Instruction/ maintenance manual of the product BDS-3960 Teledyne
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Oxygen Analyzer Teledyne Analytical Instruments i OPERA TING INSTRUCTIONS FOR M M M M O O O O D D D D E E E E L L L L B B B B D D D D S S S S - - - - 3 3 3 3 9 9 9 9 6 6 6 6 0 0 0 0 Oxygen Analyzer DANGER Tox ic g a se s a nd o r fla mm a bl e liq ui ds ma y be pr es e nt i n this mon it or ing s y ste m.
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 retri.
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.
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.
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.
BDS 3960 Teledyne Analytical Instruments vi Table of Contents Safety Messages .......................................................................... iv Table of Contents ......................................................................... vi List of Figures .
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.
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.
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 .
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) .
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 .
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.
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.
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.
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.
Introduction BDS 3960 Teledyne Analytical Instruments 16 Ac ces s D raw er: Fo r a cce ss t o t he B DS S enso r And p r ess ur e re gul at or. T h e f r ont p anel sli de s out w he n the fo ur t humb scr ews ar e l oos ened . Open i ng t he i nt e r ior gives a cces s t o m ost ci rcu i t boards t oo.
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 • Elect.
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.
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.
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 reach the sensing electrode. The reference electrode provides a potential reference for both the sensing electrode and the 2nd working electrode.
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 be opened. The inlet pressure should be regulated anywhere between 4 to 50 psig.
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.
Operational Theory BDS 3960 Teledyne Analytical Instruments 24 hydrogen, it reads 100% lower. For example, when the float ball in the flowmeter is at 0.5 SLPM, the actual flow rate of hydrogen is about 1 SLPM. The BDS oxygen sensor can tolerate exposure to acidic gases.
Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 25 The re i s a Max line and Min Lin e clearly ma r ked on the BDS s ens or body. It is a good pr ac tice to chec k the el ectrolyte le vel every mont h and ad d de-ioni zed wate r into t h e s ensor wh enever i t is con v eni ent.
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.
Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 27 as the signal is passed to a second channel of the analog to digital converter. The raw counts of the analog to digital converter for both the oxygen sensor amplifier and temperature amplifier are sent to the PPC via RS232 interface once every second along with a status byte.
Operational Theory BDS 3960 Teledyne Analytical 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 su.
Oxygen Analyzer Operational Theory Teledyne Analytical Instruments 29.
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.
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 the analyzer. The whole assembly will slide out toward the front.
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 analog concentration output. Figure 3-3: Rear Panel of the Model BDS 3960 3.
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 the analyzer goes into the span mode.
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'S CIRCUITRY AS LONG AS THE INSTRUMENT IS CONNECTED TO THE POWER SOURCE.
Oxygen Analyzer Installation Teledyne Analytical Instruments 35 4–20 mA DC % Range: Current increases linearly with increasing oxygen, from 4 mA at 0 ppm to 20 mA at full scale ppm. (Full scale = 100% of programmable range.) 4–20 mA dc Range ID: 8 mA = Low Range, 12 mA = Medium Range, 16 mA = High Range, 20 mA = 100ppm.
Installation BDS 3960 Teledyne Analytical Instruments 36 Threshold Alarm 2: • Can be configured as high (actuates when concentration is above threshold), or low (actuates when concentration is below threshold). • Can be configured as failsafe or nonfailsafe.
Oxygen Analyzer Installation Teledyne Analytical Instruments 37 Zero: • Floating input—5 to 24 V input across the + and – pins puts the analyzer into the Zero mode. Either side may be grounded at the source of the signal. 0 to 1 volt across the terminals allows Zero mode to terminate when done.
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 .
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 Contact (Over range) 3.
Installation BDS 3960 Teledyne Analytical Instruments 40 7. Pour the rest of the electrolyte into the sensor. Gas bubbles in the top portion of the sensor do not affect the sensor performance. One bottle of electrolyte is sufficient to rise the electrolyte level to the MAX line.
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 the system by turning on the switch on the rear.
Maintenance BDS 3960 Teledyne Analytical Instruments 42 Operation 4.1 Introduction Once the analyzer has been installed, it can be configured for your application.
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 the instrument to operate, the program must be launched as instructed in section 3.
Maintenance BDS 3960 Teledyne Analytical Instruments 44 • System . Pressing this button will open a second screen that consists of several variables that regulate the internal operations of the analyzer. • Training Video . This buttons launches a video player.
Oxygen Analyzer Maintenance Teledyne Analytical Instruments 45 amplifi er . The range of this count is the s ame as the B DS s enso r, 0 000 to 4095. The l ast digit is a s tatus di git—zero ind icates t h e I/O P CB is in nor mal mod e.
Maintenance BDS 3960 Teledyne Analytical Instruments 46 Figure 4.2: Parameter Selection Box 4.3.2.1 T HE D IGIT AL F ILTER The Analyzer software performs a digital operation to reduce the noise from the BDS sensor and amplifier. This filtering is reduced to around 10 ppb.
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 new background gas.
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 ambient temperature over a minimum period of 24 hours. Take the maximum and minimum oxygen readings, and the maximum and minimum temperature readings.
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.
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 either automatically or manually.
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 13.5 nA/ppb O 2 , the span will not be accepted.
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 alarm condition. For non-failsafe operation, the relay is energized in an alarm condition.
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.
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.
Oxygen Analyzer Maintenance Teledyne Analytical Instruments 55 as 0–1000 ppb, range 3 cannot be set as 0– 500 ppb since it is lower than range 2. Note: Refer to Section 4.
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.
Oxygen Analyzer Maintenance Teledyne Analytical Instruments 57 displayed. This is because windows CE® does not allow two instances of the same program.
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 with deionized water, replace burned fuses, replace backup batteries for PPC, and recalibration.
Oxygen Analyzer Maintenance Teledyne Analytical Instruments 59 Figure 5.1 Adding Water into the BDS sensor WARNING: THE SENSOR USED IN THE MODEL BDS 3960 OXYGEN ANALYZER USES ELECTROLYTE WHICH CONTAINS POTASSIUM HYDROXIDE, THAT CAN BE HARMFUL IF TOUCHED, SWALLOWED, OR INHALED.
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.
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 and components.
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 Se ns or is a ccess e d by l ooseni ng the thumbscrew on the f ront panel and slidi ng it o ut, as described e arlier.
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 gas regulator for the sampling system.
Maintenance BDS 3960 Teledyne Analytical Instruments 64 Figure 5-3: Vacuum Degassing for the BDS Oxygen Sensor.
Oxygen Analyzer Maintenance Teledyne Analytical Instruments 65.
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 with built-in in pressure regulator, oxygen scrubber and calibration valves.
Oxygen Analyzer Appendix Teledyne Analytical Instruments 67 Operating Temperature: 5-40 °C Accuracy: ±2% of full scale for all ranges at constant temperature. All accuracy specifications are contingent upon the completion of zero and span calibration.
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.
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).
Appendix BDS 3960 Teledyne Analytical Instruments 70 A-5 Application notes Pressure and flow recommendations: 3960 series analyzers require reasonably regulated sample pressures.
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 e.
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-fuel Cells. Potential for reactivity: The sensors are stable under normal conditions of use.
Oxygen Analyzer Appendix Teledyne Analytical Instruments 73 Section V - Emergency and First Aid Procedures Eye Contact: Flush eyes with water for at least 15 minutes and get immediate medical attention. Skin Contact: Wash affected area with plenty of water and remove contaminated clothing.
Appendix BDS 3960 Teledyne Analytical Instruments 74 Index ac ces s d oo r, 16 accuracy, 67 ActiveSync, 61 adding electrolyte, 39 adding water, 59 address, 68, See company address Ag/Ag 2 O electrode,.
Oxygen Analyzer Index Teledyne Analytical Instruments 75 digital to analog converter, 26 dimensions, 67 , 69 d is pl ay , 26, 66 dissolved oxygen, 20 door.
Appendix BDS 3960 Teledyne Analytical Instruments 76 reference electrode, 18, 21 refilling the sensor, 39 regulator, 32 remote calibration connection, 37 remote calibration protocol, 37 remote probe, 16 response time, 33, 66 reticulated vitreous carbon, 20 RFI, 14 ROM, 13, 26 safety information, iv sample flow.
An important point after buying a device Teledyne BDS-3960 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Teledyne BDS-3960 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Teledyne BDS-3960 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Teledyne BDS-3960 you will learn all the available features of the product, as well as information on its operation. The information that you get Teledyne BDS-3960 will certainly help you make a decision on the purchase.
If you already are a holder of Teledyne BDS-3960, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Teledyne BDS-3960.
However, one of the most important roles played by the user manual is to help in solving problems with Teledyne BDS-3960. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Teledyne BDS-3960 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
