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Oxygen Analyzer
OPERATING INSTRUCTIONS FOR
M M M M O O O O D D D D E E E E L L L L B B B B D D D D S S S S - - - - 3 3 3 3 9 9 9 9 6 6 6 6 0 0 0 0
Tox ic g a se s a nd o r fla mma ble liq uids ma y be pr es e nt in this mon itor ing s y stem.
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
Oxygen Analyzer
DANGER
P/N M71903
9/04/02
ECO # 02-232
i
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Summary of Contents for Teledyne BDS-3960
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Page 1: Teledyne Analytical Instruments
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... - Page 2 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.
- Page 3 Instrument Serial Number: _______________________ Options Included in the Instrument with the Above Serial Number: 220 VAC: Instrument configured 200-240 VAC, 50/60Hz power Teledyne Analytical Instruments...
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Page 4: Safety Messages
NOTE: Additional information and comments regarding a specific component or procedure are highlighted in the form Symbol of a note. CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL. Teledyne Analytical Instruments... - Page 5 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.
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Page 6: Table Of Contents
2.2.2 Gas Flow Rate 2.2.3 Gas Pressure 2.2.4 Temperature effect 2.2.5 Recovery from High Level Oxygen Exposure 2.2.6 Background Gas Compatibility 2.2.7 Stability 2.2.8 Maintenance 2.3 Sample System 2.4 Electronics and Signal Processing Installation ................... 30 3.1 Unpacking the Analyzer Teledyne Analytical Instruments... - Page 7 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...
- Page 8 5.5 Reinstalling Application software to PPC. 5.5 Major Internal Components 5.6 Cleaning 5.7 Troubleshooting Appendix ..................66 Specifications Recommended 2-Year Spare Parts List Drawing List 19-inch Relay Rack Panel Mount Application notes Material Safety Data Sheet Index..................... 74 Teledyne Analytical Instruments viii...
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Page 9: List Of Figures
Oxygen Analyzer List of Figures Figure 1-1: BDS-3960 Front Panel ..........15 Figure 1-2: Model BDS 3960 Rear Panel ........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 ....... - Page 10 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...
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Page 11: List Of Tables
Table 3-4: Range ID Relay Connections ........39 Table 4-1: Gas Factor for Selected Gases ........46 Table 4-2: Parameter Default Values ..........48 Table 4-2: Linear Output for a 0-100 ppm O2 Range ....55 Table 4-3: Range ID Output ............56 Teledyne Analytical Instruments... - Page 12 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.
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Page 13: Introduction
Introduction Introduction Overview 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. -
Page 14: Front Panel (Operator Interface)
Span calibrate the analyzer. • Zero calibrate the analyzer. Zero • Alarms Set the alarm setpoints and attributes for Alarm 1 and Alarm 2. • Set up the 3 user definable ranges Range for the instrument. Quit Quit analyzer application. Teledyne Analytical Instruments... -
Page 15: Figure 1-1: Bds-3960 Front Panel
Oxygen Analyzer Introduction 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. -
Page 16: Rear Panel (Equipment Interface)
Digital inputs allow external control of analyzer calibration. • To notify external equipment that Calibration Contact instrument is being calibrated and readings are not monitoring sample.• Four separate, dedicated, range Range ID Contacts relay contacts. Low, Medium, High, Cal. Teledyne Analytical Instruments... -
Page 17: Figure 1-2: Model Bds 3960 Rear Panel
Oxygen Analyzer Introduction Figure 1-2: Model BDS 3960 Rear Panel Teledyne Analytical Instruments... -
Page 18: Operational Theory
BDS Sensor 2.2.1 Principles of Operation The BDS oxygen sensor technology developed at Teledyne Analytical Instruments is a result of TAI’s heavy investment on R&D and expertise established during the half-century’s manufacturing of electrochemical oxygen sensor. It stands for Bipotentiostat Driven Sensor. - Page 19 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...
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Page 20: Figure 2.1: Cross Section Of The Bds Oxygen Sensor
A portion of oxygen in the sample gas diffuses through the diffusion barrier to be reduced at the sensing electrode to form OH the electrolyte. OH can move freely through the porous 2nd working electrode. At the counter electrode, OH is oxidized back to oxygen. Teledyne Analytical Instruments... -
Page 21: 2.2.2 Gas Flow Rate
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 as many foreign countries. To learn more about BDS technology, please visit TAI’s web page at http://www.Teledyne-AI.com... -
Page 22: Gas Pressure
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... -
Page 23: 2.2.6 Background Gas Compatibility
(see sect ion 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... -
Page 24: 2.2.7 Stability
PC boards or other area inside the analyzer. Figure 2.5: Adding DI Water to the BDS Sensor Teledyne Analytical Instruments... -
Page 25: Sample System
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... -
Page 26: Electronics And Signal Processing
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 Teledyne Analytical Instruments... - Page 27 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...
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Page 28: Figure 2-7: Bds 3960 Electronics Block Diagram
Operational Theory BDS 3960 Temperature Sensor Amplifiers Sensor Alarm 1 Alarm 2 Display 8051 processor System Alarm Other UART Outputs 0-1 VDC and 4-20 ma support Pocket electronics Figure 2-7: BDS 3960 Electronics Block Diagram Teledyne Analytical Instruments... - Page 29 Oxygen Analyzer Operational Theory Teledyne Analytical Instruments...
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Page 30: Installation
. There ar e four mount ing hol es—one in each corner of t he ri gi d f rame. The dr awings sect i on i n the r ear of thi s manual contai ns out l ine dim ensi ons and mount ing hol e spaci ng di agram s. Teledyne Analytical Instruments... -
Page 31: Figure 3-1: Model Bds 3960 Front Panel
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 Teledyne Analytical Instruments... -
Page 32: Rear Panel Connections
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. Teledyne Analytical Instruments... -
Page 33: Electrical Connections
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... -
Page 34: Primary Input Power
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 V = Medium Range, 0.75 V = High Range, 1 V = 100ppm. Teledyne Analytical Instruments... -
Page 35: Table 3-1: Analog Output Connections
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). Teledyne Analytical Instruments... -
Page 36: Table 3-2: Alarm Relay Contact Pins
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... -
Page 37: Table 3-3: Remote Calibration Connections
– Remote Zero + Remote Span – Remote Span Cal Contact Cal Contact Remote Calibration 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... - Page 38 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...
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Page 39: Electrolyte Refill Of Bds Sensor
6. 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... -
Page 40: Testing The System
Check the integrity and accuracy of the electrical connections. Make sure there are no exposed conductors Check pressure of sample gas as well as instrument air. Set the internal pressure regulator fully counterclockwise. Teledyne Analytical Instruments... -
Page 41: Powering Up The System
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... -
Page 42: Operation
LO = 100ppb , MED = 1000 ppb, Ranges: HI = 10 ppm, Over-Range = 100 Auto Ranging: Alarm Relays: Defeated, Alarm 1 at 1000 ppb, Alarm 2 at 100 ppb HI, Not failsafe, Not latching. Teledyne Analytical Instruments... -
Page 43: The Analyzer Application
Alarm 2. Pressing this button opens a new screen where Alarm 2 trigger point and options can be set. Zero. Pressing this button opens a screen for the zero calibration function. Span. Pressing this button opens the screen for the span calibration function. Teledyne Analytical Instruments... -
Page 44: The System Screen
The first four digits are the Analog to Digital counts of the BDS sensor 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... -
Page 45: 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: Digital filter—noise reduction Gas Factor—compensates for different background gases Temperature coefficient—corrects baseline drift due to temperature. Teledyne Analytical Instruments... -
Page 46: The Digital Filter
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* H2= 1.99 He= 0.90 Ar= 0.79 Teledyne Analytical Instruments... -
Page 47: Temperature Coefficient
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. Teledyne Analytical Instruments... -
Page 48: Set Defaults
Some of the default values are listed below: Table 4-2: Parameter Default Values Parameter Default Value Zero Offset Span Gas 8.00 PPM SpanFactor 24.42 (Default span factor = 100000 ppb/ 4095 ADC counts) Teledyne Analytical Instruments... -
Page 49: Calibration Of The Analyzer
Best results as well as prolonged scrubber life is attained when the oxygen concentration of the sample gas is below 1 ppm oxygen. Teledyne Analytical Instruments... -
Page 50: Zero Failure
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... -
Page 51: Span Failure
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. Teledyne Analytical Instruments... - Page 52 0 to 100,000 ppb. 2. Out-of-range direction—High or Low 3. Latch control—Latching or Non-latching. 4. On/off Control—Active or Defeated. 5. Safety Mode—Failsafe or Non-failsafe. To reset a latched alarm, go to On/off Control and select defeated. Teledyne Analytical Instruments...
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Page 53: The Range Function
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. Teledyne Analytical Instruments... -
Page 54: Figure 4.3: Range Options List Box
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 Teledyne Analytical Instruments... -
Page 55: Fixed Range Analysis
0–100 ppb O , 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) 10.4 12.0 Teledyne Analytical Instruments... -
Page 56: 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 is tapped to run the program, an error message will be Teledyne Analytical Instruments... - Page 57 - Tap on the Running Programs tab - Tap ot “TET-AI PPB OXYGEN ANALYER” on the program lists to select the Analyzer program - Tap the Activate button. Now the Analyzer program should be at the front. Teledyne Analytical Instruments...
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Page 58: Maintenance
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... -
Page 59: Fuse Replacement
Fuse Replacement 1. Place small screwdriver in notch, and pry cover off, as shown in Figure 5-2. Remove fuse holder. 2. Replace fuses. Use 2A 250 VAC 5x20 mm slow-blow. Install one at each side of fuse holder Teledyne Analytical Instruments... -
Page 60: Battery Backup Replacement
4. Slide the switch on the back of the PPC to Backup. Open the battery compartment and remove the old battery. 5. Install a new battery. Make sure that the ‘+’ side is on top facing out. 6. Replace the battery cover and move the switch to lock position. Teledyne Analytical Instruments... -
Page 61: 5.5 Reinstalling Application Software To Ppc
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 the registration was successful. If it was not successful, repeat the last two steps. Teledyne Analytical Instruments... -
Page 62: Major Internal Components
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. Troubleshooting Symptoms Possible causes and Solutions Teledyne Analytical Instruments... - Page 63 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 (TAI P/N B72098) is available from Teledyne Analytical Instruments. Teledyne Analytical Instruments...
- Page 64 Maintenance BDS 3960 Figure 5-3: Vacuum Degassing for the BDS Oxygen Sensor Teledyne Analytical Instruments...
- Page 65 Oxygen Analyzer Maintenance Teledyne Analytical Instruments...
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Page 66: Appendix
Appendix Specifications Packaging: General Purpose • Flush panel mount (Standard). Sensor: Teledyne BDS Sensor, patent pending. Sample System: All wetted parts of 316 stainless steel with built-in in pressure regulator, oxygen scrubber and calibration valves. 90 % Response Time: Less than 90 seconds at 25 °C (77 °F) on 10, and 100 ppm range. - Page 67 Analog outputs: 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. Dimensions: 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...
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Page 68: Recommended 2-Year Spare Parts List
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 l ocal r epresentative. Teledyne Analytical Instruments... -
Page 69: Drawing List
Oxygen Analyzer Appendix Drawing List D-73299 Outline Diagram 19-inch Relay Rack Panel Mount Figure A-1: Single 19" Rack Mount (dimensions in mm) Teledyne Analytical Instruments... -
Page 70: Application Notes
Conversons: 1 PSI 2.04 INCHES OF MERCURY (in. Hg.) 1 SCFH = 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... -
Page 71: Material Safety Data Sheet
Section I - Product Identification Product Name: Micro-fuel Cells Mini-Micro-fuel Cells Super Cell, all classes except T-5F Electrochemical Oxygen Sensors, all classes Manufacturer: Teledyne Electronic Technologies Analytical Instruments Address: 16380 Chestnut Street, City of Industry, CA 91749 Phone: (626) 961-9221... - Page 72 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...
- Page 73 The information is believed to be correct but does not purport to be all inclusive and shall be 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.
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Page 74: Index
20 defeated (relay out), 35 cross section, 20 de-ionized water, 58 current, 26 detection limit, 19 damage, 32 diffusion barrier, 19, 20 filling, 39 digital input maintenance, 24 span, 37 output, 21, 22, 23, 32 zero, 37 Teledyne Analytical Instruments... - Page 75 LED, 15 setting, 53 maintenance, 58 Range, 53 manuals, additional, v range ID, 16, 38 meter, 15 rear panel, 16, 32 m icro co n tr oller , 26 recovery time, 22 microprocessor, 13 reduction equation, 19 Teledyne Analytical Instruments...
- Page 76 18 response time, 33, 66 swagelock fitting, 25 reticulated vitreous carbon, 20 SYSTEM, 14 RFI, 14 Teledyne address, 68 ROM, 13, 26 temperature coefficient, 22 safety information, iv testing the system, 40 sample flow. See flowrate threshold alarm. See alarm...
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