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3000ZA Teledyne Analytical Instruments ii 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 inwhole or in part, in any form ...

Page 3 - iii; Specific Model Information; The instrument for which this manual was supplied may

Trace Oxygen Analyzer Teledyne Analytical Instruments iii 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. Anythat are incorporated i...

Page 4 - iv; Important Notice

3000ZA Teledyne Analytical Instruments iv 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 throu...

Page 5 - Safety Messages; Your safety and the safety of others is very important. We have; GENERAL WARNING/CAUTION; This warning is; Symbol

Trace Oxygen Analyzer Teledyne Analytical Instruments v Safety Messages Your safety and the safety of others is very important. We have provided many important safety messages in this manual. Please readthese messages carefully. A safety message alerts you to potential hazards that could hurt you or...

Page 6 - This manual provides information designed to guide you through

3000ZA Teledyne Analytical Instruments vi CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THEPURPOSE AND IN THE MANNER DESCRIBED INTHIS MANUAL. IF YOU USE THE ANALYZER IN A MANNER OTHERTHAN THAT FOR WHICH IT WAS INTENDED,UNPREDICTABLE BEHAVIOR COULD RESULTPOSSIBLY ACCOMPANIED WITH HAZARDOUSCONSEQUENCE...

Page 7 - vii

Trace Oxygen Analyzer Teledyne Analytical Instruments vii This is a general purpose instrument designed for use in a non-hazardousarea. It is the customer's responsibility to ensure safety especially whencombustible gases are being analyzed since the potential of gas leaksalways exist. The customer ...

Page 8 - Table of Contents

3000ZA Teledyne Analytical Instruments viii 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 (...

Page 9 - System

Trace Oxygen Analyzer Teledyne Analytical Instruments ix 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...

Page 10 - Fuse Replacement

3000ZA Teledyne Analytical Instruments x 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-Yea...

Page 11 - List of Figures

Trace Oxygen Analyzer Teledyne Analytical Instruments xi 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 Diagr...

Page 12 - xii; List of Tables; Table 3-3: Remote Calibration Connections

3000ZA Teledyne Analytical Instruments xii 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...

Page 13 - Introduction; Typical Applications

Trace Oxygen Analyzer Introduction Teledyne Analytical Instruments 1 Introduction 1.1 Overview The Teledyne Analytical Instruments Model 3000ZA Trace Oxygen Analyzer is a versatile microprocessor-based instrument fordetecting oxygen at the parts-per-million (ppm) level in a variety ofgases. This man...

Page 14 - Model Designations

Introduction 3000ZA Teledyne Analytical Instruments 2 offset and six months warranty and an expected lifetimeof 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 mic...

Page 15 - The standard 3000ZA is housed in a rugged metal case with all

Trace Oxygen Analyzer Introduction Teledyne Analytical Instruments 3 3000ZA-M: This model has current output signals (4-20-mA) for ppm range and range ID, inaddition to voltage outputs. 3000ZA-V: Gas flow through the cell block in thismodel is driven by vacuum downstreamfrom the cell block instead o...

Page 16 - Analyze

Introduction 3000ZA Teledyne Analytical Instruments 4 Function Keys: Six touch-sensitive membrane switches are used to change the specificfunction performed by the analyzer: • Analyze Perform analysis for oxygen content of a samplegas. • System Perform system-related tasks (described in detailin cha...

Page 17 - Standby Button

Trace Oxygen Analyzer Introduction Teledyne Analytical Instruments 5 Standby Button : The Standby turns off the display and outputs but circuitry is stilloperating. CAUTION: THE POWER CABLE MUST BE UNPLUGGED TOFULLY DISCONNECT POWER FROM THEINSTRUMENT. WHEN CHASSIS IS EXPOSED ORWHEN ACCESS DOOR IS O...

Page 18 - Note: If you require highly accurate Auto-Cal timing, use external

Introduction 3000ZA Teledyne Analytical Instruments 6 • Power Connection Universal AC power source. • Gas Inlet and Outlet One inlet (must be externally valved) and one exhaust out. Three inletswhen option “C” is ordered. • 9-Pin RS-232 Port Serial digital concentration signaloutput and control inpu...

Page 20 - Operational Theory; Sensor

Operational Theory 3000ZA Teledyne Analytical Instruments 8 Operational Theory 2.1 Introduction The analyzer is composed of three subsystems: 1. Zirconium Oxide (ZrO 2 ) Sensor 2. Sample System 3. Electronic Signal Processing, Display and Control The sample system is designed to accept the sample ga...

Page 21 - The sample system delivers gases to the ZrO

Trace Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 9 2.3 Sample System The sample system delivers gases to the ZrO 2 sensor from the analyzer rear panel inlet. Depending on the mode of operation eithersample or calibration gas is delivered. The Model 3000ZA sample system is des...

Page 22 - Zirconium Oxide Sensor Application Notes; Dust and oil should be filtered from the sample gas.; Electronics and Signal Processing

Operational Theory 3000ZA Teledyne Analytical Instruments 10 Figure 2-2: Flow Diagram with Options 2.4 Zirconium Oxide Sensor Application Notes The following sample gases require conditioning prior to entering the sensor: • Flammable gases such as methane, alcohol and carbonmonoxide may cause a meas...

Page 23 - In the presence of oxygen the cell generates a current. A current to

Trace Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 11 The signal processing electronics including the microprocessor, analog to digital, and digital to analog converters are located on themotherboard at the bottom of the case. The preamplifier board ismounted on top of the moth...

Page 26 - Installation; Unpacking the Analyzer

Installation 3000ZA Teledyne Analytical Instruments 14 Installation Installation of the Model 3000ZA Analyzer includes: 1. Unpacking 2. Mounting 3. Gas connections 4. Electrical connections 5. Installing the sensor 6. Testing the system. 3.1 Unpacking the Analyzer The analyzer is shipped with all th...

Page 27 - All operator controls, except the flow control needle valve, are

Trace Oxygen Analyzer Installation Teledyne Analytical Instruments 15 Figure 3-1: Front Panel of the Model 3000TA (Model 3000ZA similar) All operator controls, except the flow control needle valve, are mounted on the control panel, which is hinged on the left edge anddoubles as the door that provide...

Page 28 - Rear Panel Connections; Figure 3-3 shows the Model 3000ZA rear panel. There are ports for; Gas Connections

Installation 3000ZA Teledyne Analytical Instruments 16 3.3 Rear Panel Connections Figure 3-3 shows the Model 3000ZA rear panel. There are ports for gas, power, and equipment interface. The Zero In and Span In ports arenot included on the standard model but are available as options. Figure 3-3: Rear ...

Page 29 - AWAY; CAUTION: OPERATING THE UNIT WITHOUT RESTRICTORS CAN; SAMPLE IN

Trace Oxygen Analyzer Installation Teledyne Analytical Instruments 17 pressure applications (5-50 psig) use the restrictor that has a blue stickeron the body. • Pressurized service: Connect the restrictor with the blue dot to the Sample In port. The small circular orifice should face AWAY from the b...

Page 30 - If greater sample flow is required for improved response time,

Installation 3000ZA Teledyne Analytical Instruments 18 If greater sample flow is required for improved response time, install a bypass in the sampling system upstream of the analyzer input. EXHAUST OUT: Exhaust connections must be consistent with the hazard level of theconstituent gases. Check local...

Page 31 - The fuse block, at the right of the power cord; Figure 3-4 shows the pin layout of the Equipment Interface

Trace Oxygen Analyzer Installation Teledyne Analytical Instruments 19 Fuse Installation: The fuse block, at the right of the power cord receptacle, accepts US or European size fuses. A jumper replaces thefuse in whichever fuse receptacle is not used. Fuses are not installed atthe factory. Be sure to...

Page 32 - Pin; The nine alarm-circuit connector pins connect to the

Installation 3000ZA Teledyne Analytical Instruments 20 Table 3-1: Analog Output Connections Pin Function 3 + Range ID, 4-20 mA, floating 4 – Range ID, 4-20 mA, floating 5 + ppm Range, 4-20 mA, floating (optional) 6 – ppm Range, 4-20 mA, floating (optional) 8 + Range ID, 0-1 VDC 23 – Range ID, 0-1 V ...

Page 33 - Digital Remote Cal Inputs:

Trace Oxygen Analyzer Installation Teledyne Analytical Instruments 21 • Actuates when DC power supplied to circuits isunacceptable in one or more parameters. Permanentlyconfigured as failsafe and latching. Cannot be defeated.Actuates if self test fails. • (Reset by pressing button to remove power. T...

Page 34 - Span; – Remote Zero; Remote Calibration Protocol:

Installation 3000ZA Teledyne Analytical Instruments 22 Span: Floating input. 5 to 24 V input across the + and – pins puts the analyzer into the Span mode. Either side may be grounded at the source of the signal. 0 to 1 volt across the terminals allows Span mode to terminate when done. A synchronous ...

Page 35 - When the CRC closes, remove the span command.; A serial digital input/output for local network protocol.

Trace Oxygen Analyzer Installation Teledyne Analytical Instruments 23 3. When CRC opens again, send a span command until theCRC closes. (The CRC will quickly close.) 4. When the CRC closes, remove the span command. When CRC opens again, zero and span are done, and the sample is being analyzed. Note:...

Page 36 - The voltage from these outputs is nominally 0 V for the OFF and

Installation 3000ZA Teledyne Analytical Instruments 24 Figure 3-5: Remote Probe Connections The voltage from these outputs is nominally 0 V for the OFF and 15 VDC for the ON conditions. The maximum combined current thatcan be pulled from these output lines is 100 mA. (If two lines are ON atthe same ...

Page 37 - The digital signal output is a standard, full duplex RS-232 serial; Immediately starts an autospan.

Trace Oxygen Analyzer Installation Teledyne Analytical Instruments 25 3.3.2.3 RS-232 P ORT The digital signal output is a standard, full duplex RS-232 serial communications port used to connect the analyzer to a computer,terminal, or other digital device. It requires a standard 9-pin Dconnector. The...

Page 38 - Parity; Installing the Zirconium Oxide Sensor

Installation 3000ZA Teledyne Analytical Instruments 26 Parity none Stop Bits 1 Message Interval 2 seconds. When CRC opensagain, zero and span are done,and the sample is being analyzed. Range ID Relays: There are three dedicated Range ID relay contacts. Three ranges are assigned to relays in ascendin...

Page 40 - Operation; Enter

Operation 3000ZA Teledyne Analytical Instruments 28 Operation 4.1 Introduction Once the analyzer has been installed, it can be configured for your application. To do this you will: • Set system parameters. • Establish a security password, if desired, requiring Operatorto log in. • Establish and star...

Page 41 - Using the Data Entry and Function Buttons

Trace Oxygen Analyzer Operation Teledyne Analytical Instruments 29 4.2 Using the Data Entry and Function Buttons Data Entry Buttons: The __ arrow buttons select options from the menu currently being displayed on the VFD screen. The selected optionblinks. When the selected option includes a modifiabl...

Page 42 - Figure 4-1: Hierarchy of Available Functions; Ariel Narrow Bold; type style. Pushbutton names are printed in

Operation 3000ZA Teledyne Analytical Instruments 30 Figure 4-1: Hierarchy of Available Functions Any function can be selected at any time by pressing the appropriate button (unless password restrictions apply). The order aspresented in this manual is appropriate for an initial setup. Each of these f...

Page 43 - Function

Trace Oxygen Analyzer Operation Teledyne Analytical Instruments 31 4.3 The System Function The sub fuctions of the System function are described below. Specific procedures for their use follow the descriptions: • Auto-Cal: Used to define an automatic calibration sequence and/or start an Auto-Cal. • ...

Page 45 - Setting up an Auto-Cal; Auto—Cal

Trace Oxygen Analyzer Operation Teledyne Analytical Instruments 33 The factory default is three minutes, but the delay time is programmable. To adjust to delay time use the Left or Right arrow keys.When the time displayed on the second line blinks, it can be adjusted byPressing the Up or Down keys t...

Page 46 - Password Protection; PSWD

Operation 3000ZA Teledyne Analytical Instruments 34 Zero) OFF/ON field. Use __ arrows to set the OFF/ON field to ON. Youcan now turn these fields ON because there is a nonzero span intervaldefined. 4.3.3 Password Protection If a password is assigned, then setting the following system parameters can ...

Page 47 - Changing the; Entering the Password; A A A A A

Trace Oxygen Analyzer Operation Teledyne Analytical Instruments 35 The screen prompts you to enter the current password. If you are not using password protection, press Enter to accept TETAI as the default password. If a password has been previously installed, enter thepassword using the __ arrow ke...

Page 49 - Note: If you log off the system using the logout function in the

Trace Oxygen Analyzer Operation Teledyne Analytical Instruments 37 If an alarm is tripped, the second line will change to show which alarm it is: 0.0 ppm AnlzAL—1 Note: If you log off the system using the logout function in the system menu, you will now be required to re-enter thepassword to gain ac...

Page 50 - More; Version Self—Test; Maintenance and Troubleshooting; Version

Operation 3000ZA Teledyne Analytical Instruments 38 TRAK/HLD Auto—CalPSWD Logout More Use the __ arrow keys to blink More , then press Enter . Version Self—Test Use the __ arrow keys again to move the blinking to the Self–Test function. The screen will follow the running of the diagnostic. RUNNING D...

Page 51 - The Zero and Span Functions; A span gas with a known oxygen concentration in the range of

Trace Oxygen Analyzer Operation Teledyne Analytical Instruments 39 TRAK/HLD Auto—CalPSWD Logout More Use the __ arrow keys to blink More , then press Enter . Version Self—TestShow_Negative=NO Use the __ arrow keys and select “ Show_Negative = NO”.Use the __ arrow keys to toggle from NO to YES.Press ...

Page 52 - Zero; AUTO

Operation 3000ZA Teledyne Analytical Instruments 40 If you are using password protection, you will need to enter your password to gain access to either of these functions. Follow theinstructions in sections 4.3.3 to enter your password. Once you havegained clearance to proceed, you can enter the Zer...

Page 54 - Maintenance

Operation 3000ZA Teledyne Analytical Instruments 42 CELL FAIL/ ZERO HIGH Before replacing the cell:a. Check your span gas to make sure it is within specifications.b. Check for leaks up-stream from the cell, where oxygen may be leaking into the system. If there are no leaks and the span gas is within...

Page 56 - FCAL

Operation 3000ZA Teledyne Analytical Instruments 44 Press Enter to enter the span value into the system and begin the span calibration. Once the span has begun, the microprocessor samples the output at a predetermined rate. It calculates the difference between successivesamplings and displays this d...

Page 57 - Alarms

Trace Oxygen Analyzer Operation Teledyne Analytical Instruments 45 4.5 The Alarms Function The Model 3000ZA is equipped with 2 fully adjustable concentration alarms and a system failure alarm. Each alarm has a relaywith a set of form “C" contacts rated for 3 amperes resistive load at 250VAC. See...

Page 58 - Alarm; LO

Operation 3000ZA Teledyne Analytical Instruments 46 back to non-alarm conditions. This mode requires an alarm tobe recognized before it can be reset. In the non-latchingmode, the alarm status will terminate when processconditions revert to non-alarm conditions. 8. Are either of the alarms to be defe...

Page 59 - Dft–; Range; Front Panel

Trace Oxygen Analyzer Operation Teledyne Analytical Instruments 47 To set the other parameters use the __ arrow keys to move the blinking over to the desired parameter. Then use the __ arrow keys tochange the parameter. Once the parameters for alarm 1 have been set, press Alarms again, and repeat th...

Page 60 - Fixed Range Analysis

Operation 3000ZA Teledyne Analytical Instruments 48 L—10 M—100H—250 Mode—AUTO Use the __ arrow keys to blink the range to be set: low (L), medium (M), or high (H). Use the __ arrow keys to enter the upper value of the range (all ranges begin at 0 ppm). Repeat for each range you want to set. Press En...

Page 61 - The Analyze Function; Escape; Voltage Signal

Trace Oxygen Analyzer Operation Teledyne Analytical Instruments 49 as established by the operator for that particular range, theoutput saturates at 1 VDC(or 20 mA). However, the digitalreadout and the RS-232 output continue to read the truevalue of the oxygen concentration regardless of the analogou...

Page 62 - The analog output signal has a voltage which depends on the; In the event of loss of flow through the analyzer, if the

Operation 3000ZA Teledyne Analytical Instruments 50 80 0.8 16.8 90 0.9 18.4 100 1.0 20.0 The analog output signal has a voltage which depends on the oxygen concentration AND the currently activated analysis range. Torelate the signal output to the actual concentration, it is necessary toknow what ra...

Page 64 - Routine Maintenance; Aside from normal cleaning and checking for leaks at the gas; Cell Replacement; The ZrO

Maintenance 3000ZA Teledyne Analytical Instruments 52 Maintenance 5.1 Routine Maintenance Aside from normal cleaning and checking for leaks at the gas connections, routine maintenance is limited to replacing the sensor andfuses, and recalibration. For recalibration, see Section 4.4 Calibration . WAR...

Page 65 - Figure 5-2: Removing Fuse Block from Housing

Trace Oxygen Analyzer Maintenance Teledyne Analytical Instruments 53 4. Remove the old sensor and install a new sensor by matchingthe orientation notch on the sensor to the silkscreen on thesensor holder. Figure 5-1: Replacing the ZrO 2 Sensor 5.3 Fuse Replacement 1. Place small screwdriver in notch...

Page 66 - System Self Diagnostic Test; Power; Analog; OK

Maintenance 3000ZA Teledyne Analytical Instruments 54 2. To change between American and European fuses, removethe single retaining screw, flip Fuse Block over 180 degrees,and replace screw. 3. Replace fuse as shown in Figure 5-3. 4. Reassemble Housing as shown in Figure 5-2. American Fuses European ...

Page 67 - Preamp; Major Internal Components; The zirconium sensor is accessed by unlatching and swinging open

Trace Oxygen Analyzer Maintenance Teledyne Analytical Instruments 55 Preamp 0 OK 1 Zero too high 2 Amplifier output doesn't match test input 3 Both Failed 5.5 Major Internal Components The zirconium sensor is accessed by unlatching and swinging open the front panel, as described earlier. Other inter...

Page 68 - Problem; Press

Maintenance 3000ZA Teledyne Analytical Instruments 56 • Analysis Section • Zirconium oxide sensor • Cell block • Sample system • Power Supply • Microprocessor • Displays • 5 digit LED meter • 2 line, 20 character, alphanumeric, VFD display • RS-232 Communications Port See the drawings in the Drawing...

Page 70 - Appendix

Appendix 3000ZA Teledyne Analytical Instruments Appendix A-1 Specifications Packaging: General Purpose • Flush panel mount (Standard) • Relay rack mount. Contains either one or two instruments in one 19" relay rackmountable plate (Optional). Sensor: Zirconium oxide sensor. Cell Block: Nylon Samp...

Page 71 - Operating Temperature:

Trace Oxygen Analyzer Appendix Teledyne Analytical Instruments Power: Universal power supply 85-250 V ac, at47-63 Hz. Operating Temperature: 5-35 °C Accuracy: ±2% of full scale at constant temperature(at ca;obrated ramge).±5% of full scale over operatingtemperature range, except 0-1 ppmanalysis rang...

Page 72 - Part Number Description; TELEDYNE Analytical Instruments

Appendix 3000ZA Teledyne Analytical Instruments A-2 Recommended 2-Year Spare Parts List Qty. Part Number Description 1 C65507A Back Panel Board 1 C62371-A Front Panel Board 1 C75734A Trace Preamplifier Board 1 C73870-A Main Computer Board 1 F10 Fuse, 2A, 250V 3AG Slow Blow 2 F1296 Fuse, 2A, 250V 5x2...

Page 74 - A.5 Application Notes; APPLICATION NOTES ON RESTRICTORS,

Appendix 3000ZA Teledyne Analytical Instruments A.5 Application Notes 3000 SERIES ANALYZERS APPLICATION NOTES ON RESTRICTORS, PRESSURES, AND FLOW RECOMMENDATIONS The 3000 series analyzers require reasonably regulated sample pressures. While the 3000 analyzers are not sensitive to variations ofincomi...

Page 75 - The standard restrictor (BLUE DOT) is recommended for pressures

Trace Oxygen Analyzer Appendix Teledyne Analytical Instruments positive pressure applications as well as vacuum service applications(see manual for installation instructions). The standard restrictor (BLUE DOT) is recommended for pressures between 5 and 50 PSIG. For positive low pressure application...

Page 76 - OPERATION WITHOUT A RESTRICTOR DEVICE:

Appendix 3000ZA Teledyne Analytical Instruments To improve the system response, a by-pass can be added to increase the sample flow rate to the analyzer by a factor of ten. A by-pass providesa sample flow path around the analyzer of 2 - 18 SCFH. typically. CALIBRATION GAS: 3000 series analyzer requir...

Page 78 - Index

Index 3000ZA Teledyne Analytical Instruments Index AC power connection, 6accuracy, 58address, 59alarm, 57 concentration, 2, 6, 44configuration, 44freeze, 31relay contact pins, 20relays, 19setpoint, 45system failure, 2, 6, 10, 20, 44threshold 1, 19threshold 2, 19 ALARMS key, 28alphanumeric display, 3...