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Servomex Oxygen Analyzer DF-310E OPERATOR MANUAL
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Oxygen Analyzer
DF-310E
OPERATOR MANUAL
Copyright 2011 by Servomex 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 Servomex Corporation.
Stablex, Bi-Strata and are trademarks of Servomex Corporation. VCR is a registered
trademark of the Cajon Company.
DF-310E Operator Manual
Firmware v2.57
Manual Version 092211
Your Process Oxygen Analyzer has been designed, manufactured and is supported under ISO9001 controls, thus helping to insure the highest possible standards of quality.
Every analyzer that Servomex 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.
For more information or if you have questions, please do not hesitate to go to our website at
Servomex.com, or contact your local Servomex Business Center as found on the back cover of
this manual.
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 Servomex. 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 Servomex immediately.
3. All analyzers are shipped with the following:
Item
One bottle of Hummingbird Brand Electrolyte Blue
One bottle of Hummingbird Brand Replenishment
Solution
Power Cord with 115VAC connector
NOTE - No power cord is supplied with 220 VAC or
DC powered units
Instruction Manual
Servomex Part
Number
Electrolyte Blue
210515
210408
210450
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-310E 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-310E Process Oxygen Analyzer. Servomex designs,
manufactures, exhaustively tests, and supports every analyzer under ISO-9001 control. You
should expect every Servomex analyzer to arrive in good working order and, with proper
maintenance, provide years of trouble-free service.
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
5
Adding Electrolyte ................................................................................................14
Sample Gas Connections.......................................................................................15
4.2.1 Purging the Analyzer................................................................................15
Electrical Power Connections................................................................................16
4.3.1 AC Input Voltage (100-240 VAC)............................................................16
4.3.2 DC Input Voltage (24 VDC).....................................................................16
Power Control.......................................................................................................16
4.4.1 Startup Process.........................................................................................17
4.4.2 Powering Down .......................................................................................17
Standard Outputs...................................................................................................17
Options ................................................................................... 19
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
5.14
5.15
5.16
5.17
5.18
6
Pump ....................................................................................................................19
5.1.1 Pump Control...........................................................................................19
Battery Power .......................................................................................................19
Low Flow Alarm...................................................................................................20
Flow Control Valve...............................................................................................21
Filter.....................................................................................................................21
Pressure Regulator ................................................................................................21
Combined Filter/Pressure Regulator ......................................................................23
Stainless Steel Outlet Tubing.................................................................................24
Key Lock ..............................................................................................................24
4-20mA Analog Output .......................................................................................25
5.10.1
2-20mA Analog Output ........................................................................25
Relays .................................................................................................................25
Communication Port – RS232/485.......................................................................26
Expanded Range Scale.........................................................................................26
Panel Mount ........................................................................................................26
Rack Mount.........................................................................................................28
Dual Rack Mount ................................................................................................28
Remote Display...................................................................................................28
Case Purge ..........................................................................................................30
Sample Gas Preparation and Delivery ................................. 33
6.1
6.2
6.3
Index
Table of Figures......................................................................................................4
The STAB-EL Acid Gas System ...........................................................................33
Sample Gas Scale Factor .......................................................................................34
Sample Flow Rate and Pressure.............................................................................35
6.3.1 Flow Rate Effects on Sensor Performance ................................................36
6.3.2 Checking for Plumbing Leaks using Flow Rate Effects .............................36
6.3.3 Background Gas Effects on Indicated Flow Rate.......................................36
6.3.4 Regulator Requirements ...........................................................................36
DF-310E
1
6.4
6.5
7
Connecting to External Devices............................................43
7.1
7.2
7.3
7.4
7.5
8
The Comm Port.....................................................................................................43
Relay Ports............................................................................................................44
Analog Outputs .....................................................................................................45
7.3.1 Analog Voltage Output.............................................................................45
7.3.2 4-20mA Output ........................................................................................46
7.3.3 Alignment Procedure for Analog Voltage and Current Loop Outputs.........47
Remote Controls ...................................................................................................47
7.4.1 Remote Sensor Control – J6 Connector.....................................................47
7.4.2 Remote Pump Control – J6 Connector ......................................................48
Remote Sensor Installations...................................................................................49
7.5.1 Sensor on Remote Bracket with Optional Pump ........................................50
7.5.2 Sensor in NEMA 4 Enclosure ...................................................................51
7.5.3 Sensor in NEMA 7 Enclosure ...................................................................52
7.5.4 Temperature Control in R4/R7 Enclosures ................................................53
7.5.5 Remote Sensor Connections – Connector J7 .............................................54
7.5.6 Z-Purge Protection on R4 Enclosure .........................................................56
User Interface..........................................................................59
8.1
8.2
8.3
8.4
8.5
8.6
2
6.3.5 Pressure Regulator Purge..........................................................................37
6.3.6 Pressure Effects on Sensor Performance ...................................................37
6.3.7 Sample Outlet Backpressure Effects .........................................................38
Sample Gas Compatibility.....................................................................................38
6.4.1 Condensation ...........................................................................................38
6.4.2 Gas Solubility in Aqueous KOH Solution .................................................39
6.4.3 Reactivity with KOH Electrolyte ..............................................................39
6.4.4 Flammable Sample Gas ............................................................................39
6.4.5 Trace acids in the sample gas....................................................................39
6.4.6 Sample Gas Temperature..........................................................................40
6.4.7 Protecting the Analyzer from Process Upsets ............................................40
Calibration Gas Considerations..............................................................................40
6.5.1 Calibration Standards ...............................................................................40
6.5.2 Calibration Cylinder Regulators................................................................41
6.5.3 Purge Procedure .......................................................................................41
6.5.4 Sample Gas Delivery and Vent Pressure during Calibration.......................41
6.5.5 Background Gas Effects on Calibration.....................................................42
The Data Display Screen .......................................................................................59
Main Menu ...........................................................................................................63
8.2.1 Keypad Operation ....................................................................................64
Controls Menu ......................................................................................................65
8.3.1 Pump .......................................................................................................65
8.3.2 Sensor Polarization...................................................................................66
8.3.3 SensOFF Relay ........................................................................................66
8.3.4 P(o)w(e)r UP............................................................................................67
8.3.5 ESC .........................................................................................................67
Set-Up Menu.........................................................................................................67
8.4.1 Alarms .....................................................................................................68
8.4.2 Analog Outputs ........................................................................................70
8.4.3 Comm Port...............................................................................................73
8.4.4 Gas Scale Factor.......................................................................................74
8.4.5 Display Setup...........................................................................................74
8.4.6 Clock .......................................................................................................75
The Password Menu ..............................................................................................76
Maintenance..........................................................................................................77
8.6.1 Replenish Solution Reminder ...................................................................78
8.6.2 Oxygen Calibration ..................................................................................79
8.6.3 Diagnostics ..............................................................................................86
DF-310E
Index
9
Troubleshooting and Calibration.......................................... 93
9.1
9.2
9.3
9.4
9.5
10
10.1
10.2
11
11.1
11.2
Index
Return Material Authorization Number..................................................................93
Maintenance .........................................................................................................93
9.2.1 Calibration ...............................................................................................93
9.2.2 Storage Conditions...................................................................................94
9.2.3 Sensor Maintenance .................................................................................94
9.2.4 Procedure for Adding Replenishment Solution to the Sensor.....................95
Replaceable Parts List ...........................................................................................96
Troubleshooting....................................................................................................97
9.4.1 Sample System Leak Test (Low Flow Sensitivity) ....................................97
9.4.2 Basic Troubleshooting..............................................................................98
9.4.3 Fuse Replacement .................................................................................. 100
Shipping ............................................................................................................. 103
Theory of Operation............................................................. 105
The Oxygen Sensor ........................................................................................... 105
The Electrolyte Conditioning System ................................................................. 106
Safety .................................................................................... 107
Electrolyte Solution MSDS................................................................................ 109
Replenishment Solution MSDS.......................................................................... 115
12
Warranty ............................................................................... 119
13
Index ..................................................................................... 121
DF-310E
3
1.1 Table of Figures
Figure 1: DF-310E Oxygen Analyzer ................................................................................. 12
Figure 2: Major Internal Components................................................................................. 13
Figure 3: Quick Disconnect Fitting at Flowmeter................................................................ 15
Figure 4: DC Power Connector – J3 ................................................................................... 16
Figure 5: Data Display Screen ............................................................................................ 17
Figure 6: Rear Panel........................................................................................................... 18
Figure 7: Plumbing Configuration Options ......................................................................... 22
Figure 8: Filter Installation................................................................................................. 23
Figure 9: Regulator Installation .......................................................................................... 24
Figure 10: Combined Filter/Regulator Assembly ................................................................ 25
Figure 11: Panel Mount Configuration................................................................................ 27
Figure 12: Cutout Dimensions for Panel Mount .................................................................. 27
Figure 13: Rack Mount ...................................................................................................... 28
Figure 14: Dual Rack Mount .............................................................................................. 28
Figure 15: Remote Display................................................................................................. 29
Figure 16: Remote Display Wiring..................................................................................... 30
Figure 17: Case Purge Option............................................................................................. 31
Figure 18: J7/J8 Connector Wiring..................................................................................... 43
Figure 19: J1/J2 Connector Wiring..................................................................................... 44
Figure 20: J5/J6 Connector Wiring..................................................................................... 46
Figure 21: Analog Voltage Output and 4-20mA Adjustments.............................................. 47
Figure 22: J5/J6 Connector Wiring..................................................................................... 48
Figure 23: J3/J4 Connector Wiring..................................................................................... 49
Figure 24: Remote Sensor with Optional Pump .................................................................. 50
Figure 25: Remote Sensor Mounted in NEMA 4 Enclosure................................................. 51
Figure 26: Remote Sensor Mounted in NEMA 7 Enclosure................................................. 52
Figure 27: NEMA 7 Enclosure Mounting Dimensions ........................................................ 53
Figure 28: Temperature Control in R7 Enclosure................................................................ 54
Figure 29: Remote Sensor Connector – J7 .......................................................................... 55
Figure 30: Remote Sensor/Pump Wiring Diagram .............................................................. 55
Figure 31: Z-Purge Protection on R4 Sensor Enclosure....................................................... 56
Figure 32: Data Display and Keypad .................................................................................. 59
Figure 33: Main Menu ....................................................................................................... 63
Figure 34: Controls Menu .................................................................................................. 65
Figure 35: Sensor Shut-off Warning ................................................................................... 66
Figure 36: Setup Menu....................................................................................................... 67
Figure 37: Alarm Setup Menu ............................................................................................ 68
Figure 38: Oxygen Alarm Menu......................................................................................... 68
Figure 39: Oxygen Alarm Setup Screen (Alarm not used)................................................... 68
Figure 40: Oxygen Alarm Setup Screen (Alarm used)......................................................... 69
Figure 41: Recorder Output Setup Menu ............................................................................ 71
Figure 42: Recorder Output Setup Error ............................................................................. 72
Figure 43: Comm Port Setup Menu .................................................................................... 74
Figure 44: Display Setup.................................................................................................... 75
Figure 45: Clock Setup Screen ........................................................................................... 76
Figure 46: Password Menu................................................................................................. 76
Figure 47: Password Entry Screen ..................................................................................... 77
Figure 48: Maintenance Menu............................................................................................ 78
Figure 49: Replenishment Solution Reminder..................................................................... 78
Figure 50: Oxygen Calibration Menu ................................................................................. 79
Figure 51: Gas Scale Factor................................................................................................ 80
Figure 52: Gas Scale Factor Menu (Cont’d)........................................................................ 80
Figure 53: Span Check Menu ............................................................................................. 83
Figure 54: Calibration Convergence Screen ........................................................................ 84
Figure 55: Completed Oxygen Calibration Menu................................................................ 85
Figure 56: Diagnostics Menu.............................................................................................. 86
4
DF-310E
Index
Figure 57: Sensor Zero Menu..............................................................................................87
Figure 58: Zero Cal Warning Screen ...................................................................................88
Figure 59: Zero Cal Screen .................................................................................................88
Figure 60: Zero Cal Not Stable............................................................................................89
Figure 61: Test Output Screen.............................................................................................89
Figure 62: Test Relay Screen ..............................................................................................90
Figure 63: Memory Test Screen ..........................................................................................90
Figure 64: EXT Functions...................................................................................................91
Figure 65: Fuse Locations for DC Power Supply and Battery Backup ................................102
Figure 66: Printed Circuit Board Assembly .......................................................................102
Figure 67: Schematic of Servomex Oxygen Sensor............................................................105
Index
DF-310E
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. Servomex 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. Servomex 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-310E
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.
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.
8
DF-310E
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
3 ppb (310E-H0050M Model only)
LOW DETECTION LIMIT
3 ppb (310E-H0050M Model only)
RESOLUTION
Model
Number
S00050
S00100
S00500
S01000
S05000
S10000
S000P5
S00P10
S00P25
H0050M
H00100
H00500
H01000
H05000
H10000
H000P5
H00P10
H00P25
Range
0-50 ppm
0-100 ppm
0-500 ppm
0-1000 ppm
0-5000 ppm
0-10000 ppm
0-5 %
0-10 %
0-25 %
0-50 ppm
0-100 ppm
0-500 ppm
0-1000 ppm
0-5000 ppm
0-10000 ppm
0-5 %
0-10 %
0-25%
Auto
Scale A*
0-5
0 - 10
0 - 50
0 - 100
0 - 500
0 - 1000
0 - 0.5
0-1
0 - 2.5
Display
X.XXX
XX.XX
XX.X
XXX.X
XXX.
XXXX.
.XXX%
X.XXX%
X.XX%
Auto
Scale B*
0-50 ppm
0-100 ppm
0-500 ppm
0-1000 ppm
0-5000 ppm
0-10000 ppm
0-5 %
0-10 %
0-25 %
5 - 50
10 - 100
50 - 500
100 - 1000
500 - 5000
1000 - 10000
0.5 - 5
1 - 10
2.5 - 25
Display
XX.XX
XXX.X
XXX.X
XXXX.
XXXX.
XXXXX
X.XX
XX.XX
XX.X
XX.XX
XXX.X
XXX.
XXXX.
XXXX.
XXXXX
X.XX
XX.XX
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-310E
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. (2933 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
24 VDC (–2/+4VDC), 1A, 25 Watts; Optional Sample Pump 6W additional
EMI SENSITIVITY
10
DF-310E
Specifications
Meets CISPR – 11(90) Class B Group 1 Standard
CONSTRUCTION
WEIGHT
9.5 lbs. (4.3kg) Standard Model (no options)
DIMENSIONS - Overall
8.375"w x 8.0"h x 8.5"d (21.3 cm x 20.3 cm x 21.6 cm) (with handle and gas
fittings)
CE Approved
CSA Approved
GAS SAMPLE CONDITIONS
GAS CONNECTIONS
1/8" Compression inlet and outlet Standard
1/4" Metal-face-seal inlet (Optional)
SAMPLE INLET PRESSURE
0.2 psig to 1.0 psig; 5 - 15 psig with VCR welded sample inlet (orifice
restricted)
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-310E
11
P
P
M
4.21 [106.93]
7.59 [192.79]
7.75 [196.75]
7.84 [199.09]
2.05 [52.07]
1.17 [29.77]
7.89 [200.48]
8.33 [211.48]
9.26 [235.08]
1/8" COMPRESSION
SAMPLE OUTLET
J1
A3-COM
A1-NO
A3-NO
A1-NC
A3-NC
A2-COM
UNUSED
UNUSED
A4-COM
A2-NO
A4-NO
A2-NC
A4-NC
GND
GND
J3
J4
+24V
A OUT +
UNUSED
A OUT -
24V RTN
PUMP -
GND
PUMP +
UNUSED
UNUSED
UNUSED
FLOW-A
UNUSED
UNUSED
UNUSED
FLOW-B
J5
J6
LOOP +
EXT-1 +
LOOP -
EXT+1 -
UNUSED
EXT-2 +
UNUSED
EXT-2 -
J7
1.06 [26.92]
J2
A1-COM
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
1/8" COMPRESSION
SAMPLE INLET
(OPTIONAL 1/4" VCR COMPATABLE MALE)
Figure 1: DF-310E Oxygen Analyzer
12
DF-310E
Specifications
4 Installation and Setup
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.
ROTOMETER
VALVE (optional)
POWER SWITCH
ELECTROLYTE RESERVOIR
WITH MIN-MAX LINES
OXYGEN SENSOR
SENSOR MOUNTING
THUMB SCREWS
Figure 2: Major Internal Components
Installation and Setup
DF-310E
13
4.1 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 Hummingbird E-lectrolyte Blue for the DF-310E 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.
Remove the sensor as follows:
1) Using a ½ inch open-end wrench, remove the inlet bulkhead retainer nut
from the inlet bulkhead fitting at the back of the analyzer. Do not remove the
four small socket screws. (The VCR inlet option requires a ¾ inch wrench) If
equipped with the Stainless Steel Outlet Line option disconnect using a
wrench on the retaining nut on the rear of the cabinet.
2) Inside the enclosure, disconnect the 9-pin sensor connector located near the
front of the sensor.
3) Unscrew both sensor-mounting thumbscrews at the front of the sensormounting bracket.
4) Pull the sensor assembly forward a few inches and disconnect the
"quick-disconnect" fitting at the top of the flowmeter (for standard
downstream sensor configuration) by pushing both halves of the fitting
together and rotating one to the release position. See Figure 3.
5) Remove the sensor assembly from the instrument.
6) Unscrew the cap from the electrolyte reservoir and add the entire contents
of one bottle of E-lectrolyte Blue to the sensor.
7) Replace the cap and hand-tighten securely.
8) Reinstall the sensor by repeating steps 1 through 4 in reverse order.
9) Allow the sensor to sit with electrolyte in it for approximately 60 minutes
before flowing gas through the analyzer.
NOTE
The flats on the inlet bulkhead fitting are oriented to seat in an
anti-torque plate on the inside back of the enclosure. When reinstalling the Sensor Assembly, be sure the flats on the bulkhead
fitting properly seat in the slot of the anti-torque plate before
replacing the retainer nut.
14
DF-310E
Installation and Setup
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.
ROTATE
PULL
PUSH
ROTATE
Figure 3: Quick Disconnect Fitting at Flowmeter
4.2 Sample Gas Connections
The sample gas inlet and outlet lines at the back of the instrument have
stainless steel 1/8th inch compression bulkhead fittings (unless equipped with
the optional ¼ inch VCR inlet). 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 at the back
of the analyzer. A backup wrench is not needed since anti-torque plates inside
the cabinet secure the bulkhead fittings. Do not over-tighten the fittings.
4.2.1 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, use larger outlet tubing (1/4-inch) and/or reduce the
complexity of the outlet gas line. See page 30 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 60 minutes before powering up.
Installation and Setup
DF-310E
15
4.3 Electrical Power Connections
4.3.1 AC Input Voltage (100-240 VAC)
Make sure the power switch is in the OFF position. Plug the supplied power
cord into the connector on the rear of the analyzer. See Figure 6. The power
supply is auto-switching which means it will run properly on an input voltage
between 100 VAC and 240 VAC.
4.3.2 DC Input Voltage (24 VDC)
Make sure the power switch is in the OFF position. Using 20 gauge wire,
attach the power supply leads to the power connector J3 on the rear of the
instrument. Pin 1 (top) is positive (+24V) and Pin 3 is negative (24V RTN).
See Figure 4 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 4: DC Power Connector – J3
4.4 Power Control
AC Powered Units - Open the front door, locate the power switch and turn it
on. See Figure 2.
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 2.
16
DF-310E
Installation and Setup
4.4.1 Startup Process
3.43
P
P
M
OUT : 0.0- 100.0
*Menu
GSF: 1.003
Figure 5: Data Display Screen
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.
After power up, the analyzer will undergo a series of Diagnostic Procedures.
After approximately 5 seconds, the Servomex 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 66 for additional information)
4.4.2 Powering Down
Locate the power switch inside the front door and turn it off. See Figure 2.
4.5 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 at the back of the
analyzer. The analyzer is delivered with 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.
Installation and Setup
DF-310E
17
The analog voltage output is connected to pins J4-1 (AOUT+) and J4-2
(AOUT-). The full scale analog output is set by a jumper as described on page
45.
See page 25 for information on the optional 4-20mA output.
24V INLET
J1
J2
A1-COM
A3-COM
A1-NO
A3-NO
A1-NC
A3-NC
A2-COM
UNUSED
UNUSED
A4-COM
A2-NO
A4-NO
A2-NC
A4-NC
GND
GND
J3
J4
+24V
A OUT +
UNUSED
A OUT -
24V RTN
PUMP -
GND
PUMP +
UNUSED
UNUSED
UNUSED
FLOW-A
UNUSED
UNUSED
UNUSED
FLOW-B
J5
J6
LOOP +
EXT-1 +
LOOP -
EXT+1 -
UNUSED
EXT-2 +
UNUSED
EXT-2 -
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
AC INLET
Figure 6: Rear Panel
18
DF-310E
Installation and Setup
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 65 for additional information.
In addition the following options are available:
If factory configured, Servomex will supply the standard pump that the user
may install remotely and power through the PUMP -, + (+12VDC)
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, Servomex 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 48 for
additional information.
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
Options
DF-310E
19
configuration (see Table 1). 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 34. Approximately
12 hours is required to fully charge a battery pack (16 hours if the pump is
running) 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
Options and Outputs off, Backlight in Auto Mode
8 hours
Options and Outputs off, Backlight On
4 hours
Pump On, Backlight in Auto Mode
4 hours
Outputs on, Backlight in Auto Mode
6 hours
Table 1: Battery Operation Time
NOTE
Use only Servomex 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. If enabled, the option sounds an alarm when flow drops below
a factory-set value and the O2 reading is covered by a reverse video block
indicating ALM F FLOW. The switch can also be used with an optional
alarm relay, if enabled. See Figure 7 for examples of various Analyzer
plumbing configurations. The optional low-flow switch is included in
configurations c and d.
20
DF-310E
Options
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 is installed at the factory when ordered with the Analyzer.
However, a filter assembly may be purchased later and installed by the user.
It is mounted externally on the back panel as shown in Figure 8. The option
includes a bracket and preformed tube with fittings to connect the filter outlet
to the Analyzer inlet. The back panel of the Analyzer has three PEM nuts for
mounting the filter bracket. Use the screws supplied with the PEM nuts.
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 96 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.
5.6 Pressure Regulator
The gas pressure regulator is installed at the factory when ordered with the
Analyzer. However, a gas pressure regulator may be purchased later and
installed by the user. It is mounted on the back panel as shown in Figure 9.
The option also includes a preformed tube with fittings to connect the
regulator outlet to the Analyzer inlet. The back panel of the Analyzer has
three PEM nuts for mounting the regulator bracket. Use the supplied screws
with the PEM nuts.
Note: If the analyzer is equipped with a VCR welded sample inlet connection,
there is a .010 inch orifice at the inlet to the sensor which requires 15-20 psig
of pressure.
NOTE: For additional information on the proper purging of regulators after
installation see page 37.
Options
DF-310E
21
Figure 7: Plumbing Configuration Options
22
DF-310E
Options
SAMPLE INLET
1/8" COMPRESSION
FILTER
J1
J2
A1-COM
A3-COM
A1-NO
A3-NO
A1-NC
A3-NC
A2-COM
UNUSED
UNUSED
A4-COM
A2-NO
A4-NO
A2-NC
A4-NC
GND
GND
J3
J4
+24V
A OUT +
UNUSED
A OUT -
24V RTN
PUMP -
GND
PUMP +
UNUSED
UNUSED
UNUSED
FLOW-A
UNUSED
UNUSED
UNUSED
FLOW-B
J5
J6
LOOP +
EXT-1 +
LOOP -
EXT+1 -
UNUSED
EXT-2 +
UNUSED
EXT-2 -
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 8: Filter Installation
5.7 Combined Filter/Pressure Regulator
The gas filter and regulator are installed by the factory when ordered with the
Analyzer. However, the gas filter and regulator may be ordered later and
installed by the user. They are supplied as a unit with one mounting bracket
and mounting screws. The option also includes a preformed tube with fittings
to connect the regulator outlet to the Analyzer inlet. These should be mounted
on the back panel as shown in Figure 3-4 using the supplied screws.
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.
NOTE: For additional information on the proper purging regulators after
installation see page 37
Options
DF-310E
23
SAMPLE INLET
1/8"COMPRESSION
REGULATOR
J1
J2
A1-COM
A3-COM
A1-NO
A3-NO
A1-NC
A3-NC
A2-COM
UNUSED
UNUSED
A4-COM
A2-NO
A4-NO
A2-NC
A4-NC
GND
GND
J3
J4
+24V
A OUT +
UNUSED
A OUT -
24V RTN
PUMP -
GND
PUMP +
UNUSED
UNUSED
UNUSED
FLOW-A
UNUSED
UNUSED
UNUSED
FLOW-B
J5
J6
LOOP +
EXT-1 +
LOOP -
EXT+1 -
UNUSED
EXT-2 +
UNUSED
EXT-2 -
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 9: Regulator Installation
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.
5.9 Key Lock
An optional key lock can be installed in the door of the analyzer to prevent
access to the power switch and other internal components. The lock is
supplied with two keys.
If the analyzer is operating, the key lock does not prevent adjustments from
the front panel. Password Protection, described in the User Interface section
24
DF-310E
Options
under Setup Analyzer Menu, must be used to lockout front panel control
changes.
REGULATOR
SAMPLE INLET
1/8"COMPRESSION
FILTER
A3-NO
A3-NC
M
UNUSED
D
A4-COM
O
A4-NO
C
A4-NC
GND
J4
A OUT +
SED
A OUT -
RTN
PUMP PUMP +
SED
UNUSED
SED
FLOW-A
NUSED
UNUSED
NUSED
FLOW-B
J5
J6
LOOP +
EXT-1 +
LOOP -
EXT+1 -
UNUSED
EXT-2 +
UNUSED
EXT-2 -
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 10: Combined Filter/Regulator Assembly
5.10 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 45 for additional information.
5.10.1
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 66 for additional
information on the Sensor Off function.
5.11Relays
Up to four optional form C (SPDT) relays (contact closures) are available to
Options
DF-310E
25
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 44 for additional information.
5.12Communication 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 43 for
additional information.
5.13 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 72 for additional information.
5.14Panel Mount
A panel mount option is available. See Figure 11 and Figure 12 below for
details.
26
DF-310E
Options
P
P
M
8.71 [221.23]
4.21 [106.93]
7.59 [192.79]
4.63 [117.60]
7.75 [196.75]
2.05 [52.07]
2.04 [51.82]
1.17 [29.77]
Ø.22 [Ø5.59]
4 PL
6.50 [165.13]
7.89 [200.48]
8.33 [211.48]
9.26 [235.08]
.30 [7.62]
9.36 [237.87]
9.97 [253.11]
Figure 11: Panel Mount Configuration
Ø.22 [Ø5.59]
4 PL
4.63 [117.60]
8.44 [214.38]
1.91 [48.39]
.21 [5.27]
8.95 [227.33]
9.37 [237.87]
Figure 12: Cutout Dimensions for Panel Mount
Options
DF-310E
27
5.15Rack Mount
P
P
M
4.21 [106.93]
7.59 [192.79]
7.50 [190.50]
7.75 [196.75]
10.46 [265.68]
5.25 [133.35]
2.25 [57.15]
2.05 [52.07]
1.48 [37.59]
1.17 [29.77]
6.50 [165.13]
5.33 [135.32]
8.33 [211.48]
7.89 [200.48]
19.00 [482.60]
9.26 [235.08]
Figure 13: Rack Mount
5.16Dual Rack Mount
P
P
M
4.21 [106.93]
7.59 [192.79]
P
P
M
7.50 [190.50]
10.46 [265.68]
5.25 [133.35]
2.25 [57.15]
2.05 [52.07]
1.48 [37.59]
1.17 [29.77]
6.50 [165.13]
7.89 [200.48]
.93 [23.52]
.70 [17.73]
8.33 [211.48]
9.26 [235.08]
8.33 [211.48]
19.00 [482.60]
Figure 14: Dual Rack Mount
5.17 Remote Display
The display and keypad may be mounted remotely if noted at the time of
order. Following are the dimensions for the hole cutout and mounting screws.
The connecting cable must be shielded with the ground attached only to the
stud on the rear of the analyzer and wired as shown in Figure 16.
28
DF-310E
Options
1.21 [30.7]
6.80 [172.7]
P
P
M
4.15 [105.4]
ESC
.25 [6.4]
6.30 [160.0]
.25 [6.4]
6-32 UNC-A2 X .50 LG
THREADED MOUNTING STUDS
4 PLS
.14 [3.5]
3.30 [83.8]
3.650 [92.7]
1.63 [41.3]
.40 [10.1]
.74 [18.7]
.69 [17.4]
PHANTOM LINE REPRESENTS
THE PANEL CUT OUT TO ALLOW
CLEARANCE FOR DISPLAY
ELECTRONICS.
5.45 [138.4]
Figure 15: Remote Display
Options
DF-310E
29
Figure 16: Remote Display Wiring
5.18Case Purge
NOTE: The case purge option is available on AC powered analyzers only.
The DF-310E analyzer can be equipped with an inert gas (nitrogen) purge
system. The purge system provides improved protection against an explosion
hazard by purging the enclosure to a concentration level below the lower
explosive limit.
With a 10 scfh flow, the nitrogen purge system provides a minimum of thirty
volume changes per hour of the atmosphere inside the analyzer’s enclosure. A
low-flow switch controls the failsafe feature. AC power is connected to the
analyzer through the purge control as long as the low-flow switch contacts are
closed. In the event of a partial or full loss of purge gas flow, the low-flow
switch opens causing a hermetically sealed relay to disconnect power to the
analyzer.
The electrical and purge gas connections are at the rear of the analyzer. The
30
DF-310E
Options
purge system has a maximum supply pressure rating of 100 psig and is
connected via a 1/8-inch compression fitting. Dry nitrogen is recommended.
AC power is connected by the user at the three-terminal connector block next
to the purge gas inlet. See Figure 17.
7.92 [201.09]
SEALED AC POWER
CONTROL RELAY
J1
A3-COM
A1-NO
A3-NO
A1-NC
A3-NC
A2-COM
UNUSED
UNUSED
A4-COM
A2-NO
A4-NO
A2-NC
A4-NC
GND
GND
J3
A OUT +
UNUSED
A OUT -
24V RTN
PUMP -
GND
PUMP +
UNUSED
UNUSED
UNUSED
FLOW-A
UNUSED
UNUSED
UNUSED
FLOW-B
J6
LOOP +
EXT-1 +
LOOP -
EXT+1 -
UNUSED
EXT-2 +
UNUSED
EXT-2 -
J7
1.63 [41.35]
J4
+24V
J5
5.12 [130.05]
J2
A1-COM
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
.60 [15.33]
CABINET PURGE
FLOW SWITCH
9.70 [246.33]
8.33 [211.48]
P
P
M
9.07 [230.38]
CABINET PURGE
FLOWMETER AND
CONTROL VALVE
SAMPLE OUTLET
1/8" COMPRESSION
4.21 [106.93]
7.75 [196.75]
SAMPLE INLET
1/8" COMMPRESSION OR
1/4" VCR COMPATIBLE MALE
2.05 [52.07]
Figure 17: Case Purge Option
Options
DF-310E
31
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 2: Maximum Allowable Acid Gas Limits
Contact the local Servomex Business Center 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 Servomex for details.
There are applications where the acid gas components may exceed the upper
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
Sample Gas Preparation and Delivery
DF-310E
33
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. Contact the local Servomex Business
Center 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.
Servomex 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 changeout. For more information, contact the local Servomex Business Center.
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 79 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 3.
Contact the local Servomex Business Center for assistance with gases not
listed.
For additional information see the section on Gas Scale Factor in the User
Interface chapter on page 79.
34
DF-310E
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 3: Gas Scale Factors
6.2.1.1 Disclaimer
The method used to correct the calibration of the DF-310E 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 the local Servomex Business
Center.
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 Servomex 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-310E
35
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
to the oxygen reading.
36
DF-310E
Sample Gas Preparation and Delivery
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.
Set the delivery pressure to 5 psig (15 psi for welded sample line with
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 the conditions downstream of the analyzer. A recalibration under your
operating conditions may be desirable to remain within the stated accuracy
Sample Gas Preparation and Delivery
DF-310E
37
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. Servomex attempts to identify
all pertinent application details prior to quoting and order processing. All
non-typical 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.
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
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Sample Gas Preparation and Delivery
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. Contact the local
Servomex Business Center 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.
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
Sample Gas Preparation and Delivery
DF-310E
39
33 for more detail.
Contact the local Servomex Business Center 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 56. 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.
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. Servomex
has found that calibration standards in aluminum cylinders are very stable for
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Sample Gas Preparation and Delivery
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 (15 psi for welded sample
line with VCR connection.
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
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
Sample Gas Preparation and Delivery
DF-310E
41
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) is 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.
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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.
NOTE
When using external devices to monitor the O2 reading, the analyzer
should never be left in a menu screen unattended, but always in the O2
readout mode.
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 4: Comm Port (J8) Connector Pinout
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 18: J7/J8 Connector Wiring
Connecting to External Devices
DF-310E
43
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 Servomex 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
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 19: J1/J2 Connector Wiring
44
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
DF-310E
Connecting to External Devices
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 5: Relay Port Connectors (J1, J2) Pin Out
7.3 Analog Outputs
In addition to the wiring of the analog outputs as described below, see page 70 for additional
information on 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
J3/J4 Connector Wiring
J4-1
AOUT+
Analog Voltage Output +
J4-2
AOUT-
Analog Voltage Output -
Table 6: 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.
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. See page 13.
Remove the two screws from the rear of the unit. See page 18.
Connecting to External Devices
DF-310E
45
5. Remove the circuit board assembly from the cabinet.
6. Remove the four screws that hold the sheet metal cover in place. Remove the cover and
set aside.
7. Locate jumper # JP14 in the center, directly below the relays in the upper third of the
board.
8. Using the information in Table 7, place a jumper (short) between the appropriate pins to
obtain the desired full scale output.
9. Reassemble and install the circuit boards back into the analyzer.
10. Reconnect all cables and power up the analyzer.
11. From the Diagnostics Menu, select Test Output, and set the output to 100% full scale.
12. With a DVM, confirm that the analog output voltage is proper. If it needs to be adjusted
slightly, use the potentiometer located third from the top on the front of the circuit board,
above the Servomex symbol.
Full Scale Output Voltage
Jumper Number
5.0 VDC
None
10.0 VDC
14
Table 7: 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 20: J5/J6 Connector Wiring
J5-1
LOOP +
4-20 mA Output +
J5-2
LOOP -
4-20 mA Output -
Table 8: 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 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 66 for additional
information on the Sensor Off function.
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Connecting to External Devices
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 89 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.
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 21: Analog Voltage Output and 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 91, will indicate
to what set of EXT contacts this option is assigned, either 1 or 2.
Connecting to External Devices
DF-310E
47
J5
J6
LOOP +
EXT-1 +
LOOP -
EXT-1 -
UNUSED
EXT-2 +
UNUSED
EXT-2 -
Figure 22: J5/J6 Connector Wiring
J6-1
EXT-1 +
External Control Input (+)
J6-2
EXT-1 -
External Control Input (-)
J6-3
EXT-2 +
External Control Input (+)
J6-4
EXT-2 -
External Control Input (-)
Table 9: Remote Control Connector (J6)
While the display is in the normal O2 mode, a voltage of 5-28VDC 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. In addition, the Automatic Sensor off function is disabled.
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 30.
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 10 below) and should not share the same conduit as the sensor cable. See the
wiring diagram in Figure 30.
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DF-310E
Connecting to External Devices
Pump Cable (Must be separate from sensor cable)
Distance in Feet
Minimum Wire Size
0 – 500
#20 AWG
500 – 1000
#18 AWG
Table 10: Pump Cable Specification
J3
J4
+24V
A OUT +
UNUSED
A OUT -
24V RTN
PUMP -
GND
PUMP +
UNUSED
UNUSED
UNUSED
FLOW-A
UNUSED
UNUSED
UNUSED
FLOW-B
Figure 23: J3/J4 Connector Wiring
In addition, the following options are available:
If factory configured, Servomex 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 Servomex
supplied pump that is powered from a separate 12 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 5-28 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.
Areas of high convected or radiated heat must always 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 53)
Care must be taken to use high quality cable and techniques when making remote electrical
Connecting to External Devices
DF-310E
49
connections. See the wiring diagram in Figure 30 and refer to Table 10 and Table 11 for wire
sizes and lengths. Following are three remote sensor configurations and wiring diagrams.
Care must be taken when making up gas fittings on the sensor when mounted on a remote
bracket as shown in Figure 24 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. A 0.010 inch orifice is included with 0-50ppm sensors and must be
installed at the sensor inlet in order to control gas flow.
Contact Servomex for additional information on remote sensor installations.
7.5.1 Sensor on Remote Bracket with Optional Pump
CAUTION
Always use a backing wrench when connecting the gas sample line
to a remote sensor.
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 24: Remote Sensor with Optional Pump
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DF-310E
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 25: Remote Sensor Mounted in NEMA 4 Enclosure
Connecting to External Devices
DF-310E
51
7.5.3 Sensor in NEMA 7 Enclosure
Figure 26: Remote Sensor Mounted in NEMA 7 Enclosure
52
DF-310E
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 27: 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
temperature to an accuracy of +/- 2 degrees F.
Connecting to External Devices
DF-310E
53
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 28. Turn it clockwise to increase the temperature and counterclockwise 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 28: 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 11. 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 30 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 11: Remote Sensor Cable Sizes
54
DF-310E
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 29: Remote Sensor Connector – J7
Figure 30: Remote Sensor/Pump Wiring Diagram
Connecting to External Devices
DF-310E
55
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.
A supply of air or N2 regulated between 25 – 250 psig is required.
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]
3.14 [79.82]
2.75 [69.85]
SAMPLE INLET
1/4" COMPRESSION (STD)
1/4" VCR COMPATIBLE (OPTIONAL)
7.00 [177.80]
SAMPLE OUTLET
1/4" COMPRESSION
Figure 31: Z-Purge Protection on R4 Sensor Enclosure
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DF-310E
Connecting to External Devices
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. (pre-regulated 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.
Connecting to External Devices
DF-310E
57
8 User Interface
8.1 The Data Display Screen
When the DF-310E Process Oxygen Analyzer is powered up, it goes through a series of internal
diagnostic tests which take about five seconds. After the tests, the Servomex logo appears for
ten seconds. The display will then show the Data Display Screen as shown in Figure 32.
3.43
P
P
M
OUT : 0.0- 100.0
*Menu
GSF: 1.003
Figure 32: Data Display and Keypad
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 (%).
User Interface
DF-310E
59
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 70. 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 33, will appear.
GSF indicates the present Gas Scale Factor. The Gas Scale Factor is described on page 74. 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.
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
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User Interface
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 12: 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 oxygen sensor polarization voltage 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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61
62
3.43 ppm
DF-310E
User Interface
8.2 Main Menu
The Main Menu, Figure 33, is accessed by pressing
from the Data Display Window. Alarm
Overlay information will continue to display over the Main Menu.
Figure 33: 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 65.
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 67.
Password - Used to set passwords and indicate which menus are "password" protected
76
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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63
8.2.1 Keypad Operation
The following protocols are used to operate the Analyzer through the front keypad:
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
the previous menu.
64
to save the changes and automatically return to
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User Interface
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 34.
Figure 34: 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 67, for additional information about leaving the menu after
changing the Pump setting.
See the section on Remote Controls, page 47, for additional information on remote control of the
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.
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DF-310E
65
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 67,
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 35. 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 47, for additional information on remote control of the
sensor polarization voltage.
Figure 35: 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.
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User Interface
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. See page 25 for additional information on the 220mA option.
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
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 33, and the appropriate password is entered (if required),
Figure 36 is shown.
Figure 36: Setup Menu
Each entry in Figure 36 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.
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67
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 36, the display will present Figure 37.
Figure 37: 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.
8.4.1.1 O2 Alarms
If an O2 alarm has been selected from the Alarm Setup Screen Figure 37, the display will show
Figure 38.
Figure 38: Oxygen Alarm Menu
Figure 39: 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
39. (Oxygen ALARM 1 is used in the example shown in Figure 40.) To indicate that the alarm is
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User Interface
to be used, move the asterisk to Alm 1and press
to O2.
. For the oxygen alarms, the NU will change
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
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 40.
Figure 40: 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 37, selecting TEMP Alm (ON) will bring a display similar to
Figure 39. 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 13.
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69
Background Gas
Trip Point (scfh)
Air
Ammonia
Argon
Butane
Carbon Monoxide
Ethane
Ethylene
Helium
Hexane
Hydrogen
Methane
Nitrogen
Propylene
0.25
0.33
0.22
0.18
0.26
0.25
0.26
0.69
0.15
0.96
0.34
0.26
0.21
Table 13: Flow Switch Trip Points
From the Alarm Setup Menu, Figure 37, selecting FLOW Alm (ON) will bring a display similar
to Figure 39. 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.
8.4.1.4 Electrolyte Condition Alarm
The ELEC alarm is used to indicate electrolyte condition. From the Alarm Setup Menu, Figure
37, selecting the ELEC Alm (ON) will bring a display similar to Figure 39. 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 36, 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 36, the display will be as shown in Figure 41.
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Figure 41: 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.
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 14: Output Scaling on Standard Resolution Analyzer
If an invalid Zero to FS window is entered the following error message will be briefly displayed.
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Figure 42: 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 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 15 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 15: Output Scaling on High Resolution Analyzer
8.4.2.3 Expanded Range Scale Operation And Setup
The optional expanded range scale function 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 41, the analog outputs (0-10 VDC and 4-20 mA) are scaled over the 0 -
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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
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 36, 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 43 for more information.
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After accessing the Comm Port Menu, the display in Figure 43 will be shown.
Figure 43: 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
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 79.
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 44 below.
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Figure 44: 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.
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 36, is used to edit information regarding
the clock and calendar operation. After accessing the Clock menu, Figure 45 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.
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and
keys and then hit
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Figure 45: Clock Setup Screen
8.5 The Password Menu
The DF-310E 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 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 46.
Figure 46: 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.
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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 47. The display for a master password is identical except
the bottom line is blank instead of OP:.
Figure 47: Password Entry Screen
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 46.
After the fourth key is pressed in the Master's Password, press
to return to Figure 46.
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
local Servomex Business Center.
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 33, the
display shows Figure 48.
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Figure 48: Maintenance Menu
8.6.1 Replenish Solution Reminder
The Replenish Solution Reminder screen Figure 49 is accessed from the Maintenance Screen
Figure 48 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.
Figure 49: 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
48.
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 Hummingbird
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 68.
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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 36. After accessing the Oxygen Cal Menu, the display will
present Figure 50.
If the system has been previously recalibrated by the user, when the Oxygen Cal selection is
made, an additional line will be added to the menu that states Reset Orig Span. The section on
Maintenance and Calibration on page 93 provides more information about spanning the analyzer.
Figure 50: Oxygen Calibration Menu
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 36, or through the Oxygen Cal Menu,
Figure 50. 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 16: GSF Corrections
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Contact the factory, for assistance with gases not listed above.
When GSF is selected, the display in Figure 51 will be shown.
Figure 51: Gas Scale Factor
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 52. 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.
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 52 below.
Figure 52: Gas Scale Factor Menu (Cont’d)
Note: Scrolling down the gas list from Figure 51 to Figure 52 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.
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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 Servomex 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 local Servomex Business Center.
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 Servomex 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 50, is used to adjust the O2
calibration. Selecting Check/Adj Span will display the screen shown in Figure 53.
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Figure 53: Span Check Menu
The GSF factor of the calibration gas can be entered directly or calculated by the instrument as
described on page 79. 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 40 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
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conditions (4" Hg vacuum or higher), such as when taxing the capability of the on-board pump,
the Analyzer 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 54.
Figure 54: 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 54.
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 55. 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 55: 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 55 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
Servomex 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 56 is displayed.
Figure 56: 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 Servomex for an application specific
recommendation on checking the zero of the instrument in the field.
Should Servomex recommend checking the zero baseline calibration of the Analyzer, the
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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 97.
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 57.
Figure 57: 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
to use the factory set calibration. The Reset Orig Zero line of Figure 57 will disappear. It is
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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 58.
Figure 58: Zero Cal Warning Screen
Note: The zero baseline stabilization criteria is only verifying stability over a short time scale
(1-5 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 59 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 57.
Figure 59: Zero Cal Screen
Pressing the ESC key at any time aborts the process and returns the user to the SENSOR ZERO
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DF-310E
User Interface
menu.
If
is pressed before the “STABLE” message is displayed the screen will change as shown in
Figure 60.
Figure 60: 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 61.
Figure 61: Test Output Screen
Use the
key to set the desired output level in 10% percent steps of full scale from 0% to
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
User Interface
DF-310E
89
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 56, is used to assure that the relay
outputs are functioning. When the Test Relays option is selected, the display will show Figure
62.
Figure 62: 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 56, the display will show
Figure 63. Testing automatically begins.
Figure 63: 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,
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,
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User Interface
repeat the test. If a failure is repeated contact the local Servomex Business Center.
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 56. Pressing ESC will abort
the screen test. If an error message appears, or a pixel is inactive, contact the local Servomex
Business Center.
8.6.3.7 EXT Functions
Figure 64: 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 47 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.
User Interface
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91
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 Servomex by calling the local Business Center. See the Shipping
Section on page 103 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 2 page 33, 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 Servomex DF-310E 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, Servomex 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 Servomex for a
recommendation on calibration verification for your specific case.
For Analyzers used in clean gas applications, and operated under Normal Operating Conditions
there is no need for zero calibration checks in the field.
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DF-310E
93
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
Hummingbird Replenishment Solution (RSA), 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 Hummingbird Replenishment
Solution for optimum performance and long term reliability.
CAUTION
If the electrolyte level is low, only Hummingbird 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
electrolyte level should be checked every 1 to 2 months. If the liquid level is low, add
Hummingbird 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
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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 Hummingbird 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 solution 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 Hummingbird 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.
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95
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.
Battery - NiMH
Cable – Display to Main Board
Cable – Sensor to Main Board
Connector - (8 pin)
Connector - (4 pin)
Display assembly with PCB
Hummingbird Brand Electrolyte Blue
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 (all 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
Orifice (0.010 inch) for 0-50ppm sensor
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
Hummingbird Brand Replenishment Solution – 100ml
Hummingbird Brand Replenishment Solution – 0.5l
Hummingbird Brand Replenishment Solution – 1.0l
Hummingbird Brand Replenishment Solution – 2.0l
Oxygen Sensor
Sensor Cap - Blue
210538
210381
210394
210407
210402
210527
ELECTROLYTE_BLUE
210411
210412
210413
211282
210614
210573
210852
210517
210518
210425
210424
210430
210530
210450
210354
210470
210491
210469
210466
210408
210500
210502
210515
210514
210513
210516
Consult Servomex
210397
Table 17: Replaceable Parts
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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 between 0.5 LPM or 1.0 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 replaced.
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97
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
ABDEHIJZ
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
GCDEZ
7)
Electrolyte residue (white powdery build-up) visible
on the sensor
Z
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
LMNZ
Z
Z
11)
Span reading is unacceptably high (>50% high)
RCJZ
12)
Span reading is unacceptably low (>50% low)
RJEZ
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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 local Servomex Business Center
E)
Change the electrolyte. Use only electrolyte supplied by Servomex. 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). For best results, the sensor should sit
for 60 minutes before flowing gas through it. Then 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.
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 79 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.
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DF-310E
99
M)
Ensure that the sensor polarization voltage is turned on. See page 66.
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 Hummingbird 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 local Servomex Business Center 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.
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.
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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 96 for Servomex 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 65. 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 96 for Servomex 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 65. 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-310E
101
24VDC POWER SUPPLY PCB
FUSE 1.00A
BATTERY BACKUP PCB
FUSE 3.15A
Figure 65: Fuse Locations for DC Power Supply and Battery Backup
MAIN PCB
24VDC POWER SUPPLY PCB
BATTERY BACKUP PCB
4-20mA PCB
Figure 66: Printed Circuit Board Assembly
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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
Servomex 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 re-attachment later.
3. Remove the sensor as described on page 14.
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, contact the local
Servomex Business Center 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 must be returned freight prepaid.
Troubleshooting and Calibration
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103
10 Theory of Operation
10.1The Oxygen Sensor
The Servomex 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
Anode
Sample Gas
Cathode
Figure 67: Schematic of Servomex 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-310E
105
10.2 The Electrolyte Conditioning
System
The Process Oxygen Analyzer is equipped with Servomex'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.
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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
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DF-310E
107
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.
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11.1
Electrolyte Solution MSDS
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
Servomex 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 #
Component
EC Code/class
Concentration
7732-18-5
1310-58-3
Water
Potassium Hydroxide in
aqueous solution
231-791-2
215-181-3
C
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
Causes severe eye burns. May cause irreversible eye injury. Contact may cause
ulceration of the conjunctiva and cornea. Eye damage may be delayed.
Skin Contact
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
4. FIRST-AID MEASURES
Skin Contact
Safety
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.
DF-310E
109
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
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.
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
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
110
DF-310E
Safety
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
CAS# 7732-18-5
ZC0110000
CAS# 1310-58-3
TT2100000
LD50/ LC50
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
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
RTECS#
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.
Accumulation
No
Ecotoxicity
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
Safety
DF-310E
111
due to further dilution. The preparation is corrosive, and direct contact with fauna
will cause burns.
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
Potassium Hydroxide Solution
8
UN1814
II
Canadian
TDG
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
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
112
DF-310E
Safety
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
In case of accident or if you feel unwell, seek medical advice
immediately (show label where possible).
No information available
Safety Phrases
WGK (Water
Danger/Protection)
Canada – DSL/ NDSL
Canada - WHMIS
Canadian Ingredient
Disclosure List
16. Other Information
MSDS Creation Date:
CAS# 7732-18-5
CAS# 1310-58-3
CAS# 7732-18-5
CAS# 1310-58-3
Classification E,
D1B
CAS# 1310-58-3
09/30/94
1
Listed on Canada’s DSL List
Listed on Canada’s DSL List
Classified in accordance with the hazard criteria of the
Controlled Products Regulations and the MSDS contains all
of the information required by those regulations.
Listed on the Canadian Ingredient Disclosure List
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.
Safety
DF-310E
113
11.2 Replenishment Solution MSDS
MATERIAL SAFETY DATA SHEET
1. IDENTIFICATION OF THE SUBSTANCE
Trade Name
Replenishment Solution, RS-A
Manufacturer
Servomex 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 #
Component
EC Code/class
Concentration
7732-18-5
Water
(contains trace salts)
215-181-3
C
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
Safety
Special Exposure Hazard
Not applicable
Extinguishing Media
Not combustible. Select extinguishing media appropriate to the surrounding
fire conditions.
DF-310E
115
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
Stable
Conditions/Materials to Avoid
Strong reducing agents, acid chlorides, phosphorus trichloride,
phosphorus pentachloride, phosphorus oxychloride.
Not applicable.
Has not been reported
Hazardous Decomposition Products
Hazardous Polymerization
116
DF-310E
Safety
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
Mobility
Degradability
Accumulation
Ecotoxicity
Completely soluble in water
Not applicable.
Not applicable.
Applicable.
13. Disposal Considerations
Waste Disposal
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.
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-310E
117
12 Warranty
Servomex 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.
In addition, if the oxygen sensor in this 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-310E
119
13 Index
▲
▲, 59
▼
▼, 59
2
2-20mA Analog Output, 25
4
4-20mA Analog Output, 25
4-20mA Output, 46
4-20mA Output Fuse, 101
A
AC Power Fuse, 101
Accuracy, 9
Acknowledged Alarm, 61
Alarms, 60, 68, 69, 70
Electrolyte Condition Alarm, 70
Low Flow Alarm, 20, 69
Oxygen Alarms, 68
Temperature Alarm, 69
Analog Output, 70, 89
Menu Settings, 70
Analog Output Range, 60
Analog Voltage Output, 45
Analyzer
Process Upsets, Protection from, 40
Specifications, 9
Unpacking, 4
Warranty, 119
Analyzer Trouble, 66
Annunciator Line, 59, 63, 89
Audible, 10, 69
B
Background Gas, 79
Correction Factors, 79
Backlight (BL), 75
Backplane, 100
Battery Backup Fuse, 101
Battery Power, 19
Battery Power, NiMH, 19
Index
Baud, 74
Bits, 73
C
CAL FREEZE, 73
Calibrating, 82, 83, 84, 87, 93
Calibration, 79, 93
Case Purge, 30
Cautions, 7
Important Warnings, 7
Symbols and Explanations, 7
Check Fluid, 78
CHECK FLUID, 61
Check/Adj Cal, 79, 82
Clean Gas Applications, 93
Clock, 75
Comm Port, 73
Baud, 74
Device ID, 74
Communication Port – RS232/485
Port, 74
Condensation, 11
Contrast, 75
Controls, 63
Controls Menu, 65
Convergence, 85
coulometric, 105
D
Data Line, 59
DC Power Fuse, 101
Deadband, 69
Device ID, 74
Diagnostics, 76, 86
EXT Functions, 91
Memory Test, 90
Screen Test, 91
Sensor Temperature, 86
Sensor Zero, 86
Test Output, 89
Test Relays, 90
Dimensions, 11
DISABLING ALARMS, 67, 76, 77, 86
Display Setup, 74
E
Electrical Connections, 89
Electrolyte, 98, 99
DF-310E
121
chemical reaction, 105
Electrolyte Condition Alarm, 70
EMI Sensitivity, 10
Error, 82, 87
ESC, 59, 64, 67
Expand FS, 72
Expanded Range Scale, 26
Expanded Range Scale Output, 26, 72
ExpRng Relay, 73
EXT Functions, 91
External Devices
Comm Port, 43
Option Ports
Changing Analog Output Voltage, 45
Relay Ports, 44
Remote Controls, 47
External Devices, Connecting to, 43
F
fault condition, 66
Filter, 21
Oil/Solvent Mist, 11
Solid Particles, 11
Filter Elements, 21
Flow, 61, 69, 73, 84
flow control, 19, 48
Flow Control Valve, 21
Fuse Replacement, 100
Fuse, AC Power, 101
Fuse, Battery Backup, 101
Fuse, DC, 101
G
Gas Compatibility, 11
Gas Sample
Clean Gas Application, 93
Gas Scale Factor, 79
H
Handshaking (Serial Port), 73
Hi Stpt, 69
High-Resolution Analyzers, 72
I
IN-CAL Relay, 73
INLET PRESSURE, 11
Installation and Setup, 13
Adding Electrolyte, 14
Electrical Connections, 16
Low Flow Alarm, 20
Powering Up, 16
Pressure Regulator Installation, 21
Pressure Regulator Purge, 37
Sample Gas Connections, 15
122
Index
Standard Outputs, 17
INVALID DATA, 60, 89, 98
IRAM, 90
K
Key Lock, 24
Keypad Operation, 64
L
Leak (Plumbing), 99
Level, 75
Lo Stpt, 69
Loop Resistance (4-20 mA), 10
Low Flow Alarm, 20, 69
Low Flow Switch, 69
M
Maintenance, 63
Fuse Replacement, 100
Maintenance Menu, 77
Reset the, 78
Set the, 78
Maintenance, Analyzer, 93
Master Password, 76
Memory Error!, 61
Memory Test, 90
Menu, 60
N
NEMA 4 Enclosure, 51
NEMA 7 Enclosure, 52
New Sensor, 85
NiMH Battery Power, 19
Not Available, 68
O
Operator Password, 76
Options
4-20mA Analog Output, 25
Battery Power, 19
Case Purge, 30
Communication Port – RS-232/485, 26
Dual Rack Mount, 28
Expanded Range Scale, 26
Filter, 21
Flow Control Valve, 21
Form C Relays, 25
Key Lock, 24
Low Flow Alarm, 20
Panel/Rack Mount, 26
Pressure Regulator, 21
Pump, 19
Rack Mount, 28
DF-310E
Remote Display, 28
Remote Sensor
Temperature Control, 53
Stainless Steel Outlet Tubing, 24
Outputs, Analog, 70
OVER RANGE, 61
Oxygen Alarms, 68
P
Sensor Performance, 37
Regulator Requirements, 36
Sample Flow Rate and Pressure, 35
Sample Gas
Compatibility, 38
Reactivity with KOH Electrolyte, 39
Solubility in Aqueous KOH Solution, 39
Trace Acids, 39
Sample Gas Calibration
Panel Mount, 26
Password, 63
Misplaced, 77
Password Menu, 76
Port (Communication), 74
Power Requirements, 10
PRESSURE, 11
Pressure Regulator, 21
Procedure
Adding Replenish Solution to the
Sensor, 95
Changing the Analog Output, 47
Purging Ambient Air from Regulator,
37, 41
Pump, 19, 65
Purging, 97
R
Rack Mount, 28
Recalibration, 87
Relay, 69, 90
Relay Contact Closures, 10
Remote Controls, 47
Remote Display, 28
Remote Pump Control, 48
Remote Sensor
Temperature Control, 53
Remote Sensor Connections, 54
Remote Sensor Control, 47
Remote Sensor Installations, 49
Replenishment Sol’n Reminder, 78
Reset Orig Span, 79, 85
Reset Orig Zero, 87
Resolution, 9
ROM, 90
Rotameter, 65, 84
S
Safety, 107
Sample Gas, 79
Sample Gas Preparation and Delivery, 33
Background Gas Effects, 36
Backpressure Effects, 38
Flow Rate Effects
Leakage Checks, 36
Sensor Performance, 36
Index
Pressure Effects
Background Gas Effects, 42
Delivery and Vent Pressure, 41
Regulators, 41
Standards, 40
Sample Gas Calibrations, 40
Sample Gas Condensation, 38
Sample Gas Flammability, 39
Sample Gas Temperature, 40
Sample GSF, 34
STAB-EL Acid Gas System, 33
Sample System Leak Test, 97
Sampling Considerations
Clean Gas Application, 93
Screen Test, 91
Sensitivity, 9
SensOFF Relay, 66, 67
Sensor
anode, 105
cathode, 105
non-depleting, 105
operation, 105
SENSOR OFF, 60
Sensor Off 4-20mA Signal, 67
Sensor Polarization, 66
Sensor Temperature, 86
Sensor Zero, 86
Service
Maintenance
Calibration, 93
Sensor, 94
Storage Conditions, 94
Return Material Authorization number,
93
Shipping, 103
Return Material Authorization number,
103
Troubleshooting, 97
Troubleshooting Guide, 97
Set-Up Menu, 63, 67
SPAN REF, 83
Spare Parts List, 96
Stainless Steel Outlet, 24
Storage Temperature, 10
T
TEMP OVER RANGE, 61, 82
Temperature, 10, 69, 100
Temperature Alarm, 69
DF-310E
123
Test Output, 89
Test Relays, 90
Theory of Operation
Electrolyte Conditioning System, 106
Sensor, 105
TO, 61
Troubleshooting, 93, 98
U
UNCALIBRATED, 61, 98
UNDER RANGE, 61
Update And Quit, 74
Upstream Valve, 65
UR, 61
User Interface, 59
Data Display Screen, 59
124
Index
Main Menu, 63
W
Wait!, 61
Warranty, 119
Weight, 11
Z
ZERO CAL, 88
Zero Calibration Frequency
Clean Gas Applications, 93
ZERO REF, 87
Z-Purge, 56
DF-310E
BUSINESS CENTERS
TECHNICAL CENTERS
EUROPE (Europe and Africa)
Tel: +31 (0)79 330 1580
Fax: +31 (0)79 342 0819
Toll Free : 00800 7378 6639
USA & CANADA
Tel: +1 281 295 5800
Fax: +1 281 295 5899
Toll Free: 1 800 862 0200
LATIN AMERICA/MEXICO
Tel: +55 11 5188 8166
Fax: +55 11 5188 8169
ASIA PACIFIC
Tel: +86 (0)21 6489 7570
Fax: +86 (0)21 6442 6498
INDIA
Tel: +91 22 39342700
Fax: +91 22 39342701
MIDDLE EAST
Tel: +971 6 5570730
Fax: +971 6 5571242
www.servomex.com
Servomex Group Limited
Crowborough
East Sussex, TN6 3FB
UK
Tel: +44 (0)1892 652181
Fax:+44 (0)1892 662253
Servomex Company Inc
4 Constitution Way
Woburn, MA 01801 1087
USA
Tel: +1 781 935 4600
Fax:+1 781 938 0531
Toll Free: 1 800 433 2552
SYSTEMS ENGINEERING CENTERS
Crowborough, UK
Houston, USA
Shanghai, China
Mumbai, India
Tel: +44 (0)1892 652181
Tel: +1 281 295 5800
Tel: +86 (0)21 6489 7570
Tel: +91 22 39342700
www.hummingbirdsensing.com
Servomex has a policy of constant product improvement and reserves the right to change specifications without notice.
© Servomex Group Limited. 2011. A Spectris company. All rights reserved.