PPM. The percent 2 light will light while the instrument is measuring O concentration in 2 percent. 4. Flow Indicator and Flow Set: a flowmeter and flow set knob are provided for adjusting gas flow in standard cubic feet per hour (SCFH). 5. Liquid Crystal Display (LCD) with keypad: the L
