Teledyne BDS-3960 - Manuals

BDS 3960 Teledyne Analytical Instruments ii 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 inwhole or in part, in any for...

Page 3 - iii; Specific Model Information; The instrument for which this manual was supplied may; Instrument Serial Number:; power

Oxygen Analyzer Teledyne Analytical Instruments iii 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. Anythat are incorporated in the ...

Page 4 - Safety Messages; GENERAL WARNING/CAUTION; Technician Symbol

BDS 3960 Teledyne Analytical Instruments iv Safety Messages Your safety and the safety of others is very important. We have provided many important safety messages in this manual. Please readthese messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Eac...

Page 5 - This manual provides information designed to guide you through

Oxygen Analyzer Teledyne Analytical Instruments v IF YOU USE THE ANALYZER IN A MANNER OTHERTHAN THAT FOR WHICH IT WAS INTENDED,UNPREDICTABLE BEHAVIOR COULD RESULTPOSSIBLY ACCOMPANIED WITH HAZARDOUSCONSEQUENCES. This manual provides information designed to guide you through the installation, calibrat...

Page 6 - Table of Contents

BDS 3960 Teledyne Analytical Instruments vi Table of Contents Safety Messages .......................................................................... iv Table of Contents ......................................................................... vi List of Figures.....................................

Page 7 - vii

Oxygen Analyzer Teledyne Analytical Instruments vii 3.2 Mounting the Analyzer 30 3.3 Rear Panel Connections 32 3.3.1 Gas Connections 32 3.3.2 Electrical Connections 33 3.3.2.1 Primary Input Power 34 3.3.2.2 50-Pin Equipment Interface Connector 34 3.4 Electrolyte Refill of BDS Sensor 39 3.5 Testing t...

Page 8 - viii

BDS 3960 Teledyne Analytical Instruments viii 4.9 Switching The Program Back To The Front 56 Maintenance................................................................................. 58 5.1 Routine Maintenance 58 5.2 Adding Water to the BDS Sensor 58 5.3 Fuse Replacement 59 5.4 Battery Backup Rep...

Page 9 - ix; List of Figures

Oxygen Analyzer Teledyne Analytical Instruments ix 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 ....................

Page 11 - xi; List of Tables

Oxygen Analyzer Teledyne Analytical Instruments xi List of Tables Table 3-1: Analog Output Connections ......................................... 35 Table 3-2: Alarm Relay Contact Pins ............................................ 36 Table 3-3: Remote Calibration Connections..............................

Page 12 - xii; DANGER; COMBUSTIBLE GAS USAGE

BDS 3960 Teledyne Analytical Instruments xii DANGER COMBUSTIBLE GAS USAGE WARNING This is a general purpose instrument designed for usage in anonhazardous area. It is the customer's responsibility toensure safety especially when combustible gases are beinganalyzed since the potential of gas leaks al...

Page 13 - Introduction; Overview

Oxygen Analyzer Introduction Teledyne Analytical Instruments 13 Introduction 1.1 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 ModelBDS 3960...

Page 15 - The meter display is a Light Emitting Diode

Oxygen Analyzer Introduction Teledyne Analytical Instruments 15 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 arelegible in any lighting. It produces a continuous readout from 0-999...

Page 16 - For access t o the BDS S ensor And pr essur e regul ator.

Introduction BDS 3960 Teledyne Analytical Instruments 16 Access Drawer: For access t o the BDS S ensor And pr essur e regul ator. T he f ront panel sli des out when the four thumb screws ar e loosened. Openi ng the int er ior gives access to most ci rcui t boards t oo. 1.5 Rear Panel (Equipment Inte...

Page 18 - Operational Theory

Operational Theory BDS 3960 Teledyne Analytical Instruments 18 Operational Theory 2.1 Introduction The analyzer is composed of four subsystems: • BDS Sensor • Sample System • Pocket PC • Electronic I/O Signal Processing and Display The sample system is designed to accept the sample gas and transport...

Page 20 - The main advantage of the BDS technology lies in the unique

Operational Theory BDS 3960 Teledyne Analytical Instruments 20 The main advantage of the BDS technology lies in the unique second potentiostat. It is designed to remove dissolved oxygen and otherimpurities in the electrolyte. It eliminates the internal backgroundcurrent which previously limited the ...

Page 21 - While the 2nd working electrode allows OH

Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 21 While the 2nd working electrode allows OH - to move through, it prevents the dissolved oxygen from the top portion of the sensor to reachthe sensing electrode. The reference electrode provides a potentialreference for both the sen...

Page 22 - Pressure; The analyzer is equipped with a pressure regulator as shown in; effect; The raw output from a BDS oxygen sensor has a temperature; Recovery from High Level Oxygen Exposure

Operational Theory BDS 3960 Teledyne Analytical Instruments 22 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 beopened. The inlet pressure should be regulated anywhere between 4 to50 psig. The senso...

Page 23 - Figure 2.4 Typical Purge-down Curve After Air Saturation

Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 23 Figure 2.4 Typical Purge-down Curve After Air Saturation S h or t e n i ng t h e ai r exp o s u r e wi l l al l o w a f a s t e r se ns o r r ec o v e r y. A ty p i c a l BD S se n s o r wi l l re c o v e r t o 1 pp m i n ap p r o...

Page 24 - The BDS oxygen sensor can tolerate exposure to acidic gases. Up

Operational Theory BDS 3960 Teledyne Analytical Instruments 24 hydrogen, it reads 100% lower. For example, when thefloat ball in the flowmeter is at 0.5 SLPM, the actual flowrate of hydrogen is about 1 SLPM. The BDS oxygen sensor can tolerate exposure to acidic gases. Up to 0.2% CO 2 has no effect t...

Page 25 - There is a Max line and Min Line clearly marked on the BDS sensor; Sample System; The sample system delivers gases to the BDS sensor from the

Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 25 There is a 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 addde-ionized water into the sensor whenever it is convenient. When running dry gas throu...

Page 26 - Note that instrument air at a pressure of 70 to 80 psig is needed to; Electronics and Signal Processing; In the presence of oxygen the sensor generates a current. A current

Operational Theory BDS 3960 Teledyne Analytical Instruments 26 Note that instrument air at a pressure of 70 to 80 psig is needed to activate the proper valves. Figure 2-6: Flow Diagram 2.4 Electronics and Signal Processing T he Model BDS 3960 Oxygen Analyzer uses an 8051 m icrocontr ol l er wi th 32...

Page 27 - The raw counts of the analog to digital converter for both the

Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 27 as the signal is passed to a second channel of the analog to digitalconverter. The raw counts of the analog to digital converter for both the oxygen sensor amplifier and temperature amplifier are sent to the PPCvia RS232 interface...

Page 28 - Figure 2-7: BDS 3960 Electronics Block Diagram

Operational Theory BDS 3960 Teledyne Analytical Instruments 28 Figure 2-7: BDS 3960 Electronics Block Diagram Temperature Sensor ADC DAC 8051 processor UART PocketPC BDS Sensor 0-1 VDC and4-20 masupportelectronics Alarm 1 Alarm 2 System Alarm LED Display Other Outputs Amplifiers

Page 30 - Installation; Unpacking the Analyzer

Installation BDS 3960 Teledyne Analytical Instruments 30 Installation Installation of the Model BDS 3960 Analyzer includes: • Unpacking • Mounting • Gas connections • Electrical connections • Filling the Sensor with Electrolyte. • Testing the system. 3.1 Unpacking the Analyzer Although the analyzer ...

Page 31 - Access to the electronics, the sensor, and sampling system is

Oxygen Analyzer Installation Teledyne Analytical Instruments 31 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 theanalyzer. The whole assembly will slide out toward the front. Allowclearan...

Page 32 - Rear Panel Connections; Figure 3-3: Rear Panel of the Model BDS 3960; Gas Connections

Installation BDS 3960 Teledyne Analytical Instruments 32 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 analogconcentration output. Figure 3-3: Rear Panel of the Model BDS 3960 3.3.1 Gas Connections T h e...

Page 33 - If greater sample flow is required for improved response time,; CAUTION: CONNECT VENT LINES TO 1/4” OR LARGER; The solenoid valves of the sampling system need air; CAUTION: PRESSURE HIGHER THAN 100 PSIG CAN DAMAGE; Electrical Connections; For safe connections, no uninsulated wiring should be able to come

Oxygen Analyzer Installation Teledyne Analytical Instruments 33 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 th...

Page 34 - The power cord receptacle and fuse block are located in the same

Installation BDS 3960 Teledyne Analytical Instruments 34 3.3.2.1 P RIMARY I NPUT P OWER 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'SCIRCUITRY AS LONG AS THE INSTRUMENT IS...

Page 35 - The nine alarm-circuit connector pins connect to the

Oxygen Analyzer Installation Teledyne Analytical Instruments 35 4–20 mA DC % Range: Current increases linearly withincreasing oxygen, from 4 mA at 0ppm to 20 mA at full scale ppm. (Fullscale = 100% of programmable range.) 4–20 mA dc Range ID: 8 mA = Low Range, 12 mA = MediumRange, 16 mA = High Range...

Page 36 - Remote Calibration Protocol

Installation BDS 3960 Teledyne Analytical Instruments 36 Threshold Alarm 2: • Can be configured as high (actuates when concentrationis above threshold), or low (actuates when concentrationis below threshold). • Can be configured as failsafe or nonfailsafe. • Can be configured as latching or nonlatch...

Page 37 - Table 3-3: Remote Calibration Connections; Pin; – Remote Zero; Remote Calibration Protocol:; To properly time the Digital Remote Cal

Oxygen Analyzer Installation Teledyne Analytical Instruments 37 Zero: • Floating input—5 to 24 V input across the + and – pinsputs the analyzer into the Zero mode. Either side may begrounded at the source of the signal. 0 to 1 volt across theterminals allows Zero mode to terminate when done. Asynchr...

Page 38 - Note: The Remote Valve connections (described below) provides; open

Installation BDS 3960 Teledyne Analytical Instruments 38 W h e n t h e c o n t a c t i s OP E N , t h e an a l y z e r i s an a l y z i n g , t h e R e m o t e Ca l I n p u t s ar e be i n g po l l e d , an d a ze r o or sp a n co m m a n d c a n be se n t . When the contact is CLOSED, the analyzer ...

Page 39 - Electrolyte Refill of BDS Sensor

Oxygen Analyzer Installation Teledyne Analytical Instruments 39 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 Cont...

Page 40 - Install the sensor cap.; Testing the System; Before plugging the instrument into the power source:

Installation BDS 3960 Teledyne Analytical Instruments 40 7. Pour the rest of the electrolyte into the sensor. Gas bubbles in thetop portion of the sensor do not affect the sensor performance.One bottle of electrolyte is sufficient to rise the electrolyte levelto the MAX line. For the rest of sensor ...

Page 41 - Powering Up the System; Start

Oxygen Analyzer Installation Teledyne Analytical Instruments 41 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 thesystem by turning on the switch on the rear. Then turn on the PPC bypressing the but...

Page 42 - Operation; Once the analyzer has been installed, it can be configured for your

Maintenance BDS 3960 Teledyne Analytical Instruments 42 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: • Calibrate the instrument. • Define the three user-selectable analysis ranges, then choos...

Page 43 - The Analyzer application; Alarm 1

Oxygen Analyzer Maintenance Teledyne Analytical Instruments 43 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 theinstrument to operate, the program must be launched as instructed insection 3.6. Wh...

Page 44 - The; System; Screen; System

Maintenance BDS 3960 Teledyne Analytical Instruments 44 • System . Pressing this button will open a second screen that consists of several variables that regulate the internaloperations of the analyzer. • Training Video . This buttons launches a video player. At this point you could view a short tra...

Page 45 - Span Factor displays a number which is a factor needed to convert

Oxygen Analyzer Maintenance Teledyne Analytical Instruments 45 amplifier. The range of this count is the same as the BDS sensor, 0000 to4095. The last digit is a status digit—zero indicates the I/O PCB is in normalmode. If the I/O PCB receives a remote command to zero or span, it will letthe PPC pro...

Page 47 - Special consideration on the working range:; Note: The coefficient is different from sensor to sensor. If the

Oxygen Analyzer Maintenance Teledyne Analytical Instruments 47 * Output normalized by calibrating with a span gas in N 2 . 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 newbackground gas. The BDS 3960 will make furthe...

Page 48 - Set Defaults; Parameter

Maintenance BDS 3960 Teledyne Analytical Instruments 48 3. After the sensor has been purged for at least two weeks and the baseline is stable, monitor the oxygen reading and ambienttemperature over a minimum period of 24 hours.Take the maximum and minimum oxygen readings, and themaximum and minimum ...

Page 49 - Calibration of the Analyzer; Zero Cal

Oxygen Analyzer Maintenance Teledyne Analytical Instruments 49 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 reset to the defaults or No ...

Page 50 - ZERO; ERROR; Span Cal; SPAN

Maintenance BDS 3960 Teledyne Analytical Instruments 50 A zero calibration is not recommended during the 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 eitherautomatically or manually. I...

Page 51 - Alarms; Function

Oxygen Analyzer Maintenance Teledyne Analytical Instruments 51 4.4.2.1 S PAN F AILURE 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 13.5nA/ppb O 2 , the span will not be accepted. The analyzer will return to the ...

Page 52 - defeated

Maintenance BDS 3960 Teledyne Analytical Instruments 52 2. Are either or both of the alarms to be configured as failsafe? In failsafe mode, the alarm relay de-energizes in an alarmcondition. For non-failsafe operation, the relay is energized inan alarm condition. You can set either or both of thecon...

Page 53 - Range; Front Panel; Setting the Analog Output Ranges

Oxygen Analyzer Maintenance Teledyne Analytical Instruments 53 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 noranges are defined by the user, the instrument defaults to: Range 1 = 0–100 ppbRange 2...

Page 54 - To Set the ranges to values different than the default, click on ‘Set

Maintenance BDS 3960 Teledyne Analytical Instruments 54 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. Figure 4.4: Range Setup Screen The first screen allows you to set range 1. If you click on the...

Page 55 - Fixed Range Analysis; Signal Output; Rear Panel; Voltage Signal

Oxygen Analyzer Maintenance Teledyne Analytical Instruments 55 as 0–1000 ppb, range 3 cannot be set as 0– 500 ppb sinceit 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 ...

Page 56 - The analog output signal has a voltage which depends on the; Switching The Program Back To The; There are times that the Analyzer program may drop out of sight

Maintenance BDS 3960 Teledyne Analytical Instruments 56 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 the oxygen concentration AND the currently activated analysis range. Torelate the signal output to the actual concentration, it...

Page 58 - Maintenance; Aside from normal cleaning and checking for leaks at the gas; Adding Water to the BDS Sensor; When running dry gas through the sensor, water is extracted from

Maintenance BDS 3960 Teledyne Analytical Instruments 58 Maintenance 5.1 Routine Maintenance Aside from normal cleaning and checking for leaks at the gas connections, routine maintenance is limited to refilling sensor withdeionized water, replace burned fuses, replace backup batteries for PPC,and rec...

Page 59 - Figure 5.1 Adding Water into the BDS sensor; Fuse Replacement; Place small screwdriver in notch, and pry cover off, as shown in

Oxygen Analyzer Maintenance Teledyne Analytical Instruments 59 Figure 5.1 Adding Water into the BDS sensor WARNING: THE SENSOR USED IN THE MODEL BDS 3960OXYGEN ANALYZER USES ELECTROLYTE WHICHCONTAINS POTASSIUM HYDROXIDE, THAT CAN BEHARMFUL IF TOUCHED, SWALLOWED, ORINHALED. AVOID CONTACT WITH ANY FLU...

Page 60 - Figure 5-2: Removing Fuse Block from Housing; Battery Backup Replacement; The software application running on the PPC is mantained when

Maintenance BDS 3960 Teledyne Analytical Instruments 60 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. Ifthe unit is powered down and the ...

Page 61 - Reinstalling Application software to PPC.; regsvrce

Oxygen Analyzer Maintenance Teledyne Analytical Instruments 61 5.5 Reinstalling Application software to PPC. If the applications software on the PPC becomes corrupt or is lost, it can be restored by Downloading the Analyzer program andcomponents. Before installing the software, you must have a softw...

Page 62 - Major Internal Components; Symptoms

Maintenance BDS 3960 Teledyne Analytical Instruments 62 10. Disconnect the serial cable and run the Analyzer program from the Start pull down menu to check for successful installation. 5.5 Major Internal Components The Sensor is accessed by l ooseni ng the thumbscrew on the front panel and slidi ng ...

Page 63 - SYSTEM; Just after adding water:; from Teledyne Analytical Instruments.

Oxygen Analyzer Maintenance Teledyne Analytical Instruments 63 Read higher than expected (1), (2), (3) Read lower than expected (2), (3) Read negative (3), (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 ga...

Page 64 - Figure 5-3: Vacuum Degassing for the BDS Oxygen Sensor

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

Page 66 - Appendix; Specifications; General Purpose

Appendix BDS 3960 Teledyne Analytical Instruments 66 Appendix A-1 Specifications Packaging: General Purpose • Flush panel mount (Standard). Sensor: Teledyne BDS Sensor, patent pending. Sample System: All wetted parts of 316 stainless steel withbuilt-in in pressure regulator, oxygenscrubber and calib...

Page 68 - Recommended 2-Year Spare Parts List; Part Number Description; Note: Orders for replacement parts should include the part; TELEDYNE Analytical Instruments

Appendix BDS 3960 Teledyne Analytical Instruments 68 A-2 Recommended 2-Year Spare Parts List Qty. Part Number Description 1 C65507B Back Panel Board 1 C72914A Front Panel Board 1 C72000A Preamplifier Board (Instruction) 1 B71997A Main Computer Board 2 F1296 Fuse, 2A, 250V 5x20mm (European) Slow Blow...

Page 69 - Drawing List

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 - Application notes; Pressure and flow recommendations:; Note: The MSDS on this material is available upon request

Appendix BDS 3960 Teledyne Analytical Instruments 70 A-5 Application notes Pressure and flow recommendations: 3960 series analyzers require reasonably regulated sample pressures. While the 3960 analyzers are not sensitive to variations ofincoming pressure (provided they are properly vented to atmosp...

Page 71 - Material Safety Data Sheet; Section I - Product Identification; Environment, Health and; Section II - Physical and Chemical Data; Chemical and Common; Completely soluble

Oxygen Analyzer Appendix Teledyne Analytical Instruments 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 Technologie...

Page 72 - Section IV - Health Hazard Data

Appendix BDS 3960 Teledyne Analytical Instruments 72 Section III -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-fuelCells. Potential for reactivity: The sensors are stable unde...

Page 73 - Section VI - Handling Information; Protective measures

Oxygen Analyzer Appendix Teledyne Analytical Instruments 73 Section V - Emergency and First Aid Procedures Eye Contact: Flush eyes with water for at least 15 minutesand get immediate medical attention. Skin Contact: Wash affected area with plenty of water andremove contaminated clothing. If burningp...

Page 74 - Index

Appendix BDS 3960 Teledyne Analytical Instruments 74 Index acces s d oo r, 16accuracy, 67 ActiveSync, 61adding electrolyte, 39adding water, 59 address, 68, See company address Ag/Ag 2 O electrode, 19 air saturation, 22alarm, 51 , 66 concentration, 14, 16failure, 14, 51 high, 36low, 36relay, 35, 51 r...