Oxygen Analyzer OPERATING INSTRUCTIONS Model 3010PAC Percent Oxygen Analyzer Flush Mount Control Unit, PN D-66192B CENELEC Type Remote Probe, PN B-39923C Intrinsic Safe Barriers Assy., PN C-66426 DANGER HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING SYSTEM.
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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.
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Oxygen Analyzer Table of Contents Specific Model Information ........iv Preface ..............v Part I: Control Unit, Model PAC ..... Part I: 1-1 Part II: Intrinsic Safe Barriers ....Part II: 1-1 Remote Probe ........... Appendix ............A-1 Teledyne Analytical Instruments...
❏ 19" Rack Mount The 19" Relay Rack Mount units are available with either one or two series 3010PAC analyzer Control Units in- stalled in a standard 19" panel and ready to mount in a standard rack. See Appendix for details.
Analysis Unit, or remote probe, that can operate in a hazardous area. Part I of this manual covers the Model 3010PAC General Purpose flush- panel and/or rack-mount Control Unit only. This Control Unit is for indoor use in a nonhazardous environment.
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Instruments to be sure of a match. Where an underscore (_) appears in a model number, the unit has more than one application. For example, 3010P_C means that the same unit is part of the 3010PAC and the 3010PBC models.
Oxygen Analyzer Main Features of the Analyzer The Model 3010PAC series Oxygen Analyzers are sophisticated yet simple to use. The main features of these analyzers include: • A 2-line alphanumeric display screen, driven by microprocessor electronics, that continuously prompts and informs the operator.
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Model 3010 Model 3010PAC complies with all of the requirements of the Commonwealth of Europe (CE) for Radio Frequency Interference, Electromagnetic Interference (RFI/EMI), and Low Voltage Directive (LVD). The Analysis Unit is Intrinsically safe and CENELEC approved. The Control Unit is suitable for general purpose areas. The probe is CENELEC approved (certification code EEXIA IICT6).
Part I: Control Unit OPERATING INSTRUCTIONS Models 3010PAC Oxygen Analyzer Part I Control Unit Flush Mount Part Number: D-66192B Part I: i Teledyne Analytical Instruments...
4.3 The System Function ............. 4-3 4.3.1 Setting Display ............4-4 4.3.2 Setting up an Auto-Cal ........... 4-5 4.3.3 Password Protection ..........4-5 4.3.3.1 Entering the Password ........4-6 4.3.3.2 Installing or Changing the Password ..... 4-7 ii: Part I Teledyne Analytical Instruments...
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4.7 The Analyze Function ............ 4-17 4.8 Signal Output ..............4-17 5 Maintenance 5.1 Fuse Replacement............5-1 5.2 System Self Diagnostic Test ........... 5-2 5.3 Major Internal Components ..........5-3 5.4 Cleaning ................ 5-4 Part I: iii Teledyne Analytical Instruments...
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Model 3010 Oxygen Analyzer iv: Part I Teledyne Analytical Instruments...
Part I, this part, of this manual covers the Model 3010PAC series General Purpose flush-panel and/or rack-mount Control Units. (The Analy- sis Unit is covered in Part II of this manual.) The Control Unit is for indoor use in a nonhazardous environment only.
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VFD display: • Left & Right Arrows Select between functions currently displayed on the VFD screen. • Up & Down Arrows Increment or decrement values of functions currently displayed. 1-2: Part I Teledyne Analytical Instruments...
The Control Unit rear panel, shown in Figure 1-2, contains the electrical connectors for external inputs and outputs. The input/output functions are described briefly here and in detail in the Installation chapter of this manual. Part I: 1-3 Teledyne Analytical Instruments...
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1 Introduction Model 3010 Figure 1-2: Model 3010PAC Rear Panel • Power Connection Universal AC power source. • Analog Outputs 0-1 V dc concentration and 0-1 V dc range ID. Optional isolated 4-20 mA dc and 4-20 mA dc range ID.
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Not implemented at this printing. Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. The internal clock in the Model 3010PAC is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. Part I: 1-5...
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1 Introduction Model 3010 1-6: Part I Teledyne Analytical Instruments...
(PCB) assemblies inside the Control Unit chassis. The PCB locations are illustrated in section 5, Maintenance. Refer to Figure 2-1, Block Diagram of the 3010PAC CU Electronics: In the presence of oxygen, the sensor (in the Analysis Unit) generates a current. A current to voltage amplifier (in the Control Unit) converts this current to a voltage.
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2 Operational Theory Model 3010 Figure 2-1: Block Diagram of the 3010PAC CU Electronics 2-2: Part I Teledyne Analytical Instruments...
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0-1 V dc and the optional 4-20 mA dc analog concentration signal outputs, and the analog range ID outputs. The microprocessor monitors the power supply, and activates the system failure alarm if a malfunction is detected. Part I: 2-3 Teledyne Analytical Instruments...
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2 Operational Theory Model 3010 2-4: Part I Teledyne Analytical Instruments...
Immediately report any damage to the shipping agent. Mounting the Control Unit The Model 3010PAC Control Unit 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 a Model 3010PAC standard Control Unit front panel and mounting bezel.
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The door is spring loaded and will swing open when the button in the center of the latch (upper right corner) 3-2: Part I Teledyne Analytical Instruments...
Wire size and maximum length data appear in the Drawings in the back of this manual. Figure 3-4: Rear Panel of the Model 3010PAC Control Unit For safe connections, no uninsulated wiring should be able to come in contact with fingers, tools or clothing during normal operation.
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 3-4: Part I Teledyne Analytical Instruments...
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• Can be configured as latching or nonlatching. • Can be configured out (defeated). Threshold Alarm 2: • Can be configured as high (actuates when concen- tration is above threshold), or low (actuates when concentration is below threshold). Part I: Teledyne Analytical Instruments...
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Floating input. 5 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 3-6: Part I Teledyne Analytical Instruments...
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Cal Contact Cal Contact Remote Calibration Protocol: To properly time the Digital Remote Cal Inputs to the Model 3010PAC Analyzer, the customer's controller must monitor the Cal Relay Contact. When the contact is OPEN, the analyzer is analyzing, the Remote Cal Inputs are being polled, and a zero or span command can be sent.
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At this printing, this port is not yet functional. It is to be used for future options to the instrument. Pins 13 (+) and 29 (–). Remote Valve Connections: The 3010PAC is a single-chassis instrument, which has no Remote Valve Unit. Instead, the Remote Valve connections are used as a method for directly controlling external sample/ zero/span gas valves.
• Which alarms—if any—are tripped (AL–x ON). Each status output is followed by a carriage return and line feed. Three input functions using RS-232 have been implemented to date. They are described in Table 3-5. Part I: Teledyne Analytical Instruments...
Toggling input. Stops/Starts any status message output from the RS-232, until st<enter> is sent again. The RS-232 protocol allows some flexibility in its implementation. Table 3-6 lists certain RS-232 values that are required by the 3010PAC implementation. Table 3-6: Required RS-232 Options...
Check the integrity and accuracy of all electrical connections. Make sure there are no exposed conductors Power up the system, and test it by performing the following operations: 1. Repeat the Self-Diagnostic Test as described in chapter 4, section 4.3.5. Part I: 3-11 Teledyne Analytical Instruments...
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3 Installation Model 3010 3-12: Part I Teledyne Analytical Instruments...
If you choose not to use password protection, the default password is automatically displayed on the password screen when you start up, and you simply press Enter for access to all functions of the analyzer. Part I: 4-1 Teledyne Analytical Instruments...
Any function can be selected at any time by pressing the appropriate button (unless password restrictions apply). The order as presented in this manual is appropriate for an initial setup. 4-2: Part I Teledyne Analytical Instruments...
PSWD: Security can be established by choosing a 5 digit • password (PSWD) from the standard ASCII character set. (See Installing or Changing a Password, below, for a table of ASCII characters available.) Once a unique password is assigned and Part I: 4-3 Teledyne Analytical Instruments...
If LED meter reads all eights and points, go to step 3. b. If LED meter displays anything else, go to step 2. 2. Press button twice to turn Analyzer OFF and ON again. LED meter should now read all eights and periods. 4-4: Part I Teledyne Analytical Instruments...
Note: If you require highly accurate Auto-Cal timing, use external Auto-Cal control where possible. The internal clock in the Model 3010PAC is accurate to 2-3 %. Accordingly, internally scheduled calibrations can vary 2-3 % per day. To setup an Auto–Cal cycle: Choose System from the Function buttons.
If the password is accepted, the screen will indicate that the password restrictions have been removed and you have clearance to proceed. PSWD Restrictions Removed In a few seconds, you will be given the opportunity to change this password or keep it and go on. 4-6: Part I Teledyne Analytical Instruments...
∆ ∆ ∆ ∆ ∆ ∇ arrow keys to change the letters to the new password. The full set of 94 characters available for pass- word use are shown in the table below. Characters Available for Password Definition: ¥ " & → < > Part I: 4-7 Teledyne Analytical Instruments...
(Refer to Section 1.3) Use the < > arrow keys to position the blinking over the Logout func- tion, and press Enter to Log out. The screen will display the message: Protected Until Password Reentered 4-8: Part I Teledyne Analytical Instruments...
Part I: Control Unit 4.3.5 System Self-Diagnostic Test The Model 3010PAC has a built-in self-diagnostic testing routine. Pre- programmed signals are sent through the power supply, output board and sensor circuit. The return signal is analyzed, and at the end of the test the status of each function is displayed on the screen, either as OK or as a number between 1 and 3.
Zero or Span function. 4.4.1. Cell Failure When the sensor in the 3010PAC begins to fail, the analyzer will usually require more and more frequent calibration. If the 3010PAC analysis readings drift downward uncharacteristically, try recalibration. If recalibra- tion raises the readings temporarily, the cell may be failing.
Cell Output: ### µA The “good” reading depends on the class of cell your analyzer is using. Although the B-1 cell is standard in the 3010PAC, check Specific Model Information in the Front Matter in this manual for the class of cell you purchased.
Once Enter is pressed, the Span reading changes to the correct value. The instrument then automatically enters the Analyze func- tion. 4-12: Part I Teledyne Analytical Instruments...
Part I: Control Unit The Alarms Function The Model 3010PAC 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 V ac. See figure in chapter 3, Installation and/or the Interconnection Diagram included at the back of this manual for relay terminal connections.
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2 (AL–2). To reset a latched alarm, go to Dft– and then press either ∆ two • times or ∇ two times. (Toggle it to Y and then back to N.) –OR – 4-14: Part I Teledyne Analytical Instruments...
0–5 % High 0–10 %. The Model 3010PAC is set at the factory to default to autoranging. In this mode, the microprocessor 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.
1 V dc (or 20 mA). However, the digital readout and the RS-232 output continue to read the true value of the oxygen concentration regardless of the analog output range. 4-16: Part I Teledyne Analytical Instruments...
Part I: Control Unit The Analyze Function When the Analyze function is active, the 3010PAC is monitoring the sample gas currently flowing in the Analysis Unit cell block. All undefeated alarms are ready to activate should their respective setpoints be crossed.
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They generate a steady preset voltage (or current when using the current outputs) to represent a particular range. The following table gives the range ID output for each analysis range: Range Voltage (V) Current (mA) 0.25 0.50 0.75 CAL (0-25%) 1.00 4-18: Part I Teledyne Analytical Instruments...
1. Place small screwdriver in notch, and pry cover off, as shown in Figure 5-1. Figure 5-1: Removing Fuse Block from Housing 2. To change between American and European fuses, remove the single retaining screw, flip Fuse Block over 180 degrees, and replace screw. Part I: 5-1 Teledyne Analytical Instruments...
5 V Failure 15 V Failure Both Failed Analog DAC A (0–1 V Concentration) DAC B (0–1 V Range ID) Both Failed Preamp Zero too high Amplifier output doesn't match test input Both Failed 5-2: Part I Teledyne Analytical Instruments...
WARNING: HAZARDOUS VOLTAGES EXIST ON CERTAIN COM- PONENTS INTERNALLY WHICH MAY PERSIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED. The 3010PAC Control Units contain the following major components: • Power Supply • Motherboard (with Microprocessor, RS-232 chip, and Preamplifier PCB) •...
Do not use any harsh solvents such as paint thinner or benzine. For panel-mounted instruments, clean the front panel as prescribed in the above paragraph. DO NOT wipe front panel while the instrument is monitoring your process. 5-4: Part I Teledyne Analytical Instruments...
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Part II: Analysis Unit OPERATING INSTRUCTIONS Model 3010PAC Oxygen Analyzer Part II Intrinsic Safe Barriers Remote Probe CENELEC Type Part Number C-66426 Teledyne Analytical Instruments Part II: i...
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Model 3010PAC Oxygen Analyzer Table of Contents 1 Introduction 1.1 Overview ................ 1-1 1.2 Intrinsic Safe Barriers ............. 1-1 1.3 Area Clasificationl ............1-2 1.4 Cell Housing/Probe ............1-2 2 Operational Theory 2.1 Introduction ..............2-1 2.2 Micro-Fuel Cell Sensors ..........2-1 2.2.1 Principles of Operation ...........
Part II: Analysis Unit Introduction Overview The Analytical Instruments Model 3010PAC Remote Probe is a versatile remotely controlled instrument for detecting percent amounts of oxygen (0-1% to 0-100%) in a variety of background gases. Details are recorded in Specifications in the Appendix to this manual.
1 Introduction Model 3010PAC CAUTION: Bypassing the barriers in any way nullifies their effect, and conditions which prompted their use will prevail. If the instrument is used under any conditions contrary to the intrinsic safety design, the user assumes all risk.
Control Unit, covered in Part I of this manual. Micro-Fuel Cell Sensor 2.2.1 Principles of Operation The oxygen sensors used in the Model 3010PAC series are Micro- Fuel Cells designed and manufactured by Analytical Instruments. They are sealed plastic disposable electrochemical transducers.
2 Operational Theory Model 3010PAC being analyzed. The Micro-Fuel Cell is therefore a hybrid between a battery and a true fuel cell. (All of the reactants are stored externally in a true fuel cell.) 2.2.2 Anatomy of a Micro-Fuel Cell A Micro-Fuel Cell (MFC) is a cylinder only 1¼...
The current is propor- tional to the amount of oxygen reaching the cathode. It is measured and used to determine the oxygen concentration in the gas mixture. Teledyne Analytical Instruments Part II: 2-3...
2 Operational Theory Model 3010PAC The overall reaction for the fuel cell is the SUM of the half reactions above, or: → 2PbO 2Pb + O (These reactions will hold as long as no gaseous components capable of oxidizing lead—such as iodine, bromine, chlorine and fluorine—are present in the sample.)
100 % in the sample gas. Nominal output in air is 0.19 mA, and 90 % response time is 45 s. Expected life in flue gas is 8 months. Teledyne Analytical Instruments Part II: 2-5...
2 Operational Theory Model 3010PAC 2.2.6.3 Class B-1 Cell The class B-1 cell is for use in applications where it is exposed to less than 0.1 % of carbon dioxide, and where fast response is important. Nominal output in air is 0.50 mA, and 90 % response time is 7 s.
Oxygen Analyzer Part II: Analysis Unit Installation Installation of the Model 3010PAC Analyzer includes: 1. Unpacking, mounting, and interconnecting the Control Unit and the Analysis Unit 2. Making gas connections to the system 3. Making electrical connections to the system 4.
3 Installation Model 3010PAC If you use your own gas control valves, use the interconnect diagram in Figure 3-5 for the valves. The sensor and thermistor remain connected as in Figure 3-4, above. Installing the Micro-Fuel Cell The Micro-Fuel Cell is not installed in the cell block when the instrument is shipped.
B367 dual channel) are installed between the cell and the control unit. The barrier strips are housed in an approved bulkhead mountable barrier box (P/N E324). Refer to drawing D66191 for terminal connection. Figure 3-4: Control Unit (CU) to Analysis Unit (AU) Connector Cable Part II: Teledyne Analytical Instruments...
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3 Installation Model 3010PAC D - SUB CONNECTOR’S DESCRIPTION PIN # Description + Range ID 4-20 mA - Range ID 4-20 mA + Output 4-20 mA - Output 4-20 mA - Output 0-1 V + Range ID 0-1 V Network +...
Zero Solenoid Sample Solenoid Return 3.5 Remote Probe Connection The Models 3010PAC are split architecture (dual-chassis) instru- ments, which have a Remote Probe, or Analysis Unit. The remote probe is for receiving the oxygen sensor and thermistor signals. Remote Probe 9-pin Connector...
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3 Installation Model 3010PAC 3-6: Part II Teledyne Analytical Instruments...
Version Self—Test Cell Output: ### µA The “good” cell output range depends on the class of cell your analyzer is using. The B-1 cell is standard in the 3010PAC, but others can be speci- fied. Part II: Teledyne Analytical Instruments...
0.606 4.3 Cell Warranty The Micro-Fuel cell used in the standard Model 3010PAC is the class B-1 cell. Check Specific Model Information in the front matter of this manual for cell class in your unit, as this will affect cell life and warranty data. Also note any Addenda that may be attached to the front of this manual for special information applying to your instrument.
Power 5 V Failure 15 V Failure Both Failed Analog DAC A (0–1 V Concentration) DAC B (0–1 V Range ID) Both Failed Preamp Zero too high Amplifier output doesn't match test input Both Failed Part II: Teledyne Analytical Instruments...
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4 Maintenance Model 3010PAC 4-4: Part II Teledyne Analytical Instruments...
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Oxygen Analyzers Appendix OPERATING INSTRUCTIONS 3010PAC Model Oxygen Analyzers Appendix Flush Mount Control Unit, PN D66192B CENELEC Type Analyssis Unit, PN B39923C Appendix: A-1 Teledyne Analytical Instruments...
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Appendix Models 3010PAC Contents A-1 Model 3010PAC Specifications........A-3 A-2 Recommended 2-Year Spare Parts List ......A-5 A-3 Drawing List ..............A-6 A-5 The Zero Functions ............A-7 A-2: Appendix Teledyne Analytical Instruments...
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Oxygen Analyzers Appendix Appendix A-1 Model 3010PAC Specifications Packaging: General Purpose Control Unit • Flush panel mount (Standard). • Rack mount — Relay rack mounted to contain either one or two instruments in one 19" relay rack mountable plate (Optional).
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Appendix Models 3010PAC Power: General Purpose Control Unit Universal power supply 85-250 V ac, 47-63 Hz. Operating Temperature: 0-50 °C EMF/RFI: Immunity and Emissions designed to meet (but not yet certified to) EN 50081-1 EN 50082-2 Accuracy: ±2% of full scale at constant temperature.
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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...
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Appendix Models 3010PAC or your local representative. A-3 Drawing List D-66192B: Final Assembly/Outline Drawing, Control Unit, 3010PAC D-66192C: Final Assembly/Outline Drawing, Control Unit, 3010PAC-MA D66191: Sensor Block Interconnection Diagram C66426: Safety Barrier Housing Assembly B39923C: Final Assembly, Top 4 Probe, Percent...
Press Zero to enter the Zero function. The screen that appears allows you to select between automatic or manual zero calibration. Use the ∆∇ keys to toggle between AUTO and MAN zero settling. Stop when MAN appears, blinking, on the display. Appendix: A-7 Teledyne Analytical Instruments...
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Appendix Models 3010PAC Zero: Settling: Man <ENT> To Begin Press Enter to begin the zero calibration. After a few seconds the first of five zeroing screens appears. The number in the upper left hand corner is the first-stage zero offset. The microprocessor samples the output at a prede- termined rate.
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Micro-Fuel Cells and Super Cells, all classes except A-2C, A-3, and A-5. Electrochemical Oxygen Sensors, all classes except R-19. Micro-Fuel Cells, all classes. Manufacturer: Teledyne Analytical Instruments Address: 16830 Chestnut Street, City of Industry, CA 91749 Phone: (818) 961-9221 Customer Service:...
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Appendix Models 3010PAC Section IV – Fire and Explosion Hazard Data Flash Point: Flammable Limits: LEL: UEL: Extinguishing Media: Use extinguishing media appropriate to surrounding fire conditions. No specific agents recommended. Special Fire Fighting Wear NIOSH/OSHA approved self-contained breathing Equipment: apparatus and protective clothing to prevent contact with skin and eyes.
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If there is liquid around the cell while in the instrument, wear eye and hand protection. Cleanup Procedures: Wipe down the area several times with a wet paper towel. Use a fresh towel each time. Contaminated paper towels are considered hazardous waste. Appendix: A-11 Teledyne Analytical Instruments...
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NOTE: The above information is believed to be correct and is offered for your information, consideration, and investigation. It should be used as a guide. Teledyne Analytical Instruments shall not be held liable for any damage resulting from handling or from contact with the above product.