Teledyne BDS-3960 Operating Instructions Manual Download Page 8

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BDS 3960

Teledyne Analytical Instruments

viii

4.9

Switching The Program Back To The Front

Maintenance................................................................................. 58

5.1

Routine Maintenance

5.2

Adding Water to the BDS Sensor

5.3

Fuse Replacement

5.4

Battery Backup Replacement

5.5 Reinstalling Application software to PPC.

5.5

Major Internal Components

5.6

Cleaning

5.7

Troubleshooting

Appendix ...................................................................................... 66

A-1

Specifications

A-2

Recommended 2-Year Spare Parts List

A-3

Drawing List

A-4

19-inch Relay Rack Panel Mount

A-5

Application notes

Material Safety Data Sheet

Index............................................................................................. 74

Summary of Contents for BDS-3960

Page 1: ...ent 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 a...

Page 2: ...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...

Page 3: ...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...

Page 4: ...y 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 and und...

Page 5: ...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...

Page 6: ...tor Interface 14 1 5 Rear Panel Equipment Interface 16 Operational Theory 18 2 1 Introduction 18 2 2 BDS Sensor 18 2 2 1 Principles of Operation 18 2 2 2 Gas Flow Rate 21 2 2 3 Gas Pressure 22 2 2 4 T...

Page 7: ...on 42 4 2 The Analyzer application 43 4 3 The System Screen 44 4 3 1 Communication Information and Calibration Parameters 44 4 3 2 Setting Software Parameters Filter Gas Factor Tmp Coeff 45 4 3 2 1 Th...

Page 8: ...3 Fuse Replacement 59 5 4 Battery Backup Replacement 60 5 5 Reinstalling Application software to PPC 61 5 5 Major Internal Components 62 5 6 Cleaning 62 5 7 Troubleshooting 62 Appendix 66 A 1 Specific...

Page 9: ...I 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 Figur...

Page 10: ...BDS 3960 Teledyne Analytical Instruments x Figure 5 3 Vacuum Degassing for the BDS Oxygen Sensor 64 Figure A 1 Single 19 Rack Mount dimensions in mm 69...

Page 11: ...ections 35 Table 3 2 Alarm Relay Contact Pins 36 Table 3 3 Remote Calibration Connections 37 Table 3 4 Range ID Relay Connections 39 Table 4 1 Gas Factor for Selected Gases 46 Table 4 2 Parameter Defa...

Page 12: ...aks 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 unau...

Page 13: ...nketing Air separation and liquefaction Chemical reaction monitoring Semiconductor manufacturing Petrochemical process control Quality assurance Gas analysis certification 1 3 Main Features of the Ana...

Page 14: ...ountable case with slide out electronics drawer 1 4 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...

Page 15: ...n 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...

Page 16: ...lable through the 50 pin equipment interface connector User connections made at the rear panel include Power Connection 110 VAC power source 220 VAC optional Gas Inlet and Outlet One inlet and one exh...

Page 17: ...Oxygen Analyzer Introduction Teledyne Analytical Instruments 17 Figure 1 2 Model BDS 3960 Rear Panel...

Page 18: ...l 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...

Page 19: ...te 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 contr...

Page 20: ...rol 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...

Page 21: ...ytical 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 To learn more about poten...

Page 22: ...into the electrolyte and cause damage to the BDS sensor Pressure Regulator BDS Sensor Flowmeter Vent Oxygen Scrubber Sample Inlet Span Inlet Figure 2 3 A simplified BDS Sample System 2 2 4 Temperature...

Page 23: ...itrogen 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...

Page 24: ...ly 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 Mai...

Page 25: ...olyte 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...

Page 26: ...o 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 th...

Page 27: ...fter 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 sig...

Page 28: ...ytical Instruments 28 Figure 2 7 BDS 3960 Electronics Block Diagram Temperature Sensor ADC DAC 8051 processor UART Pocket PC BDS Sensor 0 1 VDC and 4 20 ma support electronics Alarm 1 Alarm 2 System A...

Page 29: ...Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 29...

Page 30: ...f 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 u...

Page 31: ...accomplished by loosening the thumbscrews on the front of the analyzer The whole assembly will slide out toward the front Allow clearance for the assembly to slide out when maintenance is required Lea...

Page 32: ...ith 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...

Page 33: ...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 ne...

Page 34: ...re to install the proper fuse as part of installation See Fuse Replacement in Chapter 5 Maintenance 3 3 2 2 50 PIN EQUIPMENT INTERFACE CONNECTOR Figure 3 4 shows the pin layout of the Equipment Interf...

Page 35: ...ground 24 Range 0 1 V dc 7 Range 0 1 V dc negative ground Alarm Relays The nine alarm circuit connector pins connect to the internal alarm relay contacts Each set of three pins provides one set of For...

Page 36: ...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 Contact 45 Threshold Alarm 1 normally closed contact 28...

Page 37: ...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 appr...

Page 38: ...se 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...

Page 39: ...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 2 Unscrew the sensor cap and disconnect sensor cable from the BDS s...

Page 40: ...ic 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 Check the integrity and accuracy of the gas conne...

Page 41: ...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 progra...

Page 42: ...Define the three user selectable analysis ranges then choose autoranging or select a fixed range of analysis as required Set alarm setpoints and modes of alarm operation latching failsafe etc Before...

Page 43: ...aunched the main screen will appear as shown below Figure 4 1 Main Menu The screen shows controls that should be familiar to anyone who has used a personal computer Alarm 1 Pressing this button opens...

Page 44: ...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...

Page 45: ...nvert 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...

Page 46: ...is 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 diffu...

Page 47: ...ne 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 PPC It requires no input from the user The se...

Page 48: ...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 z...

Page 49: ...e 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 Cal The BDS Sensor has a zero offset of le...

Page 50: ...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...

Page 51: ...ns 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 by the operat...

Page 52: ...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 cond...

Page 53: ...ls 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 au...

Page 54: ...rst 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 r...

Page 55: ...en 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 5...

Page 56: ...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 Ta...

Page 57: ...s 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 S...

Page 58: ...hecked periodically 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...

Page 59: ...HALED 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 M...

Page 60: ...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 fl...

Page 61: ...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 vbce...

Page 62: ...DS 3960 contains the following major components Analysis Section Sensor with stainless steel wetted parts Sample system Power Supply PCB Microprocessor base I O board with amplifier daughter board LED...

Page 63: ...ts 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...

Page 64: ...Maintenance BDS 3960 Teledyne Analytical Instruments 64 Figure 5 3 Vacuum Degassing for the BDS Oxygen Sensor...

Page 65: ...Oxygen Analyzer Maintenance Teledyne Analytical Instruments 65...

Page 66: ...seconds on 1000ppb range Software programmable response in 100 ppb range from 1 minute to 60 minutes Default is 5 minutes response time Ranges Three user definable ranges from 0 100 ppb to 0 100 ppm...

Page 67: ...cifications are contingent upon the completion of zero and span calibration All accuracy is established at constant pressure and equilibrium has been established Analog outputs 0 1 VDC percent of rang...

Page 68: ...ins 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 1 CP2237 PDA cradle 1 C58750 Oxygen Scrubber Note Orders f...

Page 69: ...Oxygen Analyzer Appendix Teledyne Analytical Instruments 69 A 3 Drawing List D 73299 Outline Diagram A 4 19 inch Relay Rack Panel Mount Figure A 1 Single 19 Rack Mount dimensions in mm...

Page 70: ...asically 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 span fl...

Page 71: ...ry CA 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 Potassiu...

Page 72: ...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...

Page 73: ...in the 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 Protect...

Page 74: ...24 advantage of 20 cross section 20 current 26 damage 32 filling 39 maintenance 24 output 21 22 23 32 stability 24 BDS sensor output output correction 23 bipotentiostat See BDS sensor block diagram 2...

Page 75: ...utlet 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 model informa...

Page 76: ...output concentration 27 signal processing 18 26 software reinstallation 61 solenoid valve external 16 SPAN 14 SPAN 50 span calibration 50 failure 50 51 span gas concentration 49 spare parts listing 6...

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