Teledyne BDS-3960 User manual

Oxygen Analyzer

Teledyne Analytical Instruments i

OPERATING INSTRUCTIONS FOR

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Oxygen Analyzer

DANGER

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.

P/N M71903

9/04/02

ECO # 02-232

BDS 3960

Teledyne Analytical Instruments ii

stored in a retrieval system, or translated into any other language or computer language in

whole or in part, in any form or by any means, whether it be electronic, mechanical,

magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne

Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-1580.

Warranty

This equipment is sold subject to the mutual agreement that it is warranted by us free from

defects of material and of construction, and that our liability shall be limited to replacing or

repairing at our factory (without charge, except for transportation), or at customer plant at

our option, any material or construction in which defects become apparent within one year

from the date of shipment, except in cases where quotations or acknowledgements provide

for a shorter period. Components manufactured by others bear the warranty of their

manufacturer. This warranty does not cover defects caused by wear, accident, misuse,

neglect or repairs other than those performed by Teledyne or an authorized service center.

We assume no liability for direct or indirect damages of any kind and the purchaser by the

acceptance of the equipment will assume all liability for any damage which may result from

its use or misuse.

We reserve the right to employ any suitable material in the manufacture of our apparatus,

and to make any alterations in the dimensions, shape or weight of any parts, in so far as

such alterations do not adversely affect our warranty.

Important Notice

T hi s in str ument p ro v id es measur ement read in g s to it s user, an d serv es as a to o l b y w h i c h

v al uabl e d at a can b e g at h er ed . The i n fo rmat i on p r ov id ed by t h e in st r umen t may assi st th e user

i n el imi nati n g po ten ti al hazard s cau sed b y his p r ocess; ho wev er , it is essent ial t hat all

p er so nn el in v ol ved in th e u se o f t he in st ru men t or it s int er f ace, wi th t h e pr ocess b ein g

measu red , be pr op er l y tr ain ed i n t he pr ocess i tself , as well as all in s t r u m e n t a t io n rel at ed to i t .

The safety of personnel is ultimately the responsibility of those who control process

conditions. While this instrument may be able to provide early warning of imminent

danger, it has no control over process conditions, and it can be misused. In particular, any

alarm or control systems installed must be tested and understood, both as to how they

operate and as to how they can be defeated. 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.

Therefore, the purchaser must be aware of the hazardous process conditions. The purchaser

is responsible for the training of personnel, for providing hazard warning methods and

instrumentation per the appropriate standards, and for ensuring that hazard warning devices

and instrumentation are maintained and operated properly.

Teledyne Analytical Instruments, the manufacturer of this instrument, cannot accept

responsibility for conditions beyond its knowledge and control. No statement expressed or

implied by this document or any information disseminated by the manufacturer or its

agents, is to be construed as a warranty of adequate safety control under the user’s process

conditions.

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. 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 Instrument with the Above Serial Number:

• 220 VAC: Instrument configured 200-240 VAC, 50/60Hz

power

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 read

these messages carefully.

A safety message alerts you to potential hazards that could hurt you

or others. Each safety message is associated with a safety alert symbol.

These symbols are found in the manual and inside the instrument. The

definition of these symbols is described below:

GENERAL WARNING/CAUTION: Refer to the

instructions for details on the specific danger. These cautions

warn of specific procedures which if not followed could cause

bodily 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 and

underlying tissue.

WARNING: ELECTRICAL SHOCK HAZARD: Dangerous

voltages appear within this instrument. This warning is

specific to an electrical hazard existing at or nearby the

component or procedure under discussion. Failure to heed this

warning could result in injury and/or death from

electrocution.

Technician Symbol: All operations marked with this symbol

are to be performed by qualified maintenance personnel only.

NOTE: Additional information and comments regarding a

specific component or procedure are highlighted in the form

of a note.

CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE

PURPOSE AND IN THE MANNER DESCRIBED IN

THIS MANUAL.

No

Symbol

Oxygen Analyzer

Teledyne Analytical Instruments v

IF YOU USE THE ANALYZER IN A MANNER OTHER

THAN THAT FOR WHICH IT WAS INTENDED,

UNPREDICTABLE BEHAVIOR COULD RESULT

POSSIBLY ACCOMPANIED WITH HAZARDOUS

CONSEQUENCES.

This manual provides information designed to guide you through

the installation, calibration and operation of your new analyzer. Please

read this manual and keep 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 information in

the form of an Addendum which discusses specific information,

procedures, cautions and warnings that may be peculiar to your

instrument.

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.

BDS 3960

Teledyne Analytical Instruments vi

Table of Contents

Safety Messages .......................................................................... iv

Table of Contents ......................................................................... vi

List of Figures............................................................................... ix

List of Tables ................................................................................ xi

Introduction ................................................................................. 13

1.1 Overview 13

1.2 Typical Applications 13

1.3 Main Features of the Analyzer 13

1.4 Front Panel (Operator 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 Temperature effect 22

2.2.5 Recovery from High Level Oxygen Exposure 22

2.2.6 Background Gas Compatibility 23

2.2.7 Stability 24

2.2.8 Maintenance 24

2.3 Sample System 25

2.4 Electronics and Signal Processing 26

Installation ................................................................................... 30

3.1 Unpacking the Analyzer 30

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 the System 40

3.6 Powering Up the System 41

Operation ..................................................................................... 42

4.1 Introduction 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 The Digital Filter 46

4.3.2.2 The Gas Factor 46

4.3.2.3 Temperature Coefficient 47

4.3.2.4 Set Defaults 48

4.4 Calibration of the Analyzer 49

4.4.1 Zero Cal 49

4.4.1.1 Zero Failure 50

4.4.2 Span Cal 50

4.4.2.1 Span Failure 51

4.5 The Alarms Function 51

4.6 The Range Function 53

4.6.1 Setting the Analog Output Ranges 53

4.6.2 Fixed Range Analysis 55

4.8 Signal Output 55

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 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 Specifications 66

A-2 Recommended 2-Year Spare Parts List 68

A-3 Drawing List 69

A-4 19-inch Relay Rack Panel Mount 69

A-5 Application notes 70

Material Safety Data Sheet 71

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

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 ................. 20

Figure 2.2: BDS sensor output at different gas flow rate ............... 21

Figure 2-3: A simplified BDS Sample System ............................... 22

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

Figure 2.5: Adding DI 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

Figure 3-3: Rear Panel of the Model BDS 3960 ........................... 32

Figure 3-4: Equipment Interface Connector Pin Arrangement....... 34

Figure 3-5: Adding Electrolyte to the BDS Sensor....................... 40

Figure 4-1: Main Menu .................................................................. 43

Figure 4.2: Parameter Selection Box............................................. 46

Figure 4.3: Range Options List Box............................................... 54

Figure 4.4: Range Setup Screen ................................................... 54

Figure 5.1 Adding Water into the BDS sensor............................... 59

Figure 5-2: Removing Fuse Block from Housing ........................... 60

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

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.................................. 37

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

BDS 3960

Teledyne Analytical Instruments xii

DANGER

COMBUSTIBLE GAS USAGE

WARNING

This is a general purpose instrument designed for usage in a

nonhazardous area. It is the customer's responsibility to

ensure safety especially when combustible gases are being

analyzed since the potential of gas 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 unauthorized substitution of any component may

adversely affect the safety of this instrument.

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.

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 Model

BDS 3960 General Purpose flush-panel and/or rack-mount units only.

These units are for indoor use in a non-hazardous environment.

1.2 Typical Applications

A few typical applications of the Model BDS 3960 are:

• Monitoring inert gas blanketing

• Air separation and liquefaction

• Chemical reaction monitoring

• Semiconductor manufacturing

• Petrochemical process control

• Quality assurance

• Gas analysis certification.

1.3 Main Features of the Analyzer

The Model BDS 3960 Oxygen Analyzer is sophisticated yet simple

to use. The main features of the analyzer include:

• Pocket PC with Windows CE operating system used as a

controller for analyzer functions.

• High resolution, accurate readings of oxygen content from

low ppb levels through 100 ppm. Large, bright, meter

readout.

• New BDS Sensing technology, patent pending.

• Versatile analysis over a wide range of applications.

• Microprocessor based electronics: 8-bit CMOS

microprocessor with 32 kB RAM and 8 kB ROM for I/O

operations.

Introduction BDS 3960

Teledyne Analytical Instruments 14

• Three user definable output ranges (from 0-100 ppb through

0-100 ppm) allow best match to users process and

equipment, plus a fixed 100 ppm over range.

• Auto Ranging allows analyzer to automatically select the

proper preset range for a given measurement. Manual

override allows the user to lock on to a specific range of

interest.

• Two adjustable concentration alarms and a system failure

alarm.

• Two way RFI protection.

• Four analog outputs: two for measurement (0–1 VDC and

Isolated 4–20 mA DC) and two for range identification.

• Convenient and versatile, steel, flush-panel or rack-

mountable 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. See Figure 1-1.

The front panel has the pocket PC, a digital meter, an alphanumeric

display, and a window for viewing the sample flowmeter.

There are no keys to press on the front panel. All interface with

the analyzer is done through the touchscreen of the pocket PC. The main

functions on the touchscreen are listed below.

• System Perform system-related tasks

(described in detail in chapter 4,

Operation.).

• Span Span calibrate the analyzer.

• Zero Zero calibrate the analyzer.

• Alarms Set the alarm setpoints and

attributes for Alarm 1 and Alarm 2.

• Range Set up the 3 user definable ranges

for the instrument.

• Quit Quit analyzer application.

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 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.

It is accurate across all analysis ranges without the discontinuity inherent

in analog range switching.

Flowmeter: Monitors the flow of gas past the sensor. Readout is 0.1 to

2.0 standard liters per minute (SLPM) of nitrogen

CAUTION: THE POWER CABLE MUST BE UNPLUGGED TO

FULLY DISCONNECT POWER FROM THE

INSTRUMENT. WHEN CHASSIS IS EXPOSED OR

WHEN ACCESS DOOR IS OPEN AND POWER

CABLE IS CONNECTED, USE EXTRA CARE TO

AVOID CONTACT WITH LIVE ELECTRICAL

CIRCUITS.

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 Interface)

The rear panel, shown in Figure 1-2, contains the gas and electrical

connectors for external inlets and outlets. The connectors are described

briefly here and in detail in Chapter 3 Installation. Except for gas, AC

power, and RS-232 communications I/O, all user connections for analog

output, alarms, calibration and remote probe contacts are available

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 exhaust out.

• Moisture By-pass Additional vent line for condensate

• Analog Outputs 0–1 VDC oxygen concentr ation plus

0-1 VDC r ange I D, and isolated

4–20 mA DC oxygen concentr ation

plus 4-20 mA DC range ID.

• Alarm Connections 2 concentration alarms and 1

system alarm.

• Remote Probe Used in the BDS 3960 for

controlling external solenoid

valves only.

• Remote Span/Zero Digital inputs allow external

control of analyzer calibration.

• Calibration 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, Cal.

Oxygen Analyzer Introduction

Teledyne Analytical Instruments 17

Figure 1-2: Model BDS 3960 Rear Panel

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 it through the analyzer without contaminating or altering the

sample prior to analysis. The BDS Sensor is an electrochemical device

that translates the amount of oxygen present in the sample into an

electrical current. The Pocket PC processes the sensor signal and sends

messages to the I/O electronics to correctly display oxygen value as well

as control other signals to the customer interface. The Electronic I/O

signal 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

interface.

2.2 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. A BDS oxygen sensor accurately translates the oxygen level in

the sample gas into to an electrical current signal.

A potentiostat contains three electrodes: a working electrode, a

reference electrode and a counter electrode. A Bipotentiostat is a

combination of two potentiostats that share the reference electrode and

the counter electrode. The potential at the working electrode is precisely

Oxygen Analyzer Operational Theory

Teledyne Analytical Instruments 19

controlled with respect to the reference electrode. The counter electrode

is used to carry the current that flow through the sensor. A potentiostat is

typically constructed with several operational amplifiers. The three

electrodes in an electrochemical cell and the operational amplifiers in

the potentiostat constitute a feedback-control loop. The potentiostat

technology has been well accepted in the field of electrochemistry, and

proven effective in eliminating polarization of the reference electrode

and automatic compensating electric resistance in the cell.

In a BDS oxygen sensor, the sensing electrode is a working

electrode that is under precise potential control as discussed above. A

stable sensing electrode potential is very critical for an oxygen sensor to

achieve high stability, low noise and large dynamic range. The reference

electrode in a BDS sensor is a Ag/Ag

2

O electrode which is well known

for its stable electrode potential and compatibility with the KOH

electrolyte 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 controlled

potential:

O

2

+ 2H

2

O + 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 counter electrode is:

4OH

-

—

>

O

2

+ 2H

2

O + 4e

-

( 2)

It is noteworthy that reaction (2) is reverse of the reaction (1). It is

indicative of a net change of zero inside a BDS sensor throughout the sensing

process. This feature produces a long-term stability for the BDS sensor.

There are two resources of oxygen being reduced at the sensing

electrode: from the sample gas and dissolved oxygen within the

electrolyte. The oxygen molecules in the sample gas diffuse to the

sensing electrode through a diffusion barrier (controlled diffusion) to

produce a current signal which is proportional to the oxygen level in the

sample gas. 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.

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 other

impurities in the electrolyte. It eliminates the internal background

current which previously limited the detection process.

The second potentiostat is located adjacent to the sensing electrode.

It uses a novel material, Reticulated Vitreous Carbon (RVC) and precise

control 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 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 enters the sensor through the gas inlet port and exits at the

gas outlet. A portion of oxygen in the sample gas diffuses through the

diffusion barrier to be reduced at the sensing electrode to form OH

-

in

the electrolyte. OH

-

can move freely through the porous 2nd working

electrode. At the counter electrode, OH

-

is oxidized back to oxygen.

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Teledyne BDS-3960 User manual

Teledyne BDS-3960 User manual

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