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Servomex Delta F Process Oxygen Analyzer Model DF-340E Instruction Manual
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Delta F Corporation
Process Oxygen Analyzer
Model DF-340E
P
P
M
Instruction Manual
Firmware Version 2.57
DELTA F CORPORATION
4 Constitution Way, Woburn, MA 01801-1087
Telephone: (781) 935-4600 FAX: (781) 938-0531
99000048
031611
The Delta F Difference
Your Process Oxygen Analyzer has been designed, manufactured and is
supported under ISO-9001 controls, thus helping to insure the highest possible
standards of quality.
Every analyzer that Delta F manufactures is tested and operated on a variety of
gas concentrations to insure that it functions properly when you receive it.
The certificate of calibration assures your analyzer has been calibrated on gases
that are traceable to NIST standards. With proper maintenance, your analyzer
should remain calibrated for years.
For a fast and successful startup, please read this manual carefully. There are
important cautions and a number of helpful hints to help you to optimize the
operation of your analyzer.
If you have questions, please do not hesitate to call Delta F Service Line at
(781) 935-5808, use our Service FAX Line at (781) 932-0053 or e-mail us at
Service@Delta-F.com.
Copyright 2011 by Delta F Corporation
No part of this publication may be reproduced, stored in a retrieval system or
transmitted in any form, or by any means including electronic, mechanical,
photocopying, recording or otherwise without prior written permission of
Delta F Corporation.
Stablex, Bi-Strata and are trademarks of Delta F Corporation. VCR is a
registered trademark of the Cajon Company.
Read Me First…
Unpacking Procedure
Follow the procedure below to unpack your Process Oxygen Analyzer.
1. Examine the condition of the packaging and its contents. If any damage
is apparent, immediately notify the carrier and Delta F. Do not proceed
with the installation.
2. Check the contents against the packing slip to make sure the shipment
is complete. Unattached equipment may be shipped with the analyzer in
supplemental packaging. Shortages should be reported to Delta F
immediately.
3. All POA analyzers are shipped with the following:
Item
Delta F Part Number
One bottle of Delta F Electrolyte
E-Lectrolyte Blue
One bottle of Delta F Replenishment Solution
Instruction Manual
RSA
99000048
4. Open the analyzer door, remove any shipping materials and verify that
nothing has come loose during transit.
5. Save the original container in the event you may need to ship the
analyzer to another location or back to the factory (see Shipping in the
Service section).
Installation and Maintenance
The DF-340E Process Oxygen Analyzer will provide years of accurate and
dependable service if it is set up, operated and maintained properly. It is
essential to make a careful and complete installation as outlined in the
Installation and Setup section of this manual
Thank You
Thank you for selecting the model DF-340E Process Oxygen Analyzer. Delta
F designs, manufactures, exhaustively tests, and supports every analyzer under
ISO-9001 control. You should expect every Delta F analyzer to arrive in
perfect working order and, with good maintenance, provide years of troublefree service. Please call the Service Phone Line at (781) 935-5808 if you need
assistance or if you have suggestions, or use our Service Fax Line at (781)
932-0053 or e-mail us at Service@Delta-F.com.
1
Table of Contents
1
Table of Contents .................................................................... 1
1.1
2
Cautions ................................................................................... 7
2.1
2.2
3
Symbols and Explanations ......................................................................................7
Important Warnings................................................................................................7
Specifications .......................................................................... 9
4
Installation and Setup............................................................ 13
4.1
4.2
4.3
4.4
4.5
4.6
5
Mounting the Enclosure........................................................................................13
Adding Electrolyte................................................................................................14
Sample Gas Connections.......................................................................................14
4.3.1 Purging the Analyzer ...............................................................................16
Electrical Power Connections................................................................................16
4.4.1 AC Input Voltage (100-240 VAC) ...........................................................17
4.4.2 DC Input Voltage (24 VDC) ....................................................................17
Power Control.......................................................................................................17
4.5.1 Startup Process ........................................................................................17
4.5.2 Powering Down .......................................................................................18
Standard Outputs ..................................................................................................18
Options ................................................................................... 21
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
6
Pump ....................................................................................................................21
5.1.1 Pump Control ..........................................................................................21
Battery Power .......................................................................................................22
Low Flow Alarm...................................................................................................22
Flow Control Valve...............................................................................................23
Filter.....................................................................................................................23
5.5.1 Filter/Regulator Mounting Bracket...........................................................24
Pressure Regulator ................................................................................................24
Filter/Regulator Combination................................................................................25
Stainless Steel Outlet Tubing ................................................................................25
4-20mA Analog Output ........................................................................................27
5.9.1 2-20mA Analog Output ...........................................................................27
Relays .................................................................................................................27
Communication Port – RS232/485 ......................................................................27
Expanded Range Scale ........................................................................................27
Electronics Enclosure with Z-Purge Protection ....................................................27
Sample Gas Preparation and Delivery ................................. 31
6.1
6.2
6.3
Index
Table of Figures......................................................................................................4
The STAB-EL Acid Gas System ...........................................................................31
Sample Gas Scale Factor.......................................................................................32
Sample Flow Rate and Pressure ............................................................................33
6.3.1 Flow Rate Effects on Sensor Performance ................................................34
6.3.2 Checking for Plumbing Leaks using Flow Rate Effects.............................34
6.3.3 Background Gas Effects on Indicated Flow Rate ......................................34
6.3.4 Regulator Requirements...........................................................................34
DF-340E
1
6.4
6.5
7
Connecting to External Devices............................................41
7.1
7.2
7.3
7.4
7.5
8
The Comm Port ....................................................................................................41
Relay Ports............................................................................................................41
Analog Outputs.....................................................................................................43
7.3.1 Analog Voltage Output ............................................................................43
7.3.2 4-20mA Output ........................................................................................44
7.3.3 Alignment Procedure for Analog Voltage and Current Loop Outputs .......44
Remote Controls ...................................................................................................45
7.4.1 Remote Sensor Control – J6 Connector ....................................................45
7.4.2 Remote Pump Control – J6 Connector......................................................46
Remote Sensor Installations ..................................................................................47
7.5.1 Sensor on Remote Bracket with Optional Pump .......................................48
7.5.2 Sensor in NEMA 4 Enclosure ..................................................................49
7.5.3 Sensor in NEMA 7 Enclosure ..................................................................50
7.5.4 Temperature Control in R4/R7 Enclosures ...............................................51
7.5.5 Remote Sensor Connections – Connector J7 .............................................52
7.5.6 Z-Purge Protection on R4 Enclosure.........................................................54
User Interface..........................................................................57
8.1
8.2
8.3
8.4
8.5
8.6
2
6.3.5 Pressure Regulator Purge .........................................................................35
6.3.6 Pressure Effects on Sensor Performance ...................................................35
6.3.7 Sample Outlet Backpressure Effects .........................................................36
Sample Gas Compatibility.....................................................................................36
6.4.1 Condensation ...........................................................................................37
6.4.2 Gas Solubility in Aqueous KOH Solution .................................................37
6.4.3 Reactivity with KOH Electrolyte ..............................................................37
6.4.4 Flammable Sample Gas............................................................................37
6.4.5 Trace acids in the sample gas ...................................................................38
6.4.6 Sample Gas Temperature .........................................................................38
6.4.7 Protecting the Analyzer from Process Upsets............................................38
Calibration Gas Considerations.............................................................................38
6.5.1 Calibration Standards...............................................................................39
6.5.2 Calibration Cylinder Regulators ...............................................................39
6.5.3 Purge Procedure .......................................................................................39
6.5.4 Sample Gas Delivery and Vent Pressure during Calibration .....................39
6.5.5 Background Gas Effects on Calibration ....................................................40
The Data Display Screen.......................................................................................57
Main Menu ...........................................................................................................61
8.2.1 Keypad Operation ....................................................................................62
Controls Menu ......................................................................................................62
8.3.1 Pump .......................................................................................................62
8.3.2 Sensor Polarization ..................................................................................63
8.3.3 SensOFF Relay.........................................................................................64
8.3.4 P(o)w(e)r UP............................................................................................64
8.3.5 ESC .........................................................................................................64
Set-Up Menu.........................................................................................................65
8.4.1 Alarms.....................................................................................................65
8.4.2 Analog Outputs........................................................................................68
8.4.3 Comm Port...............................................................................................71
8.4.4 Gas Scale Factor ......................................................................................72
8.4.5 Display Setup...........................................................................................72
8.4.6 Clock .......................................................................................................73
The Password Menu..............................................................................................73
Maintenance .........................................................................................................75
DF-340E
Index
8.6.1
8.6.2
8.6.3
9
Troubleshooting and Calibration ......................................... 89
9.1
9.2
9.3
9.4
9.5
10
10.1
10.2
11
11.1
11.2
Index
Replenish Solution Reminder...................................................................75
Oxygen Calibration..................................................................................76
Diagnostics ..............................................................................................83
Return Material Authorization Number.................................................................89
Maintenance .........................................................................................................89
9.2.1 Calibration...............................................................................................89
9.2.2 Storage Conditions...................................................................................90
9.2.3 Sensor Maintenance.................................................................................90
9.2.4 Procedure for Adding Replenishment Solution to the Sensor ....................91
Replaceable Parts List ...........................................................................................92
Troubleshooting....................................................................................................93
9.4.1 Sample System Leak Test (Low Flow Sensitivity) ....................................93
9.4.2 Basic Troubleshooting..............................................................................94
9.4.3 Fuse Replacement ....................................................................................97
Shipping ...............................................................................................................99
Theory of Operation ............................................................ 101
The Oxygen Sensor ........................................................................................... 101
The Electrolyte Conditioning System................................................................. 102
Safety .................................................................................... 103
Electrolyte Solution Material Safety Data Sheet................................................. 105
Replenishment Solution MSDS ......................................................................... 111
12
Warranty ............................................................................... 115
13
Index ..................................................................................... 117
DF-340E
3
1.1 Table of Figures
Figure 1: DF-340E Oxygen Analyzer ................................................................................. 12
Figure 2: Major Internal Components ................................................................................ 13
Figure 3: AC/DC Power Input Connections ....................................................................... 16
Figure 4: Power Control Switch ......................................................................................... 18
Figure 5: Data Display Screen ........................................................................................... 18
Figure 6: Electrical Connections ........................................................................................ 19
Figure 7: Filter and Mount................................................................................................. 23
Figure 8: Filter/Regulator Mounting Bracket ..................................................................... 24
Figure 9: Regulator and Mount .......................................................................................... 24
Figure 10: Filter/Regulator Combination and Mount.......................................................... 25
Figure 11: Plumbing Configuration Options ...................................................................... 26
Figure 12: Z Purge Option ................................................................................................. 29
Figure 13: J1/J2 Connector ................................................................................................ 42
Figure 14: J3/J4 Connector ................................................................................................ 43
Figure 15: J5/J6 Connector ................................................................................................ 44
Figure 16: Analog Output/4-20mA Adjustments................................................................ 45
Figure 17: External Control Connector – J6....................................................................... 45
Figure 18: Pump Control Connector – J4 ........................................................................... 47
Figure 19: Remote Sensor with Optional Pump.................................................................. 48
Figure 20: Remote Sensor Mounted in NEMA 4 Enclosure................................................ 49
Figure 21: Remote Sensor Mounted in NEMA 7 Enclosure................................................ 50
Figure 22: NEMA 7 Enclosure Mounting Dimensions ....................................................... 51
Figure 23: Temperature Control in R7 Enclosure............................................................... 52
Figure 24: Remote Sensor Connector – J7.......................................................................... 53
Figure 25: Remote Sensor/Pump Wiring Diagram ............................................................. 53
Figure 26: Z-Purge Protection on R4 Sensor Enclosure ...................................................... 55
Figure 27: Data Display..................................................................................................... 57
Figure 28: Main Menu....................................................................................................... 61
Figure 29: Controls Menu.................................................................................................. 62
Figure 30: Sensor Shut-off Warning .................................................................................. 64
Figure 31: Setup Menu ...................................................................................................... 65
Figure 32: Alarm Setup Menu ........................................................................................... 65
Figure 33: Oxygen Alarm Menu ........................................................................................ 66
Figure 34: Oxygen Alarm Setup Screen (Alarm not used).................................................. 66
Figure 35: Oxygen Alarm Setup Screen (Alarm used)........................................................ 67
Figure 36: Recorder Output Setup Menu............................................................................ 68
Figure 37: Recorder Output Setup Error............................................................................. 69
Figure 38: Comm Port Setup Menu.................................................................................... 71
Figure 39: Display Setup.................................................................................................... 72
Figure 40: Clock Setup Screen ........................................................................................... 73
Figure 41: Password Menu................................................................................................. 74
Figure 42: Password Entry Screen..................................................................................... 74
Figure 43: Maintenance Menu ........................................................................................... 75
Figure 44: Replenishment Solution Reminder .................................................................... 76
Figure 45: Oxygen Calibration Menu................................................................................. 76
Figure 46: Gas Scale Factor ............................................................................................... 78
Figure 47: Gas Scale Factor Menu (Cont’d) ....................................................................... 78
Figure 48: Span Check Menu............................................................................................. 80
Figure 49: Calibration Convergence Screen ....................................................................... 81
Figure 50: Completed Oxygen Calibration Menu ............................................................... 82
Figure 51: Diagnostics Menu ............................................................................................. 83
Figure 52: Sensor Zero Menu............................................................................................. 84
Figure 53: Zero Cal Warning Screen ................................................................................. 85
4
DF-340E
Index
Figure 54: Zero Cal Screen .................................................................................................85
Figure 55: Zero Cal Not Stable ...........................................................................................86
Figure 56: Test Output Screen ............................................................................................86
Figure 57: Test Relay Screen ..............................................................................................87
Figure 58: Memory Test Screen ..........................................................................................87
Figure 59: EXT Functions ..................................................................................................88
Figure 60: Fuse Locations for DC Power Supply and Battery Backup..................................98
Figure 61: Printed Circuit Board Assembly.........................................................................98
Figure 62: Schematic of Delta F Oxygen Sensor ...............................................................101
Index
DF-340E
5
2 Cautions
There are a number of warnings and cautions that must be observed to avoid
damage to the analyzer as well to insure the safety of its users. The analyzer
must be operated in a manner specified in this manual. Delta F cannot be
responsible for direct or consequential damages that result from installing or
operating the analyzer in a manner not described in this manual. Importantly,
the analyzer has been designed for use with inert, non-toxic, non-combustible
sample gases only. Delta F cannot be responsible for direct or consequential
damages that result from using the analyzer with these gases.
2.1 Symbols and Explanations
Following is a list of the various symbols used throughout this manual and their
definitions.
CAUTION
This symbol alerts the user to the presence of physically hazardous
conditions that may be dangerous to individuals or equipment.
NOTE
This symbol alerts the user to the presence of important operations
and/or maintenance information.
DANGER
This symbol alerts the user to the presence of caustic liquid. Refer to
the MSDS at the back of the manual for handling instructions.
2.2 Important Warnings
CAUTION
Do not setup or operate the Oxygen Analyzer without a complete
understanding of the instructions in this manual. Do not connect this
Analyzer to a power source until all signal and plumbing
connections are made.
CAUTION
This analyzer must be operated in a manner consistent with its
intended use and as specified in this manual.
Cautions
DF-340E
7
DANGER
The electrolyte is a caustic solution. Review the Material
Safety Data Sheet (MSDS) before handling the electrolyte
solution.
The sensor is shipped dry and must be charged with
electrolyte before it is operated.
CAUTION
Over-pressurizing the sensor can result in permanent damage to the
sensor. Limit the backpressure to the analyzer to ±1 psig.
Be sure the downstream isolation valve (if so equipped) is toggled
open before gas flow is started.
CAUTION
DO NOT SHIP THE ANALYZER WITH
ELECTROLYTE – THOROUGHLY DRAIN AND
RINSE SENSOR BEFORE SHIPPING
EMI DISCLAIMER
This Analyzer generates and uses small amounts of radio frequency
energy. There is no guarantee that interference to radio or television
signals will not occur in a particular installation. If interference is
experienced, turn-off the analyzer. If the interference disappears, try
one or more of the following methods to correct the problem:
Reorient the receiving antenna.
Move the instrument with respect to the receiver.
Place the analyzer and receiver on different AC circuits.
8
DF-340E
Cautions
3 Specifications
PERFORMANCE
ACCURACY
Standard Resolution: Greater of ± 3% of reading (not to exceed 1% of
range for % Analyzers) or 0.5% of range.
High Resolution: Greater of ±3% of reading (not to exceed 1% of
range for % range Analyzers) or ±0.02% of range (except ranges less than or
equal to100 ppm, ±3% of reading or ± 0.05% of range).
RESPONSE TIME
Typically less than 10 seconds to read 90% of a step change. Equilibrium time
depends on the specific conditions.
OXYGEN SENSITIVITY/LOW DETECTION LIMIT
3 ppb (340E-H0050M Model only)
RESOLUTION
Model
Range
Auto
Display
Auto
Display
Number
Scale A*
Scale B*
S00050
0-50 ppm
0-50 ppm
XX.XX
S00100
0-100 ppm
0-100 ppm
XXX.X
S00500
0-500 ppm
0-500 ppm
XXX.X
S01000
0-1000 ppm
0-1000 ppm
XXXX.
S05000
0-5000 ppm
0-5000 ppm
XXXX.
S10000
0-10000 ppm
0-10000 ppm
XXXXX
S000P5
0-5 %
0-5 %
X.XX
S00P10
0-10 %
0-10 %
XX.XX
S00P25
0-25 %
0-25 %
XX.X
H00100
0-100 ppm
0 - 10
XX.XX
10 - 100
XXX.X
H00500
0-500 ppm
0 - 50
XX.X
50 - 500
XXX.
H01000
0-1000 ppm
0 - 100
XXX.X
100 - 1000
XXXX.
H05000
0-5000 ppm
0 - 500
XXX.
500 - 5000
XXXX.
H10000
0-10000 ppm 0 - 1000 XXXX.
1000 - 10000
XXXXX
H000P5
0-5 %
0 - 0.5
.XXX%
0.5 - 5
X.XX
H00P10
0-10 %
0-1
X.XXX% 1 - 10
XX.XX
H00P25
0-25%
0 - 2.5
X.XX%
2.5 - 25
XX.X
*Scale A applies to High Resolution models only. Scale B extends down to 0
ppm or 0% on Standard Resolution models.
Specifications
DF-340E
9
OVERALL OPERATING TEMPERATURE RANGE
Gas sample:
32°F to 122°F (0°C to 50°C)
Sensor Temperature:
32°F to 113°F (0°C to 45°C)
Electronics Temperature:
w/sensor in enclosure: 32°F to 113°F (0°C to 45°C)
w/remote sensor: 32°F to 122°F (0°C to 50°C)
STORAGE TEMPERATURE
Not to exceed 122°F (50°C)
SENSOR TYPE
Non-depleting Coulometric
SENSOR WARRANTY
Five (5) years (limited)
ELECTRICAL, ALARMS & DISPLAY
ELECTRONICS
Microprocessor-based
DISPLAY
1.3 in (33mm) by 2.6 in (66mm) LCD graphics with backlighting
ALARMS
Audible and Displayed. Up to 7 optional alarms comprised of 4 oxygen,
temperature, low flow, and electrolyte condition.
STATUS CONDITIONS
Sensor Off, Check Fluid, Expanded Range (optional), In-Calibration status
conditions can be assigned to relays (optional).
OUTPUT
Software scalable, jumper selectable 0-5 or 0-10 VDC analog output.
Minimum load resistance is 1K.
Fully isolated 4-20 mA output. Maximum loop resistance is 1K Ohms. (29-33
VDC loop compliance voltage provided)
ALARM RELAYS
Up to four, rated at 0.3 A, 30 VDC under resistive load. Set points
independently adjustable. Contacts failsafe to alarm condition upon loss of
power. Not designed to switch AC power.
POWER REQUIREMENTS
100 – 240 VAC (auto-switching), 1.3A, 50/60 Hz or
10
DF-340E
Specifications
24 VDC (–2/+4VDC), 1A, 25 Watts; Optional Sample Pump 6 Watts
additional
EMI SENSITIVITY
Meets CISPR – 11(90) Class B Group 1 Standard
CONSTRUCTION
WEIGHT
30.0 lbs. (13.6kg) Standard Model (no options)
DIMENSIONS - Overall
14.0"w x 13.2"h x 11.5"d (35.6cm x 33.5cm x 29.0cm) (with handle and gas
fittings)
CE Approved
CSA Approved
GAS SAMPLE CONDITIONS
GAS CONNECTIONS
1/4" Compression inlet and outlet Standard
1/4" Metal-face-seal inlet (Optional)
SAMPLE INLET PRESSURE
0.2 psig to 1.0 psig
SAMPLE FLOW RATE
1.0 to 2.0 scfh standard operating limits
GAS COMPATIBILITY
Standard Sensor: All inert and passive gases, including N2, H2, CO, Ar, freons,
hydrocarbons, etc.
STAB-EL Sensor: Limited tolerance to gas compositions containing "acid"
gases such as CO2, H2S, Cl2, NOx, SO2, HCl, etc.
GAS SAMPLE MOISTURE CONTENT
No limit (avoid condensation)
OIL/SOLVENT MIST
<0.03 mg/L Standard limit
>0.03 mg/L Use filter
SOLID PARTICLES
<0.01 mg/L Standard limit, Use filter if >0.01 mg/L
Specifications
DF-340E
11
14.00 [355.6]
Ø.44 [Ø11.2]
2 PL
12.00 [304.8]
11.42 [290.2]
1/4 TURN
LATCH
P
P
M
12.00 [304.8]
13.41 [340.7]
13.24 [336.4]
13.17 [334.6]
.44 [11.2]
2 PL
1/4" COMPRESSION
SAMPLE INLET
(OPTIONAL 1/4" VCR COMPATABLE MALE)
1/4" COMPRESSION
SAMPLE OUTLET
4.38 [111.3]
2.25 [57.1]
1.44 [36.6]
AC OR DC
POWER INLET
7.69 [195.3]
8.71 [221.2]
3.01 [76.5]
8.99 [228.3]
Figure 1: DF-340E Oxygen Analyzer
12
DF-340E
Specifications
4 Installation and Setup
This oxygen analyzer has been installed in a NEMA 4 certified enclosure and
has been thoroughly tested and calibrated, however it is necessary to mount the
enclosure, make proper gas and electrical connections and to “charge” the
sensor prior to turning the analyzer on.
This procedure describes installation of the analyzer without options and with
the voltage output set to 0-10 VDC. Options may affect the setup procedure
described in this section. If your analyzer is equipped with options, refer to the
appropriate section to determine changes to the setup.
NOTE
The screens shown in this manual have values that may not match
the actual values displayed during your setup.
PUMP
ROTOMETER
ELECTROLYTE
RESERVOIR
WITH MAX - MIN
LINES
FLOW CONTROL
VALVE (FOR
VACUUM
APPLICATIONS)
FLOW CONTROL VALVE
(FOR POSITIVE PRESSURE
APPLICATIONS)
OXYGEN
SENSOR
SIGNAL OUTPUT
AC OR DC POWER
Figure 2: Major Internal Components
4.1 Mounting the Enclosure
The enclosure must be mounted according proper local codes with appropriate
hardware in an upright position with cable and plumbing connections on the
bottom. See Figure 1 for mounting hole locations.
The maximum allowable ambient temperature for the oxygen sensor is 110
Installation and Setup
DF-340E
13
degrees F (45 C). The enclosure must not be installed in areas of high heat
caused by radiation or convection.
If installed outdoors the enclosure must be shielded from the sun to avoid
overheating. In addition, a heater must be installed in the enclosure in areas
where the temperature goes below freezing.
4.2 Adding Electrolyte
DANGER
The electrolyte is a caustic solution. Review the Material Safety
Data Sheet (MSDS) before handling the electrolyte solution.
NOTE
The sensor is shipped dry and must be charged with electrolyte
before it is operated.
NOTE
Use only Delta F E-lectrolyte Blue for the DF-340E Oxygen
Analyzer. Failure to do so will void warranty. Install one bottle.
NOTE
Do not apply power before adding electrolyte and thoroughly
purging sample line.
1.
2.
3.
4.
Unscrew the cap from the electrolyte reservoir.
Add the entire contents of one bottle of E-lectrolyte Blue to the sensor.
Replace the cap and hand-tighten securely.
Allow the sensor to sit with electrolyte in it for approximately 60
minutes before flowing gas through the analyzer.
NOTE
For best performance at initial start or anytime the electrolyte is
changed, it is important to allow the sensor to sit with electrolyte in
it for 60 minutes before the gas is allowed to flow through the
sensor.
4.3 Sample Gas Connections
NOTE
For best performance at initial start or anytime the electrolyte is
changed, it is important to allow the sensor to sit with electrolyte in
it for 60 minutes before the gas is allowed to flow through the
sensor.
14
DF-340E
Installation and Setup
1. Connect the gas line to the 1/4 inch compression fitting (or optional ¼ inch
VCR fitting) marked sample inlet on the bottom of the enclosure. If
included, install the filter and regulator upstream of the gas inlet. See the
section on filter and regulator options starting on page 23. The filter should
always be first in line.
2. Open the door and slowly adjust the flow rate to 1.0 scfh as indicated on
the flowmeter using the flow control valve or pressure regulator. On
positive pressure installations do not control the flow with valve mounted
in the flowmeter (if equipped).
3. If a background gas other than nitrogen is being used, the “indicated” flow
rate must set the as shown in Table 1.
Background Gas
Flowmeter Setting (scfh)
Argon
1.2
Ethylene
1.0
Nitrogen or Air
1.0
Carbon Monoxide
1.0
Methane
0.8
Hydrogen
0.3
Helium
0.4
Table 1: Flowmeter Settings versus Background Gas
NOTE
For gas pressures between 1.0 and 5.0 psig use a high quality flow
control valve between the gas source and the analyzer to set the
flow rate. If ordered, the analyzer may have an optional Flow
Control Valve mounted on the sensor bracket.
For gas pressures above 5 psig use a high quality pressure
regulator to set the flow rate.
NOTE
Unless otherwise requested, the analyzer is factory calibrated on
nitrogen. Analyzer readings will be inaccurate if used with a
background gas other than the one for which it is calibrated. If the
analyzer was calibrated on a gas other than nitrogen, the gas will
be noted on the calibration log inside the front door and on a label
below the display.
Before connecting any gas line to the analyzer, fully install the supplied gas nut
and compression ferrule on your tubing. Connect the inlet and outlet lines to
the bulkhead fittings on the bottom of the analyzer. Do not over-tighten the
fittings.
Installation and Setup
DF-340E
15
4.3.1 Purging the Analyzer
Supply the analyzer with an N2 sample that is as low in O2 as possible.
If the analyzer outlet is at atmospheric pressure, a regulator can be used to set
the flow rate to 1.0 standard cubic feet per hour (scfh) without danger of overpressurizing the sensor. The back-pressure on the instrument should not
exceed ±1.0 psig. If the installation requires long (> 6 feet) tubing runs (or has
many bends or fittings) downstream of the analyzer, the resulting backpressure may impose a pressure at the sensor that exceeds specifications. If
this is the case reduce the complexity of the outlet gas line. See page 31 for
additional information on gas sample delivery.
NOTE
Over-pressurizing the sensor can result in permanent damage to the
sensor. Limit the backpressure to the analyzer to ±1 psig.
NOTE
Allow gas with very little oxygen to flow through the analyzer for
approximately 15 minutes before powering up.
4.4 Electrical Power Connections
CUSTOMER AC/DC POWER CONNECTION
Figure 3: AC/DC Power Input Connections
16
DF-340E
Installation and Setup
Pin #
N
G
L
AC INPUT
110 VAC 220 VAC
Neutral
Ground
Phase
Phase
Ground
Phase
Color
Blue
Green
Brown
DC INPUT
24 VDC
Color
+
White
Yellow
Table 2: Power Connector Wiring
4.4.1 AC Input Voltage (100-240 VAC)
Make sure the power switch is in the OFF position. Bring the cable through the
Type 370 Bullet Hub coupling at the bottom of the enclosure labeled Power to
the three pin power connector. See Figure 3 and Table 2 for connection
specifics. All wiring must be done according proper local codes. The power
supply is auto-switching which means it will run properly on an input voltage
between 100 VAC and 240 VAC.
4.4.2 DC Input Voltage (24 VDC)
Make sure the power switch is in the OFF position. Bring the 20 gauge wire
cable through the Type 370 Bullet Hub coupling at the bottom of the enclosure
labeled Power to the three pin power connector. See Figure 3 and Table 2 for
connection specifics. All wiring must be done according to proper local codes.
4.5 Power Control
Before applying power be sure there is pure gas running through the sensor.
AC Powered Units - Open the front door, locate the power switch and turn it
on. See Figure 4
DC Powered Units - Turn on the remote 24 VDC power source, open the
front door, locate the power switch and turn it on. See Figure 4.
4.5.1 Startup Process
After power up, the analyzer will undergo a series of Diagnostic Procedures.
After approximately 5 seconds, the Delta F Corporation logo is displayed.
After 30 seconds, a WAIT message appears for 1.5 minutes. A display then
appears that is similar to Figure 5 (values shown are only representative). The
analyzer may display OVER RANGE for the first couple of minutes. This is
normal even if the actual O2 concentration is within the range of the analyzer.
It should take less than 5 minutes for the analyzer to come on scale. The
concentration of oxygen is shown in percent (%) or parts per million (ppm)
and will slowly approach the current oxygen level. NOTE: If it takes longer
than 30 minutes to come on scale the sensor polarization voltage will
automatically be turned off. (See page 63 for additional information)
Installation and Setup
DF-340E
17
P
P
M
POWER SWITCH
AC OR DC
Figure 4: Power Control Switch
3.43
P
P
M
OUT : 0.0- 100.0
*Menu
GSF: 1.003
Figure 5: Data Display Screen
4.5.2 Powering Down
Locate the power switch inside the front door and turn it off. See Figure 4.
4.6 Standard Outputs
An output signal indicating oxygen concentration can be sent to other
instruments by using the optional fully-isolated 4-20 mA output or the standard
non-isolated 0-10 VDC analog voltage output. The analyzer is delivered with
18
DF-340E
Installation and Setup
the required mating connectors which are keyed to prevent accidental
interchange. The analog output connections are made through the Port J4 and
J5 on the rear panel as shown in Figure 6.
The standard analog voltage output is connected to pins J4-1 (AOUT+) and
J4-2 (AOUT-). The full scale analog output is set by a jumper to either 5 or 10
VDC as described on page 43.
See page 27 for information on the optional 4-20mA output.
Figure 6: Electrical Connections
Installation and Setup
DF-340E
19
5 Options
5.1 Pump
The On-board Pump allows the analyzer to operate on gas sample streams
between 2.0 psig vacuum and 2.0 psig positive pressure.
If the analyzer has a pump, it will also have a downstream Flow Control Valve
mounted in the bottom of the flow meter. When using the pump, always use
this downstream valve to control the gas flow rate and leave all up stream
valves wide open.
.
If the pump is not in use, (positive pressure application) always control the gas
flow with an upstream valve or regulator and leave all down stream valves
wide open.
CAUTION
Do not use an upstream valve to control flow if the analyzer is
operating on a pump.
5.1.1 Pump Control
The on-board pump, if equipped, can be controlled from the Controls Menu.
See page 62 for additional information.
In addition the following options are available:
If factory configured, Delta F will supply the standard pump that the user may
install remotely and power through the PUMP -, + (+24VDC) connections on
the rear panel connector J4. Control would be accomplished in the same
manner as an internal pump.
OR
If factory configured, a switch closure rated at 1A/30VDC can be supplied
between the PUMP -, + connections on the rear panel connector J4. The
contacts can be used to send a signal indicating the status of the internal pump
or to control an external, Delta F supplied pump that is powered from a
separate source.
OR
If factory configured the pump may be controlled remotely through the EXT
signal on the J6 connector. See the section on Remote Controls on page 46 for
additional information.
Options
DF-340E
21
5.2 Battery Power
Analyzers equipped with a battery pack (AC powered units only) can be
operated on battery power for four to eight hours, depending upon
configuration (see Table 3). Battery charging occurs only while the analyzer is
connected to power and the power switch is turned on. The batteries can be
charged while the instrument is not in service by turning off power to the
oxygen sensor. See the Controls Menu as shown in Figure 29. Approximately
12 hours is required to fully charge a battery pack and several charge and
discharge cycles may be required for optimum battery operation.
During battery operation “BAT” is displayed down the right side of the
display. When the battery power is low, “LOW” is displayed down the right
side of the display. In addition, the analyzer will beep. When the battery is too
low, the analyzer will shut down automatically.
When operating on AC power, and the battery is low, “CHG” is displayed on
the right side of the display. When the battery is fully charged nothing is
displayed down the right side of the display.
Turning off the backlighting conserves battery power.
Analyzer State
Length of Time the Battery
will Provide Power
Basic Analyzer (Outputs off, Backlight auto mode)
8 hours
Backlight on, outputs off
4 hours
Isolated Outputs on, Backlight off
6 hours
Backlight on, Isolated Outputs on
3.5 hours
Table 3: Battery Operation Time
NOTE
Use only Delta F P/N 16337070 when replacing the NiMH
battery pack.
In the event that the NiMH Battery Option is installed in an
analyzer that also has the Case Purge Option, the NiMH Battery
system must be disabled. This will enable the analyzer to shut down
properly in case the purge gas flow is reduced or lost completely.
5.3 Low Flow Alarm
The optional low flow alarm includes a flow switch that is located in the
enclosure on the right side. It is connected with vinyl tubing to the outlet of
the flowmeter. The option sounds an alarm when flow drops below a factoryset value. The switch can also be used with an optional alarm relay. See Figure
11 for examples of various Analyzer plumbing configurations. The optional
22
DF-340E
Options
low-flow switch is included in configurations c and d.
If the stainless steel outlet option is ordered with a low flow alarm, the flow
switch is mounted in the sample outlet line as part of the sensor assembly. A
2-pin connector is used to disconnect the switch from the analyzer.
5.4 Flow Control Valve
The upstream flow control valve is mounted behind the door and below the
Flow Indicator. It may be used to control the gas flow rate in positive pressure
installations where the inlet pressure is less than 5 psi. In addition, it may be
shut off to isolate the analyzer from the gas stream.
5.5 Filter
The filter assembly must be installed by the customer using techniques
appropriate for high purity gas flow.
Two grades of filter elements are available for the filter:
Fine grade (BQ) (< 1 micron)
Course grade (DQ) (> 1 micron)
The course grade is normally supplied. See page 92 for ordering information.
Note: The filter has two ports labeled 1 and 2. For particulate removal plumb
the filter with port 2 connected to the Analyzer's sample inlet fitting. For mist
coalescing and collection for draining, plumb the filter with port 1 connected to
the Analyzer's sample inlet fitting.
1.63 [41.3]
.81 [20.6]
.40 [10.2]
1/4" COMPRESSION
2 PL
1.19 [30.2]
1.18 [29.8]
(4.03 [102.3])
3.56 [90.4]
Figure 7: Filter and Mount
Options
DF-340E
23
5.5.1 Filter/Regulator Mounting Bracket
Ø.20 [Ø5.1]
3 PL
.06 [1.5]
3 PL
.06 [1.5]
3 PL
.40 [10.2]
.81 [20.6]
1.62 [41.3]
Figure 8: Filter/Regulator Mounting Bracket
5.6 Pressure Regulator
The regulator assembly must be installed by the customer using techniques
appropriate for high purity gas flow. NOTE: For additional information on the
proper purging regulators after installation see page 35. See Figure 8 for
details regarding the mounting of the regulator.
1.62 [41.3]
.81 [20.6]
1.19 [30.2]
.40 [10.2]
1/4" COMPRESSION
2 PL
1.55 [39.4]
SAMPLE
INLET
(4.94 [125.3])
3.90 [99.2]
Figure 9: Regulator and Mount
24
DF-340E
Options
5.7 Filter/Regulator Combination
The filter/regulator assembly must be installed by the customer using
techniques appropriate for high purity gas flow. It is supplied as a unit with one
mounting bracket and mounting screws. See Figure 8 for details regarding the
mounting of the filter/regulator assembly.
NOTE:The filter has two ports labeled 1 and 2. For particulate removal plumb
the filter with port 2 connected to the Analyzer's sample inlet fitting. For mist
coalescing and collection for draining, plumb the filter with port 1 connected to
the Analyzer's sample inlet fitting. See Figure 8 for details regarding the
mounting of the filter/regulator assembly.
NOTE: For additional information on the proper purging of regulators after
installation see page 35.
1.62 [41.3]
.81 [20.6]
1.19 [30.2]
.40 [10.2]
SAMPLE INLET
1.55 [39.4]
1/4" COMPRESSION
2 PL
(4.93 [125.3])
6.04 [153.5]
Figure 10: Filter/Regulator Combination and Mount
5.8 Stainless Steel Outlet Tubing
Analyzers can be equipped with a 1/8-inch compression stainless steel outlet
tube. When this option is provided, the analyzer cannot be equipped with the
quick-disconnect fitting at the flowmeter outlet. Because of the rigid outlet
tube, the Sensor Assembly can only be removed after both inlet and outlet
bulkhead retainer nuts are removed. A 7/16-inch wrench is needed for the inlet
nut; and a ½-inch wrench is used on the outlet nut. When reinstalling the
sensor, make sure both bulkhead fitting hex sections are oriented to seat in the
retainer blocks on the inside rear of the enclosure.
Options
DF-340E
25
Figure 11: Plumbing Configuration Options
26
DF-340E
Options
5.9 4-20mA Analog Output
The optional fully-isolated 4-20 mA output is completely isolated from all
other analog outputs and from earth ground. The maximum loop resistance is
1KThe 29-33 VDC compliance voltage is provided. Connections are made
at pins J5-1 (LOOP+) and J5-2 (LOOP-) at the back of the instrument. See
page 43 for additional information.
5.9.1 2-20mA Analog Output
If configured at the time of order, the optional 4-20mA output described above
can be reduced to 2mA when the Sensor is either turned off manually or turned
off automatically due to extended (30 minute) off scale oxygen readings. Use
of this function provides information than could be interpreted remotely as an
alarm or non-standard condition. See page 63 for additional information on the
Sensor Off function.
5.10 Relays
Up to four optional form C (SPDT) relays (contact closures) are available to
assign to alarms or system status flags. One or more alarms or status flags can
be assigned to one or more relays. The contacts are rated at 0.3A, 30 VDC
under a resistive load. Pin assignments provide relay connecting details. See
page 41 for additional information.
5.11 Communication Port – RS232/485
Either of two communication ports are available at the time of order: RS232C
or RS485. This option allows interfacing between the analyzer and other
operating systems. A “C” language software library package is available for
customized development of communication software. See page 41 for
additional information.
5.12 Expanded Range Scale
The optional expanded range scale allows the analog output scaling to be
automatically expanded to a larger value when the primary scaling range is
exceeded. See page 70 for additional information.
5.13 Electronics Enclosure with Z-Purge
Protection
Before applying power to the to the analyzer, the Z-Purge unit must be
installed and operating properly. For loss of purge protection, wire the Z-Purge
alarm contacts to a customer provided alarm. Normally open and normally
closed contacts are provided. Alternatively the contacts can be used to
interrupt the input power to the analyzer.
The switch requires either AC or DC input power, as indicated on the
faceplate. For installation and wiring instructions, see the manufacturers
information included with the switch.
NOTE: All electrical connections to the switch must be made according to
Options
DF-340E
27
applicable local and safety standards.
Procedure for setting pressure and flow through the enclosure:
1. Verify proper operation of the Z-Purge unit as described in this section,
while the environment is in a safe condition.
2. Remove the four cover screws on the Z-Purge pressure switch.
3. Check that the pressure calibration screw on the pressure switch is
backed out as far as possible to the minimum pressure setting of 0.15
inches of water. Check the enclosure pressure with a suitable
instrument if possible.
4. Close the Z-Purge pressure regulator (fully counter clock-wise)
5. Fully open the Z-Purge flowmeter needle valve. (fully clock-wise)
6. Open the instrument air/N2 supply to the Z-Purge regulator. (preregulated to the minimum pressure required to supply 50 scfh of flow
to the enclosure).
7. Open the Z-Purge regulator sufficiently to allow 50 scfh to the
enclosure.
8. Verify that the alarm pressure switch has been deactivated (is not in an
alarm condition).
9. Purge the enclosure for 15 minutes at 50 scfh.
10. Reduce the purge flow rate to a minimum of 5 to 10 scfh using the
flowmeter needle valve, making certain that the alarm pressure switch
remains deactivated (not in an alarm condition). If the purge switch
activates, confirm that the enclosure is “tight” and increase the flow
rate as necessary.
11. The analyzer may now be turned on.
28
DF-340E
Options
21.50 [546.1]
14.00 [355.6]
12.00 [304.8]
Ø.44 [Ø11.2]
2 PL
11.42 [290.2]
PURGE PROTECTION
STYSTEM (OPTIONAL)
REQUIRES 25-30 psig
INSTRUMENT AIR OR N
P
P
M
13.24 [336.4]
13.17 [334.6]
1/4" COMPRESSION
PURGE FEED
1/4" COMPRESSION
SAMPLE INLET
(OPTIONAL 1/4" VCR COMPATABLE MALE)
.44 [11.2]
2 PL
(2.20 [55.8])
1/4" COMPRESSION
SAMPLE OUTLET
1/4" COMPRESSION
PURGE FEED
4.38 [111.3]
3.41 [86.5]
2.25 [57.1]
1.44 [36.6]
AC OR DC
POWER INLET
1.19 [30.4]
7.69 [195.3]
8.71 [221.2]
3.01 [76.5]
8.99 [228.3]
Figure 12: Z Purge Option
Options
DF-340E
29
6 Sample Gas Preparation and
Delivery
6.1 The STAB-EL Acid Gas System
With the STAB-EL system oxygen measurements in sample gases containing
varying amounts of acid gases are possible. As a general guide, the data in
Table 5-1 represents the maximum allowable limits of acid gases under
continuous operation that can be tolerated with the STAB-EL system.
Measuring Range Of
Analyzer
0-50 ppm
0-100 ppm
0-500 ppm
0-1000 ppm
0-5000 ppm
0-10,000 ppm
0-5%
0-10%
0-25%
CO2*
%
SO2
ppm
H2 S
ppm
NOX
ppm
Cl2
ppm
HCL
ppm
0.1
0.2
0.2
0.4
0.6
0.8
2.0
4.0
6.0
100
200
200
500
1000
1500
2600
4000
6000
100
200
200
500
1000
1500
2600
4000
6000
100
200
200
500
1000
1500
2600
4000
6000
50
100
100
200
400
800
1400
2000
3000
50
100
100
200
400
800
1400
2000
3000
* Concentrations of CO2 are in percent. One percent is equivalent to 10,000
ppm.
Table 4: Maximum Allowable Acid Gas Limits
Contact the Delta F Customer Support Services Department, at 781-935-5808,
for recommendations on using the STAB-EL sensor on acid gases other than
those listed above.
The STAB-EL limits shown in the table represent rough guidelines for
continuous exposure. In most cases, substantially higher acid gas levels can be
tolerated on a limited duty cycle basis. For example, a 0-100 ppm sensor can
be used to sample a 100% CO2 background gas for a 15 minute period 3-4
times per week, and the balance of the time sampling from a clean gas like N2,
Ar, H2, etc. In general, a good guideline is to limit that the loading on the
STAB-EL system to not exceed the continuous limits if the total exposure is
averaged over a weekly period. Consult with Delta F for details.
There are applications where the acid gas components may exceed the upper
Sample Gas Preparation and Delivery
DF-340E
31
limits of the STAB-EL system on a continuous basis. In such circumstances a
sample dilution system can easily be fabricated to mix clean N2 with the sample
gas in a 2:1 to 20:1 ratio using simple pressure control and flowmeter
components. Depending upon the continuous acid gas level and the oxygen
level to be measured, a dilution ratio must be selected such that the resulting
O2 level is accurately measurable and at least one order of magnitude above the
O2 level in the N2 dilution gas. Consult the Delta F Customer Support Services
Department, at 781-935-5808, for specific recommendations.
Another approach when acid gas levels are continuously above the STAB-EL
limits is to enhance the inherent capabilities of the sensor by using a scrubber
system. The scrubber will remove the bulk of the acid gases, allowing the
Analyzer to provide continuous stable measurements. If a breakthrough
occurs, the sensor's ability to tolerate high levels of acid gas for limited periods
of time will avoid catastrophic loss of performance.
Delta F offers a broad range of scrubbers for applications in severe
environments. Standard scrubber columns are available in various sizes, and in
single or dual bed configurations. The columns are fabricated from clear PVC
and are designed to accept a variety of different acid gas absorbent media
which have a color-change indication to facilitate convenient change-out. For
more information, contact the Delta F Customer Support Services Department
at 781-935-5808.
6.2 Sample Gas Scale Factor
The optional GSF (Gas Scale Factor) is used to correct for changes in the rate
of oxygen diffusion when background gases other than nitrogen are present in
the process or sample gas.
In many applications, the sample GSF does not need to be altered from the
default value of 1.00. However, if the sample gas has a significantly different
diffusivity compared with nitrogen (such as helium or hydrogen), the GSF
should be applied. To use the GSF feature, the volumetric percentages of the
sample gas are entered as described on page 77 and the total GSF is
automatically calculated by the analyzer. Alternately, the GSF factor can be
entered manually.
The software in the analyzer supports gases as shown in Table 5.
Call Delta F at (781) 935-5808 for assistance with gases not listed.
For additional information see the section on Gas Scale Factor in the User
Interface chapter on page 77.
32
DF-340E
Sample Gas Preparation and Delivery
Ammonia
Argon
Butane
Carbon Monoxide
Ethane
Ethylene
Helium
Hexane
Hydrogen
Methane
Nitrogen
Propylene
NH3
Ar
C4H10
CO
C2H6
C2H4
He
C6H14
H2
CH4
N2
C3H6
Table 5: Gas Scale Factors
6.2.1.1 Disclaimer
The method used to correct the calibration of the DF-340E Oxygen Analyzer
for measurement in non-nitrogen background gases is derived from a wellknown theoretical mass transfer equation. This equation accounts for the
change in oxygen diffusion rates through different gases.
Although significant empirical work has been done in this field, it is generally
accepted that the equation may be only 85-90 percent accurate. In addition,
there is further error introduced when correcting for a "multi" component
background gas. This may result in up to an additional 3-5% error.
An alternate method when using a non-nitrogen or "multi" component
background gas for spanning is to obtain a certified Calibration standard that
has been prepared in a background gas that models the average process
sample. Care must still be used, however, as certified standards may also have
an inaccuracy associated with them.
Questions regarding the calculation of a background gas correction factor for a
specific application should be directed to Delta F Corporation (781) 935-5808.
6.3 Sample Flow Rate and Pressure
The analyzer is factory calibrated at a flow rate of 1.0 scfh, in N2, and should
be operated at that level for optimal accuracy. However, the Delta F Sensor is
relatively unaffected by gas sample flow rate, within limits. Sample flow rate
should be maintained within the recommended range of 1.0 to 2.0 scfh. The
analyzer can be operated at flow rates outside that range, but it should be
recalibrated at that different flow rate to maintain optimal accuracy.
The analyzer has a small pressure drop (0.2 to 0.5 psi), so relatively small
changes in inlet or outlet pressure causes dramatic changes in flow rate.
Consequently, it is preferable to vent the outlet to atmosphere so that outlet
pressure remains constant, leaving inlet pressure as the only variable to control.
Sample Gas Preparation and Delivery
DF-340E
33
6.3.1 Flow Rate Effects on Sensor Performance
Assuming a leak-tight system, higher flow rates may cause O2 readings to
increase by a few percent of reading above the level that would be displayed if
flow was within the recommended 1.0 to 2.0 scfh range. Lower flow rates
similarly cause O2 readings to decrease by a few percent of reading. Very low
flow rates (below 0.2 scfh) should be avoided as the sample inside of the
sensor is no longer representative of the actual sample.
The insensitivity to flow rate changes is the basis for the sample system leak
detection described below. The sensor output should be virtually constant for
readings between 0.5 and 2.0 scfh. Therefore, if O2 readings become higher at
lower flows, then ambient O2 is leaking into the sample system, or venting
from a dead space (closed pocket with trapped higher O2 level gas) in the
sample system. A higher flow rate dilutes the O2 entering the sample system
decreasing the reading. O2 readings in a leak free sample system should not go
up or down significantly with flow changes between 0.5 and 2.0 scfh.
6.3.2 Checking for Plumbing Leaks using Flow Rate
Effects
Significant measurement error can be caused by leaks in the plumbing system.
A simple test can be performed to identify oxygen intrusion leaks.
Observe the analyzer readout at two flow levels: 0.5 and 2.0 scfh. Only a
slight increase, if any, in readout will occur in a tight system as the flow is
increased. If leakage in the plumbing system exists, then the increased flow
results in a substantial decrease in oxygen readout -- typically dropping by 25
to 50 percent.
When flow sensitivity is observed, check the plumbing system for leaks. Once
proficient with this test, the user can estimate the distance to the leak based on
the response time of the reading changes.
6.3.3 Background Gas Effects on Indicated Flow Rate
If the molecular weight of the background gas is much different from N2, the
flowmeter reading is not accurate. The Rotameter type is calibrated for use in
air (or N2). Most other gases have molecular weights within ± 25 percent of
air. Since the required flow rate is not extremely critical most gases produces
reasonably correct readings. The exceptions are light gases such as Helium and
Hydrogen whose flow rates should be set to approximately one-third that of
Nitrogen or 0.3 scfh.
6.3.4 Regulator Requirements
If the pressure in the sample line varies, but does not drop below 2.0 psig, use
a regulator to drop the pressure to approximately 1.0 psig. Set final flow rate
with the sensor flow control valve.
If a regulator is not used, the flow rate changes when the pressure at the inlet
of the flow control valve changes. As long as this pressure variation does not
bring the flow rate out of the recommended flow range (1.0 - 2.0 scfh) no
regulator is required. A flow change of ±1.0 scfh may result in a small change
34
DF-340E
Sample Gas Preparation and Delivery
to the oxygen reading.
If a pressure change causes the flow rate to move outside the recommended
range, an adjustment of the flow control valve must be made. If the adjustment
is not made, and the flow rate remains outside the recommended range, the
analyzer may not be operating within its stated accuracy.
6.3.5 Pressure Regulator Purge
Regulators used on bottled calibration standards are typically equipped with 2
Bourdon pressure gauges, one to measure the cylinder pressure, and the other
to measure the outlet pressure. The regulator must have a metal (preferably
stainless steel) diaphragm. It is good practice to install a flow control valve to
adjust the flow after the regulator.
All user-added upstream plumbing should be consistent with the instrument gas
delivery components so that the highest level of integrity can be maintained.
All connections should be welded or include metal face-seal components.
Pressure gauges are not recommended on regulators used on process sample
lines because they add measurement delay time and offer opportunities for
leaks.
6.3.5.1 Regulator Purge Procedure
Before the gas is connected to the analyzer follow the procedure listed below
to purge ambient air from the regulator:
After securely attaching the regulator to the cylinder,
1. Open the regulator flow control valve slightly.
2. Open the cylinder valve.
3. Set the regulator to its maximum delivery pressure.
4. Adjust the flow control valve to allow a modest flow rate (hissing
sound).
5. Close the cylinder valve until the cylinder pressure falls to zero. If
equipped with gauges, allow the secondary (output) gauge to approach
zero. Otherwise wait for the hissing to nearly stop.
6. Immediately open the cylinder valve to restore full delivery pressure.
7. Repeat steps 5 and 6 five to ten times to thoroughly purge the regulator
and gauges.
8. Close the shut off valve on the outlet side of the regulator to isolate the
purged regulator from atmospheric contamination.
9. Set the delivery pressure to 5 psig (15psi for welded sample inlet and
VCR connection)
The above procedure insures that any ambient air trapped in the pressure
gauges and cavities of the regulator is purged prior to use. Once the regulator
is mounted, do not remove it from the cylinder until a fresh cylinder is
required.
6.3.6 Pressure Effects on Sensor Performance
If the analyzer is not vented to atmosphere, the sensor pressure is influenced by
Sample Gas Preparation and Delivery
DF-340E
35
the conditions downstream of the analyzer. A recalibration under your
operating conditions may be desirable to remain within the stated accuracy
specifications. However, in most cases the error introduced is relatively small,
and may not affect the process application.
NOTE
It is not recommended that gauges be installed upstream of the
analyzer. The presence of a gauge increases response times and
introduces potential leaks to ambient.
Sample gas line lengths, fittings and bends should be kept to a minimum to
maintain low pressure drops. Larger diameter tubing and fittings reduce
pressure drop and also lengthen response time. In general, 1/8-inch tubing
should be limited to 15-foot runs; longer runs should be made with 1/4-inch
tubing.
6.3.7 Sample Outlet Backpressure Effects
It is always recommended to vent the analyzer to atmospheric pressure.
However, if a sample vent or return line is used, attention must be given to
maintain a low and consistent backpressure so as not to affect the flow rate.
The allowable backpressure on the sensor is ±1 psig. If variations in the vent
line pressure are expected, a sub-atmospheric backpressure regulator should be
installed on the vent line to maintain an even backpressure on the analyzer.
Consider the regulator’s pressure drop (typically 1 psi) when designing the
sample vent system in order to stay within the ±1 psig pressure limits at the
sensor.
When not venting the analyzer to atmosphere, it is also suggested to install a
fairly high resolution pressure gauge immediately at the analyzer outlet.
NOTE
If a regulator or gauge is installed on the analyzer outlet, the
Stainless Steel Downstream Plumbing option should be installed.
6.4 Sample Gas Compatibility
There are a wide range of considerations in determining the gas sample
compatibility of the Process Oxygen Analyzer. Delta F attempts to identify all
pertinent application details prior to quoting and order processing. All nontypical applications concerning gas sample compatibility must be reviewed by
our in-house Application Engineers. It is impossible to accurately predict all of
the chemical tolerances under the variety of process gases and process
conditions that exist.
36
DF-340E
Sample Gas Preparation and Delivery
6.4.1 Condensation
The analyzer should be installed and operated with a sample gas that is
preconditioned (if necessary) to avoid condensation in the gas lines. Several
methods are available to minimize the possibility of condensation. If the
sample gas is a hydrocarbon, maintain the gas temperature 20° F to 40° F
above its dew point. In some applications, it may be necessary to chill the
sample gas before it enters the analyzer so that the hydrocarbons can be
condensed, collected, and removed. It is good practice to pitch the sample gas
lines to allow condensables to drain away from the analyzer. Gas sample
delivery lines that contain sample gases with high moisture content must not be
exposed to temperatures below the dew point.
6.4.2 Gas Solubility in Aqueous KOH Solution
Some sample gas constituents are soluble in the sensor’s potassium hydroxide
(KOH) electrolyte. Gases that are rated as “Soluble” to “Infinitely-Soluble”
may pose a threat to the sensor.
The sensor should have limited exposure (less than 1% by volume on a
continuous basis) to highly water soluble alcohols, such as methanol, and/or be
supplemented with periodic electrolyte changes to limit buildup within the
electrolyte.
Many gas species with infinite solubility in aqueous KOH (such as nitrous
oxide (N2O), however, do not affect the electrode or sealing materials, or
interfere with the O2 reduction/oxidation reactions. Call the 24-Hour Delta F
Service Line at (781) 935-5808 for recommendations on a specific application.
6.4.3 Reactivity with KOH Electrolyte
Many process sample streams contain various concentrations of acid gases.
Acid gases are gases that react with the basic KOH electrolyte solution to form
a neutralized solution. The sensor does not operate properly when the
electrolyte solution is neutralized.
Besides a neutralization of the electrolyte, a base reactive sample gas may have
other negative effects, such as a base-catalyzed polymerization reaction. The
O2 electrode reaction sites may become blocked by the polymerized byproduct
residue at the interface where the gas sample meets the electrolyte.
6.4.4 Flammable Sample Gas
There is nothing within the analyzer sample system that can ignite a flammable
sample gas. However, it is critical to ensure that the sample gas does not
escape from the sample system into the analyzer enclosure, or the room, where
ignition is possible. Stainless steel plumbing should be used throughout the
entire sample system if the sample gas is flammable.
Also, the analyzer enclosure can be purged with nitrogen, or the entire
Analyzer can be mounted in a purged enclosure, so that any sample gas that
escapes the plumbing is diluted.
Sample Gas Preparation and Delivery
DF-340E
37
6.4.5 Trace acids in the sample gas
With the STAB-EL Acid Gas system, oxygen measurements in sample gases
containing certain levels of acids are possible. Trace acids are common
byproducts of gas distribution system assembly and its accessories. Trace acids
can compromise the accuracy of the sensor and its construction if they are not
managed properly. See the section Stab-el Acid Gas System on page 31 for
more detail.
Contact the Delta F Customer Support Services Department at (781) 9355808 for recommendations on using the STAB-EL sensor on acid gases other
than those listed.
6.4.6 Sample Gas Temperature
Gas temperature should not exceed 50 °C (122° F), nor should it fall below
0° C (32° F). Gas temperature can be controlled by passing the gas through 5
to 10 feet of metal tubing that is within the recommended sample temperature.
Because of its low thermal mass, the gas sample quickly reaches the gas sample
line temperature.
Ideally, the analyzer should be operated at a nominal temperature of 70° F.
Calibration temperature should be close to operating temperature. If the
analyzer is to be operated at an average ambient temperature outside 65° F to
80° F, it should be recalibrated at the operating temperature for optimal
performance.
NOTE
The sensor temperature can be displayed at any time by accessing
the Diagnostics Menu, Figure 51. This temperature value is updated
at intervals of 15 to 45 seconds.
6.4.7 Protecting the Analyzer from Process Upsets
The analyzer should be protected from extended exposure to high
concentrations of oxygen or hostile gases. Automatically solenoid controlled
valves should be installed to switch the analyzer over to an N2 purge when the
process reaches some identifiable condition.
Gas line maintenance operations must also be examined for their effect on the
analyzer. For example, in many pipeline process or normal gas applications the
plumbing system is cleaned with either a liquid solvent or detergent solution.
Since either causes damage to the sensor, switch the analyzer over to a N2
bypass purge, or shut off sample flow and power to the analyzer prior to
initiating the potentially hazardous process.
6.5 Calibration Gas Considerations
Calibrations performed from a bottled, calibrated sample gas, may introduce
additional issues that could adversely affect the analyzer calibration.
38
DF-340E
Sample Gas Preparation and Delivery
6.5.1 Calibration Standards
Certified calibration standards are available from gas manufacturers. These
standards are available in steel and aluminum cylinders. Steel cylinders are less
expensive but do not dependably maintain a stable oxygen concentration for
long periods of time.
Calibration standards in aluminum cylinders are recommended. Delta F has
found that calibration standards in aluminum cylinders are very stable for long
periods of time (between 6 and 24 months) where steel cylinders should be
recalibrated every three months.
6.5.2 Calibration Cylinder Regulators
Regulators used on bottled calibration standards are typically equipped with
two Bourdon pressure gauges, one to measure the cylinder pressure, and the
other to measure the outlet pressure. The regulator must have a metal
(preferably stainless steel) diaphragm. Install a flow control valve after the
regulator to adjust the flow.
6.5.3 Purge Procedure
Before the calibration gas is connected to the analyzer follow the procedure
listed below to purge ambient air from the regulator which prevents
contamination of the gas in the cylinder rendering it useless:
After securely attaching the regulator to the cylinder,
1. Open the regulator flow control valve slightly.
2. Open the cylinder valve.
3. Set the regulator to its maximum delivery pressure.
4. Adjust the flow control valve to allow a modest flow rate
(hissing sound).
5. Close the cylinder valve until the cylinder pressure falls to zero.
If equipped with gauges, allow the secondary (output) gauge to
approach zero. Otherwise wait for the hissing to nearly stop.
6. Immediately open the cylinder valve to restore full delivery
pressure.
7. Repeat steps 5 and 6 five to ten times to thoroughly purge the
regulator and gauges.
8. Close the shut off valve on the outlet side of the regulator to
isolate the purged regulator from atmospheric contamination.
9. Set the delivery pressure to 5 psig
Once the regulator is mounted and purged, do not remove it from the cylinder
until a fresh cylinder is required.
6.5.4 Sample Gas Delivery and Vent Pressure during
Calibration
The most accurate calibration is obtained when the analyzer is plumbed into
the gas sample system so that the analyzer is under actual process operating
conditions. But when the process sample is being delivered to the analyzer
Sample Gas Preparation and Delivery
DF-340E
39
under Vacuum conditions, or being returned from the sample outlet under
either positive pressure or Vacuum conditions the operating pressure at the
sensor is likely to be quite different than under factory calibration conditions.
For systems where the gas sample is not vented to atmosphere, the analyzer
outlet should remain connected in the same manner during calibration, if
possible. This ensures that downstream pressure effects on the sensor are the
same during calibration and process monitoring.
Use the flow control valve on the regulator to meter the calibration gas to the
analyzer at the suggested 1.0 scfh flow. By leaving the analyzer’s flow
controls untouched from when the analyzer is used on process, the calibration
pressure duplicates the process sampling pressure.
6.5.5 Background Gas Effects on Calibration
6.5.5.1 Flow rate
Ideally, the calibration gas and the sample gas have the same gas composition,
and as a result, the indicated flow rate during calibration and process sampling
are identical. However, if the composition of the calibration and sample gases
are not the same, the flow rate indicated on the rotameter may need to be
adjusted. Light gases, such as H2 and He, have a higher flow rate than is
indicated on the flowmeter. As a result, the flow rate of the light gas should be
set to one third of the flow specifications found in this manual. For example:
The recommended flow rate for N2 is 1.0 scfh. In H2 or He service, the
recommended flow rate (as indicated on the analyzer flowmeter) should be
0.3 scfh.
6.5.5.2 Gas Scale Factor (GSF)
If possible, the background of the calibration gas should be the same as the
process sample gas. If not, a gas scale factor may have to be applied to the
calibration gas oxygen readings because of the difference between the diffusion
rate of oxygen in nitrogen (factory calibration gas) versus the diffusion rate in
the user’s calibration gas. The Sample Gas Preparation and Delivery section
discusses the proper setting of the gas scale factor option during calibration as
well as during process gas measurement.
40
DF-340E
Sample Gas Preparation and Delivery
7 Connecting to External Devices
The analyzer can be interfaced to a variety of external devices via the ports on the rear panel.
Alarm contacts, voltage, and current outputs, and serial communications are supported.
7.1 The Comm Port
The optional Comm Port is used for communication via RS-232C or RS-485 protocol. Up to 32
units may be accessed via RS-485. Operating parameters are 8 bits, no parity, and one stop bit.
Baud rate may be selected from the menu on the display.
A library of interface functions, written in C, is available to allow programmers to create custom
interface program for accessing the communication port. The Interface C Library Reference
Manual comes with a disk containing Microsoft and Borland versions of the object code.
The Comm port (J8) terminals are defined as follows:
J8-1
485-RX +
Data received by the analyzer from the device (RS-485)
J8-2
485-TX +
Data transmitted by the analyzer to the device (RS-485)
J8-3
232-TX
Data transmitted by the analyzer to the device (RS-232)
J8-4
232-RX
Data received by the analyzer from the device (RS-232)
J8-5
485-RX -
Data received by the analyzer from the device (RS-485)
J8-6
UNUSED
J8-7
485-TX -
Data transmitted by the analyzer to the device (RS-485)
J8-8
232-GND
Ground
Table 6: Comm Port (J8) Connector Pinout
NOTE
To avoid ground-loop conflicts when using RS-232C or RS-485 for
communications, make connections to external recorders or data
acquisition systems through a differential input, or a single-ended
input that is not referenced to Earth Ground.
When connecting the Process Oxygen Analyzer to a computer via an
RS-232 or RS-485 communication cable, a Ferrite Sleeve is required
around the cable in a single-turn configuration. It is recommended
that the proper Delta F cable be used for this purpose.
7.2 Relay Ports
Connections to four optional form C (SPDT) relays (contact closures) are provided on the rear of
Connecting to External Devices
DF-340E
41
the analyzer at connector J1 and J2. These can be used in conjunction with up to seven alarms.
The contacts are rated at 0.3A, 30 VDC under a resistive load. They are not designed to switch
AC power.
The relay contacts can be programmed for up to four Oxygen Alarms, plus Temperature, Low
Flow, Electrolyte Condition and the Replenishment Solution Reminder alarm. A relay can be
assigned to any alarm through the display menu.
The Normally Open (No alarm) contact connects to common when an alarm occurs or when
power to the instrument is lost.
Figure 13: J1/J2 Connector
J1-1
A1-COM
Alarm 1 Common
J1-2
A1-NO
Alarm 1 Normally Open
J1-3
A1-NC
Alarm 1 Normally Closed
J1-4
A2-COM
Alarm 2 Common
J1-5
UNUSED
J1-6
A2-NO
Alarm 2 Normally Open
J1-7
A2-NC
Alarm 2 Normally Closed
J1-8
GND
Ground
J2-1
A3-COM
Alarm 3 Common
J2-2
A3-NO
Alarm 3 Normally Open
J2-3
A3-NC
Alarm 3 Normally Closed
J2-4
UNUSED
J2-5
A4-COM
Alarm 4 Common
J2-6
A4-NO
Alarm 4 Normally Open
J2-7
A4-NC
Alarm 4 Normally Closed
J2-8
GND
Ground
Table 7: Relay Port Connectors (J1, J2) Pin Out
42
DF-340E
Connecting to External Devices
7.3 Analog Outputs
In addition to the wiring of the analog as described below, see page 68 for additional information
of scaling the outputs through the firmware.
7.3.1 Analog Voltage Output
Connector J4 provides connections to the non-isolated analog voltage output signal (0 to 5, or 0
to 10 VDC, selectable). For details regarding how to switch the full scale output see section
7.3.1.1 below.
J3
J4
+24V
A OUT +
UNUSED
A OUT -
24V RTN
PUMP -
GND
PUMP +
UNUSED
UNUSED
UNUSED
FLOW-A
UNUSED
UNUSED
UNUSED
FLOW-B
Figure 14: J3/J4 Connector
J4-1
AOUT+
Analog Voltage Output +
J4-2
AOUT-
Analog Voltage Output -
Table 8: Analog Voltage Output Connector (J4) Pin Out
7.3.1.1 Procedure to change the Full Scale Analog Output Voltage
The following procedure should be used to change the full scale analog output voltage. The
options are 5.0 and 10.0 VDC.
1.
2.
3.
4.
5.
Shut-off and disconnect all power from the analyzer.
Label and remove all connections from the rear of the analyzer.
Open the door and disconnect the sensor and display cables.
Remove the two screws from the rear of the unit.
Remove the four screws that hold the sheet metal cover in place. Remove the cover and
set aside.
6. Locate jumper # JP14 in the center, directly below the relays in the upper third of the
board.
7. Using the information in Table 9, place a jumper (short) between the appropriate pins to
obtain the desired full scale output.
8. Reassemble and install the circuit boards back into the analyzer.
9. Reconnect all cables and power up the analyzer.
10. From the Diagnostics Menu, select Test Output, and set the output to 100% full scale.
11. With a DVM, confirm that the analog output voltage is proper. If it needs to be adjusted
Connecting to External Devices
DF-340E
43
slightly, use the potentiometer located third from the top on the front of the circuit board,
above the Delta F symbol.
Full Scale Output Voltage
Jumper Number
5.0 VDC
None
10.0 VDC
14
Table 9: Analog Output Voltage Jumpers
7.3.2 4-20mA Output
The optional fully-isolated 4-20mA output is completely isolated from all other analog outputs
and from earth ground. The maximum loop resistance is 1KThe 29-33 VDC compliance
voltage is provided. Connections are made at pins J5-1 (LOOP+) and J5-2 (LOOP-) at the back
of the instrument.
J5
J6
LOOP +
EXT-1 +
LOOP -
EXT+1 -
UNUSED
EXT-2 +
UNUSED
EXT-2 -
Figure 15: J5/J6 Connector
J5-1
LOOP +
4-20 mA Output +
J5-2
LOOP -
4-20 mA Output -
Table 10: 4-20 mA Analog Current Loop Connector (J5) Pin Out
7.3.2.1 Sensor Off 4-20mA Signal
If configured at the time of order, the 4-20mA output can be reduced to 2mA when the Sensor is
either manually or automatically turned off.
7.3.3 Alignment Procedure for Analog Voltage and Current Loop
Outputs
All output connections should be made before the alignment is started. It is assumed for the
purpose of this alignment that the full-scale analog voltage output is 10 VDC.
Use the Test Outputs screen as described on page 86 to set the output to the desired level after
which the alignment adjustments are made as follows:
1. Set the output to 0%
2. Adjust the analog voltage output (1) to 0.000 V +/- 1mV, adjust the current loop output
(2) to 4.00mA +/- .01mA
3. Set the output to 100%
4. Adjust the analog voltage output (3) to 10.000 V +/- 1 mV, and adjust the current loop
output (4) to 20.00mA +/- .01mA.
44
DF-340E
Connecting to External Devices
0-10 VDC: SPAN ADJUSTMENT (3)
0-10 VDC: 0 VDC ADJUSTMENT (1)
4-20 mA: 4 mA ADJUSTMENT (2)
4-20 mA: 20 mA ADJUSTMENT (4)
Figure 16: Analog Output/4-20mA Adjustments
7.4 Remote Controls
7.4.1 Remote Sensor Control – J6 Connector
If equipped, the oxygen sensor can be turned on and off remotely through the pins labeled EXT 1
or EXT 2 on the J6 connector. If equipped, the EXT Functions screen, see page 88, will indicate
to what set of EXT contacts this option is assigned, either 1 or 2.
J5
J6
LOOP +
EXT-1 +
LOOP -
EXT-1 -
UNUSED
EXT-2 +
UNUSED
EXT-2 -
Figure 17: External Control Connector – J6
J6-1
EXT-1 +
External Control Input (+)
J6-2
EXT-1 -
External Control Input (-)
Connecting to External Devices
DF-340E
45
J6-3
EXT-2 +
External Control Input (+)
J6-4
EXT-2 -
External Control Input (-)
Table 11: Remote Control Connector (J6)
While the display is in the normal O2 mode, a voltage of 24 VDC applied to the appropriate
contact pairs labeled EXT 1 or EXT 2 will turn the sensor off. The oxygen sensor will stay off
until this potential is removed.
NOTE: Turning the sensor off in this way will make control of the sensor from the keypad
impossible.
NOTE: Controlling the sensor voltage in this way will disable the Automatic Sensor off function.
NOTE: The audible alarm normally associated with the sensor off function is disabled with this
option. See the wiring diagram in Figure 25.
7.4.2 Remote Pump Control – J6 Connector
The pump enables the analyzer to operate on gas sample streams between 2.0 psig vacuum and
2.0 psig positive pressure.
If the analyzer is equipped with a pump, it will also have a downstream Flow Control Valve
mounted in the bottom of the flow meter. When using the pump, always use this downstream
valve to control the gas flow rate and leave all up stream valves wide open.
If the pump is not in use, (positive pressure application) always control the gas flow with an
upstream valve or regulator and leave all down stream valves wide open.
CAUTION
Do not use an upstream valve to control flow if the analyzer is
operating on a pump.
The on-board pump, if equipped, is controlled from the Controls Menu. See the User Manual for
additional information.
Connections to power a remote pump are made through the PUMP – and PUMP + pins on
connector J4. The wires should be in a shielded cable (separate from the sensor signal) with the
shield attached to the frame ground. The pump cable should be of sufficient size for the required
run (see Table 12 below) and should not share the same conduit as the sensor cable. See the
wiring diagram in Figure 25.
Pump Cable (Must be separate from sensor cable)
Distance in Feet
Minimum Wire Size
0 – 500
#20 AWG
500 – 1000
#18 AWG
Table 12: Pump Cable Specification
46
DF-340E
Connecting to External Devices
J3
J4
+24V
A OUT +
UNUSED
A OUT -
24V RTN
PUMP -
GND
PUMP +
UNUSED
UNUSED
UNUSED
FLOW-A
UNUSED
UNUSED
UNUSED
FLOW-B
Figure 18: Pump Control Connector – J4
In addition, the following options are available:
If factory configured, Delta F will supply the standard pump that the user may install remotely and
power through the PUMP – and PUMP + connections on the rear panel connector J4. Control
would be accomplished in the same manner as a standard pump.
OR
If factory configured, a switch closure rated at 1A/30VDC can be supplied between the PUMP -,
+ connections on the rear panel connector J4. The contacts can be used to control a Delta F
supplied pump that is powered from a separate 24 VDC, .3 A source. Control of the pump would
be accomplished in the same manner as a standard pump.
OR
If equipped, the pump may also be turned on and off remotely through the pins labeled EXT 1 or
EXT 2 on the J6 connector. If equipped, the Diagnostics Screen will indicate to what set of EXT
contacts this option is assigned, either 1 or 2.
While the display is in the normal O2 mode, a voltage of 24 VDC applied to the appropriate
contact pairs labeled EXT 1 or EXT 2 will turn the pump off. The pump will stay off until this
potential is removed.
NOTE: Turning the pump off in this way will make control of the pump from the keypad
impossible.
7.5 Remote Sensor Installations
NOTE – Remote sensor installations void CSA approval, if any.
The oxygen sensor for a DF Series analyzer may be installed outside of the analyzer cabinet (if
equipped with this option). Areas of high convected or radiated heat must be avoided.
If installed outdoors the sensor enclosure must be shielded from the sun to avoid overheating. In
addition, a heater must be installed in the enclosure in areas where the temperature goes below
freezing. (See page 51) Care must be taken to use high quality cable and techniques when making
remote connections. Refer to Table 12 and Table 13 for wire sizes and lengths. Following are
three remote sensor configurations and wiring diagrams. See the wiring diagram in Figure 25.
Care must be taken when making up gas fittings on the sensor when mounted on a remote bracket
Connecting to External Devices
DF-340E
47
as shown in Figure 19 below. A backing wrench must always be used (in particular for VCR
connections) when connecting the gas sample line to the sensor. The inlet fitting, although
epoxied, is very delicate and the seal can easily be damaged if it is allowed to spin as the
connection is tightened.
Contact Delta F for additional information on remote sensor installations.
7.5.1 Sensor on Remote Bracket with Optional Pump
4.09 [103.89]
7.73 [196.29]
Ø.28 [Ø7.11]
4 PL
1.50 [38.10]
1.57 [39.88]
4.88 [123.83]
7.02 [178.28]
TEMP TEMP +
SECONDARY ELECTRODE - (WHT/BLU)
SECONDARY ELECTRODE + (WHT/RED)
SENSOR - (WHT/YEL)
SENSOR + (WHT/BLK/RED)
PUMP GROUND
PUMP +
FLOW SWITCH
FLOW SWITCH
UNUSED
1
2
3
4
5
6
7
8
9
10 11 12
Figure 19: Remote Sensor with Optional Pump
48
DF-340E
Connecting to External Devices
7.5.2 Sensor in NEMA 4 Enclosure
Ø.44 [Ø11.18] THRU
4 PL
7.00 [177.80]
PUMP
11.25 [285.62]
10.00 [254.00]
FLOW SWITCH
ROTOMETER
OXYGEN
SENSOR
FLOW CONTROL
VALVE
SAMPLE
INLET
SAMPLE
OUTLET
SIGNAL
OUTPUT
7.42 [188.58]
4.71 [119.75]
2.96 [75.30]
2.96 [75.25]
1.23 [31.36]
1.93 [49.02]
AC POWER
2.75 [69.85]
7.00 [177.80]
9.00 [228.60]
Figure 20: Remote Sensor Mounted in NEMA 4 Enclosure
Connecting to External Devices
DF-340E
49
7.5.3 Sensor in NEMA 7 Enclosure
Figure 21: Remote Sensor Mounted in NEMA 7 Enclosure
50
DF-340E
Connecting to External Devices
3.00 [76.20]
5.25 [133.35]
SAMPLE INLET
1/4" COMPRESSION
ELECTROLYTE MAINTENANCE ACCESS
FLOWMETER
WITH INTEGRAL
CONTROL VALVE
(OPTIONAL)
.75 NPT ELECTRICAL CONNECTION
TO CONTROL ENCLOSURE
Ø.44 [Ø11.11] THRU
4 PL
SAMPLE OUTLET
1/4" COMPRESSION
8.50 [215.90]
9.75 [247.65]
11.00 [279.40]
7.25 [184.15]
2.50 [63.50]
2.50 [63.50]
9.00 [228.60]
3.00 [76.20]
10.25 [260.35]
8.38 [212.73]
Figure 22: NEMA 7 Enclosure Mounting Dimensions
7.5.4 Temperature Control in R4/R7 Enclosures
R4 and R7 enclosures may be supplied with the temperature control option. Typically this option
is installed in an effort to minimize diurnal changes in outdoor installations, or when the sensor
must be kept at an elevated temperature in order to minimize condensation.
NOTE: The customer must supply the electrical power (110/220 VAC, 150 Watts) for this
option.
For most applications, the sensor and electronics are maintained at a temperature of 65-70
degrees F. The temperature controller, located in the R4 or R7 enclosure, is set at the factory and
typically requires no adjustment unless components are changed or application conditions require
higher temperatures. In the event that the enclosure temperature must be adjusted, follow the
steps below.
1) Obtain a temperature measurement device capable of measuring the desired operating
Connecting to External Devices
DF-340E
51
temperature to an accuracy of +/- 2 degrees F.
2) Open the R4 door or remove the R7 cover. Attach the temperature measuring probe to the
side of the oxygen sensor. Be sure to cover the enclosure opening to prevent cooling.
3) Turn on the analyzer and enclosure heater. Allow at least four hours for the enclosure
temperature to stabilize.
4) Locate the temperature control potentiometer on the circuit board in the enclosure above the
terminal strip. See Figure 23. Turn it clockwise to increase the temperature and counter-clockwise
to decrease it. After each adjustment re-cover the enclosure and allow at least an hour for it to
stabilize at the new temperature.
Figure 23: Temperature Control in R7 Enclosure
7.5.5 Remote Sensor Connections – Connector J7
There are three pair of connections that must be made between the oxygen sensor and connector
J7 on the electronics chassis. They are labeled SNSR + and -, SE + and – and TEMP + and -. It is
critical for optimum operation, and to prevent damage to the sensor, that the proper polarity be
maintained on all electrical connections. These connections should be made through a shielded,
twisted pair cable sized according to Table 13. The shield should be terminated only at the
Ground connection labeled GND on the same connector. To avoid ground loops, the shield
should be left open and not attached to the remote sensor chassis. See Figure 25 for wiring
connections.
Oxygen Sensor Cable Sizes
Distance in Feet
Minimum Wire Size
0 – 150
#20 AWG
150 – 250
#18 AWG
250 – 350
#16 AWG
350 – 1000
#14 AWG
Table 13: Remote Sensor Cable Sizes
52
DF-340E
Connecting to External Devices
J7
J8
TEMP +
485-RX +
TEMP -
485-TX +
UNUSED
232-TX
SNSR +
232-RX
SNSR -
485-RX -
SE+ (H+)
UNUSED
SE -
485-TX -
GND (H-)
232-GND
Figure 24: Remote Sensor Connector – J7
Figure 25: Remote Sensor/Pump Wiring Diagram
Connecting to External Devices
DF-340E
53
7.5.6 Z-Purge Protection on R4 Enclosure
Before applying power to the to the analyzer, the Z-Purge unit must be installed and operating
properly. For loss of purge protection, wire the Z-Purge alarm contacts to a customer provided
alarm. Normally open and normally closed contacts are provided. Alternatively the contacts can
be used to interrupt the input power to the analyzer.
The switch requires either AC or DC input power, as indicated on the faceplate. For installation
and wiring instructions, see the manufacturers information included with the switch.
NOTE: All electrical connections to the switch must be made according to applicable local and
safety standards.
Procedure for setting pressure and flow through the enclosure:
12. Verify proper operation of the Z-Purge unit as described in this section, while the
environment is in a safe condition.
13. Remove the four cover screws on the Z-Purge pressure switch.
14. Check that the pressure calibration screw on the pressure switch is backed out as far as
possible to the minimum pressure setting of 0.15 inches of water. Check the enclosure
pressure with a suitable instrument if possible.
15. Close the Z-Purge pressure regulator (fully counter clock-wise)
16. Fully open the Z-Purge flowmeter needle valve. (fully clock-wise)
17. Open the instrument air/N2 supply to the Z-Purge regulator. (pre-regulated to the
minimum pressure required to supply 50 scfh of flow to the enclosure).
18. Open the Z-Purge regulator sufficiently to allow 50 scfh to the enclosure.
19. Verify that the alarm pressure switch has been deactivated (is not in an alarm condition).
20. Purge the enclosure for 15 minutes at 50 scfh.
21. Reduce the purge flow rate to a minimum of 5 to 10 scfh using the flowmeter needle
valve, making certain that the alarm pressure switch remains deactivated (not in an alarm
condition). If the purge switch activates, confirm that the enclosure is “tight” and increase
the flow rate as necessary.
22. The analyzer may now be turned on.
54
DF-340E
Connecting to External Devices
16.50 [419.10]
9.00 [228.60]
7.00 [177.80]
5.00 [127.00]
7.60 [193.15]
2.00 [50.80]
PURGE PROTECTION
STYSTEM (OPTIONAL)
REQUIRES 25-30 psig
INSTRUMENT AIR OR N
12.50 [317.50]
11.25 [285.62]
12.66 [321.61]
1.25 [31.75]
1.41 [35.86]
1.00 [25.40]
7.00 [177.80]
1.93 [49.02]
1.41 [35.93]
2.75 [69.85]
3.14 [79.82]
SAMPLE INLET
1/4" COMPRESSION (STD)
1/4" VCR COMPATIBLE (OPTIONAL)
7.00 [177.80]
SAMPLE OUTLET
1/4" COMPRESSION
Figure 26: Z-Purge Protection on R4 Sensor Enclosure
Connecting to External Devices
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8 User Interface
8.1 The Data Display Screen
When the DF-340E Process Oxygen Analyzer is powered up, it goes through a series of internal
diagnostic tests which take about five seconds. After the tests, the Delta F logo appears for ten
seconds. The display will then show the Data Display Screen as shown in Figure 27.
3.43
P
P
M
OUT : 0.0- 100.0
*Menu
GSF: 1.003
Figure 27: Data Display
The numerical information shown is representative. Different values will probably be observed on
the display.
There are four pressure sensitive keys below the display. The keys are used as follows:
ESC - Returns the display to the previous screen, or may be used to move to the left
when within a data field selection.
- Scrolls up in a menu or data selection.
- Scrolls down in a menu or data selection.
- Accepts the selected (asterisk) entry, allows data field selection, and may be used
to move to the right when within a data field selection.
The Annunciator Line provides information about the status of the Analyzer, and alarm
conditions. The Annunciator Line is displayed on the Main Menu Screen.
The Data Line indicates the measured oxygen concentration (e.g. 3.43 ppm). In this manual all
concentrations will be shown in ppm O2. For instruments that display data in percent (%) O2 all
actions are identical, but engineering units will be reported in percent (%).
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Below the Data Line is a display of the Analog Output Range settings. The analog outputs are
scaled over the range displayed in this area. Factory standard analog outputs are 0-10 VDC and
Isolated 4-20 mA. Setting the analog voltage output is described on page 68. If the Analyzer is
equipped with the Expanded Range Scale option the Analog Output Range value will change
from OUT: x-xxxx to XPOUT: x-xxxx, and will appear in reverse video, when the expanded
range scale is active.
* Menu indicates that if
is pressed, the Main Menu display, Figure 28, will appear.
GSF indicates the present Gas Scale Factor. The Gas Scale Factor is described on page 72. If
the Analyzer is not equipped with the GSF option, or if N2 is selected from the GSF table, then no
GSF is displayed.
The legend "OVER RANGE" will overwrite the Oxygen display if the instrument analog to
digital converter reads a value which is over its full scale range. During an over range condition
the oxygen information is not valid. The analog output will be at maximum (pegged). An
“OVER RANGE” condition will result in a continuous alarm tone, which may be silenced by
pressing ESC.
The legend “SENSOR OFF!” will overwrite the Oxygen display if the sensor polarization voltage
is turned off by using the Sensor selection in the Controls menu. The polarization voltage will
automatically turn off if the Analyzer is OVER RANGE for more than 30 minutes. When the
sensor is off the analog output falls to zero volts and the 4-20 mA output falls to 4 mA. An
optional relay may be configured to indicate that the sensor is off. A “SENSOR OFF !” condition
will result in an intermittent alarm tone, which may be silenced by pressing ESC.
NOTE: The automatic sensor off function is disabled if the display is not in the main O2 readout
mode.
A reverse video overlay will appear over the center of the display for the following alarms:
Oxygen (1,2,3,4), Temperature (T), Flow (F), and Electrolyte Condition (E). The overlay
appears and disappears at intervals so that the Oxygen reading is still visible. If there are several
alarms in progress all of the alarm overlays will be displayed in sequence.
The overlay also indicates the set point value and whether the alarm condition is a high or low
alarm. If the alarm is a Flow or Electrolyte Condition alarm the set point is not displayed because
these alarms do not have set point values. Audible annunciation can be activated for each of the
alarms. If annunciation is activated, a continuous tone will occur when the overlay is displayed.
Pressing ESC while the overlay is displayed will silence the tone and cause the overlay to
disappear. Once an alarm has been acknowledged (by pressing ESC) its number will be
continuously displayed in the Data Display Window on the Annunciator Line. The numbers are
assigned as follows:
The alarm number will clear only after the alarm condition is over.
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In the case of simultaneous alarms, each will alternately overwrite the display. Successive presses
of ESC (as the overwrite is displayed) are necessary to clear the overwrite and annunciation. This
will not clear the alarm. Only a restoration of the condition that existed prior to the alarm will
clear the alarm.
Alarm Number
1
2
3
4
T
F
E
Function
Oxygen 1
Oxygen 2
Oxygen 3
Oxygen 4
Temperature
Flow
Electrolyte Condition
Table 14: Alarm Identification
There are also a number of special messages that can appear on the Annunciator Line of the
display:
CHECK FLUID – Indicates that a user set time period has expired after which the
electrolyte level should be checked and Replenishment Solution should be added if necessary.
TEMP OVER RANGE - Indicates that the sensor temperature is over 50C or that the
temperature probe is disconnected. This alarm results in a continuous tone that may be silenced
by pressing ESC.
UNDER RANGE - Indicates that the oxygen level is below the calibrated zero.
UNCALIBRATED - Warns that the Analyzer is not calibrated, or that NOVRAM data
has been corrupted.
If there is an acknowledged alarm indicated in the Annunciator Line, special messages will appear
in the upper left corner of the oxygen display box. Temp Over Range will show TO, and Under
Range will show UR.
EXT SENSOR! Indicates that the polarization voltage on the oxygen sensor has been
turned off remotely.
EXT PUMP Indicates that the pump has been turned on remotely.
Other possible messages, that may appear on various screens, include “Wait!”, and “Memory
Error!”. “Wait!” indicates that the instrument is performing an operation that is time consuming
(> 10 seconds), such as an internal electrical zero calibration. “Memory Error!” indicates that the
instrument has failed the boot-up memory test. The letters “CHG”, “BAT” and “LOW” may
appear vertically on the right side of the display on units equipped with the NiMH battery backup
option.
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3.43 ppm
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8.2 Main Menu
The Main Menu, Figure 28, is accessed by pressing
from the Data Display Window. Alarm
Overlay information will continue to display over the Main Menu.
Figure 28: Main Menu
The first three lines of the Main Menu display the firmware version, followed by the instrument
serial number and the range of the Analyzer.
Four screens can be accessed from the main screen:
Controls - Used to turn on the pump, the sensor voltage, choose sensor off relay, and
select power up default conditions for the above functions. See page 62.
Set-Up Menu - Used to set alarm parameters, the recorder output level and functions,
configure communication port, to enter the gas scale factor, to perform or check the span
calibration, or to install a replacement sensor. See page 65.
Password - Used to set passwords and indicate which menus are "password" protected 73
Maintenance – Used to access three screens related to replenishment solution addition,
oxygen calibration and diagnostics.
The diagram on the previous shows the "Menu Tree" for the operator interface. Sufficient detail
is provided to orient the user during instrument set-up; however, not all the program details are
illustrated in this diagram.
Each level in the Main Menu allows the user to access options for setting and testing instrument
parameters. Ellipsis (...) after an entry indicates that additional screens follow.
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8.2.1 Keypad Operation
The following protocols are used to program the Analyzer:
To access a level, use the
or
key to move the asterisk (*) to the desired level and press
.
To edit a numerical value, use the
key to highlight (reverse video) the digit to be changed.
Successive use of the
key will highlight the digits on a left to right basis. Use of the ESC key
will move the highlighting back to the left and eventually cancel any adjustment. The rightmost
digit will be the active digit for editing. Use
or
to adjust the desired value.
After the desired numerical value has been entered, press the
key until the number no longer
appears in reverse video.
The ESC key is used to return to the previous screen without changing any parameters that may
have been altered. If any parameters have been edited without updating memory, the display will
present the message "ABANDON CHANGES?,
FOR YES". All parameter changes will be
lost if the
key is pressed.
Select the UPDATE & QUIT choice using
previous menu.
to save the changes and automatically return to the
8.3 Controls Menu
The Controls menu is used to turn on or off a number of optional features of the Oxygen
Analyzer. When the Controls menu is selected, and the appropriate password is entered (if
required), the display will show Figure 29.
Figure 29: Controls Menu
8.3.1 Pump
(Optional) - After accessing the Pump entry, the pump is toggled ON or OFF by pressing . If
the Analyzer does not have a pump, NA will be displayed.
See the section on ESC, page 64, for additional information about leaving the menu after
changing the Pump setting.
See the section on Remote Controls, page 45, for additional information on remote control of the
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pump.
NOTE
Analyzers with pumps are fitted with a valve on the rotameter
(downstream of the sensor) and a valve on the sensor inlet
(upstream of the sensor). When using a pump to draw a gas sample
at less than 0.2 psig, the downstream rotameter valve is used as the
flow control valve. The sensor inlet (upstream) valve is shipped from
the factory in the fully opened (counter-clockwise) position. Its
position should not be changed unless the Analyzer is operated on
positive pressure, e.g., when measuring a sample greater than 0.2
psig (but less than the maximum limit of 10 psig) that is vented to
atmosphere. Likewise, when operating with a positive pressure the
rotameter (downstream) valve should be fully opened and the
upstream flow control valve used for flow control.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY CAUSE
THE SENSOR TO EXPERIENCE OVER OR UNDER
PRESSURE WHICH MAY CAUSE PERMANENT DAMAGE.
8.3.2 Sensor Polarization
After accessing the Sensor entry, the sensor power is toggled ON or OFF by pressing
. The
sensor ON command applies a polarizing voltage to the sensor. See the section on ESC, page 64,
for additional information about leaving the menu after changing the Sensor setting.
The Analyzer has been programmed to protect the sensor from extended operation in an overrange condition (> 30 minutes). If such a condition exists, the software will turn off the polarizing
voltage to the sensor. A message will be displayed indicating that the sensor has been turned off,
and an intermittent beep will occur as in Figure 30. The beep can be silenced and message
canceled by pressing ESC. When ESC is pressed a reverse video SENSOR OFF! legend will
overlay the oxygen display.
The user should investigate the reason for the excessively high O2 level, remedy the situation, and
then restore power to the sensor via the Controls menu. The oxygen value is approximately zero
when the sensor is off. Also, the analog outputs will go to zero, so any low Oxygen alarms set
above zero will trigger on.
NOTE: The automatic sensor off function is disabled if the display is not in the main O2 readout
mode.
See the section on Remote Controls, page 45, for additional information on remote control of the
sensor polarization voltage.
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Figure 30: Sensor Shut-off Warning
8.3.3 SensOFF Relay
When the sensor is manually turned off from the front panel, or automatically turned off because
the instrument has been over-range for more than 30 minutes, a relay may be assigned to signal
that the sensor is off. This feature is important when the Analyzer is used in an unattended area,
so that a remote operator can be notified that the instrument is no longer measuring oxygen. If
the instrument is not equipped with any relays this selection will show NA. It is possible to assign
more than one alarm or status condition to any relay. Since the status condition of the sensor,
being switched off, signifies an “Analyzer Off-line” condition, it is important to make sure that the
relay assigned to SensOFF service is only assigned to alarm conditions signifying similar levels of
alert, such as a Low Flow Alarm.
Note: Alarm or Analyzer status conditions that signal an “Analyzer off-line” fault condition (such
as sensor off) can be assigned to a single relay contact used as a trouble indicator. If the Analyzer
signal is only monitored remotely, it is suggested to route the 4-20 mADC signal through the
“Analyzer Trouble” relay such that an alarm condition will cause the relay to break the current
loop. This method allows a computerized system to be configured to detect an analyzer fault
condition whenever the 4-20 mADC signal is below 4 mA.
8.3.3.1 Sensor Off 4-20mA Signal
If configured at the time of order, the 4-20mA output can be reduced to 2mA when the Sensor is
either manually or automatically turned off.
8.3.4 P(o)w(e)r UP
When the Analyzer is powered down, and then turned back on, the pump controls default to OFF,
and the Sensor defaults to ON. This activity is the DEFAULT operational mode of the pump and
sensor. Instead, it is possible to store the states of the pump and sensor every time they change
and allow the LAST state to be reestablished when the Analyzer is powered up. The selection
“PwrUP” toggles between “DEFAULT” and “LAST”.
8.3.5 ESC
If only the Pump, or Sensor selection has been changed, and the PwrUP selection is set to
DEFAULT, the Controls menu may be exited with ESC. The new changes will be in effect. If
SensOFF Relay or PwrUP has been changed, and the changes are to be stored, or the PwrUP
selection is set to LAST, the menu should be exited by selecting Update and Quit. If the changes
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are to be discarded press ESC. The Analyzer will present the message “ABANDON
CHANGES?,
FOR YES.” Press enter and the display will return to the Data Display
Screen.
8.4 Set-Up Menu
Note: When the Set-up entry is selected from the Main Menu, a DISABLING ALARMS
message appears which notifies the user that the alarms have been temporarily disabled. The
alarm overlay messages will not show in the display. Relays will remain in the alarm state that
immediately preceded the Disabling Alarms message.
The Set-Up Menu is used to establish a variety of Analyzer parameters. When the selection is
made from the Main Menu, Figure 28, and the appropriate password is entered (if required),
Figure 31 is shown.
Figure 31: Setup Menu
Each entry in Figure 31 leads to a sub-menu. To select the desired sub-menu, use the
and
keys to place the asterisk next to it, then press
. A new display will be shown as indicated
below.
8.4.1 Alarms
The Alarms screen is used to set or determine the status of alarms. When the Alarms entry is
selected from Figure 31, the display will present Figure 32.
Figure 32: Alarm Setup Menu
To select an alarm to edit, use the
and
keys to move the asterisk. Press
when the
alarm is indicated. If (NA) is displayed next to any entry, that alarm option is Not Available.
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8.4.1.1 O2 Alarms
If an O2 alarm has been selected from the Alarm Setup Screen Figure 32, the display will show
Figure 33.
Figure 33: Oxygen Alarm Menu
Figure 34: Oxygen Alarm Setup Screen (Alarm not used)
After selecting an Alarm with the
and
keys, use
to toggle the alarm On (USED) or Off
(NU). When an unused alarm (NU) is accessed, the display will appear as shown in Figure 34.
(Oxygen ALARM 1 is used in the example shown in Figure 35.) To indicate that the alarm is to
be used, move the asterisk to Alm 1and press
. For the oxygen alarms, the NU will change to
O2.
Audible is used to toggle On or Off the audible alarm feature. The Hi Stpt (high set point) and
Lo Stpt (low set point) refer to the limits above and below which the alarm will be triggered.
Each oxygen alarm (and the temperature alarm) can be set for a high trip point and a low trip
point. This feature gives the user the ability to operate the process between limits of high and low
O2 concentration (or temperature range) using only one alarm.
Deadband refers to how far the current value must be above (for lo alarms) or below (for hi
alarms) the set point before an alarm is reset. For example, for a High Alarm (Hi Stpt) set to 50
ppm, a Low Alarm (Lo Stpt) set to 30 ppm, and the deadband (Deadbnd) set at 5 ppm, the alarm
will trigger at 50 ppm. The alarm will continue to report until the oxygen concentration falls
below 45 ppm (Set point minus Deadband). At 45 ppm, the alarm will reset.
With the Low Alarm, the alarm would trigger at 30 ppm and continue to report until the O2
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concentration increased to 35 ppm (Set point plus Deadband). At 35 ppm the alarm would reset.
Relay indicates the relay to which the alarm is assigned. The options are NU (not used), 1, 2, 3
or 4. Each relay can be assigned up to seven alarms. If more than one alarm is assigned to a
relay, any assigned alarm will trip the relay, and the relay will remain tripped until ALL alarms
assigned to it are cleared. The alarm can be assigned to only one relay.
If an active alarm is accessed, the display will indicate the present values. An example of an active
alarm (O2 Alm 1) is shown in Figure 35.
Figure 35: Oxygen Alarm Setup Screen (Alarm used)
8.4.1.2 Temperature Alarm
The TEMP alarm is used to indicate an out of range temperature condition for the sensor. From
the Alarm Setup Menu, Figure 32, selecting TEMP Alm (ON) will bring a display similar to
Figure 34. The alarm can be assigned to any one relay.
The temperature alarm is programmed in the same way as an O2 alarm. The temperature alarm
cannot be set to a value greater than 45Deg. C. It is recommended that the High Set point be set
at 40 Deg. C.
8.4.1.3 Low Flow Alarm
The FLOW alarm is used to indicate a low flow condition in the sample stream. The optional low
flow switch will trip if the gas flow rate drops below the value listed in Table 15.
From the Alarm Setup Menu, Figure 32, selecting FLOW Alm (ON) will bring a display similar to
Figure 34. The alarm can be assigned to any one relay.
The flow alarm is programmed in the same way as an O2 alarm. However, the values for Hi Stpt,
Lo Stpt and Deadbnd will indicate NA. These values cannot be accessed.
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Background Gas
Trip Point (scfh)
Air
Ammonia
Argon
Butane
Carbon Monoxide
Ethane
0.25
0.33
0.22
0.18
0.26
0.25
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Ethylene
Helium
Hexane
Hydrogen
Methane
Nitrogen
Propylene
0.26
0.69
0.15
0.96
0.34
0.26
0.21
Table 15: Flow Switch Trip Points
8.4.1.4 Electrolyte Condition Alarm
The ELEC alarm is used to indicate electrolyte condition. From the Alarm Setup Menu, Figure
32, selecting the ELEC Alm (ON) will bring a display similar to Figure 34. The alarm can be
assigned to any one relay.
The electrolyte condition alarm is programmed in the same way as an O2 alarm. However, the
values for Hi Stpt, Lo Stpt and Deadbnd will indicate NA. These values cannot be accessed.
8.4.2 Analog Outputs
The Outputs entry in the Setup Menu, Figure 31, is used to scale the full range of the analog
output (voltage and current) over a partial or full range of oxygen concentration.
NOTE: Alarm or Analyzer status conditions that signal an “Analyzer off-line” fault condition
(such as sensor off) can be assigned to a single relay contact used as a trouble indicator. If the
Analyzer signal is only monitored remotely, it is suggested to route the 4-20 mADC signal
through the “Analyzer Trouble” relay such that an alarm condition will cause the relay to break
the current loop. This method allows a computerized system to be configured to detect an
analyzer fault condition whenever the 4-20 mADC signal is below 4 mA.
After accessing the Outputs on the Setup Menu, Figure 31, the display will be as shown in Figure
36.
Figure 36: Recorder Output Setup Menu
From the Recorder Outputs menu, the recorder zero and full scale (FS) can be set. On Trace
Analyzers, the values are in ppm; on Percent Analyzers, the values are in %. The selected Zero
and FS values will be displayed underneath the oxygen reading in the Data Display Screen.
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The Zero value corresponds to the lowest possible voltage and current output (0 VDC, 4 mA),
while the FS (Full Scale) value corresponds to the maximum voltage and current output (5 or 10
VDC [see Section 4.6] and 20 mA).
8.4.2.1 Scaling Analog Output Range On Standard Resolution Analyzers
The Zero to Full Scale window (FS setting - Zero setting) can be as narrow as 10% of the
Analyzer's full scale range. This limit is based on the fact that oxygen information is in a digital
format. Like a digital photograph it is only possible to magnify the information so much before
there isn’t enough resolution and the result is too grainy to use. Analyzers are shipped with a
factory setting that corresponds to the full scale range of the Analyzer. For example, a 0-100 ppm
Analyzer on first power-up would show OUT: 0.0-100.0 underneath the oxygen reading in the
Data Display Screen. Following are examples of valid recorder output settings on a 0 – 100 ppm
standard resolution analyzer.
Output (Zero to FS)
Percentage of scale used
on a 0 – 100 ppm standard
resolution analyzer
0-10 ppm
20-40 ppm
10-50 ppm
0-100 ppm
50-85 ppm
10 % of Scale
20 % of Scale
40 % of Scale
100 % of Scale
35 % of Scale
Table 16: Output Scaling on Standard Resolution Analyzer
If an invalid Zero to FS window is entered the following error message will be briefly displayed.
Figure 37: Recorder Output Setup Error
8.4.2.2 Scaling Analog Output Range On High Resolution Analyzers
On High-Resolution Analyzers the instrument has two internal operating ranges: 0-10% of full
scale (Scale A) and 0-100% of full scale (Scale B). When the oxygen reading decreases below
10% of full scale the analyzer automatically increases it’s internal gain by a factor of ten by
switching to Scale A. This gain increase permits the front panel oxygen display to provide an
additional digit of displayed resolution. Refer to the section on Specifications page 9, for a list of
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displayed resolutions. The increased gain also permits the analog output scaling to be set for
from 10% to 100% of Scale A, in addition to 10% to 100% of Scale B. See Table 17 for details.
Using the High-Resolution model is preferred if the oxygen reading will usually be below 10% of
the analyzer full scale reading and small changes in concentration (0.1% of full scale) must be
detectable. The selected Zero and FS values will be displayed underneath the oxygen reading in
the Data Display Screen. Following are examples of valid recorder output settings on a 0 – 100
ppm high resolution analyzer.
Output (Zero to FS)
Percentage of scale used
on a 0 – 100 ppm high
resolution analyzer
0-1 ppm
2-4 ppm
1-5 ppm
0-10 ppm
0-20 ppm
20-40 ppm
10-50 ppm
0-100 ppm
50-85 ppm
10 % of Scale A
20 % of Scale A
40 % of Scale A
100 % of Scale A
20 % of Scale B
20 % of Scale B
40 % of Scale B
100 % (Factory Set)
35 % of Scale B
Table 17: Output Scaling on High Resolution Analyzer
8.4.2.3 Expanded Range Scale Operation And Setup
The optional expanded range scale allows the analog output scaling to be automatically expanded
to a larger value when the primary scaling range is exceeded. For example, in the display shown
in Figure 36, the analog outputs (0-10 VDC and 4-20 mA) are scaled over the 0 - 10.00 ppm
area. However, the Analyzer is a 0-500 ppm unit and if the oxygen value exceeds 10.00 ppm the
analog output will peg. With the expanded range option it is possible to set a larger ppm range
that will automatically rescale the analog output when the primary scale is exceeded. In the
example, the analog output is scaled over 0 - 200 ppm as soon as 10.00 ppm is exceeded. If the
oxygen level falls, the Analyzer will switch back to the original 0 - 10.00 ppm scaling as soon as
the value is below 95% of the primary scale (9.5 ppm). This scaling change only affects the
analog outputs.
When operating on the expanded range the analog output scaling information on the front panel
will change to:
When the asterisk is on the Expand FS line, each time the
key is pressed a different full scale
value will appear. In this way it is possible to scroll through a list of selections. The expanded
range full scale value must be larger than the normal FS value, or the Analyzer will not accept the
setting. Expanded range may be turned off at any time by setting Expand FS to NU. The zero
point setup on the primary range is also used when operating on the Expanded Range.
8.4.2.4 ExpRng Relay
An alarm relay may be assigned to indicate when the optional expanded range is in effect. The
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relay will be in the “Normal” state when the analog output is on the primary range scale, and will
switch to the “Alarm” state when the expanded range scale is in effect. If there are no relays
installed this option will show NA. Since it is possible to assign more than one alarm or status
condition to any alarm relay, it is important to ensure that there are no other items assigned to this
chosen relay unless it is really desired.
8.4.2.5 CAL FREEZE
When a zero or span calibration is started CAL FREEZE holds the analog output at the last valid
oxygen value prior to the calibration. The oxygen value remains held until the calibration is
completed. This feature prevents a PLC or data acquisition system from “Seeing” a calibration.
If the PLC is used to detect alarms, a calibration could involve sampling gas sources with
concentrations above process alarm set points. CAL FREEZE may be turned off so that the
analog output operates normally (follows the oxygen value) during calibration.
8.4.2.6 IN-CAL RELAY
This is a setup feature that allows an optional alarm relay to be assigned to indicate when the
instrument is in the zero or span calibration mode. This feature may be used to signal a PLC,
DCS or other external device when the instrument is in calibration (not sending “Process” O2
data). Any relay may be assigned to IN-CAL RELAY service. If the Analyzer is not equipped
with relays, this selection will be NA. Since it is possible to assign more than one alarm or status
condition to any alarm relay, it is important to ensure that there are no other items assigned to this
chosen relay unless it is really desired.
8.4.3 Comm Port
The Comm Port Menu, selected from the Setup Menu Figure 31, is used to edit information about
the external communications port. This port operates with an 8 bit, no parity, one stop bit setting.
No hardware or software handshaking is used. See the Section on Connecting to External Devices
on page 41 for more information.
After accessing the Comm Port Menu, the display in Figure 38 will be shown.
Figure 38: Comm Port Setup Menu
8.4.3.1 Port
Used to indicate if the data should be sent to the RS-232C port (232), the RS-485 (485) port or
no communication port (OFF). Optional hardware must be factory installed to support either port
option. It is not possible for the analyzer to be equipped with both the RS-232C and RS-485
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option.
8.4.3.2 Device ID:xxx
Device ID is used to indicate the identity of the Analyzer. When using multiple Analyzers on an
RS-485 loop the device ID is used as a unique address which allows Analyzers to be individually
contacted by the communication software. The device number can be edited. The valid ID
address range is 1 to 255. Even when equipped for RS-232 (one host communicating with one
analyzer) it is necessary to set a valid ID address for the analyzer. The communication protocol
uses the ID address as part of the data packet sent to the analyzer.
8.4.3.3 Baud
This setting is used to choose the data transmission rate. The options are 19200, 9600, 4800,
2400 or 1200. The Analyzer is capable of receiving 19200 Baud transmissions without requiring
hardware or software handshaking. It is suggested that the highest data rate be used that reliably
works in the application. In this way the system will be as responsive as possible.
8.4.3.4 Update And Quit
Update and Quit is used to accept the values set on this screen.
8.4.4 Gas Scale Factor
Refer to the section on Calibration on page 76.
8.4.5 Display Setup
Access to the controls related to the backlight, brightness and contrast of the display are gained
through the display setup menu. See Figure 39 below.
Figure 39: Display Setup
8.4.5.1 Backlight (BL)
Access to the control of the backlight function is gained through the Display Setup menu. Hitting
the Enter key while the BL option is highlighted will toggle through three backlight options:
on/off and auto. When the desired setting is highlighted, move to the update and quit option with
the
and
keys and then hit enter. If auto is selected, the display backlight is turned on by a
front panel key stroke and runs for 30 seconds after the last key activity. If equipped with a NiMH
battery option, the backlight will only stay on for 10 seconds if the analyzer detects a low battery
condition.
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8.4.5.2 Level
Access to the control of the level or brightness function is gained through the Display Setup
menu. Hitting the Enter key while the Level option is highlighted will toggle through four
brightness options: low/mid/high and auto. When the desired setting is highlighted, move to the
update and quit option with the
and
keys and then hit enter.
8.4.5.3 Contrast
Access to the control of the contrast function is gained through the Display Setup menu. Hitting
the Enter key while the Contrast option is highlighted will toggle through four contrast options:
low/mid/high and auto. When the desired setting is highlighted, move to the update and quit
option with the
and
keys and then hit enter.
8.4.6 Clock
The Clock Menu, selected from the Setup Menu Figure 31, is used to edit information regarding
the clock and calendar operation. After accessing the Clock menu, Figure 40 appears.
To set the current time, use the
and
keys to move the asterisk to Time. Press
and the
cursor will highlight the hours. Use the
and
keys to set the hours, press
to move to
the minutes and after setting the minutes move to and set the seconds.
To set the current date, use the
and
keys to move the asterisk to Date. Press
and the
cursor will highlight the day. Use the
and
keys to set the day, press
to move to the
month and after setting the month move to and set the year.
When complete, move to the update and quit option with the
enter.
and
keys and then hit
Figure 40: Clock Setup Screen
8.5 The Password Menu
The DF-340E Process Oxygen Analyzer may include optional password protection which can be
used to limit access to the Control Menu, the Set-Up Menu, and the Diagnostics Menu.
Note: When the Password entry is selected from the Main Menu, a DISABLING ALARMS
message appears which notifies the user that the alarms have been temporarily disabled. The
alarm overlay messages will not show in the display. Relays will remain in the alarm state that
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immediately preceded the Disabling Alarms message.
The password operates on two levels, a Master Password to establish overall control of the
system, and an Operator Password to allow partial access to the system. If the selected level
requires a password, the display will present a password prompt. The password menu is displayed
in Figure 41.
Figure 41: Password Menu
The two-letter codes adjacent to the Set-Up, Control and Diags entries in the display are used to
indicate the level of password that is required to access the Set-Up, Controls or Diagnostics
menus. There are three possible settings for each entry:
MA (Master) - Indicates that the master password must be used to access the menu.
OP (Operator)- Indicates that the operator password or master password can be used to
access the menu.
NU (Not Used) - Indicates that no password is required to access the menu.
Note: When an Analyzer is shipped from the factory no password is installed.
To enter an Operator Password or Master Password, select the desired level. The display for an
operator password is shown in Figure 42. The display for a master password is identical except
the bottom line is blank instead of OP:.
Figure 42: Password Entry Screen
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A password consists of a series of one to four keystrokes using the ESC,
and
keys.
Password entry is completed by pressing
. Any combination of these keystrokes is acceptable.
A typical password is ESC,
After the fourth key is pressed in the Operator's
Password, the display will automatically return to the Password Menu, Figure 41. After the
fourth key is pressed in the Master's Password, press
to return to Figure 41.
NOTE
The master password should be recorded in a secure location. Once
the master password has been accepted, the Analyzer will not
display it again. If the master password is misplaced, contact the
Delta F Customer Support Services Department, at 781-935-5808,
for assistance.
The master password and operator password can be changed as desired after the present master
password has been entered. The new password(s) are activated by pressing
when the asterisk
is at Update and Quit.
To password protect a menu item (Set-Up, Control, Diags) use the
or
key to place the
asterisk next to the item and press
. Subsequent pressing
will cycle through NU, OP, and
MA. When the passwords and the settings for all three menus have been set, select Update and
Quit.
8.6 Maintenance
Note: When the Maintenance entry is selected from the Main Menu, a DISABLING ALARMS
message appears which notifies the user that the alarms have been temporarily disabled. The
alarm overlay messages will not show in the display. Relays will remain in the alarm state that
immediately preceded the Disabling Alarms message.
The Maintenance Menu is used to access the Replenishment Solution Addition Reminder, Oxygen
Calibration and Diagnostics Screens. When selected from the Main Menu, Figure 28, the display
shows Figure 43.
Figure 43: Maintenance Menu
8.6.1 Replenish Solution Reminder
The Replenish Solution Reminder screen Figure 44 is accessed from the Maintenance Screen
Figure 43 and refers to the electrolyte level in the Oxygen Sensor. It is used to reset the refill
reminder flag, set the reminder frequency and to assign a relay to the Reminder Warning.
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Figure 44: Replenishment Solution Reminder
8.6.1.1 Reset the “Reminder” Flag
If the Check Fluid flag is displayed on the Data Display Screen, the first line of the Reminder
Screen allows this flag to be cleared or reset after Replenishment Solution has been added to the
oxygen sensor. Use the
and
keys to move the asterisk next to Reset Reminder Flag and
press
. Then move the asterisk down to Update and Quit and press
again to confirm the
ESC
reset action. Or, pressing
at this point will result in the question “Abandon Changes?
for
yes” and the user can press
to return to the Maintenance Menu, Figure 43.
8.6.1.2 Set the “Reminder” Flag Frequency
The Maintenance Screen allows the period of time between Replenishment Solution additions to
be automatically tracked by the analyzer. When the time period ends, the Check Fluid flag shows
on the Data Screen, reminding the user to refill the electrolyte level with Replenishment Solution.
The flag can be set from 0-12 weeks, in increments of one week. Note – the reminder frequency is
pre-set at the factory to eight weeks.
8.6.1.3 Assign the “Reminder” Relay
The Reminder flag can be assigned to any of the available relays. See the section on relay
assignment in the Oxygen Alarm section on page 66.
8.6.2 Oxygen Calibration
Analyzer calibration checks and adjustments are made from the Oxygen Cal Menu which is
entered from the Setup menu, Figure 31. After accessing the Oxygen Cal Menu, the display will
present Figure 45.
Figure 45: Oxygen Calibration Menu
If the system has been previously recalibrated by the user, when the Oxygen Cal selection is
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made, an additional line will be added to the menu that states Reset Orig Span. The section on
Maintenance and Calibration on page 89 provides more information about spanning the analyzer.
8.6.2.1 Background Gas Correction (Optional)
The optional GSF (Gas Scale Factor) is used to correct for changes in the rate of oxygen diffusion
when background gases other than nitrogen are present in the sample gas. The GSF menu can be
entered through the Set Up Menu, Figure 31, or through the Oxygen Cal Menu, Figure 45. In
many applications, the GSF is not required, i.e., GSF=1.00. However, for some background
gases with significantly different diffusivities compared to nitrogen (such helium, hydrogen, or C3
and heavier hydrocarbons), the GSF can be useful. To use GSF, enter the volumetric percentages
of the sample gas as described below. The GSF is automatically calculated. Alternately, the GSF
factor can be entered manually.
The software in the Analyzer supports the following gases in the GSF calculation:
Ammonia
Argon
Butane
Carbon Monoxide
Ethane
Ethylene
Helium
Hexane
Hydrogen
Methane
Nitrogen
Propylene
NH3
Ar
C4H10
CO
C2H6
C2H4
He
C6H14
H2
CH4
N2
C3H6
Table 18: GSF Corrections
Contact the factory, for assistance with gases not listed above.
When GSF is selected, the display in Figure 46 will be shown.
Entries for additional gases can be accessed by using the
or
keys to scroll through the
list. The entries spread across more than two screens. Continued pressing of
will give access
to the additional choices, shown in Figure 47. By moving the asterisk to the appropriate line and
pressing
, the volume percentage of the sample gas can be adjusted.
After the volumetric percent of the selected gas is entered, continue to press
until the number
is no longer in reverse video. Repeat the process for other gases in the sample gas composition.
Note: An error message will appear if the sum of gases does not equal 100%. If that occurs,
change one (or more) values and press
again.
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Figure 46: Gas Scale Factor
For percent oxygen Analyzers, assume oxygen has the same diffusivity as nitrogen. Thus, add the
percentage of oxygen to the percentage of nitrogen when entering the percentage of nitrogen.
At the bottom of the list, the display will show Figure 47 below.
Figure 47: Gas Scale Factor Menu (Cont’d)
Note: Scrolling down the gas list from Figure 46 to Figure 47 will displace one line at a time.
Because these figures are presented from the top and from the bottom of the gas list, H2
(Hydrogen) and NH3 (Ammonia) appear to be missing.
When the composition of the gas (or the GSF factor) has been entered move the asterisk to
Update & Quit and press
. The GSF will be calculated and displayed.
If the GSF factor of the gas used to calibrate the system is already known, it can be entered
directly. To enter the GSF directly, move the asterisk to the GSF line and press
. Use the
and
keys and hit
to enter the desired value.
NOTE
The GSF for the gas used to calibrate the system may be different
from that used during analysis. If the GSF is changed to reflect the
composition of the calibrating gas, be sure to reset the GSF before
analyzing samples.
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Disclaimer
The method used to correct the calibration of the Delta F Oxygen Analyzer for measurement in
non-nitrogen background gases is derived from a well known theoretical mass transfer
equation. This equation accounts for the change in oxygen diffusion rates through different
gases.
Although significant empirical work has been done in this field, it is generally accepted that the
equation may be only 85-90% accurate. In addition, there is further error introduced when
correcting for a "multi" component background gas. This may result in an additional 3-5%
error. Correcting the calibration (for all combinations of background gases) using theoretical
means has its limitations.
An alternate method when using a non-nitrogen or "multi" component background gas is to
obtain a certified oxygen calibration standard which has been prepared in a background gas
which models the average process sample. In this case any possible error introduced in using
the theoretically derived correction factor is eliminated. Caution must still be used, however,
as certified standards may also have inaccuracies associated with them.
Questions regarding the calculation of a background gas correction factor for a specific
application should be directed to the Delta F Customer Support Services Department at 781935-5808.
NOTE: In light gas (H2 or He) backgrounds, the diffusion rate of oxygen will be greater than that in nitrogen,
resulting in a higher absolute current generated by the sensor. If the sample contains an oxygen concentration
near the high-end of the instrument (e.g. 80 ppm on a 0-100 ppm unit), and consists of a light gas background,
the current generated by the sensor may be too much for the electronics to source and will effectively put the
instrument out of range. In such a case, it would be appropriate to use an analyzer of the next highest range
(e.g. 0-500 ppm). Consult Delta F for application specific details.
8.6.2.2 Check/Adj Span
Note: A calibration should be performed only after the Analyzer has been operating at least eight
hours. The door should be closed when calibrating the Analyzer to keep the sensor temperature
stable.
It is not possible to perform a Span Adjustment if the TEMP OVER RANGE condition is
occurring.
The Check/Adj Span entry in the Oxygen Cal Menu, Figure 45, is used to adjust the O2
calibration. Selecting Check/Adj Span will display the screen shown in Figure 48.
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Figure 48: Span Check Menu
The GSF factor of the calibration gas can be entered directly or calculated by the instrument as
described on page 77. The legend (nGS) indicates the number of gases used to calculate the GSF.
If n has a value of zero, it indicates that the factor was directly entered, or the default value of
GSF=1.00 was used.
The Span Reference value SPAN REF is a numerical indicator for calibration changes made in
the field. All instruments are shipped from the factory with a SPAN REF value of 1000. The
number will decrease if the sensor's output decreases and vice versa. For example: For a 100 ppm
Analyzer if a 70 ppm span gas is being used, the Analyzer reads 65 ppm, and an Oxygen Cal is
performed, the Span Reference will change to 928 ([65 ppm / 70 ppm] X 1000) following the
calibration process.
The following information should be recorded at each calibration:
Date
Span Gas Value
Old Span Ref Value
New Span Ref Value
Time spent sampling Span Gas
Note: If the sensor has lost or gained significant sensitivity, verify the quality of the gas used as
the calibration standard.
Review the section, Sampling Considerations During Calibration, on page 38 for information
regarding calibration standards, regulators, purging, and sample conditions. When introducing a
calibration gas into the sample system, it is important to maintain the same pressure and flow
conditions that occur during process monitoring.
NOTE
Over-pressurizing the Analyzer can result in permanent damage to
the sensor and optional pump. If the sample supply gas pressure
exceeds 10.0 psig, install a pressure regulator in the inlet calibration
gas line to regulate the pressure to 5.0 psig or less. The upstream
flow control valve is used to set the flow at 1.0 (scfh).
If the normal process sample is being supplied to the Analyzer under moderate vacuum conditions
(4" Hg vacuum or higher), such as when taxing the capability of the on-board pump, the Analyzer
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should be calibrated with the pump operating even if the calibration gas has sufficient pressure to
preclude the use of the pump. The operating pump will create a pressure condition at the sensor
that simulates the operating condition.
Analyzers with a pump are fitted with two flow control valves, one on the downstream rotameter
and one on the sensor inlet (upstream of the sensor). Before turning on the pump, open the
rotameter valve fully by turning it counter-clockwise. Close the upstream flow control valve
completely (clockwise). Set the calibration gas regulator to less than 10.0 psig, then attach the
calibration gas line to the Analyzer inlet. Use the upstream flow control valve to set the flow rate
to 1.0 scfh. Turn on the pump and readjust the flow rate prior to calibrating.
NOTE
Do not adjust the valve at the rotameter, leave it in the fully open
position during calibration.
For an accurate calibration, the sensor output must be stable. The time to achieve stability
depends on the range of the Analyzer and the difference between the sample gas value and the
span gas concentration. Typically, lower ppm range instruments require more time to achieve a
stable output than higher ppm or percent instruments. The use of a chart recorder is suggested to
monitor stabilization.
NOTE
Time required for the O2 reading to stabilize when on span gas can
vary from 15 to 60 minutes.
After a stable reading is obtained, enter the O2 concentration of the calibration gas. Then press
to complete the calibration.
A “Wait...” message will appear, followed by the display shown in Figure 49.
Figure 49: Calibration Convergence Screen
It may take several minutes before convergence occurs. During convergence, the Analyzer is
verifying stability of the reading before accepting the data. After convergence two short beeps
will be heard. The Analyzer's electronics can be updated to the new calibration information by
selecting Update and Quit.
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If convergence does not occur within 5 minutes, check the following:
a.
Make sure the gas connections are leak free.
b.
Make sure the sensor has been allowed sufficient time to have attained a stable reading on
the calibration gas.
c.
Check the electrical connections to the sensor.
If all items check out, allow the Analyzer to operate an additional 30 minutes on calibration gas.
Repeat the calibration. If the results are the same, acceptance of the calibration may forced by the
user by hitting the
key while in the “Convergence” screen. See Figure 49.
To leave the Calibration before completing convergence, press ESC. The previous calibration
will remain in effect.
If the system has been recalibrated by the user, when the Oxygen Cal selection is made from the
SETUP MENU the display will appear as shown in Figure 50. The number in parenthesis next to
the GSF will indicate the number of gases used (4 GaSes in the representative screen) to calculate
GSF, or it will indicate the chemical formula for a single gas used (such as He).
Figure 50: Completed Oxygen Calibration Menu
8.6.2.3 Reset Orig(inal) Span
The Reset Orig Span entry is used to restore the calibration that was made at the factory when
the unit was manufactured, or the New Sensor calibration if the sensor has been field replaced.
If the Reset Orig Span entry is selected, the display will ask Erase Cal?...
FOR YES. Press
to use the factory set calibration. The bottom line of Figure 50 will disappear, and the factory
span calibration will be restored.
8.6.2.4 New Sensor
The New Sensor entry is used after a new sensor is field installed. New sensors are supplied with
calibration information. The procedure for installing a new sensor is described in instructions
supplied with it.
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NOTE
Do not edit this entry without specific instructions from the Delta F
Customer Support Services Department. Editing the entry will alter
the stored factory calibration parameters and may cause dramatically
erroneous operation. If the entry has been accidentally accessed,
press ESC.
8.6.3 Diagnostics
Note: When the Diagnostics entry is selected from the Main Menu, a DISABLING ALARMS
message appears which notifies the user that the alarms have been temporarily disabled. The
alarm overlay messages will not show in the display. Relays will remain in the alarm state that
immediately preceded the Disabling Alarms message.
The Diagnostics menu is used to test different functions of the Analyzer. When this menu is
selected and the password is entered (if required), Figure 51 is displayed.
Figure 51: Diagnostics Menu
8.6.3.1 Sensor Temperature
The display will indicate the present sensor temperature. There is no user action with this
selection. This value does not update continuously; it is the last temperature reading before
entering the menu. To obtain a new temperature reading, leave and re-enter the Diagnostics
menu. New temperature values are available every 60 seconds.
8.6.3.2 Sensor Zero
The Sensor Zero entry is used to calibrate the zero baseline level of the sensor. The sensor zero
baseline is calibrated at the factory and should not require any adjustments or checking under
normal operating conditions. See Section 8.1.1 for details on normal operating conditions. If
operating outside normal operating conditions contact Delta F for an application specific
recommendation on checking the zero of the instrument in the field. Contact the Delta F
Customer Support Services Department at 781-935-5808.
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Should Delta F recommend checking the zero baseline calibration of the Analyzer, the following
procedure can be followed: purge the sensor with gas that is free of O2 until the output is stable.
A suitable way to obtain an oxygen-free gas is to pass a pure grade of nitrogen gas through an
oxygen purifier such as SAES MicroTorr™, Millipore Waferpure™ or Semigas Nanochem® resin
purifiers. It is necessary to have a zero gas sample source that is assured to be at least one order
of magnitude purer than the lowest resolution of the Analyzer.
Note: The difficulty in delivering a high quality zero gas to the Analyzer in the field can
introduce significant error when attempting to zero calibrate the Analyzer. It is recommended
that recalibration be done at the factory with its certified low ppb system. If checking zero
calibration in the field, ensure that the gas system used to zero calibrate the Analyzer is leak-free
by performing the low flow test described on page 93.
Reaching a stable zero for the lowest range Analyzer may require 24 hours or longer, even
assuming that the Analyzer has been running continuously for several weeks on a process
application where readings are near the detection limits of the Analyzer. It is recommended that a
recorder be used to chart the zero point, especially for low trace units. When the Sensor Zero
entry is selected, the display will present Figure 52.
Figure 52: Sensor Zero Menu
8.6.3.2.1 ZERO REF
The ZERO REF value is a numerical indicator for calibration changes made in the field. All
instruments are shipped from the factory with a ZERO REF value of 0.00. The number will
become negative, following a user zero calibration, if the sensor zero is below the factory
calibration and vice versa. This value should be recorded both before and after a Zero
Calibration.
8.6.3.2.2 Reset Orig(inal) Zero
The Reset Orig Zero entry is used to restore the zero calibration that was made at the factory
when the unit was manufactured, or the New Sensor zero calibration if the sensor has been field
replaced.
If the Reset Orig Zero entry is selected, the display will ask Erase?...
FOR YES. Press
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to use the factory set calibration. The Reset Orig Zero line of Figure 52 will disappear. It is
necessary to select Update and Quit to make the reset permanent.
8.6.3.2.3 Zero Cal(ibration)
Selecting Zero Cal will result in the display shown in Figure 53.
Figure 53: Zero Cal Warning Screen
Note: The zero baseline stabilization criteria is only verifying stability over a short time scale (15 minutes). The output on zero gas should be recorded (by manual or strip chart technique) and
stability should be monitored over a much larger time scale (18 to 24 hours for 0-1000 ppm and
lower range High Resolution Analyzers). Only when it is clear that the Oxygen reading has
reached a constant minimum value should a zero calibration be attempted.
When any key is pressed, the display will show Figure 54 without the OFFSET line. This screen
will be overwritten with a "WAIT..." message for about ten seconds and then the OFFSET: line
will appear. Two beeps will sound when the “WAIT...” message clears. When the offset is
stable, the instrument will sound two short beeps and display a "STABLE" message on the blank
line below ZERO CAL. The user has the option to accept the new offset value by pressing the
key, or not accepting the new offset value by pressing the ESC key. With either choice, the
display will return to the SENSOR ZERO Menu as seen in Figure 52.
Figure 54: Zero Cal Screen
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Pressing the ESC key at any time aborts the process and returns the user to the SENSOR ZERO
menu.
If
is pressed before the “STABLE” message is displayed the screen will change as shown in
Figure 55.
Figure 55: Zero Cal Not Stable
To accept the unstable OFFSET value press
. This is not recommended! The offset value at
this point may not be satisfactorily close to the eventual zero baseline level because the zero
baseline level is still equilibrating. To resume stabilization press ESC.
During Zero Cal the other messages that may appear below ZERO CAL are:
INVALID DATA - Indicates that the instrument's analog- to-digital converter is reading
a value which is over or under its full scale range. Check sensor's electrical connections and the
delivery of oxygen free sample gas (see PRESCALER HIGH below).
8.6.3.3 Test Output
The Test Output entry is used to calibrate the recorder. When the Test Output option is selected,
the display will show Figure 56.
Figure 56: Test Output Screen
Use the
86
key to set the desired output level in 10% percent steps of full scale from 0% to
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100%. After setting the % FS Level, press
. The analog output response should match the
%FS Level value that was entered. For example, if 80% is entered for the %FS value on a 0-10
VDC recorder, the output will be 8.000 VDC. See the sticker inside the front door that indicates
to what full-scale voltage the Analog Output has been configured.
8.6.3.4 Test Relays
The Test Relays selection in the Diagnostics Menu, Figure 51, is used to assure that the relay
outputs are functioning. When the Test Relays option is selected, the display will show Figure 57.
Figure 57: Test Relay Screen
Select the relay to be tested, then press
. The relay will toggle between on and off each time
is pressed. An audible click will occur. The condition of the relays before the test will be
restored when the test is concluded.
8.6.3.5 Memory Test
The Memory Test selection is used to test the internal memory of the Analyzer. When the
Memory test option is selected from the Diagnostics Menu, Figure 51, the display will show
Figure 58. Testing automatically begins.
Figure 58: Memory Test Screen
During the ROM test the program EPROM contents is used to calculate a checksum, which is
compared to a checksum that was stored in the EPROM at the factory. Any changes in the
program code can be detected. Next, the microprocessor internal memory (IRAM) is tested,
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followed by the system “external” random access memory (XRAM). As each portion of the
memory is successfully tested an OK will appear at the end of the line. If any memory test fails,
repeat the test. If a failure is repeated contact the Delta F Customer Support Services
Department at 781-935-5808.
8.6.3.6 Screen Test
When the screen test option is selected, the display will test each pixel. A series of horizontal
lines will appear on the display, followed by a series of vertical lines. After the test has been
completed, the display will return to the Diagnostics Menu, Figure 51. Pressing ESC will abort
the screen test. If an error message appears, or a pixel is inactive, contact the Delta F Customer
Support Services Department at 781-935-5808.
8.6.3.7 EXT Functions
Figure 59: EXT Functions
The EXT Function screen indicates to the user which, if any, functions have been factory
programmed for remote control through the J6 connector. Chosen at the time of order, the
following analyzer functions can be remotely controlled: Sensor polarizing voltage or Pump
on/off. See page 45 for additional information on wiring. NU will appear if no functions have been
enabled. It is important to note that the front panel has no control of these functions while the
analyzer is under remote control.
If the sensor polarization voltage has been turned off remotely, the display will indicate EXT
SENSOR! at the bottom.
If the pump has been turned on remotely, the display will indicate EXT PUMP at the bottom.
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9 Troubleshooting and Calibration
9.1 Return Material Authorization Number
If an analyzer has to be returned to the factory, the shipper will have to obtain a Return Material
Authorization number from Delta F by calling the Service Line at (781) 935-5808 or sending a
written request via the Service Fax Line at (781) 932-0053. See the Shipping Section on page 99
for more details.
9.2 Maintenance
The analyzer maintenance recommendations made in this manual apply to all Analyzers being
operated under Normal Operating Conditions and in clean gas applications.
A clean gas application is one in which certain process conditions are met. The sample
background gas must contain less than 10% of the acid gas limits shown in Table 4 page 31, on a
continuous basis. Solvents or other gases that are listed as “very soluble” to “infinitely soluble” in
water must make up less than 0.1% of the background gas composition. Sample condensation
must be avoided. For a hydrocarbon background gas, the sample must be kept at a temperature
of at least 40°F over the sample dewpoint. A wet sample (high water dewpoint) must be kept at a
temperature of at least 10° F over the dewpoint. The particulate density must be below the limit
of 0.03 mg/L (weight of particulate matter / volume of sample at atmospheric pressure).
Some examples of clean gas applications include monitoring of high purity gas pipelines,
compressed cylinder gases, cryogenic air separation plants, polyolefin feedstocks, glove boxes,
and semiconductor process tools.
9.2.1 Calibration
All Delta F DF-340E Process Oxygen Analyzers are calibrated with NIST (National Institute For
Standards And Technology) traceable certified gas standards at the factory prior to shipment. No
initial calibration is required upon receipt from the factory.
For Analyzers used in clean gas applications (as described above) and operated under Normal
Operating Conditions, Delta F recommends verifying the span calibration every 12 months of
continuous use. This can be accomplished by using the Analyzer to read a gas sample with a
known concentration, such as a certified cylinder gas mixture of O2 in N2 background, available
from any specialty gas supplier. For process applications containing more significant quantities of
acid gases or particulate, or where liquids may be encountered, contact Delta F for a
recommendation on calibration verification for your specific case.
For Analyzers used in clean gas applications, and operated under Normal Operating Conditions
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there is no need for zero calibration checks in the field.
NOTE
If the analyzer is used in a portable mode, the optional isolation
valves should be used during transport to preserve the stability of
the zero calibration.
9.2.2 Storage Conditions
The Oxygen sensor was drained of electrolyte and thoroughly rinsed prior to shipment. Residual
fluid will maintain in the electrode systems for several weeks during transportation and
installation. If it is intended to store the system or delay installation and start-up for two months
or more it is recommended that the sensor be filled to the bottom of the reservoir with RSA
Replenishment Solution, which is provided as part of the Start-up and Maintenance
Kit. Remember to securely replace the cap when done. For extended storage, six months or
more, additional fluid should be added to allow for normal evaporation. At time of start-up it is
recommended that any remaining Replenishment Solution be drained prior to addition of the fresh
electrolyte. Be sure that the storage location temperature does not exceed 50° C (122° F).
Storage in direct sunlight can cause temperatures to exceed the recommended limits even though
ambient temperatures may be below the maximum temperature.
9.2.3 Sensor Maintenance
The analyzer does not require routine maintenance other than adding Replenishment Solution to
the electrolyte. Exposure to dry gas for an extended time gradually extracts water from the
sensor. The electrolyte needs to be refilled occasionally with Delta F Replenishment Solution for
optimum performance and long term reliability.
CAUTION
If the electrolyte level is low, only Delta F Replenishment Solution
should be added to the sensor for optimum performance and long
term reliability. Be sure to cap the bottle immediately after use. In an
emergency, distilled water can be used as an alternative, however
this is not recommend over an extended period. Do not add
electrolyte solution to restore the electrolyte level. Do not
overfill.
The Sensor Assembly consists of two connected chambers. The operation of the sensor is
satisfactory as long as the level of electrolyte is above the minimum indicator line and below the
maximum line on the reservoir label.
One bottle of electrolyte, contains 100cc and the entire contents of the bottle should be added at
the time of startup. This quantity is sufficient for satisfactory operation. It is not necessary to add
additional electrolyte.
Typically, bone dry sample gas can extract approximately 5 to 10 cc of water per month. The
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electrolyte level should be checked every 1 to 2 months. If the liquid level is low, add Delta F
Replenishment Solution to bring the electrolyte level between the minimum and maximum
indicator lines on the reservoir label. Operation at elevated temperatures and/or with sample
gases at very low dew points will increase the frequency of replenishing the electrolyte.
The Oxygen Analyzer is equipped with an Electrolyte Condition alarm to indicate that the
electrolyte level is low. The operation of this alarm is described in the Alarms section.
9.2.4 Procedure for Adding Replenishment Solution to the Sensor
1) Open the front door.
2) Unscrew and remove the sensor cover. Remember, the electrolyte is caustic; be careful of
drips of electrolyte from the cover.
3) Add Delta F Replenishment Solution to the electrolyte solution using the supplied squeeze
bottle.
4) Fill to the max level indicator line on the reservoir label. Be careful not to spill water on the
electronics or on the outside of the sensor. Do not overfill.
5) Replace the cover securely and close the front door.
CAUTION
If the electrolyte level is low, only Delta F Replenishment Solution
should be added to the sensor for optimum performance and long
term reliability. Be sure to cap the bottle immediately after use. In an
emergency, distilled water can be used as an alternative, however
this is not recommend over an extended period. Do not add
electrolyte solution to restore the electrolyte level. Do not
overfill.
Troubleshooting and Calibration
DF-340E
91
9.3 Replaceable Parts List
Included in the following list are all major parts that are field replaceable. This list is not intended
as a recommendation of spare parts to be stored in case of failure.
When ordering replacement parts, be sure to include the analyzer serial and model numbers.
Description
P/N
Battery - NiMH
Cable – Display to Main Board
Cable – Sensor to Main Board
Connector - (8 pin)
Connector - (4 pin)
Display assembly with PCB
Electrolyte
Feet - Rubber
Filter Element - Coarse
Filter Element - Fine
Flow Meter (0-5 scfh)
Flow Meter (0-2 scfh)
Flow Meter w/Valve (0-5 scfh)
Flow Meter w/Valve (0-2 scfh)
Flow Switch (except 25% analyzer)
Flow Switch (25% analyzer only)
Fuse 24 VDC Operation - 1A
Fuse 100-240 VAC Operation - 2.5A
Fuse – Battery Backup - 3.15A
Handle Assembly
Instruction Manual
PCB - CPU
PCB – 24VDC Power Supply
PCB – Battery Backup
PCB – 4-20mA
Power Cord
Power Supply (100-240VAC)
Pump - 12 VDC w/wo Battery Backup
Replenishment Solution
Sensor
Sensor Cap - Blue
16337070
13236991
13238060
50980707
50980755
15330110
E-Lectrolyte Blue
83950001
64005011
64005012
11220841
11240361
11220842
11240362
51300014
51300017
45000044
45002521
45000043
65000000
99000048
10334840
10334850
10334870
10334863
59017300
47500025
63000321
RSA
Call Delta F
17338580
Table 19: Replaceable Parts
92
DF-340E
Troubleshooting and Calibration
9.4 Troubleshooting
The following Troubleshooting Guide helps the user resolve many of the common operational
situations that occur with the analyzer. Investigate possible remedies in the listed order.
9.4.1 Sample System Leak Test (Low Flow Sensitivity)
By far the most common reason for high Oxygen readings is a leak in the sample delivery system.
Leaks are divided into two types: real leaks and virtual leaks. A real leak is a lack of integrity in
the sample delivery system. A virtual leak is caused by Oxygen that is trapped in the upstream
plumbing and components, such as regulators and filters. This Oxygen is slowly being purged out
of the system. Virtual leaks are most common in new installations.
Determining the nature of the leak is not a difficult task. It is important to be consistent in the
approach and technique. The steps listed below will be helpful toward resolving any leak related
problems.
1)
Determine if the high reading is due to a leak or is a real indication of Oxygen level. This
can be easily done by performing a "Flow Sensitivity Test". If the Analyzer is equipped with a
pump, it is recommended that it not be used during the Flow Sensitivity Test. This test requires a
positive pressure sample delivery system. If it is not possible to provide positive sample pressure
to the Analyzer, skip to Step 2. Perform the Flow Sensitivity Test as follows:
a)
Establish a flow rate that is within the normal operating tolerances of the Analyzer.
Generally a flow rate of around 0.5 LPM or 1 SCFH is ideal.
b)
Give the Analyzer a couple of minutes to stabilize, and then carefully note the flow
rate and the Oxygen level displayed.
c)
Reduce the flow rate by 75%. In a system with good integrity, there should be
little change in the front panel display. If a leak exists, however, the reading will rise noticeably.
Allow it time to stabilize, and carefully note the flow rate and the Oxygen level displayed.
d)
Re-establish a normal flow rate and allow the Analyzer to purge for ½ hour. Note
again the flow rate and Oxygen level displayed.
e)
Repeat step c. If the Oxygen level stabilizes at a level that is close to the prior
value from step c, then the leak is real. If the reading shows a lower Oxygen level than the prior
value from step c, the leak is probably a virtual leak and continued purging should rectify the
problem.
2)
Once it has been determined that there is a leak, the next logical step is to locate it. The
easiest way to locate a leak is to close off the feed to the Analyzer from the sample delivery
system, and to allow the system to pressurize. Apply Snoop® or another type of liquid leak
detector to all of the fittings on the system. Any fitting that shows bubbles should be tightened or
Troubleshooting and Calibration
DF-340E
93
replaced.
3)
If it is not practical to remove the Analyzer from the sample delivery system, leaks can be
located by monitoring Analyzer output while applying Snoop® or another liquid leak detector to
one fitting at a time. Snoop® will not show bubbles at the low pressure required for proper
Analyzer operation. However, Snoop® will temporarily block any leak, at the fitting being
checked, and the Analyzer output will drop. It is important to give sufficient time for the
Analyzer to respond before going on to the next fitting.
The more distance between the fitting and the Analyzer, the more time should be given for the
Analyzer to respond.
9.4.2 Basic Troubleshooting
Solutions are listed in the order that they should be attempted.
POSSIBLE
SOLUTIONS
PROBLEMS
1)
Analyzer reads low
ABDEHIFJZ
2)
Analyzer reads high
ABCDEIJZ
3)
Analyzer output is noisy
AEIZ
4)
Analyzer reads high with pump on
CZ
5)
Analyzer reads 0.00 at all times
QDZ
6)
Slow speed of response
GCDEFZ
7)
Electrolyte residue (white powdery build-up) visible
on the sensor
8)
Electrolyte Condition alarm “ON”
PDEZ
9)
Display is blank, or shows an unusual appearance
KOZ
10)
Display reads any of the following:
- Over Range or TEMP OVER RANGE
- NOVRAM Failure
- Uncalibrated
11)
94
Span reading is unacceptably high (>50% high)
DF-340E
Z
LMNZ
Z
Z
RCJZ
Troubleshooting and Calibration
12)
Span reading is unacceptably low (>50% low)
RJEZ
SOLUTIONS KEY
A)
Check instrument performance using a gas standard of known Oxygen content (Span).
B)
Check that the Analyzer zero setting matches the original factory setting. Consult the
manual or the factory to verify these settings.
C)
Check the sample delivery system for leaks.
D)
Verify that the correct voltages are being supplied to the sensor. These voltages should be
checked with the leads disconnected from the sensor. The voltages measured should be as
follows:
Primary Electrodes:
Secondary Electrodes:
wht/yel (-) to wht/blk/red (+) = 1.30 ± 0.065 VDC
wht/blu (-) to wht/red (+) = 5.3 ± 0.5 VDC
Voltage levels between any other combination of wires should be less than 0.10 VDC. If there is
any deviation from these values, contact the Delta F Customer Support Service Department at
781-935-5808.
E)
Change the electrolyte. Use only electrolyte supplied by Delta F. Other types of
electrolyte can damage the sensor and will void the warranty. Always rinse and drain the cell with
distilled water at least three times before refilling the sensor with fresh electrolyte. Fill the sensor
with exactly one full bottle of electrolyte (100 cc) and top off the sensor with Delta F
Replenishment Solution to the MAX line. Allow the Analyzer to operate for several hours on
Nitrogen or other inert gas. A calibration check is recommended if performance was poor prior
to the electrolyte change.
G)
Remove and check the filter element. Replace if needed.
H)
Check for contaminated plumbing. This is most easily done by examining the rotameter (if
so equipped) or Tygon tubing downstream from the sensor for evidence of oil, powder, or other
material that may have made its way from the process to the Analyzer.
I)
Remove any devices being driven by the Analyzer output, i.e., chart recorders, data
acquisition systems, etc. Also, disconnect anything controlled by the Analyzer alarm relays.
Attempt operation with these devices removed.
J)
Ensure that the background gas is compatible with the Analyzers' current calibration.
Troubleshooting and Calibration
DF-340E
95
Otherwise, select the appropriate GSF value (if equipped with the GSF option), or offset the
display readings externally by the appropriate Background Gas Correction Factor amount. See
page 77 for more information.
K)
Press the
key once. If the display remains unchanged, power the Analyzer down
momentarily, and then power it back up.
L)
Ensure that the Analyzer has adequate sample flow.
M)
Ensure that the sensor polarization voltage is turned on. See page 63.
N)
Enter the Diagnostics menu and verify that the temperature is between 0° and 45°C. If
temperature indicates erroneously high, check for good contact at the red and black wires on the
sensor harness connector (for Analyzers having the sensor in the cabinet), or at all remote wiring
connection point (starting at rear panel connector J11 pins 1 and 2) for remote sensors. Also, in
remote sensor applications, verify that the temperature sensor wires are not reversed.
Note: The sensor temperature reading is only updated when entering the Diagnostics
menu. After checking wiring connections leave the Diagnostics menu, wait one minute, and enter
the menu again. The temperature value will be new, and should now be correct.
O)
Confirm that the power supply is turned on, operating at the proper voltage and is
connected properly to the analyzer.
P)
Add Delta F Replenishment Solution if electrolyte level is near or below “MIN” mark.
Q)
Check the sensor wiring. Make sure the nuts holding the wires to the sensor have not
come loose. Trace the wires from the sensor back to the sensor connector. Make sure that the
terminal pins are seated correctly in the connector plugs and are making good contact through the
connector. Trace the wires further back to the main PCB connector. Make sure the wires are
crimped correctly and none have broken loose.
R)
Check the accuracy and age of the calibration reference cylinder. Trace O2 standards in
steel cylinders decay over time due to oxidation of the cylinder walls. Standards below 100 ppm,
in steel cylinders, should be re-analyzed or calibrated every three months. Ideally, standards
below 100 ppm, and certainly standards below 10 ppm, should be prepared in aluminum cylinders.
Z)
Contact the Delta F Customer Support Services Department. The phone number is 781935-5808. The fax phone number is 781-932-0053. For faster service, have the instrument serial
number and model number in hand before calling. Always be certain to drain the sensor of
electrolyte before returning it to the factory for repair.
96
DF-340E
Troubleshooting and Calibration
9.4.3 Fuse Replacement
DANGER
The instrument power must be shut off before removing the fuse.
Failure to do so may expose the operator to hazardous voltages.
The operating voltage of the analyzer is marked on a label located on the rear of the cabinet.
Always use the proper fuse for the operating voltage of the analyzer.
9.4.3.1 AC Power Fuse
If configured with an integral 100-240 VAC power supply, the 5X20 mm, 250 VAC, IEC Sheet
III, Type T fuse is rated at 2.5A. There are two fuses that are located in the AC input connector
located behind the cover on the rear of the cabinet.
Refer to the spare parts list on page 92 for Delta F replacement part numbers.
9.4.3.2 DC Power Fuse
If configured for 24 VDC operation, the 1.0A type TE-5 fuse is located on the under side of the
24VDC power PCB (#10334850). See Figure 60. To access this board, the entire board set must
be removed from the cabinet after disconnecting the sensor cable, the rear connectors and
removing the two mounting screws on the rear of the cabinet. Remove the metal cover plate and
the power supply board can then be gently separated from the main CPU to access the fuse.
Refer to the spare parts list on page 92 for Delta F replacement part numbers.
9.4.3.3 Battery Backup Fuse
If configured with the Battery Backup option, the 3.5A type TE-5 fuse is located on the under
side of the battery charge PCB (#10334870). See Figure 60. To access this board, the entire
board set must be removed from the cabinet after disconnecting the sensor cable, the rear
connectors and removing the two mounting screws on the rear of the cabinet. Remove the metal
cover plate and the power supply board can then be gently separated from the main CPU to
access the fuse.
9.4.3.4 4-20mA Output Fuse
The 4-20mA analog output is fused by a fast acting, automatically resetting, 100mA circuit
breaker.
Troubleshooting and Calibration
DF-340E
97
24VDC POWER SUPPLY PCB
FUSE 1.00A
BATTERY BACKUP PCB
FUSE 3.15A
Figure 60: Fuse Locations for DC Power Supply and Battery Backup
MAIN PCB
24VDC POWER SUPPLY PCB
OR
BATTERY BACKUP PCB
4-20mA PCB
Figure 61: Printed Circuit Board Assembly
98
DF-340E
Troubleshooting and Calibration
9.5 Shipping
If it comes necessary to return the analyzer to the factory or ship it to another location, please
follow the packaging and shipping procedure below in order to prevent damage to the analyzer
during shipment.
CAUTION
Do not ship the analyzer with electrolyte - thoroughly drain and
rinse sensor before shipping
Note: If you are returning the analyzer to the factory, first call Delta F to obtain a Return
Material Authorization number (see complete details below), then proceed as follows:
1. Turn off and disconnect the power source from the analyzer.
2. Disconnect all external electrical connections (alarms, data output, etc.).Mark each for reattachment later.
3. Remove the sensor as described on page 13.
a. Drain the electrolyte into a receptacle suitable for proper disposal.
b. Rinse the sensor with distilled water at least three times. Drain the water into the
receptacle.
c. Securely hand tighten the cover.
4. Reinstall the sensor using the two sensor mounting screws.
5. Install the bulkhead lock nut. Cap the inlet fitting to prevent debris from entering.
6. Put the analyzer in its original container. Ensure that all internal components are
adequately secured. It is recommended that bubble packing or similar protective material
be added inside the container for added protection.
If you are returning the analyzer to the factory, call the Delta F Service Line at (781) 935-5808 to
obtain a Return Material Authorization number. Clearly mark the Return Material
Authorization number on the outside of the shipping container and on the packing list. The
analyzer should be returned (freight prepaid) to:
RMA #______
Delta F Corporation
4 Constitution Way
Woburn, MA 01801-1087
Troubleshooting and Calibration
DF-340E
99
10 Theory of Operation
10.1The Oxygen Sensor
The Delta F Coulometric Sensor uses an ambient temperature oxygen
reaction that is non-depleting. The cell produces a current flow that is
determined by the number of oxygen molecules that are reduced at the
cathode. The sensor reaction is driven by 1.3 Volts applied across the
electrodes. The resulting electron flow is measured as a current that is
precisely proportional to the oxygen concentration in the sample gas.
Secondary
Electrodes
KOH
1.3V Applied
4OH¯
O2
Sample Gas
Anode
Cathode
Figure 62: Schematic of Delta F Oxygen Sensor
The cathode reaction uses 4 electrons from the 1.3 volt circuit, 2 water
molecules from the electrolyte, and 1 oxygen molecule from the sample
gas to generate 4 hydroxyl ions which migrate across the reaction
chamber to the anode:
O2 + 2H2O + 4e- 4OHThe anode reaction consumes the 4 hydroxyl ions and delivers 4
electrons to the circuit, 2 water molecules back to the electrolyte, and
vents one oxygen molecule.
4O H- O2 + 2H2O + 4eThere is no net change to the electrolyte and no depletion of the sensor
or electrodes.
Theory of Operation
DF-340E
101
10.2 The Electrolyte Conditioning
System
The Process Oxygen Analyzer is equipped with Delta F's patented
electrolyte conditioning system and is composed of two specialized
electrode pairs.
The patented secondary electrode pair protects the sensing electrodes
from the deleterious effects of trace impurities inevitably found in the
electrolyte. The secondary electrodes attract and trap trace ionic
impurities present in the electrolyte, providing a scavenging function
that results in long-term zero and span stability.
102
DF-340E
Theory of Operation
11 Safety
CAUTION
Do not setup or operate the Oxygen Analyzer without a complete
understanding of the instructions in this manual. Do not connect this
Analyzer to a power source until all signal and plumbing
connections are made.
CAUTION
This analyzer must be operated in a manner consistent with its
intended use and as specified in this manual.
DANGER
Potentially hazardous AC voltages are present within this
instrument. Leave all servicing to qualified personnel. Disconnect
the AC power source when installing or removing: external
connections, the sensor, the electronics, or when charging or
draining electrolyte.
DANGER
The electrolyte is a caustic solution. Review the Material
Safety Data Sheet (MSDS) before handling the electrolyte
solution.
The sensor is shipped dry and must be charged with
electrolyte before it is operated.
CAUTION
Over-pressurizing the sensor can result in permanent damage to the
sensor. Limit the backpressure to the analyzer to ±1 psig.
Be sure the downstream isolation valve (if so equipped) is toggled
open before gas flow is started.
CAUTION
DO NOT SHIP THE ANALYZER WITH
ELECTROLYTE – THOROUGHLY DRAIN AND
RINSE SENSOR BEFORE SHIPPING
Safety
DF-340E
103
EMI DISCLAIMER
This Analyzer generates and uses small amounts of radio frequency
energy. There is no guarantee that interference to radio or television
signals will not occur in a particular installation. If interference is
experienced, turn-off the analyzer. If the interference disappears, try
one or more of the following methods to correct the problem:
Reorient the receiving antenna.
Move the instrument with respect to the receiver.
Place the analyzer and receiver on different AC circuits.
104
DF-340E
Safety
11.1
Electrolyte Solution Material Safety Data Sheet
MATERIAL SAFETY DATA SHEET
1. IDENTIFICATION OF THE SUBSTANCE
Trade Name
Electrolyte Solution, E-lectrolyte Gold, E-lectrolyte Blue, Electrolyte Black, DF-E05, DF-E06, DF-E07, DF-E09
Manufacturer
Delta F Corp., 4 Constitution Way, Woburn, MA
01801-1087, USA, Tel + 1-781-935-4600
Emergency Contact
USA: 1-800-424-9300
International: 1-813-979-0626 (collect)
Supplier and contact in UK
(for use in the UK only)
2. COMPOSITION
CAS #
7732-18-5
1310-58-3
Component
Water
Potassium Hydroxide in
aqueous solution
EC Code/class
231-791-2
215-181-3
C
Concentration
0.77N:
4.3%w/w
Risk
Phrase
Risk
Description
R35
Causes severe
burns
3. HAZARDS IDENTIFICATION
Main Hazard
Corrosive. Causes severe burns on contact with skin, eyes and mucous
membrane
CERCLA Ratings (scale 0-3)
Health = 3
Fire = 0
Reactivity = 1
NFPA Ratings (scale 0-4)
Health = 3
Fire = 0
Reactivity = 1
Persistence = 0
Potential Health Effects:
Eye Contact
Skin Contact
Causes severe eye burns. May cause irreversible eye injury. Contact may cause
ulceration of the conjunctiva and cornea. Eye damage may be delayed.
Causes skin burns. May cause deep, penetrating ulcers of the skin.
Ingestion
May cause circulatory system failure. May cause perforation of the digestive tract.
Causes severe digestive tract burns with abdominal pain, vomiting, and possible
death.
Inhalation
Inhalation under normal use would not be expected as this product is supplied as an
aqueous solution and no hazardous vapors are emitted. Effects of inhalation are
irritation that may lead to chemical pneumonitis and pulmonary edema. Causes
severe irritation of upper respiratory tract with coughing, burns, breathing difficulty,
and possible coma.
Prolonged or repeated skin contact may cause dermatitis. Prolonged or repeated eye
contact may cause conjunctivitis.
Chronic
Safety
DF-340E
105
4. FIRST-AID MEASURES
Skin Contact
In case of skin contact, remove contaminated clothing and shoes immediately. Wash
affected area with soap or mild detergent and large amounts of water for at least 15
minutes. Obtain medical attention immediately.
Eye Contact
If the substance has entered the eyes, wash out with plenty of water for at least 15 - 20
minutes, occasionally lifting the upper and lower lids. Obtain medical attention
immediately.
Ingestion
If the chemical has been confined to the mouth, give large quantities of water as a
mouthwash. Ensure the mouthwash has not been swallowed. If the chemical has
been swallowed, do NOT induce vomiting. Give 470 - 950ml (2 - 4 cups) of water or
milk. Never give anything by mouth to an unconscious person. Obtain medical
attention immediately.
Inhalation under normal use would not be expected as this product is supplied as an
aqueous solution and no hazardous vapors are emitted; however, if inhalation should
somehow occur, remove from exposure to fresh air immediately. If not breathing,
give artificial respiration. If breathing is difficult, give oxygen. Seek medical aid
immediately.
Inhalation
5. FIRE FIGHTING MEASURES
Special Exposure Hazard
Not applicable
Extinguishing Media
Not Combustible. Select extinguishing media appropriate to the
surrounding fire conditions.
Protective Equipment
Wear appropriate protective clothing to prevent contact with skin and eyes.
Wear a self-contained breathing apparatus (SCBA) to prevent contact with
thermal decomposition products.
6. ACCIDENTAL RELEASE MEASURES
Personal Protection
Use proper personal protective equipment as indicated in Section 8.
Leaks and Spills
Absorb spill with inert material (e.g., dry sand or earth), then place into a
chemical waste container. Neutralize spill with a weak acid such as vinegar
or acetic acid.
Clean-up Procedures
Wash the spillage site with large amounts of water.
7. HANDLING AND STORAGE
Handling Precautions
Complete eye and face protection, protective clothing, and appropriate
gloves must be used. Do not get in eyes, on skin, or on clothing. Wash
thoroughly after handling. Remove contaminated clothing and wash before
reuse. Do not ingest or inhale.
Storage Precautions
Store in a tightly closed container. Store in a cool, dry, well-ventilated area
away from incompatible substances. Keep away from strong acids.
8. EXPOSURE CONTROLS / PERSONAL PROTECTION
Personal Protection
106
DF-340E
Safety
Eyes
Wear appropriate protective chemical safety goggles and face shield as
described by OSHA’s eye and face protection regulations in 29 CFR
1910.133 or European Standard EN166.
Skin
Wear appropriate gloves to prevent skin exposure.
Clothing
Wear appropriate protective clothing to prevent skin exposure.
Respirators
Not Applicable. Inhalation under normal use would not be expected as this
product is supplied as an aqueous solution and no hazardous vapors are
emitted.
Airborne Exposure
This material is supplied as an aqueous solution and will not be present in
the atmosphere in normal use.
Exposure Limits
Potassium Hydroxide
UK EH40, OEL (8hr TWA) 2mg/m3
NIOSH, (8hr TWA) 2mg/m3
ACGIH, Ceiling 2mg/m3
OSHA, not listed
9. Physical & Chemical Properties
KOH Mixture
.77N aqueous solution. Colorless, odorless
Alkaline
Completely soluble in water
104.50C
-3.50C
Not applicable
Not flammable
Not applicable
1.15
16.1 mm Hg @ 200C
Molecular Formula
Physical State
pH
Solubility
Boiling Point
Melting Point
Flash Point
Flammability
Explosion Limits
Specific Gravity
Vapor Pressure
10. Stability & Reactivity
Chemical Stability
Stable
Conditions/Materials to Avoid
Incompatible materials, acids and metals
Incompatibilities with other
Materials
Reacts with chlorine dioxide, nitrobenzene, nitromethane, nitrogen
trichloride, peroxidized tetrahydrofuran, 2,4,6-trinitrotoluene,
bromoform+ crown ethers, acids alcohols, sugars, germanium
cyclopentadiene, maleic dicarbide. Corrosive to metals such as
aluminum, tin, and zinc to cause formation of flammable hydrogen gas.
Hazardous Decomposition Products
Hazardous Polymerization
Oxides of potassium
Has not been reported
11. Toxological Information
RTECS#
LD50/ LC50
Safety
CAS# 7732-18-5
ZC0110000
CAS# 1310-58-3
TT2100000
CAS# 7732-18-5
CAS# 1310-58-3
Oral, ret:LD50 = >90 ml/kg
Draize test, rabbit, skin: 50 mg/24H Severe
Oral, rat: LD50 = 273 mg/kg
DF-340E
107
Carcinogen Status
CAS# 7732-18-5
CAS# 1310-58-3
Not listed by ACGIH, IARC, NIOSH, NTP, or OSHA
Not listed by ACGIH, IARC, NIOSH, NTP, or OSHA
Potassium Hydroxide Solution is a severe eye, mucus membrane, and skin irritant.
12. Ecological Information
Mobility
Completely soluble in water
Degradability
Will degrade by reaction with carbon dioxide from the atmosphere to produce a
non-hazardous product.
No
Accumulation
Information not available. No long-term effects expected due to degradation.
The preparation is already in dilute solution and adverse aquatic effects are not
expected due to further dilution. The preparation is corrosive, and direct
contact with fauna will cause burns.
Ecotoxicity
13. Disposal Considerations
Dispose of in a manner consistent with federal, state, and local regulations.
Waste Disposal
14. Transportation Information
Hazard Class
UN
Number
Shipping Name
Packaging
Group
US DOT
Potassium Hydroxide Solution
8
UN1814
II
IATA
Potassium Hydroxide Solution
8
UN1814
II
ADR/RID
Potassium Hydroxide Solution
8
UN1814
II
IMDG Code
Canadian
TDG
Potassium Hydroxide Solution
8
UN1814
II
Potassium Hydroxide Solution
8(9.2)
UN1814
Not Available
15. Regulatory Information
US FEDERAL
TSCA
CAS# 7732-18-5
Listed on TSCA Inventory
CAS# 1310-58-3
Listed on TSCA Inventory
Health & Safety Reporting
List
None of the chemicals on Health & Safety Reporting List
Chemical Test Rules
None of the chemicals are under Chemical Test Rule
Section 12b
None of the chemicals are listed under TSCA Section 12b.
TSCA Significant New Use
Rule
None of the chemicals have a SNUR under TSCA
108
DF-340E
Safety
CERCLA Hazardous
Substances and
corresponding RQ’s
CAS# 1310-58-3
None of the chemicals have a TQP
SARA Section 302 Extremely
Hazardous Substances
SARA Codes
1000 lb final RQ; 454kg final RQ
CAS# 1310-58-3
Immediate, Reactive
Section 313
No chemicals are reportable under Section 313
Clean Air Act
Does not contain any hazardous air pollutants
Does not contain any Class 1 Ozone depletors
Does not contain any Class 2 Ozone depletors
Listed as a Hazardous Substance under the CWA
Clean Water Act
CAS# 1310-58-3
None of the chemicals are listed as Priority Pollutants under
the CWA
None of the chemicals are listed as Toxic Pollutants under
the CWA
OSHA
STATE
CAS# 7732-18-5
CAS# 1310-58-3
None of the chemicals are considered highly hazardous by
OSHA
Not present on state lists from CA, PA, MN, MA, or NJ.
Can be found on the following state right to know lists; CA,
NJ, PA, MN, MA.
California No Significant Risk Level: None of the chemicals
are listed.
California Prop 65
European/International Regulations
European Labeling in Accordance with EC Directives
Classification
Corrosive
Hazard Symbol
C
EC Number
215-181-3
Risk Phrases
R35
Causes severe burns.
R22
Harmful if swallowed
S1/2
Keep locked up and out of reach of children.
S26
In case of contact with the eyes, rinse immediately with
plenty of water and seek medical advice.
S36
Wear suitable protective clothing.
S37/39
Wear suitable gloves and eye/face protection.
S45
CAS# 7732-18-5
In case of accident or if you feel unwell, seek medical advice
immediately (show label where possible).
No information available
CAS# 1310-58-3
CAS# 7732-18-5
CAS# 1310-58-3
Classification E,
1
Listed on Canada’s DSL List
Listed on Canada’s DSL List
Classified in accordance with the hazard criteria of the
Safety Phrases
WGK (Water
Danger/Protection)
Canada – DSL/ NDSL
Canada - WHMIS
Safety
DF-340E
109
D1B
Canadian Ingredient
Disclosure List
CAS# 1310-58-3
Controlled Products Regulations and the MSDS contains all
of the information required by those regulations.
Listed on the Canadian Ingredient Disclosure List
16. Other Information
MSDS Creation Date:
09/30/94
MSDS Revised:
May 1, 2007
The information above is believed to be accurate and represents the best information currently available to us.
However, we make no warranty of merchantability or any other warranty, express or implied, with respect to
such information. Liability is expressly disclaimed for loss or injury arising out of use of this information or the
use of any materials designated. Users should make their own investigation to determine the suitability of the
information for their particular purpose.
110
DF-340E
Safety
11.2Replenishment Solution MSDS
MATERIAL SAFETY DATA SHEET
1. IDENTIFICATION OF THE SUBSTANCE
Trade Name
Replenishment Solution, RS-A
Manufacturer
Delta F Corp., 4 Constitution Way, Woburn, MA
01801-1087, USA, Tel + 1-781-935-4600
Emergency Contact
USA: 1-800-424-9300
International: 1-813-979-0626 (collect)
Supplier and contact in UK
(for use in the UK only)
2. COMPOSITION
CAS #
7732-18-5
Component
Water
(contains trace salts)
EC Code/class
215-181-3
C
Concentration
100%
Risk
Phrase
Risk
Description
3. HAZARDS IDENTIFICATION
Main Hazard
None
CERCLA Ratings (scale 0-3)
Health = 0
Fire = 0
Reactivity = 1
NFPA Ratings (scale 0-4)
Health = 0
Fire = 0
Reactivity = 1
Persistence = 0
Potential Health Effects:
Eye Contact
Skin Contact
Ingestion
Inhalation
Chronic
Not applicable.
Not applicable.
Not applicable.
Not applicable.
Not applicable.
4. FIRST-AID MEASURES
Skin Contact
Eye Contact
Not applicable.
Not applicable.
Ingestion
Inhalation
Not applicable.
Not applicable.
5. FIRE FIGHTING MEASURES
Special Exposure Hazard
Safety
Not applicable
DF-340E
111
Extinguishing Media
Not combustible. Select extinguishing media appropriate to the
surrounding fire conditions.
Protective Equipment
In the event of a fire, wear full protective clothing and NIOSH-approved
self-contained breathing apparatus with full facepiece operated in the
pressure demand or other positive pressure mode.
6. ACCIDENTAL RELEASE MEASURES
Non-hazardous material. Clean up of spills requires no special equipment or
procedures.
7. HANDLING AND STORAGE
Keep container tightly closed. Suitable for any general chemical storage area.
Protect from freezing. May react vigorously with some specific materials. Avoid contact
with all materials until investigation shows substance is compatible.
8. EXPOSURE CONTROLS / PERSONAL PROTECTION
Personal Protection
Eyes
Skin
Clothing
Respirators
None required.
None required.
Not applicable.
Not Applicable.
Airborne Exposure
Not applicable.
Exposure Limits
Not applicable.
9. Physical & Chemical Properties
Molecular Formula
Physical State
pH
Solubility
Boiling Point
Melting Point
Flash Point
Flammability
Explosion Limits
Specific Gravity
Vapor Pressure
H2O containing trace salts
Colorless, odorless liquid
6.0-8.0
Complete (100%)
1000C
00C
Not applicable
Not flammable
Not applicable
1.00
17.5 mm Hg @ 200C
10. Stability & Reactivity
Chemical Stability
112
Safety
Stable
DF-340E
Conditions/Materials to Avoid
Hazardous Decomposition Products
Hazardous Polymerization
Strong reducing agents, acid chlorides, phosphorus trichloride,
phosphorus pentachloride, phosphorus oxychloride.
Not applicable.
Has not been reported
11. Toxological Information
Toxicity (water)
CAS# 7732-18-5: Oral, rat: LD50 >90 mL/kg
Carcinogen Status
Not listed by ACGIH, IARC, NIOSH, NTP, or OSHA
12. Ecological Information
Completely soluble in water
Not applicable.
Not applicable.
Applicable.
Mobility
Degradability
Accumulation
Ecotoxicity
13. Disposal Considerations
Whatever cannot be saved can be flushed to sewer. If material becomes
contaminated during use, dispose of accordingly. Dispose of container and
unused contents in accordance with federal, state, and local requirements.
Waste Disposal
14. Transportation Information
Not regulated.
15. Regulatory Information
16. Other Information
NFPA Ratings: Health: 0 Flammability: 0 Reactivity: 0
MSDS Creation Date:
09/30/94
MSDS Revised:
December 7, 2006
The information above is believed to be accurate and represents the best information currently available to us.
However, we make no warranty of merchantability or any other warranty, express or implied, with respect to
such information. Liability is expressly disclaimed for loss or injury arising out of use of this information or the
use of any materials designated. Users should make their own investigation to determine the suitability of the
information for their particular purpose.
Safety
DF-340E
113
12 Warranty
Delta F Corporation warrants each instrument manufactured by them to be free
from defects in material and workmanship at the F.O.B. point specified in the
order, its liability under this warranty being limited to repairing or replacing, at
the Seller's option, items which are returned to it prepaid within one year from
delivery to the carrier and found, to the Seller's satisfaction, to have been so
defective.
Delta F's Sensor Warranty offers extended protection such that, if any Sensor
of a Delta F Oxygen Analyzer fails under normal use within five years from the
date of purchase, such sensor may be returned to the Seller and, if such sensor
is determined by the Seller to be defective, the Seller shall provide the Buyer a
repaired or replacement sensor at no additional cost. The original warranty
expiration date is not extended by this action.
In no event shall the Seller be liable for consequential damages. NO
PRODUCT IS WARRANTED AS BEING FIT FOR A PARTICULAR
PURPOSE AND THERE IS NO WARRANTY OF MERCHANTABILITY.
Additionally, this warranty applies only if: (i) the items are used solely under
the operating conditions and in the manner recommended in the Seller's
instruction manual, specifications, or other literature; (ii) the items have not
been misused or abused in any manner or repairs attempted thereon; (iii)
written notice of the failure within the warranty period is forwarded to the
Seller and the directions received for properly identifying items returned under
warranty are followed; and (iv) with return, notice authorizes the Seller to
examine and disassemble returned products to the extent the Seller deems
necessary to ascertain the cause of failure. The warranties stated herein are
exclusive. THERE ARE NO OTHER WARRANTIES, EITHER
EXPRESSED OR IMPLIED, BEYOND THOSE SET FORTH HEREIN, and
the Seller does not assume any other obligation or liability in connection with
the sale or use of said products.
Warranty
DF-340E
115
13 Index
▲
Battery Power, NiMH, 22
Baud, 71, 72
Bits, 71
▲, 57
▼
▼, 57
2
2-20mA Analog Output, 27
4
4-20mA Analog Output, 27
4-20mA Output, 44
4-20mA Output Fuse, 97
A
AC Power Fuse, 97
Accuracy, 9
Acknowledged Alarm, 59
Alarms, 59, 65, 66, 67, 68
Electrolyte Condition Alarm, 68
Low Flow Alarm, 22, 67
Oxygen Alarms, 66
Temperature Alarm, 67
Analog Output, 68, 86
Menu Settings, 68
Analog Output Range, 58
Analog Voltage Output, 43
Analyzer
Process Upsets, Protection from, 38
Specifications, 9
Unpacking, i
Warranty, 115
Analyzer Trouble, 64
Annunciator Line, 57, 61, 86
Audible, 10, 66
B
Background Gas, 77
Correction Factors, 77
Backlight (BL), 72
Backplane, 96
Battery Backup Fuse, 97
Battery Power, 22
Index
C
CAL FREEZE, 71
Calibrating, 79, 80, 81, 84, 89
Calibration, 76, 89
Case Purge, 27
Cautions, 7
Important Warnings, 7
Symbols and Explanations, 7
Check Fluid, 76
Check/Adj Cal, 76, 79
Clean Gas Applications, 89
Comm Port, 71
Baud, 72
Device ID, 72
Communication Port – RS232/485
Port, 71
Condensation, 11
Connections
Sample Gas, 15
Contrast, 73
Controls, 61
Controls Menu, 62
Convergence, 82
coulometric, 101
D
Data Line, 57
DC Power Fuse, 97
Deadband, 66
Device ID, 72
Diagnostics, 73, 83
EXT Functions, 88
Memory Test, 87
Screen Test, 88
Sensor Temperature, 83
Sensor Zero, 83
Test Output, 86
Test Relays, 87
Dimensions, 11
DISABLING ALARMS, 65, 73, 75, 83
Display Setup, 72
DF-340E
117
E
Electrical Connections, 86
Electrolyte, 94, 95
chemical reaction, 101
Electrolyte Condition Alarm, 68
EMI Sensitivity, 11
Error, 79, 84
ESC, 57, 62, 64
Expand FS, 70
Expanded Range Scale, 27
Expanded Range Scale Output, 27, 70
ExpRng Relay, 70
EXT Functions, 88
External Devices
Comm Port, 41
Option Ports
Changing Analog Output Voltage, 43
Relay Ports, 41
Remote Controls, 45
External Devices, Connecting to, 41
F
fault condition, 64
Filter
Oil/Solvent Mist, 11
Solid Particles, 11
Filter Elements, 23
Filter/Regulator Combination, 25
Flow, 59, 67, 71, 81
flow control, 21, 46
Flow Control Valve, 15, 23
Flow rate, 15
Fuse Replacement, 97
Fuse, AC Power, 97
Fuse, Battery Backup, 97
Fuse, DC, 97
G
Gas Compatibility, 11
Gas Sample
Clean Gas Application, 89
Gas Scale Factor, 77
H
Handshaking (Serial Port), 71
Hi Stpt, 66
High-Resolution Analyzers, 69
I
IN-CAL Relay, 71
INLET PRESSURE, 11
118
Installation and Setup, 13
Adding Electrolyte, 14
Electrical Connections, 17
Low Flow Alarm, 22
Powering Up, 18
Pressure Regulator Installation, 24
Pressure Regulator Purge, 35
Standard Outputs, 18
INVALID DATA, 58, 86, 94
IRAM, 87
L
Leak (Plumbing), 95
Level, 73
Lo Stpt, 66
Loop Resistance (4-20 mA), 10
Low Flow Alarm, 22, 67
Low Flow Switch, 67
M
Maintenance, 61
Fuse Replacement, 97
Maintenance Menu, 75
Reset the, 76
Set the, 76
Maintenance, Analyzer, 89
Master Password, 74
Material Safety Data Sheet, 105
Memory Error!, 59
Memory Test, 87
Menu, 58
MSDS, Electrolyte, 105
MSDS, Replenishment Solution, 111
N
NEMA 4 Enclosure, 49
NEMA 7 Enclosure, 50
New Sensor, 82
NiMH Battery Power, 22
Not Available, 65
O
Operator Password, 74
Options
4-20mA Analog Output, 27
Battery Power, 22
Communication Port – RS-232/485, 27
Expanded Range Scale, 27
Flow Control Valve, 15, 23
Form C Relays, 27
Low Flow Alarm, 22
Pressure Regulator, 24
DF-340E
Index
Pump, 21
Remote Sensor
Temperature Control, 51
Stainless Steel Outlet Tubing, 25
Outputs, Analog, 68
OVER RANGE, 59
Oxygen Alarms, 66
P
Password, 61
Misplaced, 75
Password Menu, 73
Port (Communication), 71
Power Requirements, 10
PRESSURE, 11
Pressure Regulator, 24
Procedure
Adding Replenish Solution to the
Sensor, 91
Changing the Analog Output, 45
Purging Ambient Air from Regulator,
35, 39
Programming Protocol, 62
Pump, 21, 62
Purging, 93
R
Recalibration, 84
Relay, 67, 87
Relay Contact Closures, 10
Remote Controls, 45
Remote Pump Control, 46
Remote Sensor
Temperature Control, 51
Remote Sensor Connections, 52
Remote Sensor Control, 45
Remote Sensor Installations, 47
Replenishment Sol’n Reminder, 75
Reset Orig Span, 77, 82
Reset Orig Zero, 84
Resolution, 9
ROM, 87
Rotameter, 63, 81
S
Safety, 103
Sample Gas, 77
Differences, 15
Sample Gas Differences, 15
Sample Gas Preparation and Delivery, 31
Background Gas Effects, 34
Backpressure Effects, 36
Flow Rate Effects
Index
Leakage Checks, 34
Sensor Performance, 34
Pressure Effects
Sensor Performance, 35
Regulator Requirements, 34
Sample Flow Rate and Pressure, 33
Sample Gas
Compatibility, 36
Reactivity with KOH Electrolyte, 37
Solubility in Aqueous KOH Solution, 37
Trace Acids, 38
Sample Gas Calibration
Background Gas Effects, 40
Delivery and Vent Pressure, 39
Regulators, 39
Standards, 39
Sample Gas Calibrations, 38
Sample Gas Condensation, 37
Sample Gas Flammability, 37
Sample Gas Temperature, 38
Sample GSF, 32
STAB-EL Acid Gas System, 31
Sample System Leak Test, 93
Sampling Considerations
Clean Gas Application, 89
Screen Test, 88
Sensitivity, 9
SensOFF Relay, 64
Sensor
anode, 101
cathode, 101
non-depleting, 101
operation, 101
SENSOR OFF, 58
Sensor Off 4-20mA Signal, 64
Sensor Polarization, 63
Sensor Temperature, 83
Sensor Zero, 83
Service, 96
Maintenance
Calibration, 89
Sensor, 90
Storage Conditions, 90
Return Material Authorization number,
89
Shipping, 99
Return Material Authorization number,
99
Troubleshooting, 93
Troubleshooting Guide, 93
Set-Up Menu, 61, 65
SPAN REF, 80
Spare Parts List, 92
Stainless Steel Outlet, 25
Storage Temperature, 10
DF-340E
119
T
TEMP OVER RANGE, 59, 79
Temperature, 10, 67, 96
Temperature Alarm, 67
Test Output, 86
Test Relays, 87
Theory of Operation
Electrolyte Conditioning System, 102
Sensor, 101
TO, 59
Troubleshooting, 89, 94
U
UNCALIBRATED, 59, 94
UNDER RANGE, 59
Update And Quit, 72
120
Upstream Valve, 63
UR, 59
User Interface, 57
Data Display Screen, 57
Main Menu, 61
W
Wait!, 59
Warranty, 115
Weight, 11
Z
ZERO CAL, 85
Zero Calibration Frequency
Clean Gas Applications, 89
ZERO REF, 84
Z-Purge, 27, 54
DF-340E
Index