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Teledyne BDS-3960 Oxygen Equipment User Manual

1. E CET TELEDYNE ANALYTICAL INSTRUMENTS Pocket PC Flowmeter Figure 1 1 BDS 3960 Front Panel 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 9 ppb and then switches to a continuous ppm readout from 0 100 00 ppm It is accurate across all analysis ranges without the discontinuity inherent in analog range switching Flowmeter Monitors the flow of gas past the sensor Readout is 0 1 to 2 0 standard liters per minute SLPM of nitrogen 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 Teledyne Analytical Instruments 15 Introduction BDS 3960 EEE IMM Access Drawer For access to the BDS Sensor And pressure regulator The front panel slides out when the four thumb screws are loosened Opening the interior gives access to most circuit boards too 1 5 Rear Panel Equipment Interface The rear panel shown in Figure 1 2 contains the gas and electrical connectors for external inlets and outlets The connectors are described briefly here and in detail in Chapter 3 nstallation Except for gas AC power and RS 232 communications I O
2. 35 Alarm Relay Contact 36 Remote Calibration Connections 37 Range ID Relay 39 Gas Factor for Selected 46 Parameter Default 48 Linear Output for a 0 100 ppm O2 Range 55 Range ID 56 Teledyne Analytical Instruments xi BDS 3960 DANGER COMBUSTIBLE GAS USAGE WARNING This is a general purpose instrument designed for usage 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 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 affiliates and agents for damage or injury from misuse or neglect of this equipment is implied or assumed Teledyne Analytical Instruments xii Oxygen Analyzer Introduction SS EE Introduction 1 1 Overview
3. 2 1 Introduction The analyzer is composed of four subsystems BDS Sensor e Sample System Pocket PC e Electronic I O Signal Processing and Display 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 BDS Sensor is an electrochemical device that translates the amount of oxygen present in the sample into an electrical current The Pocket PC processes the sensor signal and sends messages to the I O electronics to correctly display oxygen value as well as control other signals to the customer interface The Electronic I O signal processing amplifies the sensor signal digitizes the sensor reading and sends them to the pocket PC for processing Then it receives commands from the pocket PC to manipulate signals for the customer interface 2 2 BDS Sensor 2 2 1 Principles of Operation The BDS oxygen sensor technology developed at Teledyne Analytical Instruments is a result of heavy investment on R amp D and expertise established during the half century s manufacturing of electrochemical oxygen sensor It stands for Bipotentiostat Driven Sensor A BDS oxygen sensor accurately translates the oxygen level in the sample gas into to an electrical current signal A potentiostat contains three electrodes a working electrode a reference electrode and a counter electrode A Bipotentiostat is a combination of two potentiostats th
4. OPERATING INSTRUCTIONS FOR MODEL BDS 3960 Oxygen Analyzer P N M71903 9 04 02 ECO 02 232 DANGER Toxic gases and or flammable liquids may be present in this monitoring system 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 Teledyne Analytical Instruments i BDS 3960 Copyright 2002 Teledyne Analytical Instruments All Rights Reserved No part of this manual may be reproduced transmitted transcribed stored in a retrieval system or translated into any other language or computer language 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 wh
5. 55 67 connections 35 current 35 linear 55 range 14 range ID 34 56 voltage 34 output signal pins 34 override 14 oxygen level 19 oxygen standard 23 panel mount 14 platinum wire 19 polarization 19 potential reference 21 potentiostat 20 power 16 26 power cord 34 power supply 66 pressure 22 32 70 excessive 22 pressure regulator See regulator purge 49 purge down 22 rack mount 14 69 RAM 13 26 range 66 default 53 fixed 55 setting 53 Range 53 range ID 16 38 rear panel 16 32 recovery time 22 reduction equation 19 Teledyne Analytical Instruments 75 Appendix reference electrode 18 21 refilling the sensor 39 regulator 32 remote calibration connection 37 remote calibration protocol 37 remote probe 16 response time 33 66 reticulated vitreous carbon 20 RFI 14 ROM 13 26 safety information iv sample flow See flowrate sample system 18 22 25 second stage amplifier 26 self diagnostic test 60 sensing electrode 20 sensor output 21 serial number iii signal 19 signal output concentration 27 signal processing 18 26 software reinstallation 61 solenoid valve external 16 SPAN 14 SPAN 50 span calibration 50 BDS 3960 failure 50 51 span gas concentration 49 spare parts listing 68 specifications 66 subsystem 18 swagelock fitting 25 SYSTEM 14 Teledyne address 68 temperature coefficient 22 testing the system 40 threshold alarm
6. BDS 3960 OEE GI BN MI e System Pressing this button will open a second screen that consists of several variables that regulate the internal operations of the analyzer e Training Video This buttons launches a video player At this point you could view a short training video regarding BDS technology The presentation will time out and return back to the Analyzer application after a period of time e Ranges The list box is used to set the analyzer on a specific range as well as set the limits of the ranges Any function can be selected at any time by pressing the appropriate button 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 4 3 The System Screen Pressing the System button on the main screen will bring the System screen The System screen will time out in five minutes and return to the main screen Pressing the Done button will also return you to the main screen 431 Communication Information and Calibration Parameters The first block on the System screen displays information about data received calibration parameters and data sent to the I O hardware Received data 014508900 Zero Offset 0 Span Factor 38 00 Amp Gain Range ID DAC 0 0 265 The first line displays the data received from the I O PCB It consists of nine digits The first four digits are the Analog to Digital counts ofthe BDS sensor
7. PPC application 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 VDC 20 mA at the current output Even if the output is set to a fixed range the digital readout of the concentration is unaffected by the fixed range It continues to read accurately with full precision See Front Panel description in Chapter 1 The automatic fourth range is always 0 100000 ppb 100 ppm and should not be adjusted 4 6 1 Setting the Analog Output Ranges To set the ranges click on the list box on the main screen The following options will pop down ELI Range 1 Range 2 Range 3 Range4 Auto Range Set Range Teledyne Analytical Instruments 39 Maintenance BDS 3960 Figure 4 3 Range Options List Box To Set the ranges to values different than the default click on Set Range and the Set Range screen will pop up Set Range
8. The Teledyne Analytical Instruments Model BDS 3960 Oxygen Analyzer is a versatile instrument for detecting oxygen at the parts per billion ppb level in a variety of gases This manual covers the Model BDS 3960 General Purpose flush panel and or rack mount units only These units are for indoor use in a non hazardous environment 1 2 Typical Applications A few typical applications of the Model BDS 3960 are e Monitoring inert gas blanketing e separation and liquefaction e Chemical reaction monitoring e Semiconductor manufacturing e Petrochemical process control Quality assurance e Gas analysis certification 1 3 Main Features of the Analyzer The Model BDS 3960 Oxygen Analyzer is sophisticated yet simple to use The main features of the analyzer include e Pocket PC with Windows CE operating system used a controller for analyzer functions e High resolution accurate readings of oxygen content from low ppb levels through 100 ppm Large bright meter readout New BDS Sensing technology patent pending e Versatile analysis over a wide range of applications e Microprocessor based electronics 8 bit CMOS microprocessor with 32 kB RAM and 8 kB ROM for I O operations Teledyne Analytical Instruments 13 Introduction BDS 3960 EEE IMM 1 4 Three user definable output ranges from 0 100 ppb through 0 100 ppm allow best match to users process and equipment plus a fixed 100 ppm over range Auto Ranging
9. as well as prolonged scrubber life is attained when the oxygen concentration of the sample gas is below 1 ppm oxygen Teledyne Analytical Instruments 49 Maintenance BDS 3960 A zero calibration is not recommended during first 10 days of the operation of the cell The ZERO button on the Main screen is used to enter the zero calibration function Zero calibration can be performed either automatically or manually In the automatic mode an internal timer will purge sensor for five minutes before registering the zero offset of the sensor plus electronics As the timer counts down you can force the analyzer to accept the current zero offset using the Accept button Pressing the Accept button anytime during the countdown period forces the analyzer to accept the zero offset calibration Pressing Cancel will return the analyzer back to the analyze mode without accepting the zero calibration In this case the previous zero calibration values will remain as the current values 4 4 1 1 ZERO FAILURE The analyzer checks the output of the cell at the end of the span If the raw output of the cell produces an Analog to Digital converter count less than 4000 on amplifier gain 0 the zero will not be accepted The analyzer will use the previous calibration values and display at the top of the main screen ZERO CALIBRATION ERROR 44 2 Span The SPAN button on the main screen is used to span calibrate the analyzer Spa
10. assembly to slide out when maintenance is required Leave clearance of about 20 inches so that whole assembly can be pulled out of its case See Figure 3 2 20 inch clearanc Figure 3 2 Required Assembly Drawer Clearance 4 Teledyne Analytical Instruments 31 Installation BDS 3960 3 3 Rear Panel Connections Figure 3 3 shows the Model BDS 3960 rear panel There are ports for gas inlet and outlet power communication and analog concentration output Sample Vent A Span In AC Power Maca Connection mA 94 and Fuse E Rura Block pr Instrument Air In Ground Terminal Sample In 50 Pin Equipment Interface Connector Figure 3 3 Rear Panel of the Model BDS 3960 3 3 1 Gas Connections The unit is manufactured with 1 4 inch VCR fittings with the exception of instrument air fitting All of the gas connections are located on the rear of the analyzer For all VCR fittings insert a gasket TAI PN G284 between the fittings and tighten the female and male nuts until fingertight then by holding the male nut with a wrench tighten the female nut with a second wrench an additional 1 6 turn SAMPLE IN The gas of interest connections are made at the SAMPLE IN and EXHAUST OUT connections For zero calibration the sample gas is rerouted through an oxygen scrubber to supply oxygen free zero cal gas A VCR fitting is provided for the inlet c
11. 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 manufacturer or its agents is to be construed as a warranty of adequate safety control under the user s process conditions Teledyne Analytical Instruments ii Oxygen Analyzer 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 t
12. is tapped to run the program an error message will be Teledyne Analytical Instruments 56 Oxygen Analyzer Maintenance displayed This is because windows CE does not allow two instances of the same program If this occurs tap on the blue the corner of the blue bar blue bar appears either at the top of the screen or at the bottom depending on which application is at the front next to the windows logo to bring up the pop up menu Tap on Settings On the Settings form tap on the System tab Tap on the Memory icon Tap on the Running Programs tab Tap ot TET AI PPB OXYGEN ANALYER the program lists to select the Analyzer program Tap the Activate button Now the Analyzer program should be at the front Teledyne Analytical Instruments 57 Maintenance BDS 3960 Maintenance 5 1 Routine Maintenance Aside from normal cleaning and checking for leaks at the gas connections routine maintenance is limited to refilling sensor with deionized water replace burned fuses replace backup batteries for PPC and recalibration For recalibration see Section 4 4 Calibration WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL 5 2 Adding Water to the BDS Sensor When running dry gas through the sensor water is extracted from the electrolyte Therefore the electrolyte level should be checked periodically When the electrolyte level is low only de ionized water or distilled w
13. of the Model 3960 Analyzer includes e Unpacking e Mounting e Gas connections e Electrical connections e Filling the Sensor with Electrolyte e Testing the system 3 1 Unpacking the Analyzer Although the analyzer is shipped complete certain parts such as the electrolyte are wrapped separately to be installed on site as part of the installation Carefully unpack the analyzer and inspect it for damage Immediately report any damage or shortages to the shipping agent 3 2 Mounting the Analyzer The Model BDS 3960 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 BDS 3960 standard front panel and mounting bezel There are four mounting holes one in each corner of the rigid frame The drawings section in the rear of this manual contains outline dimensions and mounting hole spacing diagrams Teledyne Analytical Instruments 30 Oxygen Analyzer Installation eee ee eel Alphanumeric Display if J 740 8 Pocket PC Flowmeter Figure 3 1 Model BDS 3960 Front Panel Access to the electronics the sensor and sampling system is accomplished by loosening the thumbscrews on the front of the analyzer The whole assembly will slide out toward the front Allow clearance for the
14. personnel only NOTE Additional information and comments regarding a specific component or procedure are highlighted in the form o of a note CAUTION THE ANALYZER SHOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL Teledyne Analytical Instruments iv Oxygen Analyzer IF YOU USE THE ANALYZER IN A MANNER OTHER THAN THAT FOR WHICH IT WAS INTENDED UNPREDICTABLE BEHAVIOR COULD RESULT POSSIBLY ACCOMPANIED WITH HAZARDOUS CONSEQUENCES This manual provides information designed to guide you through the installation calibration and operation of your new analyzer Please read this manual and keep it available Occasionally some instruments are customized for a particular application or features and or options added per customer requests Please check the front of this manual for any additional information in the form of an Addendum which discusses specific information procedures cautions and warnings that may be peculiar to your instrument Manuals do get lost Additional manuals can be obtained from Teledyne at the address given in the Appendix Some of our manuals are available in electronic form via the internet Please visit our website at www teledyne ai com Teledyne Analytical Instruments BDS 3960 Table of Contents Safety Messages een Table of iere thx EX OH ERA List Of FIQUFIGS cauia aciei cea cu cd cusa d cn
15. reset to the defaults or No to keep the current values 4 4 Calibration of the Analyzer The analyzer must be calibrated prior to 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 with a concentration between 7 0 to 9 0 ppm oxygen in nitrogen This will require that calibration be performed in the 0 10 ppm analyzer range Before the cell is ready for calibration it must be purged with sample gas to a low oxygen level preferably below 0 1 ppm If the oxygen content of the sample gas is higher than 0 1 ppm a zero gas such as nitrogen having an oxygen concentration below 0 1 ppm may be required 4 4 1 Zero The BDS Sensor has a zero offset of less than 5 ppb oxygen Normally the offset slowly decreases during the first 7 to 10 days of operation and is expected to reach a steady value after this time 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 5 ppb oxygen may include 0 4 ppm oxygen in the sample gas and a 5 ppb zero offset The determination of the zero offset requires the use of oxygen free gas to the analyzer The BDS 3960 has an oxygen scrubber as an integral part of its sample system The software and electronics automatically re route the sample gas through the scrubber to provide the sensor with oxygen free gas Best results
16. sanasan dana List of ables 22 02090 ccce Introduction 1 1 Overview 1 2 Typical Applications 1 3 Main Features of the Analyzer 1 4 Front Panel Operator Interface 1 5 Rear Panel Equipment Interface Operational Theory ssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 2 1 Introduction 2 2 BDS Sensor 2 2 1 Principles of Operation 2 2 2 Gas Flow Rate 2 2 3 Gas Pressure 2 2 4 Temperature effect 2 25 Recovery from High Level Oxygen Exposure 2 2 6 Background Gas Compatibility 2 2 7 Stability 2 2 8 Maintenance 2 3 Sample System 24 Electronics and Signal Processing 61 3 1 Unpacking the Analyzer Teledyne Analytical Instruments vi Oxygen Analyzer 3 2 Mounting the Analyzer 3 3 Rear Panel Connections 3 3 1 Gas Connections 3 3 2 Electrical Connections 3 3 2 1 Primary Input Power 3 3 2 2 50 Pin Equipment Interface Connector 3 4 Electrolyte Refill of BDS Sensor 3 5 Testing the System 3 6 Powering Up the System Operation C E 4 1 Introduction 4 2 The Analyzer application 4 3 The System Screen 30 32 32 33 34 34 39 40 41 42 42 43 44 4 3 1 Communication Information and Calibration Parameters 44 4 3 2 Setting Software Parameters Filter Gas Factor Tmp Coeff 4321 The Digital Filter 4 3 2 2 Gas Factor 4 3 2 3 Temperature Coeff
17. used only as a guide Teledyne Analytical Instruments shall not be held liable for any damage resulting from handling or from contact with the above product Teledyne Analytical Instruments 73 Appendix Index access door 16 accuracy 67 ActiveSync 61 adding electrolyte 39 adding water 59 address 68 See company address Ag Ag20 electrode 19 air saturation 22 alarm 51 66 concentration 14 16 failure 14 57 high 36 low 36 relay 35 51 relay contact pins 36 resetting 52 system 36 threshold 36 ALARMS 14 amplifier saturation 47 analog to digital converter 26 Analyze button 43 applications 13 auto cal 45 automatic span mode 50 autoranging 14 53 background gas 23 BDS sensor 18 66 acid gas exposure 24 advantage of 20 Cross section 20 current 26 damage 32 filling 39 maintenance 24 output 21 22 23 32 BDS 3960 stability 24 BDS sensor output output correction 23 bipotentiostat See BDS sensor block diagram 26 28 bypass 33 70 calibration 49 contact 37 relay contact 38 remote control 36 calibration contact 16 calibration gas connection 25 carbon See reticulated vitreous carbon caution sign iv cleaning 62 combustible gas warning xii company address See company address configuring the analyzer 42 copyright ii counter electrode 18 current background 19 signal 19 current to voltage amplifier 26 damage 30 default 53 default values 42 defe
18. 1 Limit Upper Limit 10 Figure 4 4 Range Setup Screen The first screen allows you to set range 1 If you click on the Range button it will take you to the setup of range 2 Click Range again will take you to the setup of range 3 then range 4 then back again to range 1 Note that ranges and alarms are set in ppb units Note The ranges must sequentially increase from low to high for example if range 1 is set as 0 100 ppb and range 2 is set 4 Teledyne Analytical Instruments 54 Oxygen Analyzer Maintenance as 0 1000 ppb range 3 cannot be set as 0 500 ppb since it is lower than range 2 Note Refer to Section 4 3 2 2 to find maximum working range 4 6 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 click on the list box of the main screen as shown on figure 4 3 then select on the range of interest 4 8 Signal Output The standard Model BDS 3960 Oxygen Analyzer is equipped with two 0 1 VDC analog output terminals one concentration and one range ID and two isolated 4 20 mA DC current outputs one concentration and one range ID accessible from the 50 pin equipment interface connector located on the back panel See Rear Panel in Chapter 3 Installation for illustration and pin configuration of the interface connector The signal output f
19. 32 kB of RAM and 8 kB of ROM to control signal processing input output and display functions for the analyzer Most of the processing power and decision making is done by the software running on the pocket PC PPC System power is supplied from a universal power supply module designed to be compatible with any international power source The signal processing electronics including the microprocessor analog to digital and digital to analog converters are located on the I O board at the bottom of the case The preamplifier board is mounted on top of the I O board These boards are accessible by sliding the front out Figure 2 7 shows a block diagram of the analyzer electronics In the presence of oxygen the sensor 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 12 bit analog to digital converter that is located in the same chip as the microprocessor The amplifier board also reads the ambient temperature 4 Teledyne Analytical Instruments 26 Oxygen Analyzer Operational Theory as signal is passed to second channel of analog to digital converter The raw counts of the analog to digital converter for both the oxygen sensor amplifier and temperature amplifier are sent to the PPC via RS232 interface once every second along with a status byte The PPC performs processin
20. MI 3 After the sensor has been purged for at least two weeks and the baseline is stable monitor the oxygen reading and ambient temperature over a minimum period of 24 hours Take the maximum and minimum oxygen readings and the maximum and minimum temperature readings 4 Calculate the coefficient using the relation Coefficient O2 max min Temp max Temp min For example In a 24 hour run max 3 55 ppb O min 1 75 ppb Temp max 24 5 degrees C Temp min 22 1 degrees C Coefficient 3 55 1 75 ppb 24 5 22 1 C 0 75 ppb C This value is currently set to zero since the sensor is temperature controlled and should be left at zero unless qualified personnel give instructions to change it 4 3 2 4 SET DEFAULTS The Set Defaults button will reset all parameters in the software such as calibration alarm and range settings Filter Gas Factor temperature coefficient etc to their factory default values Some of the default values are listed below Table 4 2 Parameter Default Values Parameter Default Value Zero Offset 0 Span Gas 8 00 PPM SpanFactor 24 42 Default span factor 100000 ppb 4095 ADC counts 4 Teledyne Analytical Instruments 48 Oxygen Analyzer Maintenance Filter 5 minutes Gas Factor 1 00 Temperature Coef 0 ppb degree centigrade Alarm 1 setpoint 1000 ppb Alarm 2 setpoint 100 ppb Pressing the Set Defaults button brings up a confirmation dialog box Press Yes to
21. N B72098 is available from Teledyne Analytical Instruments Teledyne Analytical Instruments 63 Maintenance BDS 3960 OEE GI BN MI gt To Vacuum Figure 5 3 Vacuum Degassing for the BDS Oxygen Sensor 4 Teledyne Analytical Instruments 64 Oxygen Analyzer Maintenance Teledyne Analytical Instruments 65 Appendix Appendix BDS 3960 A 1 Specifications Packaging Sensor Sample System 90 Response Time Ranges Alarms Displays Power General Purpose Flush panel mount Standard Teledyne BDS Sensor patent pending All wetted parts of 316 stainless steel with built in in pressure regulator oxygen scrubber and calibration valves Less than 90 seconds at 25 C 77 F on 10 and 100 ppm range 90 seconds on 1000ppb range Software programmable response in 100 ppb range from 1 minute to 60 minutes Default is 5 minutes response time Three user definable ranges from 0 100 ppb to 0 100 ppm plus over range of 0 100 ppm Autoranging with range ID output One system failure alarm contact to detect power failure or sensor zero and span failure Two adjustable concentration threshold alarm contacts with fully programmable setpoints 5 digit LED display and Backlit LCD display from PPC Universal power supply 100 125 VAC at 50 60 Hz 200 240 VAC optional Teledyne Analytical Instruments 66 Oxygen Analyzer Operating Temperature Accura
22. See alarm troubleshooting 62 universal power source 16 universal power supply 26 34 66 vacuum degas kit 63 VCR fitting 25 32 vent 22 warning sign warranty 11 water addition 24 web address 21 68 website address v working electrode 18 20 ZERO 14 ZERO 50 zero calibration 50 automatic mode 50 zero offset 49 4 Teledyne Analytical Instruments 76
23. UIPMENT 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 pins two pins per output For polarity see Table 3 1 The outputs are 0 1 VDC 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 0 1 VDC Range ID 0 25 V Low Range 0 5 Medium Range 0 75 High Range 1 V 100ppm Teledyne Analytical Instruments 34 Oxygen Analyzer Installation 4 20 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 4 20 mA dc Range ID 8 mA Low Range 12 mA Medium Range 16 mA High Range 20 mA 100ppm Table 3 1 Analog Output Connections Pin Function 3 Range ID 4 20 mA floating 4 Range ID 4 20 mA floating 5 Range 4 20 mA floating 6 Range 4 20 mA floating 8 Range ID 0 1 V dc 23 Range ID 0 1 V dc negative ground 24 t Range 0 1 V dc 7 Range 0 1 V dc negative ground Alarm Relays The nine alarm circuit connector pins con
24. al representative Teledyne Analytical Instruments 68 Oxygen Analyzer A 3 Drawing List D 73299 Outline Diagram Appendix A 4 19 inch Relay Rack Panel Mount 19 00 482 60 mi 7 00 177 80 o re FR Teedyne Analytical Instroments Figure 1 Single 19 Rack Mount dimensions Teledyne Analytical Instruments Appendix BDS 3960 2 2 5 lt 4 5 Application notes Pressure and flow recommendations 3960 series analyzers require reasonably regulated sample pressures While the 3960 analyzers are not sensitive to variations of incoming pressure provided they are properly vented to atmospheric pressure the pressure must be maintained so as to provide a useable flow rate through the analyzer Any line attached to sample vent should be 1 4 or larger in diameter Flow rate recommendations A usable flow rate for a 3960 series analyzer is one which can be measured on the flowmeter This is basically 0 5 1 0 SLPM The optimum flow rate is 1 SLPM mid scale Note response time is dependent on flow rate a low flow rate will result in slow response to changes in the sample stream The span flow rate should be the approximately same as the sample flow rate Cell pressure concerns The sensors used in 3960 series analyzers are optimized to function at atmospheric pressure Bypass To improve the system
25. all user connections for analog output alarms calibration and remote probe contacts are available through the 50 pin equipment interface connector User connections made at the rear panel include Power Connection 110 VAC power source 220 VAC optional e Gas Inlet and Outlet One inlet and one exhaust out e Moisture By pass Additional vent line for condensate e Analog Outputs 0 1 VDC oxygen concentration plus 0 1 VDC range ID and isolated 4 20 mA DC oxygen concentration plus 4 20 mA DC range ID Alarm Connections 2 concentration alarms and 1 system alarm Remote Probe Used in the BDS 3960 for controlling external solenoid valves only 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 relay contacts Low Medium High Cal Teledyne Analytical Instruments 16 Oxygen Analyzer Introduction Sample Vent Span In weve pem AC Power came Connection mE O 0 and Fuse a se ors S gj am 9 Instrument Air In Ground Terminal Sample In 50 Pin Equipment Interface Connector Figure 1 2 Model BDS 3960 Rear Panel 4 Teledyne Analytical Instruments 17 Operational Theory BDS 3960 SS Operational Theory
26. allows analyzer to automatically select the proper preset range for a given measurement Manual override allows the user to lock on to a specific range of interest Two adjustable concentration alarms and a system failure alarm Two way RFI protection Four analog outputs two for measurement 0 1 VDC and Isolated 4 20 mA DC and two for range identification Convenient and versatile steel flush panel or rack mountable case with slide out electronics drawer Front Panel Operator Interface The standard BDS 3960 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 the pocket PC a digital meter an alphanumeric display and a window for viewing the sample flowmeter There are no keys to press on the front panel All interface with the analyzer is done through the touchscreen of the pocket PC The main functions on the touchscreen are listed below System Perform system related tasks described in detail in chapter 4 Operation Span Span calibrate the analyzer Zero Zero calibrate the analyzer Alarms Set the alarm setpoints and attributes for Alarm 1 and Alarm 2 Range Set up the 3 user definable ranges for the instrument Quit Quit analyzer application Teledyne Analytical Instruments 14 Oxygen Analyzer Introduction EOE Alphanumeric Digital Display Meter
27. altered as it travels through the sample system The sample system for the standard instrument incorporates 1 4 VCR fittings for sample inlet span inlet and vent and Swagelock fittings for instrument air tube connections at the rear panel The sample or calibration gas that flows through the system is monitored by a flowmeter downstream from the sensor Figure 2 6 represents the flow diagram of the sampling system In the standard instrument span gases can be connected to its own separate inlet port Solenoid valves are controlled by the software to switch the proper gas when the analyzer enters the span mode Zero gas is generated internally when the sample gas is re routed to go through an oxygen scrubber before it is fed to the sensor The life of the oxygen sensor depends in two main factors flow rate oxygen impurity being scrubbed Thus the life of the scrubber can vary depending on the sample gas being used to zero the analyzer It is recommended to change the oxygen scrubber every two years Use this as a guideline only Teledyne Analytical Instruments 25 Operational Theory BDS 3960 E Note that instrument air at a pressure of 70 to 80 psig is needed to activate the proper valves Oxygen Scrubber Vent Sample Flowmeter Inlet Span Inlet BDS Sensor Pressure Regulator Figure 2 6 Flow Diagram 2 4 Electronics and Signal Processing The Model BDS 3960 Oxygen Analyzer uses an 8051 microcontroller with
28. amplifier The range of this count is between 0000 and 4095 The following four digits are the Analog to Digital counts of the temperature Teledyne Analytical Instruments 44 Oxygen Analyzer Maintenance amplifier The range of this count is the same as the BDS sensor 0000 to 4095 The last digit is a status digit zero indicates the I O PCB is in normal mode If the I O PCB receives a remote command to zero or span it will let the PPC program know through this digit Zero Offset line displays the actual Analog to Digital count of the electronics plus sensor offset stored in the memory of the PPC The lower the number the better but a high number does not hinder the performance of the sensor very much One reason for a high count could mean that the sensor is still drifting downward and therefore an additional zero calibration might be needed to maintain accuracy Span Factor displays a number which is a factor needed to convert digital counts to PPB oxygen concentration This number should be between 10 and 40 AmpGain RangeID DAC displays the command sent to the I O PCB and determines what gain the amplifier should have and what range ID contact should open Both numbers are from 0 to 4 Usually with default ranges they should be the same but not necessarily DAC is acount number sent to the analog to digital converter of the PCB This sets the output for the concentration 0 1 vdc and 4 20 outputs Its range is fr
29. analyzer with an oxygen standard that has a similar background as the sample gas If an oxygen standard is unavailable for a particular background a Gas Factor which is determined at TAI could be used to correct the sensor output in different background see section 4 3 9 Note the gas flow meter in the analyzer is calibrated for air The error for measuring nitrogen is usually negligible But for Teledyne Analytical Instruments 23 Operational Theory BDS 3960 a ies n1 hydrogen it reads 100 lower For example when the float ball in the flowmeter is at 0 5 SLPM the actual flow rate of hydrogen is about 1 SLPM The BDS oxygen sensor can tolerate exposure to acidic gases Up to 0 2 has no effect to ppb level oxygen measurement 2 2 7 Stability The BDS sensor is essentially drift free Typically a BDS sensor requires no re calibration over an entire year period However there may be some intrusion to the zero during the maintenance See next section for details 2 2 8 Maintenance The only maintenance required on the BDS sensor is to replenish distilled or de ionized water every three to four months It is not necessary to take the analyzer out of service while adding water to the sensor but caution should be taken to avoid spilling water on the PC boards or other area inside the analyzer Figure 2 5 Adding DI Water to the BDS Sensor 4 Teledyne Analytical Instruments 24 Oxygen Analyzer Operational Th
30. as many foreign countries To learn more about BDS technology please visit TAI s web page at http www Teledyne Al com To learn more about potentiostat visit Electochemical Society s web page at http www electrochem org 2 2 2 Gas Flow Rate The output from a BDS oxygen sensor is relatively insensitive to change of gas flow rate if operated in the range of 1 3 SCFH in nitrogen The output drops when the flow rate is below 1 SCFH Figure 2 2 is a typical curve showing the sensor outputs at different flow rate Oxygen ppm 0 0 05 1 0 1 5 2 0 2 5 3 0 Gas Rate SCFH Figure 2 2 BDS sensor output at different gas flow rate Teledyne Analytical Instruments 21 Operational Theory BDS 3960 eS 2 2 3 Gas Pressure The analyzer is equipped with a pressure regulator as shown in Figure 2 3 To access the pressure regulator the front panel must be opened The inlet pressure should be regulated anywhere between 4 to 50 psig The sensor is not affected by pressure changes in the inlet as long as the analyzer vents to atmosphere If the analyzer is not vented to atmosphere the downstream pressure must not exceed 10 inch of water A clogged or restricted vent or excessive pressure will force gas into the electrolyte and cause damage to the BDS sensor Oxygen Scrubber Vent Sample Flowmeter Inlet Span Inlet BDS Sensor Pressure Regulator Figure 2 3 A simplified BDS Sample Syst
31. at share the reference electrode and the counter electrode The potential at the working electrode is precisely Teledyne Analytical Instruments 18 Oxygen Analyzer Operational Theory SSS SSS RC controlled with respect to the reference electrode The counter electrode is used to carry the current that flow through the sensor A potentiostat is typically constructed with several operational amplifiers The three electrodes in an electrochemical cell and the operational amplifiers in the potentiostat constitute a feedback control loop The potentiostat technology has been well accepted in the field of electrochemistry and proven effective in eliminating polarization of the reference electrode and automatic compensating electric resistance in the cell In a BDS oxygen sensor the sensing electrode is a working electrode that is under precise potential control as discussed above A stable sensing electrode potential is very critical for an oxygen sensor to achieve high stability low noise and large dynamic range The reference electrode in a BDS sensor is a Ag Ag O electrode which is well known for its stable electrode potential and compatibility with the KOH electrolyte in an oxygen sensor The counter electrode is made of a Platinum wire The sensing process involves electrochemical reactions inside the sensor At the sensing electrode oxygen is reduced at the controlled po
32. ated relay out 35 de ionized water 58 detection limit 19 diffusion barrier 19 20 digital input span 37 zero 37 Teledyne Analytical Instruments 74 Oxygen Analyzer digital to analog converter 26 dimensions 67 69 display 26 66 dissolved oxygen 20 door See access door door clearance 31 drawer 14 drawings 69 drift 25 electrochemical cell 19 electrochemical device 18 electrochemical reaction 19 electrode 18 electrolyte 19 20 25 30 32 39 59 electrolyte level 25 electronic block diagram See block diagram electronics 18 equipment interface connector 34 estimating temperature coefficient 47 exhaust 33 failsafe 35 features 13 feedback control loop 19 fixed range 53 See range flow diagram 25 flowmeter 15 25 calibration 23 flowrate 21 32 70 form C relay contacts 35 front panel 14 31 fuse 60 fuse block 34 fuse installation 34 gas factor 23 gas inlet 16 20 gas outlet 16 20 inlet 25 input digital 16 36 input output 26 installation 30 KOH 19 25 39 latching 35 LED 15 maintenance 58 manuals additional v meter 15 microcontroller 26 microprocessor 13 Index model information iii motherboard 26 mounting 30 moving contact 36 MSDS 71 negative reading 25 nonfailsafe 35 nonlatching 35 normally closed 35 36 normally open 35 36 20 operational amplifier 19 operational theory 18 outlet 25 33 output 21 34 analog 14 16
33. ater should be added into the sensor It typically takes about four months to dry the electrolyte from the MAX line to the MIN line when the sensor is operated on a bone dry gas line It is not necessary to turn off the power to the analyzer while adding water but care should be taken that no water is splashed outside the sensor Spilling water on the PC board could cause serious damage to the analyzer and electric shock to the personal Unscrew and take the sensor cap off Use the wash bottle provided to squeeze de ionized water into the sensor as shown in Figure 5 1 It is a good practice that water is added before reaching the MIN line Reinstall the cap after adding water Teledyne Analytical Instruments 58 Oxygen Analyzer Maintenance SS SSS M ra WARNING 5 3 Eat Figure 5 1 Adding Water into the BDS sensor THE SENSOR USED IN THE MODEL BDS 3960 OXYGEN ANALYZER USES ELECTROLYTE WHICH CONTAINS 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 BE THE ELECTROLYTE IN CASE OF EYE CONTACT IMMEDIATELY FLUSH EYES WITH WATER FOR AT LEAST 15 MINUTES CALL PHYSICIAN SEE APPENDIX MATERIAL SAFETY DATA SHEET Fuse Replacement 1 Place small screwdriver in notch and pry cover off as shown in Figure 5 2 Remove fuse ho
34. 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 this function Depending on your process you can choose to configure the alarms in a number of ways 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 4 Teledyne Analytical Instruments 51 Maintenance BDS 3960 2 Are either or both of alarms to be configured as failsafe 3 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 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 n
35. cations software on the PPC becomes corrupt or is lost it can be restored by Downloading the Analyzer program and components Before installing the software you must have a software version of ActiveSync on a separate PC computer running Windows 95 or later operating system as well as a serial communication cable or cradle TAI P N CP2237 ActiveSync is a property of Microsoft Corp and can be downloaded from their website The Analyzer program and its components can be send via email upon request Please have serial number of analyzer it will be requested 1 Connect the PPC to the serial communication cable or cradle 2 Launch ActiveSync 3 Open ActiveSync Explorer 4 Insert the backup floppy in the disk drive of the PC computer and open the Windows Explorer 5 Locate the file vbceutil dll and copy it to the windows directory of the PPC file size 15 77Kb 6 Similarly copy regsvrce program for the PPC 300 to the windows directory on the PPC file size is 7 50kb this is the version for target mips 7 Run CD setup exe to install the analyzer program 8 Move Teledyne log bmp to Analyzer directory on the PPC 9 Register vbceutil dll on the PPC as follows e Click start_Programs_explorer e Click show My Device e Double click on the windows folder e Find regsvrce program and double click to run Type path c windows vbceutil dll then press OK button Double click on regsvrce program icon to get the message that th
36. cy Analog outputs Dimensions Appendix 5 40 C 2 of full scale for all ranges at constant temperature All accuracy specifications are contingent upon the completion of zero and span calibration All accuracy is established at constant pressure and equilibrium has been established 0 1 VDC percent of range 0 1 VDC range ID 4 20 mA DC isolated percent of range 4 20 mA DC isolated range ID 19 cm high 24 9 cm wide 31 cm deep 6 96 in high 8 7 in wide 12 1 in deep Teledyne Analytical Instruments 67 Appendix BDS 3960 A 2 Recommended 2 Year Spare Parts List Qty Part Number Description 1 65507 Back Panel Board 1 72914 Front Panel Board 1 72000 Preamplifier Board Instruction 1 71997 Computer Board 2 F1296 Fuse 2A 250V 5x20mm European Slow Blow 1 CP1798 50 pin D sub interface connector 50 CP1799 Pins for CP1798 connector 1 597 125ml wash bottle for DI water 1 598 125ml electrolyte bottle 1 1076 Pipet 1 B72098 BDS sensor recovery kit 1 2237 PDA cradle 1 C58750 Oxygen Scrubber 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 Web www teledyne ai com or your loc
37. e electrolyte with nitrogen gas at a flow of 100 CCM for about 1 2 hour then pour into the provided wash bottle Ref to Figure 3 5 for the method of adding electrolyte to the sensor It is important that as the sensor is being filled with the electrolyte filling is accomplished without trapping gas bubbles in the lower part of the sensor Squirt electrolyte content into the sensor Do it slowly until the bottom parts of the sensor are fully immersed in the electrolyte Teledyne Analytical Instruments 39 Installation BDS 3960 EEE EE 1 7 Pour the rest of the electrolyte into the sensor Gas bubbles in the top portion of the sensor do not affect the sensor performance One bottle of electrolyte is sufficient to rise the electrolyte level to the MAX line For the rest of sensor life no further electrolyte addition is needed 8 Install the sensor cap 9 Do not connect the sensor s electric connector at this stage Figure 3 5 Adding Electrolyte to the BDS Sensor 3 5 Testing the System Before plugging the instrument into the power source e Check the integrity and accuracy of the gas connections Make sure there are no leaks Gas connection should allow for some movement on the drawer assembly so that the pressure regulator and the sensor connector cable can be reached inside e Check the integrity and accuracy of the electrical connections Make sure there are no exposed conductors e Check pressure of sample gas as w
38. e registration was successful If it was not successful repeat the last two steps Teledyne Analytical Instruments 61 Maintenance BDS 3960 10 Disconnect serial cable and run Analyzer program from Start pull down menu to check for successful installation 5 5 Major Internal Components The Sensor is accessed by loosening the thumbscrew on the front panel and sliding it out as described earlier Other internal components can be accessed the same way The gas piping is illustrated in Figure 2 3 and the major electronic component locations are described in Chapter 2 WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL The BDS 3960 contains the following major components e Analysis Section e Sensor with stainless steel wetted parts e Sample system e Power Supply PCB e Microprocessor base I O board with amplifier daughter board LED display PCB e Palm Portable Computer with Windows See the drawings in the Drawings section in back of this manual for details 5 6 Cleaning If the instrument is unmounted at time of cleaning disconnect the instrument from the power source Close the front panel access drawer 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 DO NOT wipe front panel while the instrument is controlling your process 5 7 Troubleshooting Symptoms Possible causes and So
39. ell as instrument air Set the internal pressure regulator fully counterclockwise 4 Teledyne Analytical Instruments 40 Oxygen Analyzer Installation 3 6 Powering Up the System Before powering up the system set the pressure regulator to minimum to prevent damage due to incorrect setting Power up the system by turning on the switch on the rear Then turn on the PPC by pressing the button on its left side Make sure that the Analyzer application is running If the Analyzer application is not running launch it by following the these steps Tap on Start found on the taskbar either at the bottom or the top of the LCD screen of the PPC to pull down a menu Tap on Programs to bring up the programs browser Then tap on the Analyzer icon found in the browser This should launch the Analyzer application Adjust the internal pressure regulator until gas flow is in the middle of the flowmeter around the 1 SLPM mark Purge the sensor for about 15 minutes then proceed to connect the sensor cable Close the assembly drawer and tighten the thumb screws Purge the analyzer until readings decrease below 50 ppb Teledyne Analytical Instruments 41 Maintenance BDS 3960 Operation 4 1 Introduction Once the analyzer has been installed it can be configured for your application To do this you will Set system parameters e Calibrate the instrument e Define the three user selectable analysis ranges th
40. em 2 2 4 Temperature effect The raw output from a BDS oxygen sensor has a temperature coefficient about 0 25 C That is an average value it changes as temperature changes This temperature effect is compensated by the software throughout the operation temperature range 5 40 C 2 2 5 Recovery from High Level Oxygen Exposure The ambient air contains about 210 000 000 ppb 2 1 x 10 oxygen Figure 2 4 is a typical purge down curve for a new BDS sensor which had been air saturated It is normal to take several hours even days for an air saturated BDS to purge down to a low ppb level Teledyne Analytical Instruments 22 Oxygen Analyzer Operational Theory Range Switched Oxygen Reading 0 2 4 6 8 10 12 14 16 18 20 22 Time hours Figure 2 4 Typical Purge down Curve After Air Saturation Shortening the air exposure will allow a faster sensor recovery A typical BDS sensor will recover to ppm in approximately 25 minutes to 100 ppb after 80 min and 10 ppb in about 8 hours after suffering a ten minute exposure to air 2 2 6 Background Gas Compatibility The BDS oxygen sensor will work in inert gas backgrounds including nitrogen hydrogen argon helium and ethane The sensor output however is different in different background gases For example the sensor output in a hydrogen background is twice as much as it would be in a nitrogen background Therefore it is recommended to calibrate the
41. en choose autoranging or select a fixed range of analysis as required e Set alarm setpoints and modes of alarm operation latching failsafe etc Before you configure your BDS 3960 these default values are in effect Ranges LO 100ppb MED 1000 ppb HI 10 ppm Over Range 100 ppm Auto Ranging ON Alarm Relays Defeated Alarm 1 at 1000 ppb Alarm 2 at 100 ppb HI Not failsafe Not latching Teledyne Analytical Instruments 42 Oxygen Analyzer Maintenance SSS a re 4 2 The Analyzer application The Pocket Personal Computer PPC is the brains of the analyzer The PPC runs the Analyzer program installed by TAI For the instrument to operate the program must be launched as instructed in section 3 6 When the program is launched the main screen will appear as shown below TET AI PPB ANALYZER Auto 0 1000 PPB Temperature 1 ALARM 2 System Training Video Figure 4 1 Main Menu The screen shows controls that should be familiar to anyone who has used a personal computer e Alarm 1 Pressing this button opens a new screen where Alarm trigger point and options can be set e Alarm 2 Pressing this button opens a new screen where Alarm 2 trigger point and options can be set e Zero Pressing this button opens a screen for the zero calibration function e Span Pressing this button opens the screen for the span calibration function Teledyne Analytical Instruments 43 Maintenance
42. ends on the viscosity of the background gas according to the laws of diffusion the output of the sensor becomes inversely proportional to the viscosity of the background gas The output of the sensor can be predicted by looking up the viscosity of the new background gas and compare it to the viscosity of at the same temperature Using values obtained from the a science handbook the following gas factor coefficients for the BDS sensors are calculated Table 4 1 Gas Factor for Selected Gases N2 1 2 1 99 0 90 Ar 0 79 Teledyne Analytical Instruments 46 Oxygen Analyzer Maintenance SS SSS M ra Output normalized by calibrating with a span gas in The values in Table 4 1 are theoretical but should give a first approximation as to what the output of the sensor will be in the new background gas The BDS 3960 will make further refinements once the proper gas factor is input The working range of adjustment is 0 25 to 2 50 This factor will divide the output For example if the factor is set to 2 00 the output of the sensor when read by the PPC application will be divided by two Special consideration on the working range Changing the gas correction factor has an effect on the maximum working range of the analyzer e g if a gas factor of 2 00 is selected the maximum working range of the analyzer is 50 ppm Any reading above this may satu
43. eory There is Max line and Min Line clearly marked on the BDS sensor body It is a good practice to check the electrolyte level every month and add de ionized water into the sensor whenever it is convenient When running dry gas through the sensor the gas carries out moisture from the sensor Therefore the electrolyte 10 KOH in water inside the sensor is gradually concentrated during the sensor operation It typically takes about four months for the electrolyte level to drop from the Max line to Min line When adding water to increase the electrolyte level from the Min line to the Max line it is typical that the oxygen reading will drift down about 10 ppb in an hour If the oxygen content in the sample gas is very close to zero the analyzer may display a negative reading during this period The sensor will recover by itself during the following week This drift down then recover back phenomenon is caused by the quick dilution of the electrolyte and re establishment of a new equilibrium inside the sensor To minimize this effect add a small amount of water each time and do this before the electrolyte level reaches the Min line 2 3 Sample System The sample system delivers gases to the BDS sensor from the analyzer rear panel inlet Depending on the mode of operation either sample or calibration gas is delivered The Model BDS 3960 sample system is designed and fabricated to ensure that the oxygen concentration of the gas is not
44. g See Remote Calibration Protocol below Table 3 3 Remote Calibration Connections Pin 9 11 10 12 40 4 Remote Cali Function Remote Zero Remote Zero Remote Span Remote Span Cal Contact Cal Contact bration Protocol To properly time the Digital Remote Cal Inputs to the Model BDS 3960 Analyzer the customer s controller must monitor the Cal Relay Contact Teledyne Analytical Instruments 37 Installation BDS 3960 When contact is OPEN analyzer is analyzing 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 close again For example 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 s
45. g on this data to calculate oxygen concentration temperature as well as decisions regarding the condition of the alarm contacts range amplifier gain solenoid control and the analog output required After processing the PPC sends a message back to I O board via RS232 with commands for all the I O functions The 8051 microprocessor in the I O board evaluates this data and the appropriate control signals are directed to the LED display alarms contacts range ID contacts and digital to analog converter The analog to digital converter is a 12 bit device located in the microprocessor IC The output of the digital to analog converter with the help of some support electronics produces the 4 20 mA DC and the 0 1 VDC analog concentration signal outputs Signals from the power supply are also monitored and through the microprocessor the system failure alarm is activated if a malfunction is detected Failure to communicate with the PPC will also trigger the System alarm Teledyne Analytical Instruments 27 Operational Theory BDS 3960 ees Temperature Sensor Amplifiers BDS Sensor 8051 processor Display 0 1 VDC and 4 20 ma Pocket support PC electronics Figure 2 7 BDS 3960 Electronics Block Diagram Teledyne Analytical Instruments 28 Oxygen Analyzer Operational Theory i Teledyne Analytical Instruments 29 Installation BDS 3960 Installation St Installation
46. he box Instrument Serial Number Options Included in the Instrument with the Above Serial Number 220 VAC Instrument configured 200 240 VAC 50 60Hz power 4 Teledyne Analytical Instruments BDS 3960 Safety Messages Your safety and the safety of others is very important We have provided many important safety messages in this manual Please read these messages carefully A safety message alerts you to potential hazards that could hurt you or others Each safety message is associated with a safety alert symbol These symbols are found in the manual and inside the instrument The definition of these symbols is described below GENERAL WARNING CAUTION Refer to the instructions for details on the specific danger These cautions warn of specific procedures which if not followed could cause bodily Injury and or damage instrument CAUTION HoT SURFACE WARNING This warning is specific to heated components within the instrument Failure to heed the warning could result in serious burns to skin and underlying tissue WARNING ELECTRICAL SHOCK HAZARD Dangerous AN voltages appear within this instrument This warning is specific to an electrical hazard existing at or nearby the component or procedure under discussion Failure to heed this warning could result in injury and or death from electrocution Technician Symbol All operations marked with this symbol are to be performed by qualified maintenance
47. ich defects become apparent within one year from the date of shipment except in cases where quotations or acknowledgements 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 authorized 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 instrumentation 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
48. icient 4 3 2 4 Set Defaults 4 4 Calibration of the Analyzer 4 4 1 Zero Cal 4 4 1 1 Zero Failure 4 4 2 Span Cal 4 4 2 1 Span Failure 4 5 The Alarms Function 4 6 The Range Function 4 6 1 Setting the Analog Output Ranges 4 6 2 Fixed Range Analysis 4 8 Signal Output Teledyne Analytical Instruments 45 46 46 47 48 49 49 50 50 51 51 53 53 55 55 vil BDS 3960 4 9 Maintenance 5 1 5 2 5 3 5 4 5 5 5 5 5 6 5 7 Appendix A 1 A 2 A 3 A 4 A 5 Switching The Program Back To The Front Routine Maintenance Adding Water to the BDS Sensor Fuse Replacement Battery Backup Replacement Reinstalling Application software to PPC Major Internal Components Cleaning Troubleshooting Specifications Recommended 2 Year Spare Parts List Drawing List 19 inch Relay Rack Panel Mount Application notes Material Safety Data Sheet Teledyne Analytical Instruments 56 58 58 58 59 60 61 62 62 62 66 66 68 69 69 70 71 Oxygen Analyzer List of Figures E Figure 1 1 BDS 3960 Front 15 Figure 1 2 Model BDS 3960 Rear 17 Figure 2 1 Cross Section of the BDS Oxygen Sensor 20 Figure 2 2 BDS sensor output at different gas flow rate 21 Figure 2 3 A simplified BDS Sample System 22 Figure 2 4 Typica
49. ignals to ensure that the zero and span gas valves will be controlled synchronously Range ID Relays There are four dedicated Range ID relay contacts The first three ranges are assigned to relays in ascending order Low range is assigned 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 over Range 100 ppm Table 3 4 lists the pin connections There is contact opening to indicate what range the analyzer is on The contacts open when the analyzer is on that range Teledyne Analytical Instruments 38 Oxygen Analyzer Installation Table 3 4 Range ID Relay Connections Pin Function 21 Range 1 ID Contact 38 Range 1 ID Contact 22 Range 2 ID Contact 39 Range 2 ID Contact 19 Range 3 ID Contact 18 Range 3 ID Contact 34 Range 4 ID Contact Over range 35 Range 4 ID Contact Over range 3 4 Electrolyte Refill of BDS Sensor The BDS sensor is shipped dry It must be filled with the electrolyte before operation The electrolyte is a caustic solution 10 KOH supplied in five 50 ml bottles Review the Material Safety Data Sheet MSDS in Section A 6 before handling the electrolyte To refill the BDS sensor 1 Loosen the thumb screws on the front and slide the drawer halfway out Unscrew the sensor cap and disconnect sensor cable from the BDS sensor Pour the electrolyte from the five small bottles into a larger container Sparge th
50. l Purge down Curve After Air Saturation 23 Figure 2 5 Adding DI Water to the BDS Sensor 24 Figure 2 6 Flow Diagram 26 Figure 2 7 BDS 3960 Electronics Block Diagram 28 Figure 3 1 Model BDS 3960 Front Panel 31 Figure 3 2 Required Assembly Drawer Clearance 31 Figure 3 3 Rear Panel of the Model BDS 3960 32 Figure 3 4 Equipment Interface Connector Pin Arrangement 34 Figure 3 5 Adding Electrolyte to the BDS Sensor 40 Figure 1 MENU oco eoo Eee tpe teo teo 43 Figure 4 2 Parameter Selection Box e 46 Figure 4 3 Range Options List 54 Figure 4 4 Range Setup Screen esf 54 Figure 5 1 Adding Water into the BDS sensor 59 Figure 5 2 Removing Fuse Block from Housing 60 Teledyne Analytical Instruments ix BDS 3960 Figure 5 3 Vacuum Degassing for the BDS Oxygen Sensor 64 Figure A 1 Single 19 Rack Mount dimensions in mm 69 Teledyne Analytical Instruments X Oxygen Analyzer List of Tables Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table 4 1 Table 4 2 Table 4 2 Table 4 3 Analog Output
51. lder 2 Replace fuses Use 2A 250 VAC 5x20 mm slow blow Install one at each side of fuse holder Teledyne Analytical Instruments 59 Maintenance BDS 3960 1 Figure 5 2 Removing Fuse Block from Housing 5 4 Battery Backup Replacement The software application running on the PPC is mantained when power is removed from the analyzer by a single 3 volt lithium battery If the unit is powered down and the battery power is low you run the risk of losing the program To prevent this from happening replace the backup battery as often as six months Use a CR2032 or DL2032 for replacement Note Make sure that the main battery of the PPC is charged when you change the backup battery or you will the software application If the software application is lost for any reason use the installation floppy disk as instructed in section 5 5 Power Analyzer down Loosen the thumb screws of the front panel and slide the drawer assembly out Remove the two screws on the back of the front panel that hold the PPC in place then remove the PPC Slide the switch on the back of the PPC to Backup Open the battery compartment and remove the old battery Install a new battery Make sure that the side is on top facing out Replace the battery cover and move the switch to lock position Teledyne Analytical Instruments 60 Oxygen Analyzer Maintenance 5 5 Reinstalling Application software to PPC If the appli
52. lutions Teledyne Analytical Instruments 62 Oxygen Analyzer Read higher than expected Read lower than expected Read negative Noise signal Slow response Causes and solution keys Maintenance 1 2 3 2 3 3 4 3 5 5 1 Gas leak Make sure to use new VCR gaskets high quality valves and gas regulator for the sampling system Tighten each connection 2 Improper gas flow rate adjust the inlet pressure to obtain 0 5 1 SLPM flow rate 3 Improper calibration of the analyzer Press the SYSTEM button on Main menu screen of the PPC to bring the System screen Then press the Set default button This will return the analyzer to its defaults settings in calibration and zero values Recalibrate the analyzer with a high quality standard gas if it is necessary Be warned this will set defaults to ranges and alarms settings as well 4 Just after adding water The analyzer will recover by itself 5 Gas entered and is trapped in the sensor This could happen if the sensor is filled with the electrolyte improperly or the sensor is pressurized because of a clogged vent To remedy this situation uninstall the sensor and take off the cap carefully then apply a vacuum degas process as shown in the Figure 5 4 Degassing in a 28 inch mercury vacuum for 5 minutes is sufficient to remove the gas bubbles Reinstall the sensor into the analyzer Note A low cost vacuum degas kit P
53. mergency and First Aid Procedures NOTE Clean up procedures Eye Contact Skin Contact Flush eyes with water for at least 15 minutes and get immediate medical attention Wash affected area with plenty of water and remove contaminated clothing If burning persists seek medical attention Ingestion Give plenty of cold water Do not induce vomiting Seek medical attention Do not administer liquids to an unconscious person Inhalation Liquid inhalation is unlikely Section VI Handling Information The oxygen sensors are sealed and under normal circumstances the contents of the sensors do not present a health hazard The following information is given as a guide in the event that a cell leaks Protective clothing Protective measures during cell replacement NOTE Disposal Rubber gloves chemical splash goggles Wipe down the area several times with a wet paper towel Use a fresh towel each time Before opening the bag containing the sensor cell check the sensor cell for leakage If the sensor cell leaks do not open the bag If there is liquid around the cell while in the instrument put on gloves and eye protection before removing the cell Should be in accordance with all applicable state local and federal regulations The above information is derived from the MSDS provided by the manufacturer The information is believed to be correct but does not purport to be all inclusive and shall be
54. n calibration can be performed automatically or manually In the automatic mode an internal timer will purge sensor for five minutes before taking in the zero offset of the sensor plus electronics Again the ACCEPT button can be pressed at anytime during the countdown period to accept the zero offset calibration Pressing the CANCEL button will return the analyzer to the analyze mode without accepting the zero calibration The previous zero calibration will still be in effect Teledyne Analytical Instruments 50 Oxygen Analyzer Maintenance 4 4 2 1 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 1 5 nA ppb or more than 13 5 nA ppb the span will not be accepted The analyzer will return to the previous calibration values and display at the top of the main screen SPAN CALIBRATION ERROR 4 5 The Alarms Function The Model BDS 3960 is equipped with 2 fully adjustable concentration alarms and a system failure alarm Each alarm has a relay with a set of form C contacts rated for 3 amperes resistive load at 250 VAC 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 Chapter 3 Installation The concentration alarms can be configured from the PPC software as either high or low alarms
55. nect 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 contact connections The contact connections are shown in Table 3 2 They are capable of switching up to 3 amperes at 250 VAC into a resistive load The connectors are Threshold Alarm 1 e Can be configured as high actuates when concentration is above threshold or low actuates when concentration is below threshold e Can be configured as failsafe or nonfailsafe e Can be configured as latching or nonlatching e Can be configured out defeated Teledyne Analytical Instruments 33 Installation BDS 3960 Threshold Alarm 2 Can be configured as high actuates when concentration is above threshold or low actuates when concentration is below threshold Can be configured as failsafe or nonfailsafe Can be configured as latching or nonlatching Can be configured out defeated System Alarm Actuates when DC power supplied to circuits is unacceptable in one or more parameters Permanently configured as failsafe and latching Cannot be defeated Actuates if communication with PPC fails Further detail can be found in Chapter 4 Section 4 5 Table 3 2 Alarm Relay Contact Pins Pin 45 28 46 42 44 43 36 20 37 Contact Threshold Alarm 1 normally closed contact Threshold Alarm 1 moving contact Threshold Alarm 1 normally open contact Thresh
56. old Alarm 2 normally closed contact Threshold Alarm 2 moving contact Threshold Alarm 2 normally open contact System Alarm normally closed contact System Alarm moving contact 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 Teledyne Analytical Instruments 36 Oxygen Analyzer Installation SSS SSS eel Zero Floating input S 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 option internal valves operate automatically Span Floating input S 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 C option internal valves operate automatically Cal Contact This relay contact is closed while analyzer is spanning and or zeroin
57. om 0 to 4095 A large discrepancy between AmpGain and RangeID would point to a hardware problem e g AmpGain RangeID DAC 0 4 265 4 3 2 Setting Software Parameters Filter Gas Factor Tmp Coeff There are three parameters that are under the control of the user and are accessible from the parameter selection box as shown below These are e Digital filter noise reduction Gas Factor compensates for different background gases e Temperature coefficient corrects baseline drift due to temperature Teledyne Analytical Instruments 45 Maintenance BDS 3960 Select Factor to Adjust Filter Gas Factor Tmp Coeff Figure 4 2 Parameter Selection Box 4 3 2 1 THE DIGITAL FILTER The Analyzer software performs a digital operation to reduce the noise from the BDS sensor and amplifier This filtering is reduced to around 10 ppb If the signal exceeds 10 ppb the filter disengages in order to track the transient faster The number approximately corresponds to the response time of the filter in minutes from 10 to 90 The range is from 1 to 60 minutes of the 90 response time Five minutes is the default 4 3 2 2 The Gas Factor The gas factor coefficient in the BDS 3960 15 the ratio of the output of the sensor taken in a N2 background over the output of the sensor in the new background gas The output of the sensor depends on the mechanics of diffusion Since the diffusion coefficient of oxygen dep
58. on latching mode the alarm status will terminate when process conditions revert to non alarm conditions 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 The defeat function can also be used to reset a latched alarm See procedures below Each of the concentration alarms have their own button on Main display of the PPC application ALARM 1 and ALARM 2 Once you press on the alarm buttons you will be presented with alarm setup screen 25 3 4 5 Five parameters can be changed on the alarm setup screen Value of the alarm level ppb oxygen value can be set from 0 to 100 000 ppb Out of range direction High or Low Latch control Latching or Non latching On off Control Active or Defeated Safety Mode Failsafe or Non failsafe To reset a latched alarm go to On off Control and select defeated Teledyne Analytical Instruments 52 Oxygen Analyzer Maintenance 4 6 The Range Function The Range function allows the operator to program up to four concentration ranges to correlate with the DC analog outputs If no ranges are defined by the user the instrument defaults to Range 1 0 100 ppb Range 2 0 1000 ppb Range 3 0 10000 ppb Range 4 0 100000 ppb The Model BDS 3960 is set at the factory to default to autoranging In this mode the
59. onnection The inlet gas pressure should be regulated to pressures between 5 to 50 psig so that the internal regulator can be adjusted to maintain a flow between 0 5 to 1 0 SLPM If pressure is too low the flow will drop below 0 5 SLPM which is below the threshold to which the sensor is sensitive see Section 2 2 2 If pressure is too high it will force gas into the electrolyte and cause damage to the sensor The internal pressure regulator is helpful if the sample pressure varies 4 Teledyne Analytical Instruments 32 Oxygen Analyzer Installation If greater sample flow is required for improved response time install a bypass in the sampling system upstream of the analyzer input SPAN IN Span gas is connected to this port and it is automatically routed by solenoid valves when the analyzer goes into the span mode Its pressure should be about the same as the inlet pressure of the sample gas This will ensure that flow remains unchanged when switching between calibration and sample gases and this in turn increases accuracy of the calibration 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 if required CAUTION CONNECT VENT LINES TO 1 4 OR LARGER DIAMETER TUBING AIR INLET The solenoid valves of the sampling system need air pressure to actuate them Use the com
60. or concentration 15 linear over the currently selected analysis range For example if the analyzer is set on a range that was defined as 0 100 ppb then the output would be as shown in Table 4 2 Table 4 2 Linear Output for a 0 100 ppm O2 Range Voltage Signal Current Signal ppb O Output VDC Output mA DC 0 0 0 4 0 10 0 1 5 6 20 0 2 7 2 30 0 3 8 8 40 0 4 10 4 50 0 5 12 0 Teledyne Analytical Instruments 55 Maintenance BDS 3960 OEE GI BN MI 60 0 6 13 6 70 0 7 15 2 80 0 8 16 8 90 0 9 18 4 100 1 0 20 0 The analog output signal has a voltage which depends on 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 autoranging mode 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 Table 4 3 gives the range ID output for each analysis range Table 4 3 Range ID Output Range Voltage V Current mA Range 1 0 25 8 Range 2 0 50 12 Range 3 0 75 16 Range 4 1 00 20 4 9 Switching The Program Back To The Front There are times that the Analyzer program may drop out of sight from the front of the screen even though it is still running If Analyzer program icon
61. ostat is located adjacent to the sensing electrode It uses a novel material Reticulated Vitreous Carbon RVC and precise control of the potential to remove the dissolved oxygen and impurities in the electrolyte efficiently As the result the BDS sensor achieves an outstanding feature of absolute zero output in the absence of oxygen Sensor Body al Electrolyte m d 2nd Working Electrode Reference Electrode Sensing Electrode Gas Outlet Gas Inlet Diffusion Barrier Figure 2 1 Cross Section of the BDS Oxygen Sensor Figure 2 1 shows the schematic of a BDS oxygen sensor The sample gas enters the sensor through the gas inlet port and exits at the gas outlet A portion of oxygen in the sample gas diffuses through the diffusion barrier to be reduced at the sensing electrode to form OH in the electrolyte can move freely through the porous 2nd working electrode At the counter electrode is oxidized back to oxygen Teledyne Analytical Instruments 20 Oxygen Analyzer Operational Theory While the 2nd working electrode allows to move through it prevents the dissolved oxygen from the top portion of the sensor to reach the sensing electrode The reference electrode provides a potential reference for both the sensing electrode and the 2nd working electrode NOTE BDS technology and sensor is a patent pending technology of Teledyne Analytical Instruments in the United State of America as well
62. pression fitting and 1 4 tubing to connect instrument air compressed air with pressure in the range of 70 to 80 psig CAUTION PRESSURE HIGHER THAN 100 PSIG CAN DAMAGE 1 THE SOLENOID VALVES 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 Teledyne Analytical Instruments 33 Installation BDS 3960 EEE EE 1 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 power supply requires 100 120 VAC 50 60 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 may not be installed at the factory Be sure to install the proper fuse as part of installation See Fuse Replacement in Chapter 5 Maintenance 3 3 2 2 50 PIN EQ
63. rate the amplifier 4 3 2 3 TEMPERATURE COEFFICIENT The output of the sensor is affected by temperature There are two types of temperature compensation on the BDS 3960 One is the compensation to high levels of oxygen more than 100 ppb This effect is transparent to the user and is handled by the software application on the It requires no input from the user The second compensation involves the baseline drift due to temperature This value is generally set at the factory but can be modified or adjusted by the user Since the sensor is temperature controlled the default is zero The following discussion is just information on its possibilities The baseline drift temperature coefficient is a number with units of ppb degree centigrade and must be matched to the sensor s characteristic drift over temperature This coefficient ranges from 0 50 to 1 75 ppb C Note The coefficient is different from sensor to sensor If the sensor is replaced a new coefficient must be entered TAI can supply this coefficient or it may be determined by the user The coefficient can be adjusted between 0 00 and 5 00 using the Up and Down buttons on the instrument To estimate it in the field 1 Set the coefficient to zero 2 Run the analyzer on Zero calibration gas for two weeks or until a baseline stability is reached i e the oxygen reading does not fluctuate 4 Teledyne Analytical Instruments 47 Maintenance BDS 3960 OEE GI BN
64. response a bypass can be added to increase the sample flow rate to the analyzer by a factor of ten A by pass provides a sample flow path around the analyzer of 2 18 SCFH typically Conversons 1 PSI 2 04 INCHES OF MERCURY in Hg 1SCFH 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 Teledyne Analytical Instruments 70 Oxygen Analyzer Appendix Material Safety Data Sheet Section Product Identification Product Name Manufacturer Address Phone Technical Support Environment Health and Safety Date Prepared Micro fuel Cells Mini Micro fuel Cells Super Cell all classes except T 5F Electrochemical Oxygen Sensors all classes Teledyne Electronic Technologies Analytical Instruments 16380 Chestnut Street City of Industry CA 91749 626 961 9221 626 934 1673 626 934 1592 11 23 98 Section Il Physical and Chemical Data Chemical and Common Names CAS Number Melting Point Range Boiling Point Range Specific Gravity pH Solubility in Water Percent Volatiles by Vol Appearance and Odor Potassium Hydroxide KOH 1596 w v Lead Pb pure KOH 1310 58 3 Pb 7439 92 1 KOH 15 w v Pb pure 10 to 0 C 328 100 to 115 C 1744 C 1 09 20 C 11 34 gt 14 N A Completely soluble Insoluble None N A Colorless odorless Grey me
65. tal solution odorless Teledyne Analytical Instruments 71 Appendix BDS 3960 gt Section Physical Hazards Potential for fire and explosion The electrolyte in the Micro fuel Cells is not flammable There are no fire or explosion hazards associated with Micro fuel Cells Potential for reactivity The sensors are stable under normal conditions of use Avoid contact between the sensor electrolyte and strong acids Section IV Health Hazard Data Primary route of entry Ingestion eye skin contact Exposure limits OSHA PEL 0 05 mg cu m Pb ACGIH TLV 2 mg cu m KOH Effects of overexposure Ingestion The electrolyte could be harmful or fatal if swallowed Oral LD50 RAT 3650 mg kg Eye The electrolyte is corrosive eye contact could result in permanent loss of vision Dermal The electrolyte is corrosive skin contact could result in a chemical burn Inhalation Liquid inhalation is unlikely Signs symptoms of exposure Contact with skin or eyes will cause a burning sensation and or feel soapy or slippery to touch Medical conditions aggravated by exposure None Carcinogenicity NTP Annual Report on Carcinogens Not listed LARC Monographs Not listed OSHA Not listed Other health hazards Lead is listed as a chemical known to the State of California to cause birth defects or other reproductive harm Teledyne Analytical Instruments 72 Oxygen Analyzer Appendix Section V E
66. tential 290 4e 40H 1 There is no net electrochemical reaction at reference electrode since it is connected to the high impedance input of the operation amplifier The electrochemical reaction at the counter electrode is O 29 0 4 2 It is noteworthy that reaction 2 is reverse of the reaction 1 It is indicative of a net change of zero inside a BDS sensor throughout the sensing process This feature produces a long term stability for the BDS sensor There are two resources of oxygen being reduced at the sensing electrode from the sample gas and dissolved oxygen within the electrolyte The oxygen molecules in the sample gas diffuse to the sensing electrode through a diffusion barrier controlled diffusion to produce a current signal which is proportional to the oxygen level in the sample gas However the dissolved oxygen in the electrolyte also diffuses through the electrolyte It is reduced at the sensing electrode and produces a background current This background current represents the detection limit of an oxygen sensor Teledyne Analytical Instruments 19 Operational Theory BDS 3960 i 1 The main advantage of the BDS technology lies in the unique second potentiostat It is designed to remove dissolved oxygen and other impurities in the electrolyte It eliminates the internal background current which previously limited the detection process The second potenti

Teledyne BDS-3960 Oxygen Equipment User Manual

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