Teledyne BDS-3960 User Manual

Oxygen Analyzer
OPERATING INSTRUCTIONS FOR
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Oxygen Analyzer
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P/N M71903
9/04/02
ECO # 02-232
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.
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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 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.
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Oxygen Analyzer
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
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BDS 3960
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.
No
Symbol
CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE
NOTE: Additional information and comments regarding a specific component or procedure are highlighted in the form of a note.
PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL.
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Oxygen Analyzer
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.
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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
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Oxygen Analyzer
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
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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
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Oxygen Analyzer
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
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Figure 5-3: Vacuum Degassing for the BDS Oxygen Sensor....... 64
Figure A-1: Single 19" Rack Mount (dimensions in mm) ............... 69
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Oxygen Analyzer
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
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BDS 3960
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.
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Oxygen Analyzer Introduction
Introduction
1.1 Overview
The Teledyne Analytical Instruments Model BDS 3960 Oxygen Analyzer is a versatile instrument for detecting oxygen at the parts-per­billion (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.
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Introduction BDS 3960
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.
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Oxygen Analyzer Introduction
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.
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Introduction BDS 3960
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.
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Oxygen Analyzer Introduction
Figure 1-2: Model BDS 3960 Rear Panel
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Operational Theory BDS 3960
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
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Oxygen Analyzer Operational Theory
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/Ag2O 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
+ 2H2O + 4e
2
-
— > 4OH
-
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- — > O2 + 2H2 O + 4e
-
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.
(1)
( 2)
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Operational Theory BDS 3960
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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Oxygen Analyzer Operational Theory
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.
NOTE: BDS technology and sensor is a patent pending
technology of Teledyne Analytical 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 potentiostat, visit Electochemical Society’s web page at http://www.electrochem.org
2.2.2 Gas Flow Rate
The output from a BDS oxygen sensor is relatively insensitive to change of gas flow rate if operated in the range of 1 - 3 SCFH (in nitrogen). The output drops when the flow rate is below 1 SCFH. Figure
2.2 is a typical curve showing the sensor outputs at different flow rate.
Figure 2.2: BDS sensor output at different gas flow rate
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Operational Theory BDS 3960
O
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. The sensor is not affected by pressure changes in the inlet as long as the analyzer vents to atmosphere. If the analyzer is not vented to atmosphere, the downstream pressure must not exceed 10 inch of water. A clogged or restricted vent or excessive pressure will force gas into the electrolyte and cause damage to the BDS sensor.
xygen Scrubber
Vent
Sample
Inlet
Span
Inlet
Pressure Regulator
Flowmeter
BDS Sensor
Figure 2-3: A simplified BDS Sample System
2.2.4 Temperature effect
The raw output from a BDS oxygen sensor has a temperature coefficient about 0.25% / °C. That is an average value, it changes as temperature changes. This temperature effect is compensated by the software throughout the operation temperature range (5 – 40°C).
2.2.5 Recovery from High Level Oxygen Exposure
The ambient air contains about 210,000,000 ppb (2.1 x 108) oxygen. Figure 2.4 is a typical purge-down curve for a new BDS sensor which had been air saturated. It is normal to take several hours, even days for an air saturated BDS to purge down to a low ppb level.
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Oxygen Analyzer Operational Theory
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 ox i m a t el y 25 m i nu t e s , t o 10 0 pp b af t e r 80 m i n , an d 10 pp b i n ab ou t 8 ho u r s , af t e r s u f f e r i n g a t e n- m i n u t e ex p os u r e to ai r .
2.2.6 Background Gas Compatibility
T he BDS oxygen sensor wi l l work in i ner t gas backgr ounds, i ncludi ng ni t rogen, hydr ogen, ar gon, heli um and ethane. The sensor out put, however, i s dif fer ent in di ff erent backgr ound gases. For exam pl e, t he sensor output i n a hydr ogen background is twi ce as much as it woul d be in a ni tr ogen background. Therefor e, i t is recom mended to cali br ate t he analyzer wit h an oxygen standar d that has a sim il ar background as the sam pl e gas. If an oxygen st andar d is unavai l able for a par ti cul ar background, a Gas F act or which is det er mi ned at TAI coul d be used t o cor rect the sensor out put in dif f er ent backgr ound (see sect ion 4.3.9) .
Note: the gas flow meter in the analyzer is calibrated for air. The
error for measuring nitrogen is usually negligible. But for
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