Teledyne 2010A User manual

i

Teledyne Analytical Instruments

Thermal Conductivity Analyzer

OPERATING INSTRUCTIONS FOR

Model 2010A

Thermal Conductivity Analyzer

HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING

SYSTEM.

PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.

HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FOR

A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.

ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING. BEFORE

CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/

MANAGER.

DANGER

P/N M70194

07/19/05

ECO # 05-0131

Teledyne Analytical Instruments

ii

Model 2010A

scribed, stored in a retrieval system, or translated into any other language or computer lan-

guage in whole or in part, in any form or by any means, whether it be electronic, mechani-

cal, magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne

Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-1580.

Warranty

This equipment is sold subject to the mutual agreement that it is warranted by us

free from defects of material and of construction, and that our liability shall be limited

to replacing or repairing at our factory (without charge, except for transportation), or at

customer plant at our option, any material or construction in which defects become ap-

parent within one year from the date of shipment, except in cases where quotations or

acknowledgments provide for a shorter period. Components manufactured by others bear

the warranty of their manufacturer. This warranty does not cover defects caused by wear,

accident, misuse, neglect or repairs other than those performed by Teledyne or an autho-

rized service center. We assume no liability for direct or indirect damages of any kind and

the purchaser by the acceptance of the equipment will assume all liability for any damage

which may result from its use or misuse.

We reserve the right to employ any suitable material in the manufacture of our ap-

paratus, and to make any alterations in the dimensions, shape or weight of any parts, in so

far as such alterations do not adversely affect our warranty.

Important Notice

This instrument provides measurement readings to its user, and serves as a tool by

which valuable data can be gathered. The information provided by the instrument may as-

sist the user in eliminating potential hazards caused by his process; however, it is essential

that all personnel involved in the use of the instrument or its interface, with the process

being measured, be properly trained in the process itself, as well as all instrumentation

related to it.

The safety of personnel is ultimately the responsibility of those who control pro-

cess conditions. While this instrument may be able to provide early warning of imminent

danger, it has no control over process conditions, and it can be misused. In particular, any

alarm or control systems installed must be tested and understood, both as to how they

operate and as to how they can be defeated. Any safeguards required such as locks, labels,

or redundancy, must be provided by the user or specically requested of Teledyne at the

time the order is placed.

Therefore, the purchaser must be aware of the hazardous process conditions.

The purchaser is responsible for the training of personnel, for providing hazard warning

methods and instrumentation per the appropriate standards, and for ensuring that hazard

warning devices and instrumentation are maintained and operated properly.

Teledyne Analytical Instruments, the manufacturer of this instrument, cannot

accept responsibility for conditions beyond its knowledge and control. No statement ex-

pressed or implied by this document or any information disseminated by the manufacturer

or its agents, is to be construed as a warranty of adequate safety control under the user’s

process conditions.

iii

Teledyne Analytical Instruments

Thermal Conductivity Analyzer

Table of Contents

Specic Model Information ..................................iv

Part I: Control Unit, Model 2010A .......... Part I: 1-1

Part II: Analysis Unit, Model 2010A ...... Part II: 1-1

Appendix ...........................................................A-1

Teledyne Analytical Instruments

iv

Model 2010A

Specic Model Information

The instrument for which this manual was supplied may incorporate one or more

options not supplied in the standard instrument. Commonly available options are listed be-

low, with check boxes. Any that are incorporated in the instrument for which this manual

is supplied are indicated by a check mark in the box.

Instrument Serial Number: _______________________

Options Included in the Instrument with the Above Serial Number:

q C: Auto Calibration valves (zero/span/sample) built-in gas control

valves are electronically controlled to provide synchronization

with the analyzer’s operations.

q G: Stainless steel cell block with nickel laments and Stainless

Steel ttings and tubing.

q H: Stainless steel cell block with gold laments for corrosive gas

streams and Stainless Steel ttings and tubing.

q K: 19” Rack Mount option with one or two analyzer Control

Units installed and ready to mount in a standard rack.

q K2: 19” Rack Mount option with two Control Units mounted.

q K3: 19” Rack Mount option with one Control Unit mounted and a

blank cover installed in the second Control Unit location.

q L: Gas selector panel consisting of sample/ref ow meters and

control valves for metering input of sample/calibrations sup-

port gases.

q F: Flame Arrestors for Class 1, Div. 1, Groups C/D service.

q P: Flame Arrestors for Class 1, Div. 1, Groups C/D service, and

Auto Cal valves option (Ref. C above) and GP use.

q Q: Flame Arrestors for Group B (hydrogen) service, and Auto Cal

valves option (Ref. C above)

q O: Flame Arrestors for Group B (hydrogen)

q R: Sealed Reference Cell

v

Teledyne Analytical Instruments

Thermal Conductivity Analyzer

Table of Contents

1 Introduction

1.1 Overview ......................................................................... 1-1

1.2 Typical Applications ......................................................... 1-2

1.3 Main Features of the Analyzer ........................................ 1-2

1.4 Model Designations ........................................................ 1-3

1.5 Operator Interface (Front Panel) .....................................

1-3

1.6 Recognizing Difference Between LCD & VFD ................ 1-5

1.7 Equipment Interface (Rear Panel) .................................. 1-5

1.8 Gas Connections ............................................................ 1-7

2 Operational Theory

2.1 Introduction ..................................................................... 2-1

2.2 Sensor Theory ................................................................ 2-1

2.2.1 Sensor Conguration ................................................ 2-1

2.2.2 Calibration ................................................................ 2-2

2.2.3 Effects of Flowrate and Gas Density ........................ 2-3

2.2.4 Measurement Results .............................................. 2-3

2.3 Electronics and Signal Processing .................................. 2-3

2.4 Temperature Control ....................................................... 2-5

3 Installation

3.1 Unpacking the Analyzer .................................................. 3-1

3.2 Mounting the Control Unit ............................................... 3-1

3.3 Electrical Connections (Rear Panel) ............................... 3-3

3.3.1 Primary Input Power ................................................ 3-4

3.3.2 Fuse Installation ...................................................... 3-4

3.3.3 Analog Outputs ........................................................ 3-4

3.3.4 Alarm Relays ........................................................... 3-6

3.3.5 Digital Remote Cal Inputs ........................................ 3-7

3.3.6 Range ID Relays ..................................................... 3-8

3.3.7 Network I/O .............................................................. 3-8

3.3.8 RS-232 Port ............................................................. 3-9

3.3.9 Remote Probe Connector ........................................ 3-9

3.4 Testing the System ......................................................... 3-16

3.5 Warm Up at Power Up ................................................... 3-16

4 Operation

4.1 Introduction ..................................................................... 4-1

4.2 Using the Data Entry and Function Buttons .................... 4-1

4.3 The System Function ...................................................... 4-4

Teledyne Analytical Instruments

vi

Model 2010A

4.3.1 Setting the Display ................................................. 4-5

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

4.3.3.2 Installing or Changing the Password ..............

4-7

4.3.4 Logging Out .............................................................

4-9

4.3.5 System Self-Diagnostic Test .................................... 4-9

4.3.6 The Model Screen ................................................... 4-10

4.3.7 Checking Linearity with Algorithm ............................ 4-10

4.4 The

Zero and Span Functions ........................................ 4-11

4.4.1 Zero Cal ...................................................................

4-12

4.4.1.1 Auto Mode Zeroing ......................................... 4-12

4.4.1.2 Manual Mode Zeroing ..................................... 4-13

4.4.1.3 Cell Failure ...................................................... 4-14

4.4.2 Span Cal .................................................................. 4-14

4.4.2.1 Auto Mode Spanning ...................................... 4-15

4.4.2.2 Manual Mode Spanning .................................. 4-15

4.5 The Alarms Function ...................................................... 4-16

4.6 The Range Select Function ............................................ 4-18

4.6.1 Manual (Select/Dene Range) Screen .................... 4-19

4.6.2 Auto (Single Application) Screen ............................. 4-19

4.6.3 Precautions .............................................................. 4-21

4.7 The Analyze Function ..................................................... 4-21

4.8 Programming .................................................................. 4-22

4.8.1 The Set Range Screen ............................................ 4-23

4.8.2 The Curve Algorithm Screen ................................... 4-25

4.8.2.1 Checking the Linearization ............................. 4-25

4.8.2.2 Manual Mode Linearization ............................. 4-26

4.8.2.3 Auto Mode Linearization ................................. 4-27

4.9 Special Function Setup ................................................... 4-28

4.9.1 Output Signal Reversal ............................................ 4.28

4.9.2 Special - Inverting Output ........................................ 4-28

4.9.3 Special - Polarity Coding ......................................... 4-29

4.9.4 Special - Nonlinear Application Gain Preset ............ 4-29

Maintenance

5.1 Routine Maintenance ...................................................... 5-1

5.2 System Self Diagnostic Test ........................................... 5-1

5.3 VFD Display .................................................................... 5-2

5.4 Fuse Replacement .......................................................... 5-2

5.5 Major Internal Components ............................................. 5-3

5.6 Cleaning .......................................................................... 5-5

vii

Teledyne Analytical Instruments

Thermal Conductivity Analyzer

5.7 Phone Numbers .............................................................. 5-5

Appendix

A-1 Specications .................................................................. A-1

A-2 Recommended 2-Year Spare Parts List ..........................

A-3

A-3 Drawing List .................................................................... A-4

A-4 TG Option Calibration..................................................... A-5

Teledyne Analytical Instruments

viii

Model 2010A

COMBUSTIBLE GAS USAGE WARNING

DANGER

The customer should ensure that the principles of operating of

this equipment are well understood by the user. Misuse of this

product in any manner, tampering with its components, or un-

authorized substitution of any component may adversely affect

the safety of this instrument.

Since the use of this instrument is beyond the control of Tele-

dyne, no responsibility by Teledyne, its afliates, and agents

for damage or injury from misuse or neglect of this equipment

is implied or assumed.

Part I 1-1

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

Introduction

1.1 Overview

The Model 2010 is a family of split conguration conductivity analyz-

ers. Each analyzer consist of a Control Unit suitable for installation in a

general purpose area, and a Analysis Unit which is housed in an explosion-

proof enclosure. The Analysis Unit enclosure is rated for NEMA 4/7 Class

I, Div. 1, Groups B,C,D and is approved by U/L and CSA.

The Analytical Instruments Model 2010A Thermal Conductivity

Analyzer is a versatile microprocessor-based instrument for measuring a

component gas in a background gas, or in a specic mixture of background

gases. It compares the thermal conductivity of a sample stream with that of

a reference gas of known composition. The 2010A can—

• measure the concentration of one gas in a mixture of two gases.

• measuretheconcentrationofagasinaspecicmixtureofback

-

ground gases.

• measure the purity of a sample stream containing a single impu-

rity or a mixture of impurities.

The standard 2010A is pre-programmed with automatic linearization

algorithms for a large number of gases and gas mixtures. The factory can

add to this data base for custom applications, and the sophisticated user can

add his own unique applications.

This manual section covers the Model 2010A General Purpose ush-

panel and rack-mount control units only. These control units are for

indoor use in a nonhazardous environment.

Many of the Model 2010A features covered in this manual are op-

tional, selected according to the customers specic application. Refer to the

specic model information sheet (page IV) for the options incorporated in

the instrument.

Teledyne Analytical Instruments

1-2 Part

1 Introduction Model 2010A

1.2 Typical Applications

A few typical applications of the Model 2010A are:

• Power generation

• Air liquefaction

• Chemical reaction monitoring

• Steel manufacturing and heat treating

• Petrochemical process control

• Quality assurance

• Refrigeration and storage

• Gas proportioning control.

1.3 Main Features of the Analyzer

The main features of the Model 2010A Thermal Conductivity Ana-

lyzer include:

• Threeindependent,userdenable,analysisrangesallowupto

three different gas applications with one concentration range

each, or up to three concentration ranges for a single gas appli-

cation,oranycombination.

• Specialrecalibrationrangeformultipleapplications.Recalibrat-

ingone,recalibratesall.

• Automatic, independent linearization for each range.

• Auto Ranging allows analyzer to automatically select the proper

preset range for a given single application. Manual override al-

lowstheusertolockontoaspecicrangeofinterest.

• RS-232 serial digital port for use with a computer or other digi-

tal communications device.

• Sixadjustableconcentrationsetpointswithtwoalarmsanda

system failure alarm relay.

• Extensive self-diagnostic testing, at startup and on demand.

• A2-linealphanumericdisplayscreen,drivenbymicroprocessor

electronics, that continuously prompts and informs the operator.

• High resolution, accurate indication of target or impurity gas

concentrationfromlarge,bright,meterreadout.(0-9999ppm

through0-100%dependingontypesofgasinvolved.)

• Standard, proven sensor cell design.

• Wide range of custom applications, ranges, and linearization.

Part I 1-3

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

• Microprocessorbasedelectronics:8-bitCMOSmicroprocessor

with32kBRAMand128kBROM.

• Autoandremotecalibrationcapabilities.

• Fouranalogoutputs:twoformeasurement(0–1VdcandIso-

lated4–20mAdc)andtwoforrangeidentication.

• Compactandversatiledesign:Smallfootprint,yetinternalcom-

ponentsareaccessible.

1.4 Model Designations

The Model 2010A is ordinarily custom programmed at the factory to

t the customer’s application. Many parameters, including the number of

channels, the gas application, the materials specication of the sampling

system, and others, are options. The most common options, are covered in

this manual. See the Specic Model Information checklist in the front mat-

ter of this manual for those that apply to your Model 2010A analyzer. Some

standard models that are not covered in this manual are listed here.

Models 2000A: Bothanalysissectionandcontrolunitareinasingle

general purpose enclosure.

Models 2020: Boththeanalysissectionandcontrolunitareinasingle

explosion proof enclosure.

1.5 Operator Interface (Front Panel)

The standard 2010A 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, and an

alphanumeric display. They are described briey here and in detail in the

Operations chapter of this manual.

Function Keys: Six touch-sensitive membrane switches are used to

change the specic function performed by the analyzer:

• Analyze Perform analysis for target-gas content of a sample

gas.

• System Performsystem-relatedtasks(describedindetailin

chapter 4, Operation.).

• Span  Spancalibratetheanalyzer.

• Zero  Zerocalibratetheanalyzer.

Teledyne Analytical Instruments

1-4 Part

1 Introduction Model 2010A

• Alarms Setthealarmsetpointsandattributes.

• Range Setuptheuserdenablerangesfortheinstrument.

Data Entry Keys: Six touch-sensitive membrane switches are used to

input data to the instrument via the alphanumeric VFD (Vacuum Fluores-

cent Display) display:

• Left & Right Arrows Selectbetweenfunctionscurrently

displayedontheVFDscreen.

• Up & Down Arrows Incrementordecrementvaluesof

functions currently displayed.

• Enter MovesVFDontothenextscreeninaseries.Ifnone

remains, returns to the Analyze screen.

• Escape MovesVFDbacktothepreviousscreeninaseries.If

none remains, returns to the Analyze screen.

Digital Meter Display: The meter display is a VFD device that

produces large, bright, 7-segment numbers that are legible in any lighting.

It produces a continuous trace readout from 0-9999 ppm or a continuous

Figure 1-1: Model 2010A Front Panel

Part I 1-5

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

percent readout from 1-100 %. It is accurate across all analysis ranges.

Alphanumeric Interface Screen: The VDF screen is an easy-to-use

interface between operator and analyzer. It displays values, options, and

messages that give the operator immediate feedback.

Standby Button: The Standby turns off the display and

outputs, but circuitry is still operating.

CAUTION: The power cable must be unplugged to fully

disconnect power from the instrument. When

chassis is exposed or when access door is open

and power cable is connected, use extra care to

avoid contact with live electrical circuits.

Access Door: For access to the thermal conductivity sensor or the

front panel electronics, the front panel swings open when the latch in the

upper right corner of the panel is pressed all the way in with a narrow

gauge tool. Accessing the main electronics circuit board requires unfasten-

ing rear panel screws and sliding the electronics drawer out of the case.

(See chapter 5.)

1.6 Recognizing Difference Between LCD & VFD

LCD (Liquid Crystal Display) has GREEN background with BLACK

characters. VFD has DARK background with GREEN characters. In the

case of VFD (Vacuum Fluorescent Display) - NO CONTRAST ADJUST-

MENT IS NEEDED.

1.7 Equipment Interface (Rear Panel)

The rear panel, shown in Figure 1-2, contains the electrical connec-

tors for external input and output. The connectors are described briey here

and in detail in chapter 3, Installation.

Teledyne Analytical Instruments

1-6 Part

1 Introduction Model 2010A

Figure 1-2: Model 2010A Rear Panel

• Power Connection 85-250VACpowersource.

• Analog Outputs 0-1Vdcconcentrationplus0-1Vdc

rangeID,andisolated4-20mAdcplus

4-20mAdcrangeID.

• Alarm Connections 2concentrationalarmsand1system

alarm.

• RS-232 Port Serial digital concentration signal out-

put and control input.

• Remote Probe Usedinthe2010Atointerfacetheex-

ternal Analysis Unit.

• Remote Span/Zero Digitalinputsallowexternalcontrolof

analyzercalibration.

• Calibration Contact To notify external equipment that in-

strumentisbeingcalibratedandread-

ings are not monitoring sample.

• Range ID Contacts Fourseparate,dedicated,range-identi-

cationrelaycontacts(01,02,03,CAL).

• Network I/O Serial digital communications for local

networkaccess.Forfutureexpansion.

Not implemented at this printing.

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

Part I 1-7

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

Auto-Cal control where possible. The internal clock in the

Model 2010A is accurate to 2-3 %. Accordingly, internally

scheduled calibrations can vary 2-3 % per day.

Teledyne Analytical Instruments

1-8 Part

1 Introduction Model 2010A

Part I 2-1

Thermal Conductivity Analyzer Part I: Control Unit

Teledyne Analytical Instruments

Operational Theory

2.1 Introduction

The analyzer is composed of two subsystems:

1. Thermal Conductivity Sensor

2. Electronic Signal Processing, Display and Control.

The sensor is a thermal conductivity comparator that continuously

compares the thermal conductivity of the sample gas with that of a reference

gas having a known conductivity.

The electronic signal processing, display and control subsystem simpli-

fies operation of the analyzer and accurately processes the sampled data. A

microprocessor controls all signal processing, input/output, and display

functions for the analyzer.

2.2 Sensor Theory

For greater clarity, Figure 2-1 presents two different illustrations, (a)

and (b), of the operating principle of the thermal conductivity cell.

2.2.1 Sensor Configuration

The thermal conductivity sensor contains two chambers, one for the

reference gas of known conductivity and one for the sample gas. Each

chamber contains a pair of heated filaments. Depending on its thermal

conductivity, each of the gases conducts a quantity of heat away from the

filaments in its chamber. See Figure 2-1(a).

The resistance of the filaments depends on their temperature. These

filaments are parts of the two legs of a Wheatstone bridge circuit that unbal-

ances if the resistances of its two legs do not match. See Figure 2-1(b).

2-2 Part I

2 Operational Theory Model 2010A

Teledyne Analytical Instruments

Figure 2-1: Thermal Conductivity Cell Operating Principle

If the thermal conductivities of the gases in the two chambers are

different, the Wheatstone bridge circuit unbalances, causing a current to flow

in its detector circuit. The amount of this current can be an indication of the

amount of impurity in the sample gas, or even an indication of the type of

gas, depending on the known properties of the reference and sample gases.

The temperature of the measuring cell is regulated to within 0.1 °C by a

sophisticated control circuit. Temperature control is precise enough to com-

pensate for diurnal effects in the output over the operating ranges of the

analyzer. (See Specifications in the Appendix for details.)

2.2.2 Calibration

Because analysis by thermal conductivity is not an absolute measure-

ment, calibration gases of known composition are required to fix the upper

and lower parameters (“zero” and “span”) of the range, or ranges, of analy-

sis. These gases must be used periodically, to check the accuracy of the

analyzer.

During calibration, the bridge circuit is balanced, with zero gas against

the reference gas, at one end of the measurement range; and it is sensitized

with span gas against the reference gas at the other end of the measurement

range. The resulting electrical signals are processed by the analyzer electron-

ics to produce a standard 0-1V, or an isolated 4–20 mA dc, output signal, as

described in the next section.

Part I 2-3

Thermal Conductivity Analyzer Part I: Control Unit

Teledyne Analytical Instruments

2.2.3 Effects of Flowrate and Gas Density

Because the flowrate of the gases in the chambers affects their cooling

of the heated filaments, the flowrate in the chambers must be kept as equal,

constant, and low as possible.

When setting the sample and reference flowrate, note that gases lighter

than air will have an actual flowrate higher than indicated on the flowmeter,

while gases heavier than air will have an actual flowrate lower than indi-

cated. Due to the wide range of gases that are measured with the Thermal

Conductivity Analyzer, the densities of the gases being handled may vary

considerably.

Then, there are limited applications where the reference gas is in a

sealed chamber and does not flow at all. These effects must be taken in

consideration by the user when setting up an analysis.

2.2.4 Measurement Results

Thermal conductivity measurements are nonspecific by nature. This fact

imposes certain limitations and requirements. If the user intends to employ

the analyzer to detect a specific component in a sample stream, the sample

must be composed of the component of interest and one other gas (or spe-

cific, and constant, mixture of gases) in order for the measured heat-transfer

differences to be nonambiguous.

If, on the other hand, the user is primarily interested in the purity of a

process stream, and does not require specific identification of the impurity,

the analyzer can be used on more complex mixtures.

2.3 Electronics and Signal Processing

The Model 2010A Thermal Conductivity Analyzer uses an 8031

microcontroller, Central Processing Unit—(CPU) with 32 kB of RAM and

128 kB of ROM to control all signal processing, 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. (See Major Internal Components in chapter 5 Maintenance for 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 5.4. These boards are accessible after

2-4 Part I

2 Operational Theory Model 2010A

Teledyne Analytical Instruments

removing the back panel. Figure 2-2 is a block diagram of the Analyzer

electronics.

Figure 2-2: Block Diagram of the Model 2010A Electronics

Thermistor

Sensor

Heater

Temperature

Control

Fi ne

Adjustment

Coarse

Adjustment

Aut o-

Range

M

U

X

A to D

Convert er

Digitial to

Analog

Conver ter

(DAC)

0-1 V dc

Concentration

and Range

4-20 mA dc

Concentration

and Range

Differential

Amplifier

Varia bl

e

Gai n

Amplifier

Central

Processing

Unit

(CPU)

Alarm 1

Alarm 2

System

Failure

Alar m

RS- 232

Range

Contacts (4)

External

Valv e

Cont rol

Remote Span

Control

Remote Zero

Contr ol

Cal

Contact

Keyboa rd

Displays

Processing

Selt-Test Signal to MUX

Powe r

Supply

A to D Conv

To CPU

Temperature

Control

Heat er

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Teledyne 2010A User manual

Teledyne 2010A User manual

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