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Teledyne BDS 3000, Operating Instructions Manual

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Teledyne BDS 3000 Operating Instructions Manual Download Page 45

Oxygen Analyzer

Installation

Teledyne Analytical Instruments

31

For operations frequently encountering oxygen levels above 100

ppm, TAI’s Micro-Fuel-Cell type of oxygen sensor is recommended.

The maximum working range with a background of nitrogen gas is

100 ppm.  The maximum working range is different for other gas
backgrounds.  See Section 4.3.9.

Summary of Contents for BDS 3000

Page 1: ...xic 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...

Page 2: ...BDS 3000 Teledyne Analytical Instruments ii Before conducting any maintenance or servicing consult with authorized supervisor manager...

Page 3: ...ight 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 d...

Page 4: ...boxes Any that are incorporated in the instrument for which this manual is supplied are indicated by a check mark in the box Instrument Serial Number _______________________ Options Included in the In...

Page 5: ...ly Injury and or damage the 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...

Page 6: ...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 inf...

Page 7: ...Panel Equipment Interface 5 Operational Theory 7 2 1 Introduction 7 2 2 BDS Sensor 7 2 2 1 Principles of Operation 7 2 2 2 Gas Flow Rate 10 2 2 3 Gas Pressure 11 2 2 4 Temperature effect 11 2 2 5 Rec...

Page 8: ...Delay 37 4 3 2 Setting up an Auto Cal 38 4 3 3 Password Protection 39 4 3 3 1 Entering the Password 40 4 3 3 2 Installing or Changing the Password 41 4 3 4 Logout 43 4 3 5 System Self Diagnostic Test...

Page 9: ...yze Function 59 4 8 Signal Output 59 Maintenance 65 5 1 Routine Maintenance 65 5 2 Adding Water to the BDS Sensor 65 5 3 Fuse Replacement 66 5 4 System Self Diagnostic Test 67 5 5 Major Internal Compo...

Page 10: ...Sensor 13 Figure 2 6 Flow Diagram 14 Figure 2 7 Electronic Component Location 16 Figure 2 8 BDS 3000 Electronics Block Diagram 17 Figure 3 1 Model BDS 3000 Front Panel 20 Figure 3 2 Required Front Do...

Page 11: ...5 1 Adding water into the BDS sensor 66 Figure 5 2 Removing Fuse Block from Housing 67 Figure 5 3 Installing Fuses 67 Figure 5 4 Rear Panel Screws 69 Figure 5 5 Vacuum Degassing for the BDS Oxygen Sen...

Page 12: ...Table 3 2 Alarm Relay Contact Pins 25 Table 3 3 Remote Calibration Connections 26 Table 3 4 Range ID Relay Connections 27 Table 4 1 Characters Available for Password Definition 42 Table 4 2 Linear Ou...

Page 13: ...s 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...

Page 14: ......

Page 15: ...ications of the Model BDS 3000 are Monitoring inert gas blanketing Air separation and liquefaction Chemical reaction monitoring Semiconductor manufacturing Petrochemical process control Quality assura...

Page 16: ...continuous power supply monitoring Two way RFI protection RS 232 serial digital port for use with a computer or other digital communication device Four analog outputs two for measurement 0 1 VDC and I...

Page 17: ...n Span calibrate the analyzer Zero Zero calibrate the analyzer Alarms Set the alarm setpoints and attributes Range Set up the 3 user definable ranges for the instrument Data Entry Keys Six touch sensi...

Page 18: ...itching Alphanumeric Interface Screen The VFD screen is an easy to use interface from operator to analyzer It displays values options and messages that give the operator immediate feedback Flowmeter M...

Page 19: ...those depicted are optional and may not appear on your instrument The connectors are described briefly here and in detail in Chapter 3 Installation Figure 1 2 Model BDS 3000 Rear Panel Power Connecti...

Page 20: ...libration 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...

Page 21: ...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...

Page 22: ...l O2 2H2O 4e 4OH 1 There is no net electrochemical reaction at the reference electrode since it is connected to the high impedance input of the operation amplifier The electrochemical reaction at the...

Page 23: ...eves an outstanding feature of absolute zero output in the absence of oxygen Figure 2 1 Cross Section of the BDS Oxygen Sensor Figure 2 1 shows the schematic of a BDS oxygen sensor The sample gas ente...

Page 24: ...gn countries To learn more about BDS technology please visit TAI s web page at http www Teledyne AI com To learn more about potentiostat visit Electochemical Society s web page at http www electrochem...

Page 25: ...vent or excessive pressure will force gas into the electrolyte and cause damage to the BDS sensor Figure 2 3 BDS Sample System 2 2 4 Temperature effect The raw output from a BDS oxygen sensor has a te...

Page 26: ...rent 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 analyzer...

Page 27: ...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 cautio...

Page 28: ...s 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...

Page 29: ...se boards are accessible after removing the back panel Figure 2 8 is a block diagram of the Analyzer electronics In the presence of oxygen the sensor generates a current A current to voltage amplifier...

Page 30: ...Operational Theory BDS 3000 Teledyne Analytical Instruments 16 Figure 2 7 Electronic Component Location...

Page 31: ...Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 17 Figure 2 8 BDS 3000 Electronics Block Diagram...

Page 32: ...Operational Theory BDS 3000 Teledyne Analytical Instruments 18...

Page 33: ...any damage or shortages to the shipping agent 3 2 Mounting the Analyzer The Model BDS 3000 is for indoor use in a general purpose area It is NOT for hazardous environments of any type The standard mod...

Page 34: ...access to the sensor and cell block inside the instrument The door is spring loaded and will swing open when the button in the center of the latch upper right corner is pressed all the way in with a...

Page 35: ...al and analog concentration output Figure 3 3 Rear Panel of the Model Ultra Trace 3000 3 3 1 Gas Connections The unit is manufactured with 1 4 inch VCR fittings For a safe connection SAMPLE IN In the...

Page 36: ...xhaust stream vents to an appropriately controlled area if required 3 3 2 Electrical Connections For safe connections no uninsulated wiring should be able to come in contact with fingers tools or clot...

Page 37: ...nel 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 Ou...

Page 38: ...nd 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...

Page 39: ...ct 42 Threshold Alarm 2 normally closed contact 44 Threshold Alarm 2 moving contact 43 Threshold Alarm 2 normally open contact 36 System Alarm normally closed contact 20 System Alarm moving contact 37...

Page 40: ...ibration Connections Pin Function 9 Remote Zero 11 Remote Zero 10 Remote Span 12 Remote Span 40 Cal Contact 41 Cal Contact Remote Calibration Protocol To properly time the Digital Remote Cal Inputs to...

Page 41: ...synchronously Range ID Relays 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 R...

Page 42: ...If two lines are ON at the same time each must be limited to 50 mA etc If more current and or a different voltage is required use a relay power amplifier or other matching circuitry to provide the ac...

Page 43: ...yte from the five small bottles into a larger container 4 Sparge the electrolyte with nitrogen gas at a flow of 100 CCM for about 1 2 hour then pour into the provided wash bottle 5 Ref to Figure 3 7 f...

Page 44: ...utes Make sure the gas flow rate is within 0 5 1 SLPM Power up the system and conduct the Self Diagnostic Test as described in Chapter 4 Section 4 3 5 It takes two minutes for the microprocessor to te...

Page 45: ...ations frequently encountering oxygen levels above 100 ppm TAI s Micro Fuel Cell type of oxygen sensor is recommended The maximum working range with a background of nitrogen gas is 100 ppm The maximum...

Page 46: ...Installation BDS 3000 Teledyne Analytical Instruments 32...

Page 47: ...autoranging or select a fixed range of analysis as required Set alarm setpoints and modes of alarm operation latching failsafe etc Before you configure your BDS 3000 these default values are in effect...

Page 48: ...via the function buttons The six function buttons on the analyzer are Analyze This is the normal operating mode The analyzer monitors the oxygen content of the sample displays the percent of oxygen an...

Page 49: ...Oxygen Analyzer Operation Teledyne Analytical Instruments 35 Figure 4 1 Hierarchy of Functions and Subfunctions...

Page 50: ...Installing or Changing the Password below for a table of ASCII characters available Once a unique password is assigned and activated the operator MUST enter the UNIQUE password to gain access to set...

Page 51: ...GasBkgn Set the gas correction factor This function adjusts the calibration of the sensor when the background gas is changed Trbsht Displays useful information for troubleshooting purposes TempComp C...

Page 52: ...ing HOLD or TRACK But when HOLD is selected the concentration alarms will remain frozen for the time displayed in the second line of the TRAK HLD menu after the analyzer returns to the Analyze mode Th...

Page 53: ...o then press ENTER again You won t be able to set OFF to ON if a zero interval is entered A Span Every or Zero Every screen appears Span Every 0 d Start 0 h from now Use __ arrows to set an interval v...

Page 54: ...will enter the default TETAI password for you Press System to enter the System mode TRAK HLD Auto Cal PSWD Logout More Use the __arrow keys to scroll the blinking over to PSWD and press ENTER to selec...

Page 55: ...ss ENTER to change the password either the default TETAI or the previously assigned password or press ESCAPE to keep the existing password and move on If you chose ENTER to change the password the pas...

Page 56: ...our password and press ENTER when finished Your password will be stored in the microprocessor and the system will immediately switch to the Analyze screen and you now have access to all instrument fun...

Page 57: ...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...

Page 58: ...Function The response time on the most sensitive range ppb range is user definable from approximately 1 60 minutes The adjustable filter allows the user to tune the response of the analyzer to best ba...

Page 59: ...change of output This is helpful when the gas background needs to be changed and only a calibration bottle with nitrogen background is used The default setting is 1 00 for nitrogen gas background To s...

Page 60: ...s the SYSTEM key and access the Trbsht on the third screen GasBkgnd TempComp Trbsht Press the ENTER key The VFD display will scroll through four screens with a five seconds delay each The values shown...

Page 61: ...3 12 Extended Analog Output Function To access this function press the SYSTEM key to enter it s menu Select the More function to move on to the second screen of the system menu Version Diag Xout Neg...

Page 62: ...l do this temperature compensation without the need to enter a coefficient The BDS Sensor baseline exhibits temperature dependency too and it is different from sensor to sensor A temperature coefficie...

Page 63: ...mbient temperature over a minimum period of 24 hours Take the maximum and minimum readings and the maximum and minimum temperature readings 4 Calculate the coefficient using the relation Coefficient O...

Page 64: ...or improved accuracy If so desired the analyzer is equipped to provide this function However we do not recommend carrying out the cal zero during the first 10 days of the operation of the cell The ZER...

Page 65: ...of the slope is not very sensitive it is recommended that zero gas be purging a few minutes before starting the Auto mode zeroing This will ensure cell stability on the new Zero settings 4 4 1 2 MANU...

Page 66: ...concentration Span calibration can also be performed in manual mode where the operator determines when the span concentration reading is acceptable and manually exits the function 4 4 2 1 AUTO MODE SP...

Page 67: ...nt automatically returns to the analyze mode 4 4 2 2 MANUAL MODE SPANNING Press SPAN to start the Span function The screen that appears allows you to select whether the span calibration is to be perfo...

Page 68: ...s 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 O2 the span will not be accepted The analyzer will return to the previous...

Page 69: ...hich 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 concentra...

Page 70: ...ake sure that AL 1 is blinking AL 1 AL 2 Choose Alarm Set up alarm 1 by moving the blinking over to AL 1 using the __ arrow keys Then press ENTER to move to the next screen AL 1 10 000 ppm HI Dft N Fs...

Page 71: ...t 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...

Page 72: ...ppb or ppm units depending on concentration All concentration data outputs change from ppb units to ppm when the concentration is above 1 0 ppm Range Low L is always a ppb range and cannot be set high...

Page 73: ...8 Signal Output The standard Model BDS 3000 Oxygen Analyzer is equipped with two 0 1 VDC analog output terminals accessible on the back panel one concentration and one range ID and two isolated 4 20...

Page 74: ...ration 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...

Page 75: ...Oxygen Analyzer Operation Teledyne Analytical Instruments 61 Table 4 3 Range ID Output Range Voltage V Current mA LO 0 25 8 MED 0 50 12 HI 0 75 16 0 1000 ppm 1 00 20...

Page 76: ...Operation BDS 3000 Teledyne Analytical Instruments 62 Figure 4 2 Analyzer Power up Sequence...

Page 77: ...Oxygen Analyzer Operation Teledyne Analytical Instruments 63 Figure 4 3 Analyzer Span Sequence...

Page 78: ...Operation BDS 3000 Teledyne Analytical Instruments 64 Figure 4 4 Analyzer Zero Sequence...

Page 79: ...ically When the electrolyte level is low only de ionized water or distilled water should be added into the sensor It typically takes about four months to dry the electrolyte from the MAX line to the M...

Page 80: ...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 S...

Page 81: ...g Fuse Block from Housing American Fuses European Fuses Figure 5 3 Installing Fuses 5 4 System Self Diagnostic Test 1 Press the SYSTEM button to enter the system mode 2 Use the __arrow keys to move to...

Page 82: ...Major Internal Components The Sensor is accessed by unlatching and swinging open the front panel as described earlier Other internal components are accessed by removing the rear panel and sliding out...

Page 83: ...oprocessor Displays 5 digit LED meter 2 line 20 character alphanumeric VFD display RS 232 Communications Port See the drawings in the Drawings section in back of this manual for details Figure 5 4 Rea...

Page 84: ...4 Noise signal 3 5 Slow response 5 Causes and solution keys 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...

Page 85: ...y a vacuum degas process as shown in the Figure 5 5 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 v...

Page 86: ...Maintenance BDS 3000 Teledyne Analytical Instruments 72...

Page 87: ...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 Ranges T...

Page 88: ...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...

Page 89: ...0 pin D sub interface connector 50 CP1799 Pins for CP1798 connector 1 B597 125ml wash bottle for DI water 1 B598 125ml electrolyte bottle 1 P1076 Pipet 1 B72098 BDS sensor recovery kit Note Orders for...

Page 90: ...Appendix BDS 3000 Teledyne Analytical Instruments 76 A 3 Drawing List D 71902 Outline Diagram A 4 19 inch Relay Rack Panel Mount Figure A 1 Single 19 Rack Mount dimensions in mm...

Page 91: ...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 O2 changes in the sample stream The spa...

Page 92: ...Appendix BDS 3000 Teledyne Analytical Instruments 78...

Page 93: ...91749 Phone 626 961 9221 Technical Support 626 934 1673 Environment Health and Safety 626 934 1592 Date Prepared 11 23 98 Section II Physical and Chemical Data Chemical and Common Names Potassium Hyd...

Page 94: ...ffects 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 D...

Page 95: ...e event that a cell leaks Protective clothing Rubber gloves chemical splash goggles Clean up procedures Wipe down the area several times with a wet paper towel Use a fresh towel each time Protective m...

Page 96: ...Appendix MSDS Teledyne Analytical Instruments 82...

Page 97: ...g 2 57 available characters 42 background gas 12 BDS sensor 7 30 73 acid gas exposure 13 advantage of 8 cross section 9 current 15 damage 22 filling 28 maintenance 13 output 10 11 12 22 stability 13 B...

Page 98: ...8 Filter 37 filter function 44 fixed range 57 See range flow diagram 14 flow restriction device See restrictor flowmeter 4 14 calibration 12 flowrate 10 22 77 form C relay contacts 24 front panel 2 20...

Page 99: ...ge ID 6 15 27 38 rear panel 5 21 69 recovery time 11 reduction equation 8 reference electrode 7 10 refilling the sensor 29 regulator 22 remote calibration connection 26 remote calibration protocol 26...

Page 100: ...arm See alarm TRACK 38 tracking readings 37 TRAK HLD 37 Trbsht 37 troubleshooting 70 ultra trace 30 universal power source 5 universal power supply 15 22 74 vacuum degas kit 71 vacuum fluorescent disp...

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