Teledyne Oxygen Equipment P NM70946 User Manual

OPERATING INSTRUCTIONS FOR  
Model  
UltraTrace 3000  
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.  
P/NM70946  
12/10/99  
ECO#99-0483  
ONLYAUTHORIZEDPERSONNELSHOULDCONDUCTMAINTENANCEAND/ORSERVICING. BEFORE  
CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/  
MANAGER.  
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Trace Oxygen Analyzer  
Specific Model Information  
Theinstrumentforwhichthismanualwassuppliedmayincorporateoneor  
moreoptionsnotsuppliedinthestandardinstrument.Commonlyavailable  
optionsarelistedbelow,withcheckboxes.Anythatareincorporatedinthe  
instrumentforwhichthismanualissuppliedareindicatedbyacheckmarkinthe  
box.  
InstrumentSerialNumber: _______________________  
OptionsIncludedintheInstrumentwiththeAboveSerialNumber:  
q Ultra Trace 3000-V: InstrumentconfiguredforVacuumService  
q 19" Rack Mnt: The19"RelayRackMountunitsareavailablewithone  
UltraTrace3000seriesanalyzersinstalledinastandard  
19"panelandreadytomountinastandardrack.  
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Model Ultra Tace 3000  
Table of Contents  
1 Introduction  
1.1 Overview........................................................................ 1-1  
1.2 Typical Applications ....................................................... 1-1  
1.3 Main Features of the Analyzer ....................................... 1-1  
1.4 Model Designations ....................................................... 1-2  
1.5 Front Panel (Operator Interface) ..................................... 1-3  
1.6 Rear Panel (Equipment Interface) .................................. 1-5  
2 OperationalTheory  
2.1 Introduction .................................................................... 2-1  
2.2 Micro-Fuel Cell Sensor .................................................. 2-1  
2.2.1 Principles of Operation ............................................ 2-1  
2.2.2 Anatomy of a Micro-Fuel Cell .................................. 2-2  
2.2.3 Electrochemical Reactions ...................................... 2-3  
2.2.4 The Effect of Pressure.............................................. 2-4  
2.2.5 Calibration Characteristics ...................................... 2-4  
2.2.6 TEC Cooling System ............................................... 2-4  
2.3 Sample System.............................................................. 2-5  
2.4 Electronics and Signal Processing ................................ 2-8  
3 Installation  
3.1 Unpacking the Analyzer................................................. 3-1  
3.2 Mounting the Analyzer ................................................... 3-1  
3.3 Rear Panel Connections ................................................ 3-3  
3.3.1 Gas Connections ................................................... 3-3  
3.3.2 Electrical Connections ........................................... 3-4  
3.3.2.1 Primary Input Power....................................... 3-4  
3.3.2.2 50-pin Interface Connector............................. 3-5  
3.3.3 Remote Probe Connector ...................................... 3-8  
3.4 Installing the Micro-Fuel Cell ......................................... 3-10  
3.5 Testing the System......................................................... 3-10  
4 Operation  
4.1 Introduction .................................................................... 4-1  
4.2 Using the Data Entry and Function Buttons ................... 4-2  
4.3 The System Function ..................................................... 4-3  
4.3.1 Tracking the O2 Readings during CAl & Alarm ....... 4-4  
4.3.2 Setting up an Auto-Cal........................................... 4-5  
4.3.3 Password Protection .............................................. 4-6  
4.3.3.1 Entering the Password ................................... 4-7  
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4.3.3.2 Installing or Changing the Password ............. 4-8  
4.3.4 Logout.................................................................... 4-9  
4.3.5 System Self-Diagnostic Test .................................. 4-9  
4.3.6 Version Screen ...................................................... 4-10  
4.3.7 Filter Function ........................................................ 4-11  
4.4 Calibration of the Analyzer............................................. 4-11  
4.4.1 Zero Cal ................................................................. 4-11  
4.4.1.1 Auto Mode Zeroing ........................................ 4-12  
4.4.1.2 Manual Mode Zeroing.................................... 4-13  
4.4.1.3 Cell Failure .................................................... 4-13  
4.4.2 Span Cal................................................................ 4-14  
4.4.2.1 Auto Mode Spanning ..................................... 4-14  
4.4.2.2 Manual Mode Spanning................................. 4-15  
4.4.3 Span Failure .......................................................... 4-16  
4.5 Switching of Sample Streams ........................................ 4-17  
4.5.1 Special notes on hydrogen gas stream .................. 4-17  
4.6 The Alarms Function...................................................... 4-17  
4.7 The Range Function ...................................................... 4-20  
4.7.1 Setting the Analog Output Ranges......................... 4-20  
4.7.2 Fixed Range Analysis............................................ 4-21  
4.8 The Analyze Function.................................................... 4-23  
4.9 Signal Output ................................................................. 4-23  
Maintenance  
5.1 Routine Maintenance..................................................... 5-1  
5.2 Cell Replacement .......................................................... 5-1  
5.2.1 Storing and Handling Replacement Cells ............... 5-1  
5.2.2 When to Replace a Cell ........................................... 5-2  
5.2.3 Removing the Micro-Fuel Cell ................................. 5-2  
5.2.4 Installing a New Micro-Fuel Cell.............................. 5-4  
5.2.5 Cell Warranty ........................................................... 5-4  
5.3 Fuse Replacement......................................................... 5-5  
5.4 System Self Diagnostic Test........................................... 5-5  
5.5 Major Internal Components............................................ 5-6  
5.6 Cleaning ........................................................................ 5-7  
5.7 Troubleshooting ............................................................. 5-8  
Appendix  
A-1 Model Ultra Tace 3000 Specifications ............................ A-1  
A-2 Recommended 2-Year Spare Parts List ......................... A-3  
A-3 Drawing List ................................................................... A-4  
A-4 19-Inch Relay Rack Panel Mount................................... A-4  
A-5 Application Notes on Pressures and Flow ..................... A-5  
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Model Ultra Tace 3000  
DANGER  
COMBUSTIBLE GAS USAGE WARNING  
This is a general purpose instrument designed for use in a  
nonhazardous 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 unau-  
thorized substitution of any component may adversely affect  
the safety of this instrument.  
Since the use of this instrument is beyond the control of  
Teledyne, no responsibility byTeledyne, its affiliates, and agents  
for damage or injury from misuse or neglect of this equipment is  
implied or assumed.  
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Ultra Trace Oxygen Analyzer  
Introduction 1  
Introduction  
1.1 Overview  
The Teledyne Analytical Instruments Model 3000 Ultra Trace Oxygen  
Analyzer is a versatile microprocessor-based instrument for detecting oxygen  
at the parts-per-billion (ppb) level in a variety of gases. This manual covers  
the Model Ultra Trace 3000 General Purpose flush-panel and/or rack-mount  
units only. These units are for indoor use in a nonhazardous environment.  
1.2 Typical Applications  
A few typical applications of the Model Ultra Trace 3000 are:  
Monitoringinertgasblanketing  
Airseparationandliquefaction  
Chemicalreactionmonitoring  
Semiconductormanufacturing  
Petrochemicalprocesscontrol  
Qualityassurance  
Gasanalysiscertification.  
1.3 Main Features of the Analyzer  
The Model 3000 Ultra Trace Oxygen Analyzer is sophisticated yet  
simple to use. The main features of the analyzer include:  
A 2-line alphanumeric vacuum fluorescent display (VFD) screen,  
drivenbymicroprocessorelectronics, thatcontinuouslyprompts  
and informs the operator.  
High resolution, accurate readings of oxygen content from low  
ppm levels through 25%. Large, bright, meter readout.  
Stainless steel cell block (wetted surfaces).  
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1 Introduction  
Model Ultra Trace 3000  
Advanced Micro-Fuel Cell, designed for trace analysis, has a 0-  
250 ppb low range with less than a 100 ppb offset and six  
months warranty and an expected lifetime of one year.  
Versatile analysis over a wide range of applications.  
Microprocessorbasedelectronics:8-bitCMOSmicroprocessor  
with 32 kB RAM and 128 kB ROM.  
Three user definable output ranges (from 0-250 ppb through 0-  
1000 ppm) allow best match to users process and equipment, plus  
a fixed 1000 ppm over range.  
Auto Ranging allows analyzer to automatically select the proper  
preset range for a given measurement. Manual override allows  
the user to lock onto a specific range of interest.  
Twoadjustableconcentrationalarmsandasystemfailurealarm.  
Extensive self-diagnostic testing, at startup and on demand, with  
continuouspower-supplymonitoring.  
Two way RFI protection.  
RS-232 serial digital port for use with a computer or other digital  
communicationdevice.  
Four analog outputs: two for measurement (01 V dc and  
Isolated 420 mA dc) and two for range identification.  
Convenient and versatile, steel, flush-panel orrack-mountable  
case with slide-out electronics drawer.  
1.4 Model Designations  
Ultra Trace 3000: Standard model for sample under pressure  
Ultra Trace 3000-V: Instrument configured for Vacuum Service  
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Ultra Trace Oxygen Analyzer  
Introduction 1  
1.5 Front Panel (Operator Interface)  
The standard Ultra Trace 3000 is housed in a rugged metal case with all  
controls and displays accessible from the front panel. See Figure 1-1. The  
front panel has thirteen buttons for operating the analyzer, a digital meter, an  
alphanumeric display, and a window for viewing the sample flowmeter.  
Function Keys: Six touch-sensitive membrane switches are used to  
change the specific function performed by the analyzer:  
Door Latch  
Digital Meter  
Alphanumeric  
Display  
Sample System  
Flow Indicator  
Standby Switch  
Function Buttons  
Data Entry Buttons  
Figure 1-1: Model Ultra Trace 3000 Front Panel  
Analyze Perform analysis for oxygen content of a sample gas.  
System Performsystem-relatedtasks(describedindetailin  
chapter 4, Operation.).  
Span  
Zero  
Span calibrate the analyzer.  
Zero calibrate the analyzer.  
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1 Introduction  
Model Ultra Trace 3000  
Alarms Set the alarm setpoints and attributes.  
Range Set up the 3 user definable ranges for the instrument.  
Data Entry Keys: Six touch-sensitive membrane switches are used to  
input data to the instrument via the alphanumeric VFD display:  
Left & Right Arrows  
Selectbetweenfunctionscurrently  
displayed on the VFD screen.  
Up & Down Arrows  
Increment or decrement values of  
functionscurrentlydisplayed.  
Enter Moves VFD display on to the next screen in a series. If  
none remains, returns to the Analyze screen.  
Escape Moves VFD display back to the previous screen in a  
series. If none remains, returns to the Analyze screen.  
Digital Meter Display: The meter display is a Light Emitting Diode  
(LED) device that produces large, bright, 7-segment numbers that are legible  
in any lighting. It produces a continuous readout from 0-999 ppb and then  
switches to a continuous ppm readout from 0-9999.9 ppm. It is accurate  
across all analysis ranges without the discontinuity inherent in analog range  
switching.  
Alphanumeric Interface Screen: The VFD screen is an easy-to-use  
interface from operator to analyzer. It displays values, options, and messages  
that give the operator immediate feedback.  
NeedleValve: To adjust flow of gas sample  
Flowmeter: Monitors the flow of gas past the sensor. Readout is 0.2 to  
2.4 standard liters per minute (SLPM) of nitrogen  
Standby Button: The Standby turns off the display and outputs,  
butcircuitryisstilloperating.  
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 Micro-Fuel Cell, the front panel  
swings open when the latch in the upper right corner of the panel is pressed  
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Ultra Trace Oxygen Analyzer  
Introduction 1  
all the way in with a narrow gauge tool. Accessing the main circuit board  
requires unfastening rear panel screws and sliding the unit out of the case.  
1.6 Rear Panel (Equipment Interface)  
The rear panel, shown in Figure 1-2, contains the gas and electrical  
connectors for external inlets and outlets. Some of those depicted are op-  
tional and may not appear on your instrument. The connectors are described  
briefly here and in detail in chapter 3 Installation.  
T el e d y n e A n a ly tic a l In stru m e n ts  
!
!
Figure 1-2: Model Ultra Trace 3000 Rear Panel  
Power Connection  
Universal AC power source.  
Gas Inlet and Outlet One inlet and one exhaust out.  
Analog Outputs  
01 V dc oxygen concentration plus 0-1  
V dc range ID, and isolated 420 mA dc  
oxygen concentration plus 4-20 mA dc  
range ID.  
Alarm Connections  
2 concentration alarms and 1 system  
alarm.  
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1 Introduction  
Model Ultra Trace 3000  
RS-232 Port  
Serialdigitalconcentrationsignaloutput  
and control input.  
Remote Probe  
Used in the Ultra Trace3000 for  
controllingexternalsolenoidvalves  
only.  
Remote Span/Zero  
Digital inputs allow external control of  
analyzercalibration.  
Calibration Contact To notify external equipment that  
instrument is being calibrated and  
readings are not monitoring sample.  
Range ID Contacts  
Network I/O  
Four separate, dedicated, range relay  
contacts. Low, Medium, High, Cal.  
Serialdigitalcommunicationsforlocal  
network access. For future expansion.  
Not implemented at this printing.  
Note: If you require highly accurate Auto-Cal timing, use external  
Auto-Cal control where possible. The internal clock in the  
Model Ultra Trace 3000 is accurate to 2-3 %. Accordingly,  
internally scheduled calibrations can vary 2-3 % per day.  
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Ultra Trace Oxygen Analyzer  
Operational Theory 2  
Operational Theory  
2.1 Introduction  
The analyzer is composed of three subsystems:  
1. Micro-fuelCellSensor  
2. SampleSystem  
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 Micro-fuel Cell is an electrochemical galvanic device that  
translates the amount of oxygen present in the sample into an electrical  
current. The electronic signal processing, display and control subsystem  
simplifies operation of the analyzer and accurately processes the sampled  
data. The microprocessor controls all signal processing, input/output and  
display functions for the analyzer.  
2.2 Micro-Fuel Cell Sensor  
2.2.1 Principles of Operation  
The oxygen sensor used in the Model Ultra Trace 3000 series is a  
Micro-fuel Cell, Model B-2CXL designed and manufactured by Analytical  
Instruments. Itisasealedplasticdisposableelectrochemicaltransducer.  
The active components of the Micro-fuel Cell are a cathode, an anode,  
and the aqueous KOH electrolyte in which they are immersed. The cell  
converts the energy from a chemical reaction into an electrical current in an  
external electrical circuit. Its action is similar to that of a battery.  
There is, however, an important difference in the operation of a battery  
as compared to the Micro-fuel Cell: In the battery, all reactants are stored  
within the cell, whereas in the Micro-fuel Cell, one of the reactants (oxygen)  
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2 Operational Theory  
Model Ultra Trace 3000  
comes from outside the device as a constituent of the sample gas being  
analyzed. The Micro-Fuel Cell is therefore a hybrid between a battery and a  
true fuel cell. (All of the reactants are stored externally in a true fuel cell.)  
2.2.2 Anatomy of a Micro-Fuel Cell  
The Micro-Fuel Cell is a cylinder only 1¼ inches in diameter and 1¼  
inches thick. It is made of an extremely inert plastic, which can be placed  
confidently in practically any environment or sample stream. It is effectively  
sealed, although one end is permeable to oxygen in the sample gas. The  
other end of the cell is a contact plate consisting of two concentric foil rings.  
The rings mate with spring-loaded contacts in the sensor block assembly and  
provide the electrical connection to the rest of the analyzer. Figure 2-1  
illustratestheexternalfeatures.  
Figure 2-1: Micro-fuel Cell  
Refer to Figure 2-2, Cross Section of a Micro-Fuel Cell, which illus-  
tratesthefollowinginternaldescription.  
Figure 2-2. Cross Section of a Micro-Fuel Cell (not to scale)  
At the top end of the cell is a diffusion membrane of Teflon, whose  
thickness is very accurately controlled. Beneath the diffusion membrane lies  
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Ultra Trace Oxygen Analyzer  
Operational Theory 2  
the oxygen sensing elementthe cathodewith a surface area almost 4 cm2.  
The cathode has many perforations to ensure sufficient wetting of the upper  
surface with electrolyte, and it is plated with an inert metal.  
The anode structure is below the cathode. It is made of lead and has a  
proprietary design which is meant to maximize the amount of metal available  
forchemicalreaction.  
At the rear of the cell, just below the anode structure, is a flexible  
membrane designed to accommodate the internal volume changes that occur  
throughout the life of the cell. This flexibility assures that the sensing mem-  
brane remains in its proper position, keeping the electrical output constant.  
The entire space between the diffusion membrane, above the cathode,  
and the flexible rear membrane, beneath the anode, is filled with electrolyte.  
Cathode and anode are submerged in this common pool. They each have a  
conductor connecting them to one of the external contact rings on the contact  
plate, which is on the bottom of the cell.  
2.2.3 Electrochemical Reactions  
The sample gas diffuses through the Teflon membrane. Any oxygen in  
the sample gas is reduced on the surface of the cathode by the following  
HALF REACTION:  
O2 + 2H2O + 4e4OH–  
(cathode)  
(Four electrons combine with one oxygen moleculein the presence of  
water from the electrolyteto produce four hydroxyl ions.)  
When the oxygen is reduced at the cathode, lead is simultaneously  
oxidized at the anode by the following HALF REACTION:  
Pb + 2OHPb+2 + H2O + 2e–  
(anode)  
(Two electrons are transferred for each atom of lead that is oxidized.  
Therefore it takes two of the above anode reactions to balance one cathode  
reactionandtransferfourelectrons.)  
The electrons released at the surface of the anode flow to the cathode  
surface when an external electrical path is provided. The current is propor-  
tional to the amount of oxygen reaching the cathode. It is measured and used  
to determine the oxygen concentration in the gas mixture.  
The overall reaction for the fuel cell is the SUM of the half reactions  
above, or:  
2Pb + O2 2PbO  
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2 Operational Theory  
Model Ultra Trace 3000  
(These reactions are specific to oxygen as long as no gaseous components  
capable of oxidizing leadsuch as iodine, bromine, chlorine and fluorineare  
present in the sample.)  
In the absence of oxygen, no current is generated.  
2.2.4 The Effect of Pressure  
In order to state the amount of oxygen present in the sample in ppb or  
parts-per-million of the gas mixture, it is necessary that the sample diffuse into  
the cell under constant pressure.  
If the total pressure increases, the rate that oxygen reaches the cathode  
through the diffusing membrane will also increase. The electron transfer, and  
therefore the external current, will increase, even though the oxygen concentra-  
tion of the sample has not changed. It is therefore important that the sample  
pressure at the fuel cell (usually vent pressure) remain relatively constant  
betweencalibrations.  
2.2.5 Calibration Characteristics  
Given that the total pressure of the sample gas on the surface of the  
Micro-Fuel Cell input is constant, a convenient characteristic of the cell is that  
the current produced in an external circuit is directly proportional to the rate at  
which oxygen molecules reach the cathode, and this rate is directly propor-  
tional to the concentration of oxygen in the gaseous mixture. In other words it  
has a linear characteristic curve, as shown in Figure 2-3. Measuring circuits do  
not have to compensate for nonlinearities.  
In addition, since there is zero output in the absence of oxygen, the  
characteristic curve has close to an absolute zero (less than ± 0.1 ppm oxygen).  
Depending upon the application, zeroing may still be used to compensate for  
the combined zero offsets of the cell and the electronics.  
2.2.6 TEC Cooling System  
Ultra Trace 3000 analyzers include an advance Thermal Electric  
Cooler (TEC) system. This system enhances the performance of the Micro-fuel  
Cell by cooling it and regulating its operating temperature. The TEC system  
includes a TEC module, a temperature control PCB, a separate power supply,  
a thermistor, and a special insulated cellblock. The system is used to regulate  
the cell temperature at 11 degrees C. Operating the Micro-fuel Cell at a low  
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Ultra Trace Oxygen Analyzer  
Operational Theory 2  
temperature minimizes the cell offset (typically less than 75 PPB). A second  
benefit of the TEC system is that by regulating the cell temperature the  
analyzer becomes tolerant of thermal transients.  
The TEC module is a solid-state semiconductor heat pump. Passing  
DC current through the TEC module produces heat flow though the device.  
One side of the device will become hot and the other side will become cold.  
The TEC module is attached to a heat-sink which is cooled by a fan. This is  
required to maintain the hot side at an acceptable temperature. The hot side  
temperature limits the overall performance of the TEC module. The fan  
draws air into the bottom of the analyzer, this air is forced over the heat sink  
and exits through the left side of the analyzer. The power for the TEC device  
is supplied by a Pulse Width Modulated (PWM) proportional switching  
temperature controller. The temperature controller PCB supplies a 12 volt  
pulse whose duty cycle is proportional to the cooling required. The tempera-  
ture controller PCB uses a thermistor to monitor the temperature of the of cell  
block. Power for the fan, and the temperature controller PCB is supplied by  
a separate 12VDC power supply.  
Figure 2-3. Characteristic Input/Output Curve for a Micro-Fuel Cell  
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2 Operational Theory  
Model Ultra Trace 3000  
2.3 Sample System  
The sample system delivers gases to the Micro-Fuel Cell sensor from  
the analyzer rear panel inlet. Depending on the mode of operation either  
sample or calibration gas is delivered.  
The Model Ultra Trace 3000 sample system is designed and fabricated  
to ensure that the oxygen concentration of the gas is not altered as it travels  
through the sample system.  
The sample system for the standard instrument incorporates 1/4" VCR  
for sample inlet and outlet tube connections at the rear panel. The sample or  
calibration gas that flows through the system is monitored by a flowmeter  
downstream from the cell. Figure 2-4 shows the piping layout and flow  
diagram for the standard model.  
Figure 2-4: Piping Layout  
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Ultra Trace Oxygen Analyzer  
Operational Theory 2  
Figure 2-5: Flow Diagram-Sample Under Pressure  
-Standard Model Ultra Trace 3000  
-Do not exceed 10" Hg Vacuum-  
Figure 2-5-1: Flow Diagram-Sample at Zero Pressure  
-Model Ultra Trace 3000-V  
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2 Operational Theory  
Model Ultra Trace 3000  
Figure 2-5 is the flow diagram for the sampling system. In the standard  
instrument, calibration gases can be connected directly to the Sample In port  
by teeing to the port with appropriate valves.  
2.4 Electronics and Signal Processing  
The Model Ultra Trace 3000 Oxygen Analyzer uses an 8031 microcon-  
troller with 32 kB of RAM and 128 kB of ROM to control all signal pro-  
cessing, input/output, and display functions for the analyzer. System power  
is supplied from a universal power supply module designed to be compatible  
with any international power source. Figure 2-6 shows the location of the  
power supply and the main electronic PC boards.  
The signal processing electronics including the microprocessor, analog  
to digital, and digital to analog converters are located on the motherboard at  
the bottom of the case. The preamplifier board is mounted on top of the  
motherboard as shown in the figure. These boards are accessible after re-  
moving the back panel. Figure 2-7 is a block diagram of the Analyzer  
electronics.  
Universal  
Power Supply  
Front Panel  
Display Board  
TEC Power Supply  
Slide-out  
Electronics  
Drawer  
Temperature  
Controller  
Board  
Motherboard  
Preamplifier  
PCB  
Figure 2-6: Electronic Component Location Inside the Model Ultra Trace 3000  
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Ultra Trace Oxygen Analyzer  
Operational Theory 2  
Current  
Second  
Stage  
to Voltage  
Amplifier  
Amplifier  
Sensor  
A to D  
Converter  
Thermistor  
T E C  
Power  
Supply  
Auto  
Range  
HEAT  
SINK  
FAN  
Temperature  
Controller  
System  
Failure  
Alarm  
Micro-  
Processor  
Processing  
Displays  
Self Test  
Signal  
Concentration  
Range  
D to A  
0-1 V  
Converter  
4-20 mA  
0-1 V  
4-20 mA  
Figure 2-7: Block Diagram of the Model Ultra Trace 3000 Electronics  
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2 Operational Theory  
Model Ultra Trace 3000  
In the presence of oxygen the cell generates a current. A current to  
voltage amplifier converts this current to a voltage, which is further amplified  
in the second stage amplifier.  
The output from the second stage amplifier is sent to an 18 bit analog  
to digital converter controlled by the microprocessor.  
The digital concentration signal along with input from the control panel  
is processed by the microprocessor, and appropriate control signals are  
directed to the display, alarms and communications port. The same digital  
information is also sent to a 12 bit digital to analog converter that produces  
the 4-20 mA dc and the 0-1 V dc analog concentration signal outputs, and  
the analog range ID outputs.  
Signals from the power supply are also monitored, and through the  
microprocessor, the system failure alarm is activated if a malfunction is  
detected.  
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Ultra Trace Oxygen Analyzer  
Installation 3  
Installation  
Installation of the Model Ultra Trace 3000 Analyzer includes:  
1. Unpacking  
2. Mounting  
3. Gas connections  
4. Electricalconnections  
5. InstallingtheMicro-FuelCell  
6. Testing the system.  
3.1 Unpacking the Analyzer  
Although the analyzer is shipped complete, certain of the parts, such as  
fuses and sensors, are wrapped separately to be installed on site as part of the  
installation. Carefully unpack the analyzer and inspect it for damage. Imme-  
diately report any damage or shortages to the shipping agent.  
3.2 Mounting the Analyzer  
The Model Ultra Trace 3000 is for indoor use in a general purpose  
area. It is NOT for hazardous environments of any type.  
The standard model is designed for flush panel mounting. Figure 3-1 is  
an illustration of the Ultra Trace 3000 standard front panel and mounting  
bezel. There are four mounting holesone in each corner of the rigid frame.  
The drawings section in the rear of this manual contains outline dimensions  
and mounting hole spacing diagrams.  
On special order, a 19" rack-mounting panel can be provided. For rack  
mounting, one Ultra Trace 3000 series analyzer is flush-panel mounted on  
the rack panel. See Appendix for dimensions of the mounting panel.  
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3 Installation  
Model Ultra Trace 3000  
ULTRATRACE 3000  
Latch  
6.7”  
ULTRA TRACE ANALYZER  
System  
2.0  
1.0  
Analyze  
Span  
Zero  
Hinge  
Range  
Alarms  
Set Flow  
Standby  
Escape  
Enter  
10”  
Figure 3-1: Front Panel of the Model Ultra Trace 3000  
All operator controls are mounted on the control panel, which is hinged  
on the left edge and doubles as the door that provides access to the sensor  
and cell block inside the instrument. The door is spring loaded and will  
swing open when the button in the center of the latch (upper right corner) is  
pressed all the way in with a narrow gauge tool (less than 0.18 inch wide),  
such as a small hex wrench or screwdriver Allow clearance for the door to  
open in a 90-degree arc of radius 7.125 inches. See Figure 3-2.  
Provide 1 inch of air clearance at the bottom and sides of the instrument  
for proper air flow for TEC fun.  
Failure to provide such a clearance will cause damage to the TEC  
system. Do not restrict this openings.  
Figure 3-2: Required Front Door Clearance  
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Ultra Trace Oxygen Analyzer  
Installation 3  
3.3 Rear Panel Connections  
Figure 3-3 shows the Model Ultra Trace 3000 rear panel. There are  
ports for gas inlet and outlet, power, communication, and both digital and  
analogconcentrationoutput.  
Te le dyne A n alytic a l Ins tru m e nts  
!
!
Figure 3-3: Rear Panel of the Model Ultra Trace 3000  
3.3.1 Gas Connections  
The unit is manufactured with 1/4 inch VCR fittings. For a safe connec-  
tion:  
SAMPLE IN: In the standard model, gas connections are made at the  
SAMPLE IN and EXHAUST OUT connections. Calibration gases must be  
Tee'd into the Sample inlet with appropriate valves. A VCR fitting is pro-  
vided for the inlet connection.  
The inlet gas pressure should be reasonably regulated. Pressures be-  
tween 1 and 50 psig are acceptable as long as the pressure, once established,  
will keep the front panel flowmeter reading in an acceptable range (0.5 to 2.0  
SLPM). For non-pressurized sample or very low pressure, (less than 1 psig)  
vacuum service plumbing is recommended. (See next section: Vacuum  
Service).  
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3 Installation  
Model Ultra Trace 3000  
If greater sample flow is required for improved response time, install a  
bypass in the sampling system upstream of the analyzer input.  
VACUUM SERVICE: If the sample pressure is at atmospheric or  
very low pressure, the instrument must be ordered with the vacuum service  
option. This will ensure that the flow control valve is located on the exhaust  
side of the Micro-Fuel Cell.  
EXHAUST OUT: Exhaust connections must be consistent with the  
hazard level of the constituent gases. Check Local, State, and Federal laws,  
and ensure that the exhaust stream vents to an appropriately controlled area,  
ifrequired.  
3.3.2 Electrical Connections  
For safe connections, no uninsulated wiring should be able to come in  
contact with fingers, tools or clothing during normal operation.  
CAUTION: Use Shielded Cables. Also, use plugs that provide  
excellent EMI/RFI protection. The plug case must be  
connected to the cable shield, and it must be tightly  
fastened to the analyzer with its fastening screws.  
Ultimately, it is the installer who ensures that the  
connections provide adequate EMI/RFI sielding.  
3.3.2.1  
Primary Input Power  
The power cord receptacle and fuse block are located in the same  
assembly. Insert the power cord into the power cord receptacle.  
CAUTION: Power is applied to the instrument's circuitry as  
long as the instrument is connected to the power  
source. The red  
switch on the front panel is for  
switching power on or off to the displays and out-  
puts only.  
The universal power supply requires a 85250 V ac, 47-63 Hz power  
source.  
Fuse Installation: The fuse block, at the right of the power cord  
receptacle, accepts US or European size fuses. A jumper replaces the fuse in  
whichever fuse receptacle is not used. Fuses are not installed at the factory.  
Be sure to install the proper fuse as part of installation. (See Fuse Replace-  
ment in chapter 5, maintenance.)  
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Ultra Trace Oxygen Analyzer  
Installation 3  
3.3.2.2  
50-Pin Equipment Interface Connector  
Figure 3-4 shows the pin layout of the Equipment Interface connector.  
The arrangement is shown as seen when the viewer faces the rear panel of  
the analyzer. The pin numbers for each input/output function are given  
where each function is described in the paragraphs below.  
Figure 3-4: Equipment Interface Connector Pin Arrangement  
Analog Outputs: There are four DC output signal pinstwo pins per  
output. For polarity, see Table 3-1. The outputs are:  
01 V dc % of Range: Voltage rises linearly with increasing oxygen, from  
0 V at 0 ppm to 1 V at full scale ppm. (Full scale =  
100% of programmable range.)  
01 V dc Range ID:  
0.25 V = Low Range, 0.5 V = Medium Range,  
0.75 V = High Range, 1 V = Air Cal Range.  
420 mA dc % Range: Current increases linearly with increasing oxygen,  
from 4 mA at 0 ppm to 20 mA at full scale ppm.  
(Full scale = 100% of programmable range.)  
420 mA dc Range ID: 8 mA = Low Range, 12 mA = Medium Range, 16  
mA = High Range, 20 mA = Air Cal Range.  
Table 3-1: Analog Output Connections  
Pin  
3
Function  
+ Range ID, 4-20 mA, floating  
Range ID, 4-20 mA, floating  
+ % Range, 4-20 mA, floating  
% Range, 4-20 mA, floating  
+ Range ID, 0-1 V dc  
4
5
6
8
23  
Range ID, 0-1 V dc, negative ground  
24 + % Range, 0-1 V dc  
% Range, 0-1 V dc, negative ground  
7
Alarm Relays: The nine alarm-circuit connector pins connect to the  
internal alarm relay contacts. Each set of three pins provides one set of Form  
C relay contacts. Each relay has both normally open and normally closed  
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3 Installation  
Model Ultra Trace 3000  
contact connections. The contact connections are shown in Table 3-2. They  
are capable of switching up to 3 amperes at 250 V ac into a resistive load.  
The connectors are:  
Threshold Alarm 1: Can be configured as high (actuates when concen-  
tration is above threshold), or low (actuates when  
concentrationisbelowthreshold).  
Can be configured as failsafe or nonfailsafe.  
Can be configured as latching or nonlatching.  
Can be configured out (defeated).  
Threshold Alarm 2: Can be configured as high (actuates when concen-  
tration is above threshold), or low (actuates when  
concentrationisbelowthreshold).  
Can be configured as failsafe or nonfailsafe.  
Can be configured as latching or nonlatching.  
Can be configured out (defeated).  
SystemAlarm:  
Actuates when DC power supplied to circuits is  
unacceptable in one or more parameters. Permanently  
configured as failsafe and latching. Cannot be de-  
feated. Actuates if self test fails.  
(Reset by pressing  
press again and any other button EXCEPT  
Systemtoresume.  
button to remove power. Then  
Further detail can be found in chapter 4, section 4-5.  
Table 3-2: Alarm Relay Contact Pins  
Pin Contact  
45 Threshold Alarm 1, normally closed contact  
28 Threshold Alarm 1, moving contact  
46 Threshold Alarm 1, normally open contact  
42 Threshold Alarm 2, normally closed contact  
44 Threshold Alarm 2, moving contact  
43 Threshold Alarm 2, normally open contact  
36 System Alarm, normally closed contact  
20 System Alarm, moving contact  
37 System Alarm, normally open contact  
Digital Remote Cal Inputs: Accept 0 V (off) or 24 V dc (on) inputs  
for remote control of calibration. (See Remote Calibration Protocol below.)  
See Table 3-3 for pin connections.  
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Ultra Trace Oxygen Analyzer  
Installation 3  
Zero:  
Span:  
Floating input. 5 to 24 V input across the + and pins puts  
the analyzer into the Zero mode. Either side may be  
grounded at the source of the signal. 0 to 1 volt across the  
terminals allows Zero mode to terminate when done. A  
synchronous signal must open and close the external zero  
valve appropriately. See Remote Probe Connector. (The C  
optioninternalvalvesoperateautomatically.)  
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 signal must open and close external span valve  
appropriately. See Figure 3-5 Remote Probe Connector. (The  
Coptioninternalvalvesoperateautomatically.)  
Cal Contact: This relay contact is closed while analyzer is spanning  
and/or zeroing. (See Remote Calibration Protocol below.)  
Table 3-3: Remote Calibration Connections  
Pin  
9
Function  
+ Remote Zero  
Remote Zero  
+ Remote Span  
Remote Span  
Cal Contact  
11  
10  
12  
40  
41  
Cal Contact  
Remote Calibration Protocol: To properly time the Digital Remote  
Cal Inputs to the Model Ultra Trace 3000 Analyzer, the customer's controller  
must monitor the Cal Relay Contact.  
When the contact is OPEN, the analyzer is analyzing, the Remote Cal  
Inputs are being polled, and a zero or span command can be sent.  
When the contact is CLOSED, the analyzer is already calibrating. It  
will ignore your request to calibrate, and it will not remember that request.  
Once a zero or span command is sent, and acknowledged (contact  
closes), release it. If the command is continued until after the zero or span is  
complete, the calibration will repeat and the Cal Relay Contact (CRC) will  
closeagain.  
Forexample:  
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3 Installation  
Model Ultra Trace 3000  
1) Test the CRC. When the CRC is open, Send a zero command  
until the CRC closes (The CRC will quickly close.)  
2) When the CRC closes, remove the zero command.  
3) When CRC opens again, send a span command until the CRC  
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: The Remote Valve connections (described below) provides  
signals to ensure that the zero and span gas valves will be  
controlled synchronously.  
Range ID Relays: Four dedicated Range ID relay contacts. The first  
three ranges are assigned to relays in ascending orderLow range is as-  
signed to Range 1 ID, Medium range is assigned to Range 2 ID, and High  
range is assigned to Range 3 ID. The fourth range is reserved for the Air Cal  
Range (25%). Table 3-4 lists the pin connections.  
Table 3-4: Range ID Relay Connections  
Pin  
21  
38  
22  
39  
19  
18  
34  
35  
Function  
Range 1 ID Contact  
Range 1 ID Contact  
Range 2 ID Contact  
Range 2 ID Contact  
Range 3 ID Contact  
Range 3 ID Contact  
Range 4 ID Contact (Air Cal)  
Range 4 ID Contact (Air Cal)  
Network I/O: A serial digital input/output for local network protocol.  
At this printing, this port is not yet functional. It is to be used for future  
options to the instrument. Pins 13 (+) and 29 ().  
Remote Valve Connections: The Ultra Trace 3000 is a single-chassis  
instrument, which has no Remote Valve Unit. Instead, the Remote Valve  
connections are used as a method for directly controlling external sample/  
zero/span gas valves. See Figure 3-5.  
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Ultra Trace Oxygen Analyzer  
Installation 3  
Figure 3-5: Remote Probe Connections  
The voltage from these outputs is nominally 0 V for the OFF and  
15 V dc for the ON conditions. The maximum combined current that can be  
pulled from these output lines is 100 mA. (If two lines are ON at the same  
time, each must be limited to 50 mA, etc.) If more current and/or a different  
voltage is required, use a relay, power amplifier, or other matching circuitry  
to provide the actual driving current.  
In addition, each individual line has a series FET with a nominal ON  
resistance of 5 ohms (9 ohms worst case). This can limit the obtainable  
voltage, depending on the load impedance applied. See Figure 3-6.  
Figure 3-6: FET Series Resistance  
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3 Installation  
Model Ultra Trace 3000  
3.4 Installing the Micro-Fuel Cell  
The Micro-Fuel Cell, Model B-2CXL is not installed in the cell block  
when the instrument is shipped. Install it before the analyzer is placed in  
service.  
The Micro-Fuel cell is located inside the stainless steel cell block behind  
the front panel (see Figure 3-8). To install the cell:  
1. Remove power to the instrument by unplugging the power cord  
at the power source.  
2. Open the front panel door by pressing the release button on the  
top right corner of the door all the way in with a narrow gauge  
tool.  
3. With one hand hold the top of the cell block while unscrewing  
the plastic ring holder. Once the plastic ring is loose, remove the  
top of the cell block.  
CAUTION:  
The cell is shipped separately inside two bags filled with oxygen-free  
inert gas. Extreme care must be taken to ensure that the cell is exposed to air  
for the very minimum amount of time, including during installation.  
As an example, an air exposure of 3 to 5 minutes may require 24 hours  
or longer before the cell recovers to less than 0.5 ppm on an oxygen free  
sample gas. On the other hand, if the air exposure is limited to less than 10  
seconds, the recovery time will be reduced to two hours, or less.  
3.5 Testing the System  
Before plugging the instrument into the power source:  
Check the integrity and accuracy of the gas connections. Make  
sure there are no leaks.  
Check the integrity and accuracy of the electrical connections.  
Make sure there are no exposed conductors  
Check that inlet sample pressure is within the accepted range (se  
section3.3.1).  
Power up the system, and test it by performing the following  
operations:  
1. Repeat the Self-Diagnostic Test as described in chapter 4, section  
4.3.5.  
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Ultra Trace Oxygen Analyzer  
Installation 3  
COLLAR  
CELL BLOCK  
SENSOR  
O-RING  
CELL HOLDER  
Figure 3-8: Installing the Micro-Fuel Cell  
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3 Installation  
Model Ultra Trace 3000  
IMPORTANT:` In the event of loss of flow through the analyzer, if  
the vent is vented to a location of high oxygen  
content, oxygen will back diffuse through the vent  
line and in most cases quickly saturate the cell with  
oxygen which can then require a quite long purge  
down time for the sensor when then exposed to low  
oxygen concentrations. In the event that flow is to  
be interrupted into the analyzer, it is suggested that  
the user do one of the following:  
1.  
2.  
Bag the sensor in nitrogen during this time  
Install a shut off valve on the vent port of the ana-  
lyzer or somewhere within the users sample system.  
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Ultra Trace Oxygen Analyzer  
Operation 4  
Operation  
4.1 Introduction  
Once the analyzer has been installed, it can be configured for your  
application. To do this you will:  
Setsystemparameters:  
Establish a security password, if desired, requiring Operator  
to log in.  
Establish and start an automatic calibration cycle, if desired.  
Calibratetheinstrument.  
Define the three user selectable analysis ranges, then choose  
autoranging or select a fixed range of analysis, as required.  
Set alarm setpoints, and modes of alarm operation (latching,  
failsafe,etc).  
Before you configure your Ultra Trace 3000, these default values are in  
effect:  
Ranges: LO = 250ppb ppm, MED = 1 ppm, HI = 10 ppm.  
Auto Ranging: ON  
Alarm Relays: Defeated, Alarm 1 at10.000 ppm, Alarm 2 at 1.000  
ppm HI, Not failsafe, Not latching.  
Zero: Auto, every 0 days at 0 hours.  
Span: Auto, at 008.00 ppm, every 0 days at 0 hours.  
If you choose not to use password protection, the default password is  
automatically displayed on the password screen when you start up, and you  
simply press Enter for access to all functions of the analyzer.  
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4 Operation  
Model Ultra Trace 3000  
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 option  
blinks.  
When the selected option includes a modifiable item, the arrow  
buttons can be used to increment or decrement that modifiable item.  
The Enter button is used to accept any new entries on the VFD screen.  
The Escape button is used to abort any new entries on the VFD screen that  
are not yet accepted by use of the Enter button.  
Figure 4-1 shows the hierarchy of functions available to the operator via  
the function buttons. The six function buttons on the analyzer are:  
Analyze. This is the normal operating mode. The analyzer  
monitors the oxygen content of the sample, displays the percent  
of oxygen, and warns of any alarm conditions.  
System. The system function consists of six subfunctions that  
regulate the internal operations of the analyzer:  
Auto-Cal setup  
Show negative readings  
Passwordassignment  
Self-Testinitiation  
Checking software version  
Logging out.  
Set digital filter  
Zero. Usedtosetupazerocalibration.  
Span. Used to set up a span calibration.  
Alarms. Used to set the alarm setpoints and determine whether  
each alarm will be active or defeated, HI or LO acting, latching,  
and/orfailsafe.  
Range. Used to set up three analysis ranges that can be switched  
automatically with auto-ranging or used as individual fixed  
ranges.  
Any function can be selected at any time by pressing the appropriate  
button (unless password restrictions apply). The order as presented in this  
manual is appropriate for an initial setup.  
Each of these functions is described in greater detail in the following  
procedures. The VFD screen text that accompanies each operation is repro-  
duced, at the appropriate point in the procedure, in a Monospacedtype  
style. Pushbutton names are printed in Oblique type.  
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Ultra Trace Oxygen Analyzer  
Operation 4  
ANALYZE  
SYSTEM  
Perform Oxygen  
Analysis of  
the Sample  
SPAN  
TRAK/HLD  
ZERO  
Set Instrument  
Span  
ALARMS  
Perform  
Self-Diagnostic  
Test  
Set Instrument  
Zero  
RANGE  
Initiate  
Automatic  
Calibration  
Set Alarm  
Setpoints  
Define Analysis  
Ranges  
Confrigure Mode  
of Alarm  
Operation  
Set Password  
Logout  
Neg  
Filter  
Figure 4-1: Hierarchy of Functions and Subfunctions  
4.3 The System Function  
The subfuctions 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.  
PSWD: Security can be established by choosing a 5 digit  
password (PSWD) from the standard ASCII character set. (See  
Installing or Changing the Password, below, for a table of  
ASCII characters available.) Once a unique password is assigned  
and activated, the operator MUST enter the UNIQUE password  
to gain access to set-up functions which alter the instrument's  
operation, such as setting the instrument span or zero setting,  
adjusting the alarm setpoints, or defining analysis ranges.  
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4 Operation  
Model Ultra Trace 3000  
After a password is assigned, the operator must log out to  
activate it. Until then, anyone can continue to operate the  
instrument without entering the new password.  
Only one password can be defined. Before a unique password  
is assigned, the system assigns TETAI by default. This allows  
access to anyone. After a unique password is assigned, to defeat  
the security, the password must be changed back to TETAI.  
Logout: Logging out prevents unauthorized tampering with  
analyzersettings.  
More: Select and enter More to get a new screen with  
additionalsubfunctionslisted.  
Self–Test: The instrument performs a self-diagnostic test to  
check the integrity of the power supply, output boards and  
amplifiers.  
Version: Displays Manufacturer, Model, and Software Version  
ofinstrument.  
Neg: The operator selects whether display can show negative  
oxygen readings or not.  
TRAK/HLD: The operator sets whether the instrument analog  
outputs track the concentration change during calibration and sets  
a time delay for the concentration alarms after calibration.  
ꢀilter: This is to set the response time of the digital filter in the  
LO range.  
4.3.1 Tracking the Oxygen Readings during Calibration  
and Alarm delay  
The user has the option of setting the preferenc as to whether the analog  
outputs track the display readings during calibration or not. To set the prefer-  
ence, press the System key once and the first System menu will appear in the  
VFD display:  
TRAK/HLD Auto-Cal  
PSWD Logout More  
TRAK/HLD should be blinking. To enter this system menu press the  
Enter key once:  
Output Sttng: TRACK  
Alarm Dly: 10 min  
Or  
Output Sttng: HOLD  
Alarm Dly: 10 min  
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Operation 4  
In the first line, TRACK or HOLD should be blinking. The operator  
can toggle between TRACK and HOLD with the Up or Down keys. When  
TRACK is selected, the analog outputs (0-1 VDC and 4-20 ma) and the  
range ID contacts will track the instrument readings during calibration (either  
zero or span). TRACK is the factory default.  
When HOLD is selected, the analog outputs (0-1 VDC and 4-20 ma)  
and the range ID contacts will freeze on their last state before entering one of  
the calibration modes. When the instrument returns to the Analyze mode,  
either by a successful or an aborted calibration, there will be a three-minute  
delay before the analog outputs and the range ID contacts start tracking  
again.  
The concentration alarms freeze on their last state before entering  
calibration regardless of selecting HOLD or TRACK. But, when HOLD is  
selected the concentration alarms will remain frozen for the time displayed in  
the second line of the TRAK/HLD menu after the analyzer returns to the  
Analyze mode.  
The factory default is three minutes, but the delay time is program-  
mable. 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 by Pressing the  
Up or Down keys to increase or decrease its value. The minimum delay is 1  
minute, the maximum is 30.  
This preference is stored in non-volatile memory so that it is recovered  
if power is removed from the instrument.  
4.3.2 Setting up an Auto-Cal  
When proper automatic valving is connected (see chapter 3, installa-  
tion), the Analyzer can cycle itself through a sequence of steps that automati-  
callycalibratestheinstrument.  
Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal  
control where possible. The internal clock in the Model 3000-XL is  
acurate to 2-3 %. Accordingly, internally scheduled calibrations can  
vary 2-3 % per day.  
To setup an Auto–Cal cycle:  
CAUTION:  
We do not recommend frequent Zero adjustments of the cell. A newly  
installed cell may take 7-10 days of operation to reach a steady Zero  
(typically less than 0.2 ppm). If required, the instrument may be zeroed  
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4 Operation  
Model Ultra Trace 3000  
after this initial stabilizing period and may be checked again after a addi-  
tional 7-10 day frequency of zero adjustment is at the discretion of the user  
(once a month is suggested).  
Choose System from the Function buttons. The LCD will display five  
subfunctions.  
TRAK/HLD Auto—Cal  
PSWD Logout More  
Use < > arrows to blink Auto—Cal, and press Enter. A new screen for  
Span/Zero set appears.  
Span OFF Nxt: 0d 0h  
Zero OFF Nxt: 0d 0h  
Press < > arrows to blink Span(or Zero), then press Enter again.  
(You wont be able to set O to ON if a zero interval is entered.) A Span  
Every ... (or Zero Every ...) screen appears.  
Span Every 0 d  
Start 0 h from now  
Use arrows to set an interval value, then use < > arrows to move to  
the start-time value. Use arrows to set a start-time value.  
To turn ON the Span and/or Zero cycles (to activate Auto-Cal): Press  
System again, choose AutoCal, and press Enter again. When the Span/  
Zero values screen appears, use the < > arrows to blink the Span (or Zero)  
OFF/ONfield. Use arrows to set the OFF/ONfield to ON. You can now  
turn these fields ONbecause there is a nonzero span interval defined.  
4.3.3 Password Protection  
If a password is assigned, then setting the following system parameters  
can be done only after the password is entered: span and zero settings,  
alarm setpoints, analysis range definitions, switching between autoranging  
and manual override, setting up an auto-cal, and assigning a new password.  
However, the instrument can still be used for analysis or for initiating a self-  
test without entering the password.  
If you have decided not to employ password security, use the default  
password TETAI. This password will be displayed automatically by the  
microprocessor. The operator just presses the Enter key to be allowed total  
accesstotheinstrumentsfeatures.  
NOTE: If you use password security, it is advisable to keep a copy of the  
password in a separate, safe location.  
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Ultra Trace Oxygen Analyzer  
Operation 4  
4.3.3.1  
EnteringthePassword  
To install a new password or change a previously installed password,  
you must key in and ENTER the old password first. If the default password  
is in effect, pressing the ENTER button will enter the default TETAI pass-  
word for you.  
Press System to enter the System mode.  
TRAK/HLD AutoCal  
PSWD Logout More  
Use the < > arrow keys to scroll the blinking over to PSWD, and press  
Enter to select the password function. Either the default TETAI password or  
AAAAA place holders for an existing password will appear on screen de-  
pending on whether or not a password has been previously installed.  
T E T A I  
Enter PWD  
or  
A A A A A  
Enter PWD  
The screen prompts you to enter the current password. If you are not  
using password protection, press Enter to accept TETAI as the default pass-  
word. If a password has been previously installed, enter the password using  
the < > arrow keys to scroll back and forth between letters, and the ∇  
arrow keys to change the letters to the proper password. Press Enter to enter  
the password.  
If the password is accepted, the screen will indicate that the password  
restrictions have been removed and you have clearance to proceed.  
PSWD Restrictions  
Removed  
In a few seconds, you will be given the opportunity to change this  
password or keep it and go on.  
Change Password?  
<ENT>=Yes <ESC>=No  
Press Escape to move on, or proceed as in Changing the Password,  
below.  
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4 Operation  
Model Ultra Trace 3000  
4.3.3.2  
InstallingorChangingthePassword  
If you want to install a password, or change an existing password,  
proceed as above in Entering the Password. When you are given the oppor-  
tunity to change the password:  
Change Password?  
<ENT>=Yes <ESC>=No  
Press Enter to change the password (either the default TETAI or the  
previously assigned password), or press Escape to keep the existing pass-  
word and move on.  
If you chose Enter to change the password, the password assignment  
screenappears.  
T E T A I  
<ENT> To Proceed  
or  
A A A A A  
<ENT> To Proceed  
Enter the password using the < > arrow keys to move back and forth  
between the existing password letters, and the arrow keys to change the  
letters to the new password. The full set of 94 characters available for pass-  
word use are shown in the table below.  
Characters Available for Password Definition:  
A
K
U
_
i
s
}
)
3
=
B
L
V
`
j
t
*
4
>
C
M
W
a
k
u
!
+
5
?
D
N
X
b
l
v
"
'
6
@
E
O
Y
c
m
w
#
-
7
F
P
Z
d
n
x
$
.
8
G
Q
[
e
o
y
%
/
9
H
R
¥
f
p
z
&
0
:
I
S
]
g
q
{
'
1
;
J
T
^
h
r
|
(
2
<
When you have finished typing the new password, press Enter. A  
verification screen appears. The screen will prompt you to retype your  
passwordforverification.  
A A A A A  
Retype PWD To Verify  
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Ultra Trace Oxygen Analyzer  
Operation 4  
Wait a moment for the entry screen. You will be given clearance to  
proceed.  
A A A A A  
<ENT> TO Proceed  
Use the arrow keys to retype your password and press Enter when  
finished. Your password will be stored in the microprocessor and the system  
will immediately switch to the Analyze screen, and you now have access to  
allinstrumentfunctions.  
If all alarms are defeated, the Analyze screen appears as:  
0.0  
ppm Anlz  
Range: 0 100  
If an alarm is tripped, the second line will change to show which alarm  
itis:  
0.0  
ppm Anlz  
AL1  
NOTE: If you log off the system using the logout function in the system  
menu, you will now be required to re-enter the password to gain  
access to Span, Zero, Alarm, and Range functions.  
4.3.4 Logout  
The Logout function provides a convenient means of leaving the  
analyzer in a password protected mode without having to shut the instrument  
off. By entering Logout, you effectively log off the instrument leaving the  
system protected against use until the password is reentered. To log out,  
press the System button to enter the System function.  
TRAK/HLD AutoCal  
PSWD Logout More  
Use the < > arrow keys to position the blinking over the Logout  
function, and press Enter to Log out. The screen will display the message:  
Protected Until  
Password Reentered  
4.3.5 System Self-Diagnostic Test  
The Model 3000 has a built-in self-diagnostic testing routine. Pre-  
programmed signals are sent through the power supply, output board and  
sensor circuit. The return signal is analyzed, and at the end of the test the  
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4 Operation  
Model Ultra Trace 3000  
status of each function is displayed on the screen, either as OK or as a num-  
ber between 1 and 3. (See System Self Diagnostic Test in chapter 5 for  
number code.)  
The self diagnostics are run automatically by the analyzer whenever the  
instrument is turned on, but the test can also be run by the operator at will.  
To initiate a self diagnostic test during operation:  
Press the System button to start the System function.  
TRAK/HLD AutoCal  
PSWD Logout More  
Use the < > arrow keys to blink More, then press Enter.  
Version SelfTest  
Neg-N Filter-5  
Use the < > arrow keys again to move the blinking to the Self–Test  
function. The screen will follow the running of the diagnostic.  
RUNNING DIAGNOSTIC  
Testing Preamp 83  
During preamp testing there is a countdown in the lower right corner of  
the screen. When the testing is complete, the results are displayed.  
Power: OK Analog: OK  
Preamp: 3  
The module is functioning properly if it is followed by OK. A number  
indicates a problem in a specific area of the instrument. Refer to Chapter 5  
Maintenance and Troubleshooting for number-code information. The results  
screen alternates for a time with:  
Press Any Key  
To Continue...  
Then the analyzer returns to the initial System screen.  
4.3.6 Version Screen  
Move the < > arrow key to More and press Enter. With Version  
blinking, press Enter. The screen displays the manufacturer, model, and  
softwareversioninformation.  
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Ultra Trace Oxygen Analyzer  
Operation 4  
4.3.7 Filter Function  
The response time on the most sensitive range (ppb range) is user  
definable from approximately 1-60 minutes. The adjustable filter allows the  
user to tune the response of the analyzer to best balance sensor noise and  
response time requirements. The factory default setting is 5 minutes. The  
actual response time will depend on the users sample system (the length and  
size the tubing of tubing as well as the sample flow rate).  
The filter setting can be accessed by selecting SYSTEM on the keypad  
followed by MORE on the display with the <> keys. The filter function is  
then selected and changed using the arrow keys. Press ENTER and ANA-  
LYZE to return to analyze mode.  
In the event of an over-range condition, the filter rate will automatically  
switch to a faster setting (approximately 45 sec. response time) for the  
duration of the over-range or upset condition. This feature allows the ana-  
lyzer to quickly respond to and track an upset condition.  
4.4 Calibration of the Analyzer  
The analyzer must be calibrated prior to its use. For most applications  
where the desired range of measurement is 0 to 10 ppm, or less we  
recommend the analyzer be calibrated using a span gas as detailed below:  
Span Gas Calibration  
Before the cell is ready for calibration, it must be purged with sample  
gas to a low oxygen level preferably below 0.1 ppm. However, if the  
oxygen contact of the sample gas is higher than 0.1 ppm, a zero gas such as  
nitrogen with oxygen level below 0.1 ppm may be required.  
The recommended span gas concentration is between 7.0 to 9.0 ppm  
oxygen in nitrogen, and will require calibration be performed in the 0-10  
ppm analyzer range.  
4.4.1 Zero Cal  
The B-2CXL cell has a zero offset of less than 0.1 ppm oxygen. Nor-  
mally, the offset slowly decreases during the first 7 to 10 days of operation,  
and is expected to reach a steady value after this time.  
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4 Operation  
Model Ultra Trace 3000  
Generally, the value of the zero offset is part of the oxygen reading of  
the sample gas as shown by the analyzer readout. As an example, a reading  
of 0.5 ppm oxygen may include 0.4 ppm oxygen in the sample gas and a 0.1  
ppm zero offset.  
The determination of the zero offset requires the use of oxygen free gas  
to the analyzer. We recommend the use of nitrogen gas with a scrubber to  
assure oxygen levels below 20 ppb.  
The user may decide to eliminate the zero offset for improved accu-  
racy. If so desired the analyzer is equipped to provide this function. How-  
ever, we do not recommend carying out the cal zero during the first 10 days  
of the operation of the cell.  
The Zero button on the front panel is used to enter the zero calibration  
function. Zero calibration can be performed in either the automatic or manual  
mode. In the automatic mode, an internal algorithm compares consecutive  
readings from the sensor to determine when the output is within the accept-  
able range for zero. In the manual mode, the operator determines when the  
reading is within the acceptable range for zero. Make sure the zero gas is  
connected to the instrument. If you get a CELL $AILURE message skip to  
section 4.4.1.3.  
4.4.1.1  
AutoModeZeroing  
Press Zero to enter the zero function mode. The screen allows you to  
select whether the zero calibration is to be performed automatically or manu-  
ally. Use the arrow keys to toggle between AUTO and MAN zero set-  
tling. Stop when AUTO appears, blinking, on the display.  
Zero: Settling: AUTO  
<ENT> To Begin  
Press Enter to begin zeroing.  
####  
Slope=####  
PPM Zero  
ppm/s  
The beginning zero level is shown in the upper left corner of the dis-  
play. As the zero reading settles, the screen displays and updates information  
on Slope (unless the Slope starts within the acceptable zero range and does  
not need to settle further).  
Then, and whenever Slope is less than 0.08 for at least 3 minutes,  
instead of Slope you will see a countdown: 5 Left, 4 Left, and so fourth.  
These are five steps in the zeroing process that the system must complete,  
AFTER settling, before it can go back to Analyze.  
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Ultra Trace Oxygen Analyzer  
Operation 4  
####  
4 Left=###  
PPM Zero  
ppm/s  
The zeroing process will automatically conclude when the output is  
within the acceptable range for a good zero. Then the analyzer automatically  
returns to the Analyze mode.  
Because the reading of the slope is not very sensitive, it is recom-  
mended that zero gas be purging a few minutes before starting the Auto  
mode zeroing. This will ensure cell stability on the new Zero settings.  
4.4.1.2  
ManualModeZeroing  
Press Zero to enter the Zero function. The screen that appears allows  
you to select between automatic or manual zero calibration. Use the keys  
to toggle between AUTO and MAN zero settling. Stop when MAN appears,  
blinking, on the display.  
Zero: Settling: Man  
<ENT> To Begin  
Press Enter to begin the zero calibration. After a few seconds the first  
of five zeroing screens appears. The number in the upper left hand corner is  
the first-stage zero offset. The microprocessor samples the output at a prede-  
termined rate. It calculates the differences between successive samplings and  
displays the rate of change as Slope= a value in parts per million per second  
(ppm/s).  
####  
Slope=####  
ppm Zero  
ppm/s  
NOTE: It takes several seconds for the true Slope value to display. Wait  
about 10 seconds. Then, wait until Slope is sufficiently close to zero  
before pressing Enter to finish zeroing .  
Generally, you have a good zero when Slope is less than 0.05 ppm/s  
for about 30 seconds. When Slope is close enough to zero, press Enter. In a  
few seconds, the screen will update.  
Once zero settling is completed, the information is stored in the  
microprocessor, and the instrument automatically returns to the Analyze  
mode.  
4.4.1.3  
CellFailure  
Cell failure in the Ultra Trace 3000 is usually associated with inability  
to zero the instrument down to a satisfactorily low ppm reading correspond-  
ing to a current of 2 nanoamps (approx. 1 ppm). When this occurs, the  
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4 Operation  
Model Ultra Trace 3000  
instrument returns back to analyzer mode without taking the zero calibration.  
The Ultra Trace 3000 system alarm trips, and the LCD displays a failure  
message.  
#.#  
ppm Anlz  
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.  
c. Check if more purging time with Zero calibration gas is needed.  
If there are no leaks and the span gas is within specification, replace the  
cell as described in chapter 5, Maintenance.  
The failure alarm and failure message will reset after entering the Zero  
mode.  
4.4.2 Span Cal  
The Span button on the front panel is used to span calibrate the ana-  
lyzer. Span calibration can be performed using the automatic mode, where  
an internal algorithm compares consecutive readings from the sensor to  
determine when the output matches the span gas concentration. Span cali-  
bration can also be performed in manual mode, where the operator deter-  
mines when the span concentration reading is acceptable and manually exits  
thefunction.  
4.4.2.1  
AutoModeSpanning  
Press Span to enter the span function. The screen that appears allows  
you to select whether the span calibration is to be performed automatically or  
manually. Use the arrow keys to toggle between AUTO and MAN span  
settling. Stop when AUTO appears, blinking, on the display.  
Span: Settling: AUTO  
<ENT> For Next  
Press Enter to move to the next screen.  
Calib. Holding time  
Cal hold: 5 min  
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Ultra Trace Oxygen Analyzer  
Operation 4  
This menu allows the operator to set the time the analyzer should be  
held in the AUTO span mode, after the readings of the analyzer settle. Five  
minutes is the default, but it could be adjusted anywhere from 1 to 60 min-  
utes by using the UP or DOWN keys.  
Press Enter to move to the next screen.  
Span Val: 008.00 ppm  
<ENT>Span <UP>Mod #  
Use the arrow keys to enter the oxygen-concentration mode  
(999.99 ppm is maximum value of span gas allowed). Use the < > arrow  
keys to blink the digit you are going to modify. Use the arrow keys  
again to change the value of the selected digit. When you have finished  
typing in the concentration of the span gas you are using, press Enter to  
begintheSpancalibration.  
####  
ppm  
Span  
Slope=####  
ppm/s  
The beginning span value is shown in the upper left corner of the  
display. As the span reading settles, the screen displays and updates informa-  
tion on Slope. Spanning automatically ends when the span output corre-  
sponds, within tolerance, to the value of the span gas concentration. Then the  
instrumentautomaticallyreturnstotheanalyzemode.  
4.4.2.2  
ManualModeSpanning  
Press Span to start the Span function. The screen that appears allows  
you to select whether the span calibration is to be performed automatically or  
manually.  
Span: Settling:MAN  
<ENT> For Next  
Use the keys to toggle between AUTO and MAN span settling. Stop  
when MAN appears, blinking, on the display. Press Enter to move to the  
next screen.  
Press Enter to move to the next screen.  
Calib. Holding time  
Cal hold: 5 min  
This menu allows the operator to set the time the analyzer should be  
held in the AUTO span mode. It does not have any effect in the MANual  
mode. Just press Enter key to continue.  
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4 Operation  
Model Ultra Trace 3000  
Span Val: 008.00ppm  
<ENT>Span <UP>Mod #  
Press (<UP>) to permit modification (Mod #) of span value.  
Use the arrow keys to enter the oxygen concentration of the span gas  
you are using (999.99 is maximum value of span gas). The < > arrows  
choose the digit, and the arrows choose the value of the digit.  
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  
predeterminedrate. Itcalculatesthedifferencebetweensuccessivesamplings  
and displays this difference as a Slope on the screen. It takes several seconds  
for the first Slope value to display. Slope indicates the rate of change of the  
Span reading. It is a sensitive indicator of stability.  
####  
Slope=####  
% Span  
ppm/s  
When the Spanvalue displayed on the screen is sufficiently stable,  
press Enter. (Generally, when the Spanreading changes by 1 % or less of  
the full scale of the range being calibrated, for a period of ten minutes it is  
sufficiently stable.) Once Enter is pressed, the Spanreading changes to the  
correct value. The instrument then automatically enters the Analyze func-  
tion.  
4.4.3 Span Failure  
The analyzer checks the output of the cell at the end of the span. If the  
raw output of the cell is less than 0.5 uA/ppm O2, the span will not be  
accepted. The analyzer will return to the previous calibration values, trigger  
the System Alarm, and display in the VFD:  
SpanFailed!!  
This message will be shown for five seconds and the instrument shall  
return to the Analyze mode. In the upper right hand corner of the VFD  
display FCALwill be shown. This message flag will help the operator  
troubleshoot in case calibration was initiated remotely. To reset the alarm  
and the flag message, the analyzer must be properly spanned.  
A trace cell is unlikely to fail span. As explained before, when the  
sensor reaches the end of its useful life, the zero offset begins to rise until the  
analyzer finds the zero unsatisfactory. Nevertheless, feeding the wrong span  
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Ultra Trace Oxygen Analyzer  
Operation 4  
gas or electronics failure could set this feature off at the end of the span.  
Consider this before replacing the cell.  
4.5 Switching of Sample Streams  
The Model Ultra Trace 3000 may be used to monitor more than one  
type of sample gas, such as nitrogen and helium, or two streams of nitrogen  
containing low (less than 1 ppm) and high (500 to 1000 ppm) concentrations  
of oxygen.  
For these applications, we recommend the following parameters and  
conditionsbefollowed:  
1. While switching streams, such as between nitrogen and helium, both  
the gas streams must be made to flow continuosly even through only one  
stream is going through the analyzer at one time. Failure to do so may result  
in spikes in output when the dead-ended stream is switched in. For more  
discussion of this, read the Technical Bulletin - TB00001, dated 3-98. This  
Bulletin is available upon request from TATAI.  
2. The analyzer is capable of handling the switching of streams without  
effecting the sensitivity of the cell. This switching of streams between  
nitrogen and helium will not require SPAN adjustment. However, care must  
be taken to keep sample flow rates in the desired levels, as the flowmeter is  
calibrated for air and nitrogen streams only.  
3. The analyzer can withstand repeated switching of streams between  
low oxygen levels of less than 1 ppm and high oxygen levels of 5000 to  
1000 ppm. Again, care must be taken to ensure proper and continuous flows  
atalltimes.  
4.5.1  
Special Notes on Hydrogen Gas Stream  
The standard oxygen cell, Model B-2CXL, though tested in nitrogen  
gas streams is expected to perform well in hydrogen streams. However, for  
certain applications such as continuous monitoring of very low levels of  
oxygen in hydrogen, the user may request cells that have been specifically  
tested in hydrogen streams. Consult Teledyne for further details.  
4.6 The Alarms Function  
The Model Ultra Trace 3000 is equipped with 2 fully adjustable con-  
centration alarms and a system failure alarm. Each alarm has a relay with a  
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4 Operation  
Model Ultra Trace 3000  
set of form C" contacts rated for 3 amperes resistive load at 250 V ac. See  
Figure 3-5 in Chapter 3, Installation and/or the Interconnection Diagram  
included at the back of this manual for relay terminal connections.  
The system failure alarm has a fixed configuration as described in  
chapter3Installation.  
The concentration alarms can be configured from the front panel as  
either high or low alarms by the operator. The alarm modes can be set as  
latching or non-latching, and either failsafe or non-failsafe, or, they can be  
defeated altogether. The setpoints for the alarms are also established using  
thisfunction.  
Decide how your alarms should be configured. The choice will depend  
upon your process. Consider the following four points:  
1. Which if any of the alarms are to be high alarms and which if any  
are to be low alarms?  
Setting an alarm as HIGH triggers the alarm when the oxygen  
concentration rises above the setpoint. Setting an alarm as LOW  
triggers the alarm when the oxygen concentration falls below the  
setpoint.  
Decide whether you want the alarms to be set as:  
Both high (high and high-high) alarms, or  
One high and one low alarm, or  
Both low (low and low-low) alarms.  
2. Are either or both of the alarms to be configured as failsafe?  
In failsafe mode, the alarm relay de-energizes in an alarm  
condition. For non-failsafe operation, the relay is energized in an  
alarm condition. You can set either or both of the concentration  
alarms to operate in failsafe or non-failsafe mode.  
3. Are either of the alarms to be latching?  
In latching mode, once the alarm or alarms trigger, they will  
remain in the alarm mode even if process conditions revert back  
to non-alarm conditions. This mode requires an alarm to be  
recognized before it can be reset. In the non-latching mode, the  
alarm status will terminate when process conditions revert to non-  
alarmconditions.  
4. Are either of the alarms to be defeated?  
The defeat alarm mode is incorporated into the alarm circuit so  
that maintenance can be performed under conditions which  
would normally activate the alarms.  
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Ultra Trace Oxygen Analyzer  
Operation 4  
The defeat function can also be used to reset a latched alarm.  
(See procedures, below.)  
If you are using password protection, you will need to enter your  
password to access the alarm functions. Follow the instructions in section  
4.3.3 to enter your password. Once you have clearance to proceed, enter the  
Alarm function.  
Press the Alarm button on the front panel to enter the Alarm function.  
Make sure that AL–1 is blinking.  
AL1  
AL2  
Choose Alarm  
Set up alarm 1 by moving the blinking over to AL1 using the < >  
arrow keys. Then press Enter to move to the next screen.  
AL1 10.000 ppm HI  
DftN FsN LtchN  
Five parameters can be changed on this screen:  
Value of the alarm setpoint, AL1 #### ppm (oxygen);  
value can be set from 0 to 999 ppb + 1.000-1000.00 ppm.  
Out-of-range direction, HI or LO  
Defeated? DftY/N (Yes/No)  
Failsafe? FsY/N (Yes/No)  
Latching? LtchY/N (Yes/No).  
To define the setpoint, use the < > arrow keys to move the  
blinking over to AL1 ####. Then use the arrow keys to  
change the number. Holding down the key speeds up the  
incrementing or decrementing. (Remember, the setpoint units are  
ppm O2.)  
To set the other parameters use the < > arrow keys to move the  
blinking over to the desired parameter. Then use the arrow  
keys to change the parameter.  
Once the parameters for alarm 1 have been set, press Alarms  
again, and repeat this procedure for alarm 2 (AL2).  
To reset a latched alarm, go to Dft– and then press either two  
times or two times. (Toggle it to Y and then back to N.)  
OR –  
Go to Ltch– and then press either two times or two times.  
(Toggle it to N and back to Y.  
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4 Operation  
Model Ultra Trace 3000  
Alarm Hysterisis: There is alarm hysterisis to prevent chatter of the  
alarm contacts. It is set to 0.2 ppm for alarms set above 1 ppm,  
and 10 ppb for alarms set below 1 ppm.  
4.7 The Range Function  
The Range function allows the operator to program up to three concen-  
tration ranges to correlate with the DC analog outputs. If no ranges are  
defined by the user, the instrument defaults to:  
Low = 0250 ppb  
Med = 01 ppm  
High = 010 ppm.  
The Model Ultra Trace 3000 is set at the factory to default to  
autoranging. In this mode, the microprocessor automatically responds to  
concentration changes by switching ranges for optimum readout sensitivity.  
If the current range limits are exceeded, the instrument will automatically  
shift to the next higher range. If the concentration falls to below 90% of full  
scale of the next lower range, the instrument will switch to that range. A  
corresponding shift in the DC percent-of-range output, and in the range ID  
outputs, will be noticed.  
The autoranging feature can be overridden so that analog output stays  
on a fixed range regardless of the oxygen concentration detected. If the  
concentration exceeds the upper limit of the range, the DC output will  
saturate at 1 V dc (20 mA at the current output).  
However, the digital readout and the RS-232 output of the concentra-  
tion are unaffected by the fixed range. They continue to read accurately with  
full precision. See Front Panel description in Chapter 1.  
The automatic fourth range is always 0-1000 ppm and is not program-  
mable.  
4.7.1 Setting the Analog Output Ranges  
To set the ranges, enter the range function mode by pressing the  
Range button on the front panel.  
L250 ppb  
M1 ppm  
H10 ppm ModeAUTO  
Use the < > arrow keys to blink the range to be set: low (L), medium  
(M), or high (H).  
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Ultra Trace Oxygen Analyzer  
Operation 4  
Use the arrow keys to enter the upper value of the range (all ranges  
begin at 0). Repeat for each range you want to set. Press Enter to accept the  
values and return to Analyze mode. (See note below.)  
Note: The ranges must be increasing from low to high, for example, if range  
1 is set as 0500 ppb and range 2 is set as 010 ppm, range 3 cannot  
be set as 05 ppm since it is lower than range 2.  
Ranges, and alarms, are set in ppb or ppm units depending on concen-  
tration. All concentration-data outputs change from ppb units to ppm when  
the concentration is above 1.0 ppm. Range Low (L) is always a ppb range  
and cannot be set higher than 1000 ppb nor lower than 10 ppb. Ranges  
medium (M) and High (H) can only be set in ppm. The Medium (M) range  
can be set between 1 and 10 ppm, while the high (H) range can be set  
between 10 and 1000 ppm.  
4.7.2 Fixed Range Analysis  
The autoranging mode of the instrument can be overridden, forcing the  
analyzer DC outputs to stay in a single predetermined range.  
To switch from autoranging to fixed range analysis, enter the range  
function by pressing the Range button on the front panel.  
Use the < > arrow keys to move the blinking over AUTO.  
Use the arrow keys to switch from AUTO to $X/L, $X/M, or $X/H to  
set the instrument on the desired fixed range (low, medium, or high).  
L250ppb  
M1 ppm  
H10 ppm ModeFX/L  
or  
L250 ppb  
M1 ppm  
H10 ppm ModeFX/M  
or  
L250 ppb  
M1 ppm  
H10 ppm ModeFX/H  
Press Escape to re-enter the Analyze mode using the fixed range.  
NOTE: When performing analysis on a fixed range, if the oxygen concentra-  
tion rises above the upper limit (or default value) as established by the  
operator for that particular range, the output saturates at 1 V dc (or 20  
mA). However, the digital readout and the RS-232 output continue to  
read the true value of the oxygen concentration regardless of the  
analog output range.  
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4 Operation  
Model Ultra Trace 3000  
4.8 The Analyze Function  
Normally, all of the functions automatically switch back to the Analyze  
function when they have completed their assigned operations. Pressing the  
Escape button in many cases also switches the analyzer back to the Ana-  
lyze function. Alternatively, you can press the Analyze button at any time  
to return to analyzing your sample.  
4.9 Signal Output  
The standard Model Ultra Trace 3000 Oxygen Analyzer is equipped  
with two 01 V dc analog output terminals accessible on the back panel  
(one concentration and one range ID), and two isolated 420 mA dc  
current outputs (one concentration and one range ID).  
See Rear Panel in Chapter 3, Installation, for illustration.  
The signal output for concentration is linear over the currently selected  
analysis range. For example, if the analyzer is set on range that was defined  
as 0100 ppm O2, then the output would be:  
Voltage Signal Current Signal  
ppm O2  
Output (V dc)  
Output (mA dc)  
0
10  
20  
30  
40  
50  
60  
70  
80  
90  
100  
0.0  
0.1  
0.2  
0.3  
0.4  
0.5  
0.6  
0.7  
0.8  
0.9  
1.0  
4.0  
5.6  
7.2  
8.8  
10.4  
12.0  
13.6  
15.2  
16.8  
18.4  
20.0  
The analog output signal has a voltage which depends on the oxygen  
concentration AND the currently activated analysis range. To relate the  
signal output to the actual concentration, it is necessary to know what range  
the instrument is currently on, especially when the analyzer is in the  
autorangingmode.  
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Ultra Trace Oxygen Analyzer  
Operation 4  
To provide an indication of the range, a second pair of analog output  
terminals are used. They generate a steady preset voltage (or current when  
using the current outputs) to represent a particular range. The following table  
gives the range ID output for each analysis range:  
Range  
Voltage (V)  
Current (mA)  
LO  
0.25  
8
MED  
0.50  
0.75  
1.00  
12  
16  
20  
HI  
(0-1000ppm)  
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4 Operation  
Model Ultra Trace 3000  
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Ultra Trace Oxygen Analyzer  
Maintenance 5  
Maintenance  
5.1 Routine Maintenance  
Aside from normal cleaning and checking for leaks at the gas connec-  
tions, routine maintenance is limited to replacing Micro-Fuel cells and fuses,  
and recalibration. For recalibration, see Section 4.4 Calibration.  
WARNING: SEE WARNINGS ON THE TITLE PAGE OF THIS  
MANUAL.  
5.2 Cell Replacement  
The B-2CXL Micro-Fuel Cell is a sealed electrochemical transducer  
with no electrolyte to change or electrodes to clean. When the cell reaches  
the end of its useful life, it is replaced. The spent fuel cell should be dis-  
carded according to local regulations. This section describes fuel cell care as  
well as when and how to replace it.  
5.2.1 Storing and Handling Replacement Cells  
To have a replacement cell available when it is needed, TAI recom-  
mends that one spare cell be purchased 9-10 months after commissioning the  
Ultra Trace 3000, or shortly before the end of the cell's one year warranty  
period.  
CAUTION: Do not stockpile cells. The warranty period starts on  
the day of shipment.  
The spare cell should be carefully stored in an area that is not subject to  
large variations in ambient temperature (75 °F nominal) or to rough handling.  
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5 Maintenance  
Model Ultra Trace 3000  
WARNING: THE SENSOR USED IN THE MODEL 3000 TRACE  
OXYGEN ANALYZER USES ELECTROLYTES  
WHICH CONTAIN TOXIC SUBSTANCES, MAINLY  
LEAD AND POTASSIUM HYDROXIDE, THAT CAN  
BE HARMFUL IF TOUCHED, SWALLOWED, OR  
INHALED. AVOID CONTACT WITH ANY FLUID OR  
POWDER IN OR AROUND THE UNIT. WHAT MAY  
APPEAR TO BE PLAIN WATER COULD CONTAIN  
ONE OF THESE TOXIC SUBSTANCES. IN CASE OF  
EYE CONTACT, IMMEDIATELY FLUSH EYES WITH  
WATER FOR AT LEAST 15 MINUTES. CALL PHYSI-  
CIAN. (SEE APPENDIX, MATERIAL SAFETY DATA  
SHEET.)  
CAUTION: Do not disturb the integrity of the cell package until  
the cell is to actually be used. If the cell package is  
punctured and air is permitted to enter, the cell will  
require an excessively long time to reach zero after  
installation(1-2weeks!).  
5.2.2 When to Replace a Cell  
Cell failure in the Ultra Trace 3000 is usually characterized by a  
significant increase in the zero offset of more than 1.0 ppm (2 nanoamps  
sensor output approximately) oxygen or the inability to calibrate the sensor.  
When this occurs, the Ultra Trace 3000 will still Zero but the system alarm  
trips, and the LCD displays a failure message.  
#.#  
ppm Anlz  
CELL ꢀAIL/ ZERO HIGH  
Before replacing the cell:  
a. Check your span and zero 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.  
c. Check if more purging time with zero calibration gas is needed.  
If there are no leaks and the span gas is within specification, replace the  
cell.  
The failure alarm and the failure message will reset after re-entering the  
zero mode again.  
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Ultra Trace Oxygen Analyzer  
Maintenance 5  
5.2.3 Removing the Micro-Fuel Cell  
The Micro-Fuel cell is located inside the stainless steel cell block behind  
the front panel (see Figure 5-1). To remove an existing cell:  
1. Remove power to the instrument by unplugging the power cord  
at the power source.  
2. Open the front panel door by pressing the release button on the  
top right corner of the door all the way in with a narrow gauge  
tool.  
3. With one hand hold the top of the cell block while unscrewing  
the plastic ring holder. Once the plastic ring is loose, remove the  
top of the cell block.  
COLLAR  
CELL BLOCK  
SENSOR  
O-RING  
CELL HOLDER  
Figure 5-1: Removing the Micro-Fuel  
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5 Maintenance  
Model Ultra Trace 3000  
5.2.4 Installing a New Micro-Fuel Cell  
Before installing a new cell, check the O-ring in the base of the cell  
holder. Replace if worn or damaged.  
1. Verify that the 0-ring is properly located.  
2. Place the cell on cell holder with the screen side facing down.  
3. Place the cell block on top of the cell holder.  
4. Hold the cell block with one hand and rotate the collar clockwise.  
5. To determine if the assembly is fully seated, rotate the cell block  
slightly.  
6. When fully seated, the cell block can be rotated with three fingers  
but considerable drag will be felt.  
5.2.5 Cell Warranty  
The Class B-2CXL Micro-Fuel cell is used in the Model Ultra Trace  
3000. This cell is warranted for 6 months from the date of shipment. Note  
any Addenda attached to the front of this manual for special information  
applying to your instrument.  
With regard to spare cells, warranty period begins on the date of ship-  
ment. The customer should purchase only one spare cell (per section 5.2.1).  
Do not attempt to stockpile spare cells.  
The B-2CXL cell is not designed for applications where CO2 is a  
major component in the sample, however concentrations of 1,000 ppm or  
less will not adversely effect the cell performance. Consult TAI for the  
appropriate cell for measuring trace oxygen in the presence of CO2.  
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.  
If you have a warranty claim, you must return the cell in question to the  
factory for evaluation. If it is determined that failure is due to faulty work-  
manship or material, the cell will be replaced at no cost to you.  
Note: Evidence of damage due to tampering or mishandling will  
render the cell warranty null and void.  
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Ultra Trace Oxygen Analyzer  
Maintenance 5  
5.3 Fuse Replacement  
1. Place small screwdriver in notch, and pry cover off, as shown in  
Figure 5-2.  
Figure 5-2: Removing Fuse Block from Housing  
2. To change between American and European fuses, remove the  
single retaining screw, flip Fuse Block over 180 degrees, and  
replacescrew.  
3. Replace fuse as shown in Figure 5-3.  
4. Reassemble Housing as shown in Figure 5-2.  
American Fuses  
European Fuses  
Figure 5-3: Installing Fuses  
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5 Maintenance  
Model Ultra Trace 3000  
5.4 System Self Diagnostic Test  
1. Press the System button to enter the system mode.  
2. Use the < > arrow keys to move to More, and press Enter.  
3. Use the < > arrow keys to move to Self-Test, and press Enter.  
The following failure codes apply:  
Table 5-1: Self Test Failure Codes  
Power  
0
1
2
3
OK  
5 V Failure  
15 V Failure  
Both Failed  
Analog  
0
1
2
3
OK  
DAC A (01 V Concentration)  
DAC B (01 V Range ID)  
Both Failed  
Preamp  
0
1
2
3
OK  
Zero too high  
Amplifier output doesn't match test input  
Both Failed  
5.5 Major Internal Components  
The Micro-Fuel cell is accessed by unlatching and swinging open the  
front panel, as described earlier. Other internal components are accessed by  
removing the rear panel and sliding out the entire chassis. See Figure 5-4,  
below. The gas piping is illustrated in Figure 2-4, and the major electronic  
components locations are shown in Figure 2-5, in chapter 2.  
WARNING: SEE WARNINGS ON THE TITLE PAGE OF THIS  
MANUAL.  
The Ultra Trace 3000 contains the following major components:  
AnalysisSection  
Micro Fuel Cell (B-2CXL)  
Cell block with stainless steel wetted parts  
Samplesystem  
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Ultra Trace Oxygen Analyzer  
Maintenance 5  
TEC cooler assembly  
Power Supplys  
Microprocessor  
Displays  
5 digit LED meter  
2 line, 20 character, alphanumeric, VFD display  
RS-232 Communications Port.  
TEC temperature controller PCB  
See the drawings in the Drawings section in back of this manual  
fordetails.  
X
X
X
X
X
Te le dyne A n alytic a l Ins tru m e nts  
!
!
X
X
X
X
X
Figure 5-4: Rear-Panel Screws  
To detach the rear panel, remove only the 14 screws marked with an X.  
5.6 Cleaning  
If instrument is unmounted at time of cleaning, disconnect the instru-  
ment from the power source. Close and latch the front-panel access door.  
Clean outside surfaces with a soft cloth dampened slightly with plain clean  
water. Do not use any harsh solvents such as paint thinner or benzene.  
For panel-mounted instruments, clean the front panel as prescribed in  
the above paragraph. DO NOT wipe front panel while the instrument is  
controllingyourprocess.  
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5 Maintenance  
Model Ultra Trace 3000  
5.7 Troubleshooting  
Problem:  
Erratic readings of the Oxygen concentration as reported by the analyzer.  
Possible Cause:  
The analyzer may have been calibrated in an inaccurate fashion.  
Solution:  
Turn the analyzer off, then turn back on again. Press the System key when  
prompted by the analyzer "Press System for default Values". This will  
return the analyzer to its default settings in calibration and zero values. If  
erratic behavior continues clean sensor contacts or replace the sensor.  
Possible Cause:  
Atmospheric Oxygen may be diffusing in through the vent and affecting the  
oxygen level which the sensor sees.  
Solution:  
Increase flow rate and/or length or vent tubing in order to dilute or minimize  
the diffusion of oxygen from the vent back to the sensor.  
Problem:  
Inaccurate zero operation (i.e. the user has zeroed the analyzer accidentally  
on gas much higher than one would normally use for a zero gas).  
Solution:  
Turn the analyzer off, then back on again. Press the System key when  
prompted by the analyzer "Press System for default Values". This will  
return the analyzer to its default settings in calibration and zero values. Now  
proceed to carefully calibrate and zero the analyzer.  
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Ultra Trace Oxygen Analyzer  
Appendix  
Appendix  
A-1 Specifications  
Packaging: General Purpose  
Flush panel mount (Standard).  
Relay rack mount. Contains one  
instrumentsin one 19" relay rack mountable  
plate(Optional).  
Sensor: Teledyne B-2CXL trace analysis Micro-Fuel  
Cell.  
Cell Block: 316stainlesssteel.  
SampleSystem: All wetted parts of 316 stainless steel.  
90 % Response Time: Less than 30 seconds at 25 °C (77 °F) on 10  
ppm range.  
120 seconds on 250 ppb range, programmable  
response in ppb range.  
Ranges: Three user definable ranges from 0250 ppb to  
01,000 ppm, plus over range of 0-1,000 ppm.  
Autoranging with range ID output.  
Alarms: One system-failure alarm contact to detect  
power failure or sensor-zero and span failure.  
Twoadjustableconcentrationthresholdalarm  
contactswithfullyprogrammablesetpoints.  
Displays: 2-line by 20-character, VFD screen, and one 5  
digit LED display.  
DigitalInterface: Full duplex RS-232 communications port.  
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Appendix  
Model Ultra Trace 3000  
Power: Universal power supply 85-250 V ac, at  
47-63 Hz.  
OperatingTemperature: 5-40 °C  
Accuracy: ±2% of full scale for all ranges except 0-250  
ppb range, at constant temperature.  
For 0-250 ppb range accuracy is as follows:  
±5 ppb at constant temperature.  
±10 ppb over temperature variation of 20° -  
30°C.  
±15 ppb over temperature variation of 15° -  
35°C.  
Allaccuracyspecificationsarecontingent  
upon the completion of zero ans span calibra-  
tion.  
All accuracy is established at constant pres-  
sure and equilibrium has been established.  
Analog outputs: 0-1 V dcpercent-of-range,  
0-1 V dc range ID.  
4-20 mA dc(isolated) percent-of-range,  
4-20 mA dc (isolated) range ID.  
Dimensions: 19 cm high, 24.9 cm wide, 31 cm deep (6.96  
in high, 8.7 in wide, 12.2 in deep).  
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Ultra Trace Oxygen Analyzer  
Appendix  
A-2 Recommended 2-Year Spare Parts List  
QTY.  
PART NUMBER  
DESCRIPTION  
1
1
1
1
1
1
3
3
CP2037  
C65507  
C62371-B  
C71410  
C70941  
C62365-A  
F9  
TEC Cooler  
Back Panel Board  
Front Panel Board  
PreamplifierBoard(Instruction)  
TEC Controller PCB  
Main Computer Board  
Fuse, 1A, 250V 3AG Slow Blow  
F1275  
Fuse, 1A, 250V 5x20mm (European)  
Slow Blow  
1
1
O286  
O-ring  
C6689-B2CXL  
Micro-FuelCell(donotstoreformore  
than6months)  
1
CP1798  
F1498  
50 pin D-sub interface connector  
Fan  
1
50  
CP1799  
Pins for CP1798 connector  
A minimum charge is applicable to spare parts orders.  
Note: Orders for replacement parts should include the part number (if  
available) and the model and serial number of the instrument for  
which the parts are intended.  
Orders should be sent to:  
Teledyne Analytical Instruments  
16830 Chestnut Street  
City of Industry, CA 91749-1580  
Phone (626) 934-1500, Fax (626) 961-2538  
TWX (910) 584-1887 TDYANYL COID  
or your local representative.  
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Appendix  
Model Ultra Trace 3000  
A-3 Drawing List  
B-71228 PipingDiagram  
A-4 19-inch Relay Rack Panel Mount  
Figure A-1: Single 19" Rack Mounts  
(dimensions in mm)  
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Ultra Trace Oxygen Analyzer  
Appendix  
A-5  
Ultra Trace 3000 SERIES ANALYZERS  
APPLICATION NOTES ON  
PRESSURES AND FLOW RECOMMENDATIONS  
3000seriesanalyzersrequirereasonablyregulatedsamplepressures.  
Whilethe3000analyzersarenotsensitivetovariationsofincomingpressure  
(providedtheyareproperlyventedtoatmosphericpressure)Thepressuremust  
bemaintainedastoprovideauseableflowratetroughtheanalyzer.Anyline  
attachedtosampleventshouldbe1/4orlarger indiameter.  
FLOW RATE RECOMMENDATIONS:  
Ausableflowratefora3000seriesanalyzerisonewhichcanbe  
measuredontheflowmeter.Thisisbasically 0.5-2.0SLPM.Theoptimum  
flowrateis1SLPM (midscale). Note:responsetimeisdependentonflow  
rate,alowflowratewillresultinslowresponsetoO2changesinthesample  
stream.Thespanflowrateshouldbetheapproximatelysameasthesampleflow  
rate.  
CELL PRESSURE CONCERNS:  
Thesensorsusedin3000seriesanalyzersareoptimized tofunctionat  
atmosphericpressure.Atpressuresotherthanatmosphericthediffusionrateof  
O2willbedifferentthanoptimumvalue.HigherpressureswillproducefasterO2  
diffusionrates resultinginhigherO2reading andshortercelllife.Tousea3000  
seriesanalyzeratacellpressureotherthanatmospheric,theanalyzermustbe  
calibratedwithaknowncalibrationgasatthenewcellpressuretoadjustforthe  
differentdiffusionrate.Cellpressuresbelow2/3atmosphericarenot  
recommendedbecausetheytendtocauseexcessiveinternalexpansionwhich  
mayresultinsealfailure.  
Foroperationatcellpressuresotherthanatmosphericcaremustbe  
takennottochangethesamplepressurerapidlyorcelldamagemayoccur.For  
cellpressuresaboveatmospheric,cautionmustbeexercisedtoavoidover  
pressuringthecellholder.  
FLOWCONTROLVALVE:  
All3000seriesanalyzershaveaflowcontroldevice.Thisdeviceisa  
needlevalve,and servestwofunctionsinthesamplepath.Thefirstfunctionisto  
limittheflowrateofthesamplethroughtheanalyzer.Theneedlevalveischosen  
tooperateoveraspecificrangeofpressuresandprovideauseableflowrate  
overthatrange.  
Thesecond functionthattheneedlevalveprovidesisapressuredrop.  
Thisdeviceisselectedtoprovidetheonlysignificant pressuredropinthe  
samplepath.  
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Appendix  
Model Ultra Trace 3000  
BY-PASS:  
Toimprovethesystemresponse, aby-passcanbeaddedtoincrease  
thesampleflowratetotheanalyzerbyafactoroften.Aby-passprovidesa  
sampleflowpatharoundtheanalyzerof 2-18SCFH.typically.  
CONVERSIONS:  
1 PSI  
1 SCFH  
=
=
2.04 INCHES OF MERCURY (in. Hg.)  
0.476 SLPM  
NOTE: The MSDS on this material is available upon request  
through the Teledyne Environmental, Health and  
Safety Coordinator. Contact at (626) 934-1592  
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