Teledyne Insta-Trans, Operating Instructions Manual

Page 1: ...Personal protective equipment may be required when servicing this instrument Hazardous voltages exist on certain components internally which may persist for a time even after the power is turned off and disconnected Only authorized personnel should conduct maintenance and or servicing Before conducting any maintenance or servicing consult with authorized supervisor manager P N M72103 08 02 10 ...

Page 2: ...ht 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 o...

Page 3: ...ot 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 _______________________ Insta Trans Transmitter Model ____________ Cell Class A2C A5 B1 B2C L2C B71875 Insta Trace B73016 Insta Trace ...

Page 4: ...Cell Sensor 5 2 2 1 Principles of Operation 5 2 2 2 Anatomy of a Micro fuel Cell 6 2 2 3 Electrochemical Reactions 7 2 2 4 The Effect of Pressure 8 2 2 5 Calibration Characteristics 8 2 3 Sample System 10 2 4 Electronics and Signal Processing 11 Installation 13 3 1 Unpacking the Transmitter 13 3 2 Mounting the Transmitter 13 3 3 Gas Connections 13 3 4 Electrical Connections 15 3 5 Installing the M...

Page 5: ...tion 20 Maintenance 23 5 1 Routine Maintenance 23 5 2 Cell Replacement 23 5 2 1 Storing and Handling Replacement Cells 23 5 2 2 When to Replace a Cell 24 5 2 3 Removing the Micro fuel Cell 24 5 2 4 Cell Warranty 24 5 3 Insta Trace Sensor 26 Appendix 29 Specifications 29 Recommended Spare Parts List 30 Drawings 32 ...

Page 6: ...a Micro fuel Cell 7 Figure 2 3 Characteristic Input Output Curve for a Micro fuel Cell 9 Figure 2 4 Gas and Other Connections to the Transmitter 10 Figure 2 5 Electronics Block Diagram 12 Figure 3 1 Insta Trans Connections and Mounting Dimensions 14 Figure 4 1 Insta Trace Operation 21 Figure 5 1 Cell Removal 26 Figure 5 2 Cell Removal Insta Trace 28 ...

Page 7: ...of gas leaks always exist The customer should ensure that the principles of operating of this equipment is well understood by the user Misuse of this product in any manner tampering with its components or unauthorized substitution of any component may adversely affect the safety of this instrument Since the use of this instrument is beyond the control of Teledyne no responsibility by Teledyne its ...

Page 8: ...Insta Trans Teledyne Analytical Instruments viii ...

Page 9: ...ual approved when installed in accordance with drawing D 73226 located in the back of this manual 1 2 Typical Applications A few typical applications of the Insta Trans are Monitoring inert gas blanketing Air separation and liquefaction Chemical reaction monitoring Semiconductor manufacturing Petrochemical process control Quality assurance Gas analysis certification 1 3 Main Features of the Transm...

Page 10: ... 1 1 shows the decimal point DP location for the various ranges Function Keys Six touch sensitive membrane switches are used to set the range and calibrate the transmitter RANGE Selects the Range mode and sets the desired range COARSE Selects the Coarse calibration mode FINE Selects the Fine calibration mode RUN Selects the Run mode Used to adjust the calibration upward in Coarse and Fine mode Use...

Page 11: ...Trace Oxygen Transmitter Introduction Teledyne Analytical Instruments 3 Figure 1 1 Range Selection ...

Page 12: ...Introduction Insta Trans Teledyne Analytical Instruments 4 ...

Page 13: ...e sampled data 2 2 Micro fuel Cell Sensor 2 2 1 Principles of Operation The oxygen sensor used in the Insta Trans series is a Micro fuel Cell designed and manufactured by Analytical Instruments It is a sealed plastic disposable electrochemical transducer The active components of the Micro fuel Cell are a cathode an anode and the 15 aqueous KOH electrolyte in which they are immersed The cell conver...

Page 14: ... contacts in the sensor block assembly and provide the electrical connection to the rest of the analyzer Figure 2 1 illustrates the external features Figure 2 1 Micro fuel Cell Refer to Figure 2 2 Cross Section of a Micro fuel Cell which illustrates the following internal description At the top end of the cell is a diffusion membrane of Teflon whose thickness is very accurately controlled Beneath ...

Page 15: ... 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 t...

Page 16: ...amount of stored anode material 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 parts per million or a percentage 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 ...

Page 17: ...ar 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 oxygen the characteristic curve has close to an absolute zero within 0 5 ppm oxygen Figure 2 3 Characteristic Input Output Curve for a Micro fuel Cell ...

Page 18: ...ion of the gas is not altered as it travels through the sample system The sample encounters almost no dead space This minimizes residual gas pockets that can interfere with trace analysis The sample system for the standard instrument incorporates 1 8 inch tube fittings for sample inlet and outlet connections For metric system installations 6 mm adapters can be supplied with each instrument to be u...

Page 19: ...plifier in proportion to the temperature changes in the block This change is inversely proportional to the change in the cell output due to the same temperature changes The result is a signal that is temperature independent The output from the second stage amplifier is sent to the 3 1 2 digit DVM Display and voltage to current converter driver The 3 1 2 digit DVM Display provides a visual indicati...

Page 20: ...Operational Theory Insta Trans Teledyne Analytical Instruments 12 Figure 2 5 Electronics Block Diagram ...

Page 21: ...mage Immediately report any damage to the shipping agent 3 2 Mounting the Transmitter The Insta Trans is intended for indoor or outdoor use The Insta Trans transmitter is provided with a wall mount bracket Refer to Figure 3 1 for mounting information and dimensions The display and operator control switches are located on the top of the transmitter This should be taken into consideration when deter...

Page 22: ...rn beyond finger tight 2 Hold the fitting body steady with a backup wrench and with another wrench rotate the nut another 1 1 4 turns Figure 3 1 Insta Trans Connections and Mounting Dimensions SAMPLE IN Gas connections are made at the SAMPLE IN and EXHAUST OUT connections The gas pressure in should be reasonably regulated A flow control device must be installed before the sample in port if the sam...

Page 23: ...tructure or attaching a ground cable with lug 3 8 to the left side mounting bolt The signal and power are supplied by a single 4 pin electrical connector on the left side of the analyzer The Insta Trans is supplied with a twenty four inch cable which mates with the power signal connector Other cable lengths are available or the mating connector can be supplied for customer use see spare parts list...

Page 24: ...d in determining the minimum voltage requirement The minimum operating voltage required with a 500 foot 20 gage cable and a 250 ohm load resistor is 14 4 VDC 9 3V 5 1 250 ohms x 20ma For Intrinsically Safe IS installation special considerations are required The Insta Trans analyzer has been designed to be Intrinsically Safe when used with a properly selected and installed safety barrier This desig...

Page 25: ...mitter is being energizer for the first time or has been disconnected from the power for a long period of time wait about 60 seconds for the 0 1 Farad storage capacitor to charge up before attempting any tests 2 If the right three digits of the LCD display are blank the transmitter is in an over range condition Push the RANGE button once to enter the Range Select mode Observe that the RNG annuncia...

Page 26: ...nstruments 18 6 Push the and buttons Observe that the gas concentration reading goes up and down in fine increments as the buttons are pushed 7 Push the RUN button Observe that the FIN and RNG annunciators go out The transmitter is now in Run mode ...

Page 27: ...cover if the instrument is used for trace oxygen analysis immediately following calibration in air Connect the calibration gases to the transmitter according to the instructions given in Section 3 3 Gas Connections observing all the prescribed precautions The gas supply should be off or set to a low flow before connecting it to the transmitter and be sure not to obstruct the sample vent CAUTION IN...

Page 28: ...de 4 Adjust the COARSE range up or down using the and keys until the display reads the value that is closest to the calibration gas oxygen concentration level 5 When set to a value close to the calibration gas concentration level press FINE to select the Fine mode 6 Adjust the FINE range up or down until the display reads the value of the calibration gas oxygen concentration level If unable to red...

Page 29: ...Trace Oxygen Transmitter Operation Teledyne Analytical Instruments 21 Figure 4 1 Insta Trace Operation ...

Page 30: ...Operation Insta Trans Teledyne Analytical Instruments 22 ...

Page 31: ...spent fuel cell should be discarded 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 recommends that one spare cell be purchased 9 10 months after commissioning the Insta Trans or shortly before the end of the cell s one year warranty per...

Page 32: ...ls off sharply towards zero at the end Cell failure in the Insta Trans is usually characterized by the inability to span or excessive offset when used on low ppm ranges Before replacing the cell 1 Check your span gas to make sure it is within specifications 2 Check for leaks downstream from the cell where oxygen may be leaking into the system If there are no leaks and the span gas is OK replace th...

Page 33: ...enda 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 shipment The customer should purchase only one spare cell per section 5 2 1 Do not attempt to stockpile spare cells The B1 B2C Insta Trace and L2C cells are not designed for applications where CO2 is a major component in the sample however i...

Page 34: ...Trace Sensor patent pending provides rapid sensor installation recovery time The Insta Trace system allows a new sensor to be installed and working at low ppm parts per million in a matter of minutes The insta Trace option includes the Insta Trace Sensor and a special Insta Trace cell holder the B2 cell adapter is not used ...

Page 35: ...g installation thus allowing rapid recovery to low ppm levels For best results the proper installation must be followed To install the Insta Trace The Insta Trans transmitter must be purged with sample gas at a flow rate of approximately 0 2 SCFH during installation Remove the Insta Trace cell holder by unscrewing the collar see Figure 5 2 Remove the Insta Trace sensor from the double bags Remove ...

Page 36: ...Maintenance Insta Trans Teledyne Analytical Instruments 28 Figure 5 2 Cell Removal Insta Trace ...

Page 37: ...uracy 2 of full scale at constant temperature and pressure at the temperature and pressure of calibration except 1ppm on 0 10ppm range 5 of full scale over operating temperature range once thermal equilibrium has been reached except 1ppm on 0 10ppm range Response Time 90 Sensor Response Time Electronic Response Time 40 seconds 77 F 25 C with standard cell Operating Temperature 32 122 F 0 50 C Rela...

Page 38: ...1159A PCB Display 1 D71159B PCB Logic Board 1 D71159C PCB I O 1 C6689 A2C A2C Micro fuel Cell 1 C6689 A5 A5 Micro fuel Cell 1 C6689 B1 B1 Micro fuel Cell 1 C6689 B2C B2C Micro fuel Cell 1 B73016 Insta Trans Sensor A type 1 B71875 Insta Trans Sensor B type 1 CP2070 Connector Power Signal 2 O290 O Rings 1 B72087 Insta Trace Cell Holder Application Dependant Only 1 required A minimum charge is applic...

Page 39: ... Teledyne Analytical Instruments 31 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 Web www teledyne ai com or your local representative ...

Page 40: ...Appendix Insta Trans Teledyne Analytical Instruments 32 Drawings ...