Teledyne 2010B User manual

i

Teledyne Analytical Instruments

Thermal Conductivity Analyzer

OPERATING INSTRUCTIONS FOR

Model 2010B

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 M70845

11/22/00

ECO # 00-0517

0.0 % Anlz

AL-1

2010B

Thermal Conductivity Analyzer

Teledyne Analytical Instruments

Teledyne Analytical Instrumentsii

Model 2010B

transcribed, stored in a retrieval system, or translated into any other language or computer

language in whole or in part, in any form or by any means, whether it be electronic,

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

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

1580.

Warranty

This 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

apparent 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

apparatus, 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

assist 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 instrumen-

tation related to it.

The safety of personnel is ultimately the responsibility of those who control process

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 specifically 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

expressed or implied by this document or any information disseminated by the manufactur-

er 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

Specific Model Information................................. iv

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

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

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

Teledyne Analytical Instrumentsiv

Model 2010B

Specific Model Information

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

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

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

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

Instrument Serial Number: _______________________

Options Included in the Instrument with the Above Serial Number:

❑❑

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

valves are electronically controlled to provide synchronization

with the analyzer’s operations.

❑❑

❑ G: Stainless steel cell block with nickel filaments and Stainless

Steel fittings and tubing.

❑❑

❑ H: Stainless steel cell block with gold filaments for corrosive gas

streams and Stainless Steel fittings and tubing.

❑❑

❑ K: 19" Rack Mount option with one or two analyzer Control

Units installed and ready to mount in a standard rack.

❑❑

❑ K2: 19" Rack Mount option with two Control Units mounted.

❑❑

❑ K3: 19" Rack Mount option with one Control Unit mounted and a

blank cover installed in the second Control Unit location.

❑❑

❑ L: Gas selector panel consisting of sample/ref flow meters and

control valves for metering input of sample/calibrations support

gases.

❑❑

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

❑❑

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

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

❑ ❑

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

valves option (Ref. C above)

❑ ❑

❑ O: Flame Arrestors for Group B (hydrogen)

❑❑

❑

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 Configuration .............................................. 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

Teledyne Analytical Instrumentsvi

Model 2010B

4.3 The

System

Function..................................................... 4-4

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/Define 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

vii

Teledyne Analytical Instruments

Thermal Conductivity Analyzer

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

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

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

Appendix

A-1 Specifications................................................................. A-1

A-2 Recommended 2-Year Spare Parts List......................... A-3

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

Teledyne Analytical Instrumentsviii

Model 2010B

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

unauthorized 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 by Teledyne, its affiliates, 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 configuration conductivity analyzers.

Each analyzer consist of a Control Unit suitable for installation in a general

purpose area-enclosure rated NEMA-4, 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 2010B Thermal Conductivity Analyzer is

a versatile microprocessor-based instrument for measuring a component gas in a

background gas, or in a specific mixture of background gases. It compares the

thermal conductivity of a sample stream with that of a reference gas of known

composition. The 2010B can—

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

• measure the concentration of a gas in a specific mixture of back-

ground gases.

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

ty or a mixture of impurities.

The standard 2010B 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 2010B General Purpose flush-panel

and rack-mount control units only.

Many of the Model 2010B features covered in this manual are optional,

selected according to the customers specific application. Refer to the specific

model information sheet (page IV) for the options incorporated in the instrument.

Teledyne Analytical Instruments1-2 Part I

1 Introduction Model 2010B

1.2 Typical Applications

A few typical applications of the Model 2010B 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 2010B Thermal Conductivity Analyzer

include:

• Three independent, user definable, analysis ranges allow up to

three different gas applications with one concentration range

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

tion, 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

allows the user to lock onto a specific range of interest.

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

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.

Part I 1-3

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

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

• 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 Isolat-

ed 4–20 mA dc) and two for range identification.

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

ponents are accessible.

1.4 Model Designations

The Model 2010B is ordinarily custom programmed at the factory to fit the

customer’s application. Many parameters, including the number of channels, the

gas application, the materials specification of the sampling system, and others,

are options. The most common options, are covered in this manual. See the

Specific Model Information checklist in the front matter of this manual for those

that apply to your Model 2010B 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 2010B 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 briefly here and in detail in the Operations chapter

of this manual.

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

change the specific 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.).

Teledyne Analytical Instruments1-4 Part I

1 Introduction Model 2010B

• Span Span calibrate the analyzer.

• Zero Zero calibrate the analyzer.

• Alarms Set the alarm setpoints and attributes.

• Range Set up the 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 (Vacuum Fluorescent

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.

Figure 1-1: Model 2010B Front Panel

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AL-1

2010B

Thermal Conductivity Analyzer

Outer Door

(Open)

Viewing

Window

Outer Door

Latch

Teledyne Analytical Instruments

Digital

Meter

LCD

Screen

Inner Door

Latch

(Pressing the latch button

will open the inner Door)

Control

Panel

Part I 1-5

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

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 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 unfastening 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 ADJUSTMENT IS

NEEDED.

1.7 Equipment Interface (Rear Panel)

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

external input and output. The connectors are described briefly here and in detail

in chapter 3, Installation.

Teledyne Analytical Instruments1-6 Part I

1 Introduction Model 2010B

Figure 1-2: Model 2010B 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.

Part I 1-7

Teledyne Analytical Instruments

Thermal Conductivity Analyzer Part I: Control Unit

• Alarm Connections 2 concentration alarms and 1 system

alarm.

• RS-232 Port Serial digital concentration signal output

and control input.

• Remote Probe Used in the 2010B to interface the

external Analysis Unit.

• Remote Span/Zero Digital inputs allow external control of

analyzer calibration.

• Calibration Contact To notify external equipment that

instrument is being calibrated and

readings are not monitoring sample.

• Range ID Contacts Four separate, dedicated,

range-identification 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

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

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

scheduled calibrations can vary 2-3 % per day.

Teledyne Analytical Instruments1-8 Part I

1 Introduction Model 2010B

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 2010B

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 2010B 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 2010B

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 2010B Electronics

Thermistor

Sensor

Heater

Temperature

Control

Fine

Adjustment

Coarse

Adjustment

Auto-

Range

M

U

X

A to D

Converter

Digitial to

Analog

Converter

(DAC)

0-1 V dc

Concentration

and Range

4-20 mA dc

Concentration

and Range

Differential

Amplifier

Variable

Gain

Amplifier

Central

Processing

Unit

(CPU)

Alarm 1

Alarm 2

System

Failure

Alarm

RS-232

Range

Contacts (4)

External

Valve

Control

Remote Span

Control

Remote Zero

Control

Cal

Contact

Keyboard

Displays

Processing

Selt-Test Signal to MUX

Power

Supply

A to D Conv

To CPU

Temperature

Control

Heater

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