Buhler BA 4510 Installation And Operation Instructions Manual
Analysentechnik
Installation and Operation Instructions
Original instructions
Portable Oxygen Analyser
BA 4510
BE550013
09/2018
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
E-Mail: analyse@buehler-technologies.com
Internet: www.buehler-technologies.com
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: analyse@buehler-technologies.com
Read this instruction carefully prior to installation and/or use. Pay attention particularly to all advises and safety instructions to prevent injuries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2018
Document information
Document No...........................................................BE550013
Version.........................................................................09/2018
BA 4510
Table of Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended Use......................................................................................................................................................................................................... 2
1.2 Ordering instructions ........................................................................................................................................................................................ 2
1.3 Scope of delivery.................................................................................................................................................................................................. 2
1.4 BA 4510 Layout......................................................................................................................................................................................................2
1.4.1 Principle of Measurement .................................................................................................................................................................2
1.4.2 Measuring Requirements ..................................................................................................................................................................3
1.4.3 General Design ..................................................................................................................................................................................... 4
1.4.4 BA 4510 Layout...................................................................................................................................................................................... 6
2 Safety instructions.........................................................................................................................................................................................................8
2.1 Important Information......................................................................................................................................................................................8
2.2 General hazard warnings .................................................................................................................................................................................9
3 Transport and Storage................................................................................................................................................................................................ 10
4 Installation and connection....................................................................................................................................................................................... 11
4.1 Installation site requirements........................................................................................................................................................................ 11
4.2 Preparing for Operation................................................................................................................................................................................... 11
5 Operation and Parametrisation ...............................................................................................................................................................................13
5.1 Operation..............................................................................................................................................................................................................13
5.1.1 Switching On and Measurement Display ................................................................................................................................... 13
5.1.2 Setting the Sample Gas Flow Rate................................................................................................................................................. 13
5.1.3 Measurement Monitoring............................................................................................................................................................... 13
5.1.4 Status/Error Messages ......................................................................................................................................................................13
5.2 Parametrisation................................................................................................................................................................................................. 14
5.2.1 Adjustable Parameters ..................................................................................................................................................................... 14
5.2.2 Programming Menus........................................................................................................................................................................14
5.3 Calibration............................................................................................................................................................................................................17
5.3.1 Zero Gas Calibration.......................................................................................................................................................................... 17
5.3.2 Span Gas Calibration......................................................................................................................................................................... 17
6 Maintenance.................................................................................................................................................................................................................. 18
6.1 Replacing the Fuse ............................................................................................................................................................................................ 18
7 Service and repair.........................................................................................................................................................................................................20
7.1 Troubleshooting ............................................................................................................................................................................................... 20
8 Disposal............................................................................................................................................................................................................................21
9 Appendix.........................................................................................................................................................................................................................22
9.1 Technical Data ....................................................................................................................................................................................................22
9.2 Basics of using potentiometric ZrO2 solid electrolyte sensors in optimal combustion processes ...........................................23
9.3 Activated Carbon Filter: Description and Use........................................................................................................................................... 25
9.3.1 Filter Design .........................................................................................................................................................................................25
9.3.2 Filter use and functionality ............................................................................................................................................................ 26
9.3.3 Replacing the Activated Carbon.................................................................................................................................................... 26
10 Attached Documents................................................................................................................................................................................................... 27
iBühler Technologies GmbHBE550013 ◦ 09/2018
BA 4510
1 Introduction
1.1 Intended Use
The BA 4510 analyser is used for continuous measurement of the oxygen concentration of industrial, laboratory and inert gases
as well as in the process of mixing and manufacturing special forming gases. Here, in inert gases the concentration of free oxygen, and in gas mixtures the concentration of bonded oxygen can be measured. The oxygen content of sample gas is measured
and displayed continuously. Deviations from the configurable set points are signalled. The purity and required protective effect
of inert gases is monitored. So specific production processes under inert gas can be monitored.
1.2 Ordering instructions
Device model
Item no. Description
55 15 000 BA 4510
55 15 001 BA 4510 KIZ
1.3 Scope of delivery
– Analyser
– Product documentation
– Connection/mounting accessories (optional)
1.4 BA 4510 Layout
1.4.1 Principle of Measurement
Determining the oxygen concentration in gases is often an established requirement in gases in the industrial sector, but also in
laboratories. Gases with an obvious oxygen concentration which fluctuates based on the temperature are most commonly
measured. The BA 4510 uses the NERNST equation as the basis for determining the oxygen concentration in gases.
U
=
RT
zF
ln
p
O
p
O
2
,sample gas
2
,air
Where:
U: Cell voltage in mV
R: Molar gas constant, R=8.31441 J/mol*K
T: Measuring temperature in K
F: Faraday constant, F=9.6485*10
4
C/mol
z: Valency of involved ions
Po
2Air:
Partial pressure of oxygen on the reference electrode in dry air in Pa
Po
2samplegas:
Partial pressure of oxygen on the measuring electrode in sample gas in Pa
The BA 4510 has a sensor which uses the conductivity of oxide ions in zirconium dioxide ceramics with stabilising additives. The
conductivity of the oxide ions of zirconium dioxide increases exponentially with the temperature and reaches adequate values
above 600°C (1112°F).
The ceramic oxide ion conductor is used as a gas-tight tube through which gas to be measured is conducted. The ceramic tube is
axially symmetrical inside a thermally well-insulated electric oven. The electrodes of the galvanic measuring cell are platinum.
The electrode on the outside of the tube, surrounded by dry air, serves as a reference electrode with a constant, established electrode potential.
Provided the total pressures of the gasses are about equal at both electrodes, volume concentrations can be expected instead of
partial pressures. After adding the numeric value for the constants in equation
(I)
results in the following conditional equation
for the oxygen concentration.
2 Bühler Technologies GmbH BE550013 ◦ 09/2018
BA 4510
=
2
,air
=
20.64
U
T
U
T
φ
φ
φ
●
●
e
e
●
O
)(
)(
46.42
zF
R
O
2
,sample gas
O
2
,sample gas
Where:
Φ oxygen concentration in the sample gas in Vol.%
U: Potential difference in mV
T: Measuring temperature in K
20.64 oxygen concentration in air with a relative humidity of 50 % in Vol.%
1.4.2 Measuring Requirements
1.4.2.1 General Information
Sample gas can have free or bonded oxygen. Without sufficient "
free oxygen
" in addition to combustible gas components, a
chemical balance will occur on the hot board electrode. The cell then measures the concentration of the "
equilibrium oxygen
".
(The basics are explained in the appendix Basics of using potentiometric ZrO2 solid electrolyte sensors in optimal combustion
processes [> page23].)
Here the following dependencies apply:
U ~ T
Contains free oxygen
U
~
1
T
Contains bonded oxygen
The conditional equation
(II)
applies to both sample gases with free oxygen as well as for reduced gas mixtures which only con-
tain bonded oxygen, e.g. in H2/H2O or CO/CO2 mixtures.
1.4.2.2 Sample Gas Flow Rate
The sample gas flow rate must be between 5 and 10 L/h to ensure exact measurement. If the low flow rate is too low, the contamination effects of the gas lines (leaks, permeabilities, desorptions) will cause reading errors. If the flow rate is too high, asymmetric cooling of the sensor can cause measurement errors.
A differential pressure sensor measures the gas flow. When over- or underrunning the limit, the device will output an error message yet continue measuring.
When operating the device with the internal gas pump, the flow rate controls the pump. The gas flow will always be set to an
optimal flow rate of 7 L/h.
1.4.2.3 Measurement Accuracy
The manufacturer only guarantees a measuring error of < 5% (relative error) when measuring oxygen concentrations with an
order of 2*105 …10 ppm (this manual uses the unit ppm is used in the sense of Vol.-ppm). When measuring oxygen concentrations of 10…1 ppm, the relative error is under 5 % provided the gas supply has no leaks or permeabilities.
When measuring oxygen concentrations < 10 ppm, user must consider the following aspects when analysing the measured
value:
– composition of the sample gas (e.g. presence of reducing gas components)
– special production process conditions (e.g. material components)
– sample gas temperature
3Bühler Technologies GmbHBE550013 ◦ 09/2018
BA 4510
NOTICE
To minimise the measuring error when measuring minimal oxygen concentrations, ensure the following measurement and equipment requirements are met:
a) Choose a location for extracting the sample gas to rule out any layers forming at the
extraction site.
b) The transport path for the sample gas to the measuring cell must be as short as pos-
sible to prevent a shift in the chemical balance along the way as best possible.
c) All gas supply and discharge lines must be absolutely tight.
d) Measuring oxygen concentrations < 1000 ppm requires stainless steel lines.
e) If the sample gas contains reducing components (e.g. alcohols), the concentration of
free oxygen cannot be determined, as chemical reactions occur at the electrode. In
these cases it is advisable to pass the sample gas through an activated carbon filter
before the gas inlet.
1.4.3 General Design
1.4.3.1 General Overview
This device is available in a portable, compact laboratory design. The general structure of the device is shown in figure 1.
Pressure regulator
(needle valve, optional
Gas inlet
Gas outlet
Flow meter
Measuring cell
Diaphragm pumps
Analysis electronics with display
Data exchange
Fig.1: General layout, components
The sample gas is pushed into the measuring cell at minimal overpressure or, on the version with pump, suctioned through the
measuring cell. A needle valve and/or a pressure regulator can be installed before the gas inlet to control the flow rate. On the
version with pump the flow rate is kept at a constant by regulating the pump output.
4 Bühler Technologies GmbH BE550013 ◦ 09/2018
BA 4510
1.4.3.2 Solid Electrolyte Measuring Cell Design Principle
1 Ceramic tube
2 Ceramic cover for the reference electrode
3 Measuring electrode
4 Reference electrode
5 Thermocouple
6 Reference electrode connecting wire
7 Measuring electrode connecting wire
The measuring cell is a zirconium dioxide ceramic tube with two electrodes made from platinum wire. Inside the tube the
sample gas flows through is the measuring electrode. The electrode outside of the tube serves as reference electrode with constant electrode potential. The electrodes and the ceramic tube from a voltaic cell (solid electrolyte measuring cell).
For favourable oxide ions conductivity values of the zirconium dioxides and prevent interference reactions due to unbalance
with flammable components in the sample gas, the measuring cell is heated to 750 °C. A thermocouple on the measuring cell determines the current measuring temperature T. An electronic control circuit ensures a constant measuring temperature.
CAUTION Risk of overheating
Overheating will damage the device.
Heating results in heat loss in the inert gas measuring device. Therefore do not place
items on or in close proximity of the device.
The block diagram in the next chapter how measurements are processed electronically.
1.4.3.3 Electronic Processing of Measurements
The following block diagram outlines how signals are processed.
Measuring cell
Cell voltage
amplifier
Thermovoltage
amplifier
On-screen
keyboard
Heater
control
Microcontroller
Power
supply
0.8 A (resettable)
1.0 A
100...24 0V AC, 47...63 Hz
Relay output
RS232
Analog output
Measuring cell monitor
Fig.2: BA 4510 block diagram
5Bühler Technologies GmbHBE550013 ◦ 09/2018
BA 4510
1.4.4 BA 4510 Layout
1.4.4.1 Mechanical Design
All components (main electronics, flow meter, pump, mains filter, measuring cell) are located inside a portable housing.
1.4.4.2 Electric Supply
The BA 4510 connects to the mains via fixed cord set.
The BA 4510 is designed as a tabletop device. The operating position is horizontal with a maximum tilt of 30°.
1.4.4.3 Front
The displays and controls are located in the front. A display shows the measured value in Vol.% or Vol.-ppm, depending on the
value and programming.
1 Vol.% corresponds to 104 Vol.-ppm, 1 Vol.-ppm corresponds to 0.0001 Vol.%.
A light diode serves as status light and indicates specific operating conditions or warnings in colour and possibly flashing (see
Operation and Control)
On the right is the keyboard used to select the view or program the device.
1.4.4.4 Back panel
At the back of the device are the gas inlet and outlet, a d-sub port for the RS232 interface and the mains switch. The mains cable
is fixed to the device.
6 Bühler Technologies GmbH BE550013 ◦ 09/2018
BA 4510
1.4.4.5 Pin assignment
Serial port
RS232
Transfer rate max. 19200 baud, adjustable
Stopbits 1
Data bits 8
Parity none
Handshake without
Serial interface protocol (CR= carriage return)
Input Response Parameter
M2CR M2x.xxExxCR Oxygen concentration in ppm
A1CR A1xxxCR Cell voltage in mV
A2CR A2xxxCR Measuring temperature in °C
Error messages:
0 ERROR0 Transmission error
1 ERROR1 Warm up
2 ERROR2 Cell temperature too low
3 ERROR3 Thermocouple defect
4
5
6 ERROR6 System error
Analog output
Output
4 - 20 mA
Output
potential-free
Pin 1,2 measurement signal output 4-20 mA
Pin 3,4 potential-free connections for limit relays:
Note:
If the limit is breached, the limit relay opens and triggers a
general alarm.
7Bühler Technologies GmbHBE550013 ◦ 09/2018
BA 4510
2 Safety instructions
2.1 Important Information
Operation of the device is only valid if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technologies GmbH can not be held responsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep
this manual for later use.
Please particularly note the following analyser instructions:
– Always transport the equipment diligently and carefully. Strong impact and shock may damage the measuring cells in the
analyser or shorten their life!
– Disconnect from the mains before opening the device.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
In this manual, the following warning signs are used:
Warning against hazardous situations General notice
Warning against electrical voltage Disconnect from mains
Warning against respiration of toxic gases Wear respirator
Warning against acid and corrosive substances Wear eye/face protection
Warning against potentially explosive atmospheres Wear protection gloves
Warning against hot surface
8 Bühler Technologies GmbH BE550013 ◦ 09/2018
Loading...