Summary of the content on the page No. 1
Trace Oxygen Analyzer
OPERATING INSTRUCTIONS FOR
MODEL 3000ZA
Trace Oxygen Analyzer
P/N M75739
4/10/04
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.
Before conducting any
Summary of the content on the page No. 2
3000ZA Copyright © 2003 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 T
Summary of the content on the page No. 3
Trace Oxygen Analyzer Specific Model Information The instrument for which this manual was supplied may incorporate one or more options not supplied in the standard instrument. Commonly available options are listed below, with check boxes. Any that are incorporated in the instrument for which this manual is supplied are indicated by a check mark in the box. Instrument Serial Number: _______________________ Options Included in the Instrument with the Above Serial Number: 3000ZA-C: In addition t
Summary of the content on the page No. 4
3000ZA Important Notice Model 3000ZA complies with all of the requirements of the Commonwealth of Europe (CE) for Radio Frequency Interference, Electromagnetic Interference (RFI/EMI), and Low Voltage Directive (LVD). The following International Symbols are used throughout the Instruction Manual. These symbols are visual indicators of important and immediate warnings and when you must exercise CAUTION while operating the instrument. See also the Safety Information on the next page. STAND-BY: Ins
Summary of the content on the page No. 5
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. The definition of these symbols is described below: GENERAL WARNING/CAUTION: Refer to the instruc
Summary of the content on the page No. 6
3000ZA 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 and operation of your new analyzer. Please read this manual and keep it available. Occasionally, some instruments are customized for
Summary of the content on the page No. 7
Trace Oxygen Analyzer 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 operation of this equipment is well understood by the user. Misuse of this product in any manner, tampering with its components, or unauthorized substitution of any component may adversely affec
Summary of the content on the page No. 8
3000ZA Table of Contents Safety Messages..............................................................v 1.1 Overview 1 1.2 Typical Applications 1 1.3 Main Features of the Analyzer 1 1.4 Model Designations 2 1.5 Front Panel (Operator Interface) 3 1.6 Rear Panel (Equipment Interface) 5 Operational Theory..........................................................8 2.1 Introduction 8 2.2 ZrO Sensor 8 2 2.2.1 Principles of Operation 8 2.3 Sample System 9 2.4 Zirconium Oxide Sensor Applicatio
Summary of the content on the page No. 9
Trace Oxygen Analyzer Operation ....................................................................... 28 4.1 Introduction 28 4.2 Using the Data Entry and Function Buttons 29 4.3 The System Function 31 4.3.1 Tracking the Oxygen Readings during Calibration 32 4.3.2 Setting up an Auto-Cal 33 4.3.3 Password Protection 34 4.3.3.1 Entering the Password 34 4.3.3.2 Installing or Changing the Password 35 4.3.4 Logout 37 4.3.5 System Self-Diagnostic Test 37 4.3.6 Version Screen 38 4.3.7 Showing Nega
Summary of the content on the page No. 10
3000ZA 5.3 Fuse Replacement 53 5.4 System Self Diagnostic Test 54 5.5 Major Internal Components 55 5.6 Cleaning 56 5.7 Troubleshooting 56 Appendix ........................................................................58 A-1 Specifications 58 A-2 Recommended 2-Year Spare Parts List 60 A-3 Drawing List 61 A-4 19-inch Relay Rack Panel Mount 61 A.5 Application Notes 62 Index ...............................................................................66 Teledyne Analytical Instruments x
Summary of the content on the page No. 11
Trace Oxygen Analyzer List of Figures Figure 1-1: Model 3000ZA Front Panel 3 Figure 1-2: Model 3000ZA Rear Panel 5 Figure 2-1: Model 3000ZA Sample System 9 Figure 2-2: Flow Diagram with Options 10 Figure 2-3: Component Location 12 Figure 2-4: Electronic Block Diagram 13 Figure 3-1: Front Panel 15 Figure 3-2: Required Front Door Clearance 15 Figure 3-3: Rear Panel 16 Figure 3-4: Equipment Interface Connector Pin Arrangement 19 Figure 3-5: Remote Probe Connections 24 Figure 3-6: FET Series Resis
Summary of the content on the page No. 12
3000ZA List of Tables Table 3-1: Analog Output Connections 20 Table 3-2: Alarm Relay Contact Pins 21 Table 3-3: Remote Calibration Connections 22 Table 3-4: Range ID Relay Connections 23 Table 3-5: Commands via RS-232 Input 25 Table 3-6: Required RS-232 Options 25 Table 4-1: Output Signals 49 Table 4-2: Range ID Output Voltage 50 Table 5-1: Self-test Failure Codes 54 Table 5-2: Troubleshooting 56 Teledyne Analytical Instruments xii
Summary of the content on the page No. 13
Trace Oxygen Analyzer Introduction Introduction 1.1 Overview The Teledyne Analytical Instruments Model 3000ZA 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 3000ZA General Purpose flush- panel and/or rack-mount units with CE mark. These units are for indoor use in a non-hazardous environment. 1.2 Typical Applications A few typical applications of the Model 3000ZA
Summary of the content on the page No. 14
Introduction 3000ZA offset and six months warranty and an expected lifetime of more than three years. 0-1 ppm range is possible too. • No reference gas required • Versatile analysis over a wide range of applications. • Microprocessor based electronics: 8-bit CMOS microprocessor with 32 kB RAM and 128 kB ROM. • Three user definable output ranges (from 0-1 ppm through 0-250 ppm) allow best match to users process and equipment. • Auto ranging allows analyzer to automatically select the proper prese
Summary of the content on the page No. 15
Trace Oxygen Analyzer Introduction 3000ZA-M: This model has current output signals (4-20- mA) for ppm range and range ID, in addition to voltage outputs. 3000ZA-V: Gas flow through the cell block in this model is driven by vacuum downstream from the cell block instead of upstream pressure. The internal restrictor is located downstream from the cell block to support this configuration. All other standard features are present in this model. 1.5 Front Panel (Operator Interface) The standard 3000Z
Summary of the content on the page No. 16
Introduction 3000ZA Function Keys: Six touch-sensitive membrane switches are used to change the specific function performed by the analyzer: • Analyze Perform analysis for oxygen content of a sample gas. • System Perform system-related tasks (described in detail in chapter 4, Operation.). • Span Span calibrate the analyzer. • Zero Zero calibrate the analyzer. • Alarms Set the alarm setpoints and attributes. • Range Set up the 3 user definable ranges for the instrument. Data Entry Keys: Six touch
Summary of the content on the page No. 17
Trace Oxygen Analyzer Introduction Standby Button : The Standby turns off the display and outputs but circuitry is still operating. CAUTION: THE POWER CABLE MUST BE UNPLUGGED TO FULLY DISCONNECT POWER FROM THE INSTRUMENT. WHEN CHASSIS IS EXPOSED OR WHEN ACCESS DOOR IS OPEN AND POWER CABLE IS CONNECTED, USE EXTRA CARE TO AVOID CONTACT WITH LIVE ELECTRICAL CIRCUITS. Access Door: For access to the ZrO sensor, the front panel swings open when the 2 latch in the upper right corner of the panel is
Summary of the content on the page No. 18
Introduction 3000ZA • Power Connection Universal AC power source. • Gas Inlet and Outlet One inlet (must be externally valved) and one exhaust out. Three inlets when option “C” is ordered. • 9-Pin RS-232 Port Serial digital concentration signal output and control input. • 50-Pin Equipment Interface Port Analog Outputs: 0–1 VDC oxygen concentration plus 0-1 V dc range ID Alarm Connections: 2 concentration alarms and 1 system alarm. Remote Valve: Used in the 3000ZA for controlling external sol
Summary of the content on the page No. 19
Trace Oxygen Analyzer Introduction scheduled calibrations can vary 2-3 % per day. Teledyne Analytical Instruments 7
Summary of the content on the page No. 20
Operational Theory 3000ZA Operational Theory 2.1 Introduction The analyzer is composed of three subsystems: 1. Zirconium Oxide (ZrO ) Sensor 2 2. Sample System 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 ZrO sensor is a device that translates the 2 amount of oxygen present in the sample into an electrical current. The electroni
