Teledyne Oxygen Equipment 319R User Manual

MODEL  
319R  
OXYGEN DETECTOR  
INSTRUCTION MANUAL  
P/N M59608  
ECO# 95-416  
7/10/95  
TELEDYNE BROWN EGINEERING  
AnalyticalInstruments  
 
Table of Contents  
1.0 Introduction  
Main Features ............................................................................................... 1  
Micro-Fuel Cell ............................................................................................ 2  
Z-2 Cell Warranty Conditions ...................................................................... 2  
2.0 Installation & Operation  
Precautions.................................................................................................... 3  
Location & Mounting ................................................................................... 3  
Analysis Unit Connection............................................................................. 4  
AC Power ..................................................................................................... 4  
DC Power ..................................................................................................... 4  
Output Signals .............................................................................................. 4  
Alarm Terminal Connection......................................................................... 5  
Sensor Installation or Replacement .............................................................. 5  
Setting Alarms .............................................................................................. 6  
Calibration .................................................................................................... 7  
3.0 Maintenance  
Replacing the Fuse........................................................................................ 9  
Replacing the Sensor .................................................................................... 10  
Z-2 Cell Warranty Conditions ...................................................................... 11  
Appendix  
Specifications................................................................................................ 13  
Spare Parts List............................................................................................. 14  
Drawing List ................................................................................................. 15  
Material Safety Data Sheet ........................................................................... 16  
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AnalyticalInstruments  
 
TELEDYNE BROWN EGINEERING  
AnalyticalInstruments  
 
319R  
Introduction 1.0  
Introduction  
The Teledyne Brown Engineering Analytical Instruments (TBE)  
Model 319R Oxygen Detector measures the percent of oxygen in a wide  
range of gases and gas mixtures. Modular and compact design provide  
outstanding performance and reliable on-line monitoring and make the  
319R virtually maintenance-free.  
A special range on the 319R enables you to calibrate in ambient air.  
The Micro-Fuel Cell produces an output that corresponds linearly to the  
oxygen concentration; the absence of oxygen produces zero current. This  
means you can use ambient air (20.9% oxygen) to calibrate, eliminating  
the need for special span gases.  
The Model 319R contains a main PC board and power supply/inter-  
connection board housed in a rack mount enclosure. The oxygen probe can  
be separated from the unit by as much as 6 feet, depending on the level of  
electromagnetic noise in the operating environment.  
Main Features  
1. Two Ranges of Analysis. The Model 319R Oxygen Monitor  
features two analysis ranges: 0–200 PPM and 0–1999 PPM. A 0-25%  
range is accessible only during calibration to allow calibration in air.  
2. Liquid Crystal Display Digital Readout. The digital front panel  
LCD continuously displays and updates O2 monitoring levels and displays  
values when calibrating the instrument and setting the alarms. Note that the  
display will not read higher than 199.9 on the 200 PPM range and 1999 on  
the 2000 PPM range.  
3. Percent of Range Alarms. Three (3) alarm relays are provided:  
one high and one low alarm, which are user adjustable, and one low alarm,  
factory set as a cell fail alarm at 2% of full scale.  
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1.0 Introduction  
319R  
4. Proven Sensor. The 319R uses the Class Z-2 Micro-Fuel Cell,  
warranted for 6 months, with a life expectancy of 6 months.  
5. Analog Voltage Output. The Model 319R provides customer  
connections to external devices, such as computers, recorders, alarms, etc.,  
at 0–10 VDC, negative ground, plus contact closures for range identifica-  
tion. Custom voltage outputs, either grounded or isolated, are available as  
options.  
6. Analog Current Output. The Model 319R has a 4–20 mA current  
output suitable for connection to external devices that use a 4–20 mA  
input.  
7. Over-Range/Cell Failure Visual Indicator. The Model 319R has  
a LED (Light Emitting Diode) to the left of the Liquid Crystal Display.  
The LED will blink when the oxygen reading exceeds 105% of scale, or a  
cell failure alarm is activated.  
Micro-Fuel Cell  
The Model 319R uses a Class Z-2 Micro-Fuel Cell. The Micro-Fuel  
Cell measures the concentration of oxygen in a gas stream. The analysis is  
specific for oxygen; i.e. the measuring cell will not generate an output  
current unless oxygen is present in the sample gas. Therefore, the analyzer  
has an absolute zero, and requires no zero gas. Span calibration is per-  
formed with atmospheric air as the span gas.  
To eliminate any inaccuracies due to the positive temperature coeffi-  
cient of the Micro-Fuel Cell, a thermistor circuit and network of precision  
resistors produce a negative coefficient of matching characteristics. The  
variable element (thermistor) in the compensation network is in the same  
assembly as the Micro-Fuel Cell, exposing both devices to the same tem-  
perature conditions.  
Warranty Conditions  
Customers having warranty claims must return the cell in question to  
the factory for evaluation. If it is determined that failure is due to faulty  
material or workmanship the cell will be replaced free of charge.  
CAUTION: Evidence of tampering or abuse will render the warranty null  
and void.  
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319R  
Installation & Operation 2.0  
Installation & Operation  
Precautions  
1. Read this chapter in its entirety before installing the unit.  
2. Upon receipt of the instrument, inspect the entire unit for  
damage. Notify the shipper if any damage is found. Check the  
unit, probe, and included accessories for broken or loose parts.  
3. The sample must be free of entrained solids and water. A high  
humidity sample is ideal since it will prevent water loss from  
the cell electrolyte.  
4. The Micro-Fuel Cell sensor electrolyte is caustic. Do not  
attempt to open or repair the sensor. Leaking or exhausted  
sensors should be disposed of in accordance with local  
regulations. Please refer to the Material Safety Data Sheet in the  
Appendix to learn about potential hazards and corrective action  
in case of accident.  
5. Do not scratch, puncture, or damage the sensing membrane of  
the Micro-Fuel Cell sensor. Damage to the membrane will  
require replacement of the sensor.  
Location & Mounting  
The unit is designed to be panel-mounted in a general purpose area,  
away from moisture and the elements. The unit should be installed at  
viewing level in a sheltered area.  
Refer to the Outline diagram (dwg. C-57490) for the physical dimen-  
sions of the analyzer.  
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2.0 Installation & Operation  
319R  
The analysis unit should be installed in the process at a maximum  
distance of 6 feet away from the main unit, depending upon the level of  
electromagnetic noise in the operating environment.  
Analysis Unit Connection  
The receptacle for the analysis unit cable is located in the lower left-  
hand corner of the rear panel. The 6-pin Minifit fitting is keyed to fit only  
one way in the receptacle; do not force it in. The other end of the cable is  
made of four separate wires; these should be connected to the terminal strip  
on the analysis unit as follows:  
Red:  
#1  
#2  
#3  
#4  
Black:  
Green:  
White:  
The green and white connectors can be  
interchanged, but be consistent.  
}
Refer to the probe interconnection dwg. A-58154.  
Sample flow and pressure should not create significant backpressure  
past the sensor; 2 SCFH (atmospheric pressure) is nominal.  
AC Power (International Ranges)  
A 6-foot power cord is supplied with the Model 319R. Plug the  
female end of the power cord into the receptacle in the upper left-hand  
corner of the rear panel. The unit is now ready to be plugged into an AC  
power source (85-264 VAC, 47-440 Hz).  
The ON/OFF switch is located to the right of the power cord recep-  
tacle.  
DC Power  
If you have ordered the 10-36 VDC power option, install DC power  
via the terminal strip on the rear panel of the unit.  
Output Signals  
Terminals for 4-20 mA, 0-10 VDC, and range identification are  
labeled on the rear panel of the analyzer, along with high alarm, low alarm,  
and sensor failure block terminals.  
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319R  
Installation & Operation 2.0  
Alarm Terminal Connection  
SPDT relay contacts are provided for each of the 3 alarms. There are  
9 terminals available on the back panel of the system for alarm circuit  
connection. The explanation for the relay terminals abbreviations is as  
follows:  
NC= Normally closed  
C = Common  
NO= Normally open  
The alarm relay circuits are designed for failsafe operation, meaning  
that the relays are activated (energized) during normal operation. If power  
fails, or if an alarm setpoint is exceeded, the relay will become de-ener-  
gized.  
Sensor Installation or Replacement  
CAUTION: The sensor electrolyte is caustic. Do not let it come in contact  
with skin. If it does, immediately flush affected area with water.  
Consult the Emergency First Aid procedures in the Material  
Safety Data Sheet in the Appendix.  
Do not attempt to open or repair the sensor. Leaking or ex-  
hausted sensors should be disposed of in accordance with  
local regulations. Please refer to the Material Safety Data Sheet  
in the Appendix to learn about potential hazards and corrective  
action in case of accident.  
To install the cell:  
1. Turn the unit off by placing the power switch (on the rear panel  
of the analyzer) in the OFF position.  
2. Disconnect the red and black leads from the terminal strip.  
Remove the spent cell by pulling up on it and twisting slightly.  
3. Remove the new Micro-Fuel Cell from its protective bag.  
CAUTION: Do not scratch, puncture, or damage the sensing membrane of  
the Micro-Fuel Cell sensor. Damage to the membrane will  
require replacement of the sensor.  
4. Attach the red lead of the new cell to terminal #1 and the black  
lead to terminal #2.  
5. Replace the cell on the cell holder by pushing and twisting until  
it strikes bottom.  
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2.0 Installation & Operation  
319R  
Setting Alarms  
The alarms can be adjusted over the full scale range, and they are set  
as a percent of full scale. Thus, an alarm set to indicate 192 on the display  
while on the 200 PPM O2 range will activate at 192 PPM O2 on the 200  
PPM O2 range and at 1920 O2 on the 2000 O2 range (96% of full scale). To  
set the alarms:  
1. Place the range switch located below the front panel display in  
the 2000 PPM range position (or highest range available).  
2. Place the power switch in the ON position.  
3. To set the high alarm, hold down the SET HI ALARM button  
while turning the potentiometer to the right of the button until  
the display reads the desired concentration.  
4. To set the low alarm, hold down the SET LO ALARM button  
while turning the potentiometer to the right of the button until  
the display reads the desired concentration.  
5. Remember, the System/Cell Failure alarm is factory set at 2%  
of full scale; should this alarm trigger, the LED to the left of the  
front panel display will blink.  
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319R  
Installation & Operation 2.0  
Calibration  
To calibrate the 319R:  
1. Place the power switch in the ON position.  
2. Allow the LCD reading to stabilize.  
3. Expose the sensor to ambient air (20.9%) or instrument grade  
air. If the analyzer goes overrange, the display will go blank  
and the LED to the left of the display will blink. Hold down the  
SPAN button until the LED stops blinking.  
4. While holding down the SPAN AT 20.9% button, adjust the  
potentiometer to the right of the button until the display is  
stable and reads 20.9%.  
5. Release the button. The unit is now calibrated.  
6. The alarms will be disabled for about 25 seconds after the  
SPAN button is released. Disabling the alarms allows air to be  
purged from the sample system without tripping any alarm set  
below span, or 21%.  
NOTE: Do not attempt to adjust any alarm setpoints while the alarms are  
disabled during the 25-second period.  
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2.0 Installation & Operation  
319R  
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319R  
Maintenance 3.0  
Maintenance  
Replacing the Fuse  
If the unit will not turn on when plugged in and switched ON (via the  
power switch), or you suspect a blown fuse, replace the fuse using the  
following procedure:  
1. Disconnect the AC power and place the power switch located  
on the rear panel in the OFF position.  
2. The fuse is located next to the power cord receptacle in the  
upper left-hand corner of the rear panel. Remove the power  
cord from the receptacle.  
3. Insert a small flat-blade screwdriver into the slot in the  
receptacle wall nearest the fuse and gently pry open the fuse  
receptacle. The fuse holder will slide out. The fuse in use is  
visible in the clip. To open the spare fuse compartment, push on  
one end until it slides out.  
4. Remove the bad fuse and replace it with a 5X20 mm 1A, 250V  
fast acting fuse for AC units (TBE P/N F-1189 ), or 1/2A fast  
acting fuse for DC units (P/N F-51).  
Figure 5-1: Replacing the fuse (AC power).  
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3.0 Maintenance  
319R  
5. Replace the fuse holder into its receptacle, pushing in firmly  
until it clicks.  
In units with DC power, the fuse is located on the rear panel above the  
ON/OFF switch. Open the fuse holder by unscrewing and removing the  
knob marked FUSE. The fuse will be located inside the knob.  
Replacing the Sensor  
The characteristics of the Micro-Fuel Cell are similar to those of a  
mercury battery in that both provide an almost constant output through  
their useful life, and then fall off sharply towards zero at the end. If the  
sample being analyzed has a low oxygen concentration, cell failure will  
probably be indicated by the inability to properly calibrate the analyzer.  
You will find that very little adjustment of the span potentiometer will be  
required to keep the analyzer calibrated properly during the duration of a  
given cell’s useful life. If large or many turn adjustments (clockwise) are  
required to calibrate the instrument, or calibration cannot be achieved  
within the range of the control, the cell needs replacing. Read the following  
section (Cell Warranty) before replacing the cell. Cell installation instruc-  
tions are in Chapter 2: Cell Installation.  
In addition, if the LCD displays “00.0” when the unit is plugged in,  
and the power switch is in the ON position, the sensor needs to be re-  
placed.  
IMPORTANT: After replacing the Micro-Fuel Cell, proceed to Chapter 2:  
Calibration.  
To offset the possibility of not having a replacement cell available  
when needed, a spare cell can be ordered shortly after the instrument is in  
service, and each time after cell replacement thereafter.  
NOTE: Do not stockpile cells, as the cell warranty begins on date of  
shipment.  
Only one cell per instrument should be in reserve. The spare cell  
should be carefully stored in an area not subject to large variations in  
ambient temperature (75° F nominal), and in such a way to eliminate any  
possibility of damage. Under no circumstance should you disturb the  
integrity of the cell package until the cell is to be used. If the cell package  
is punctured and air permitted to enter, the cell will immediately start to  
react to the presence of oxygen.  
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319R  
Maintenance 3.0  
Warranty Conditions  
The Class Z-2 cell used in the 319R is warranted for six (6) months of  
service from the date of shipment. Customers having warranty claims must  
return the cell in question to the factory for evaluation. If it is determined  
that failure is due to faulty material or workmanship, the cell will be  
replaced free of charge.  
CAUTION: Evidence of tampering or abuse will render the warranty null  
and void.  
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3.0 Maintenance  
319R  
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319R  
Appendix  
Appendix  
Specifications  
Ranges:  
0–200 PPM, 0–1999 PPM O2, and 0–  
25% calibration range  
Sensitivity: 1% of full scale  
Signal Output:  
Standard: 0–10 VDC, negative ground  
4-20 mA, negative ground  
plus contact closures for range  
identification.  
Display:  
Digital 7 segment, 3½-digit LCD with  
over range indicator.  
Alarms:  
One high alarm, adjustable & fail-safe.  
One low alarm, adjustable & fail-safe.  
One low alarm, fixed at 2% full scale and  
fail-safe.  
Accuracy:  
±2% of full scale at constant temperature  
and pressure of calibration  
±5% of full scale throughout operating  
temperature range (once temperature  
equilibrium has been reached).  
90% of full scale in 35 seconds.  
32 °F to 122 °F (0°C to 50°C)  
85-264 VAC, 47-440 Hz or 10-36 VDC,  
user specified, 10 W max.  
Response:  
Operating Temp. Range:  
Power:  
Enclosure:  
Cell Type:  
General purpose, panel mount  
Z-2  
Cell Warranty: 6 months  
Cell Life (Expected):  
6 months  
Dimensions:  
2.75 "H × 6.0 "W × 2.75 "D  
(63.5 mm × 152.4 mm × 63.5 mm)  
Faceplate: 3.75 "H × 7.0 "W  
(95.25 mm × 177.8 mm)  
Probe unit: 4.0 "H × 6.0 "W × 3 "D  
(101.6 mm × 152.4 mm × 76.2 mm)  
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Appendix  
319R  
Spare Parts List  
QTY. P/N DESCRIPTION  
1
1
1
4
4
1
C57304 PC board, main  
A33748 Thermistor assembly  
C6689-Z2 Micro-Fuel Cell, Z-2  
F1189  
F51  
Fuse, 1A (AC)  
Fuse, ½A (DC)  
A59264 Probe to analyzer cable, 6 feet  
A minimum charge of US $20.00 is applicable to spare parts orders.  
IMPORTANT: Orders for replacement parts should include the part num-  
ber and the model and serial number of the system for  
which the parts are intended.  
Send orders to:  
TELEDYNE BROWN ENGINEERING  
Analytical Instruments  
16830 Chestnut Street  
City of Industry, CA 91749-1580  
Telephone: (818) 961-9221  
TWX: (910) 584-1887 TDYANYL COID  
Fax: (818) 961-2538  
or your local representative  
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319R  
Appendix  
Drawing List  
C-57490 Outline diagram  
A-58154 Probe interconnection diagram  
D-57302 Electronic PCB schematic diagram  
C-57305 Power supply PCB schematic diagram  
C-57307 Power supply PCB assembly diagram  
B-58123 Analysis unit (probe) outline  
Note: 319R analyzers with 25% and 100% range modifications incorporate  
the following changes:  
100% range modified circuit changes:  
1.  
2.  
3.  
4.  
JP2 - connects pins 1 and 2  
R52 is 12.5K  
R30 is 7.5K  
R35 is 1.5K  
25% range modified circuit changes:  
1.  
2.  
3.  
4.  
JP2 - connects pins 1 and 2  
R52 is 50K  
R30 is 28K  
R35 is 11K  
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Appendix  
319R  
Material Safety Data Sheet  
Section I – Product Identification  
Product Name: Micro-Fuel Cells and Super Cells, all classes except A-2C, A-3,  
and A-5.  
Electrochemical Oxygen Sensors, all classes except R-19.  
Mini-Micro-Fuel Cells, all classes.  
Manufacturer: Teledyne Brown Engineering Analytical Instruments  
Address:  
Phone: (818) 961-9221  
Customer Service: Extension 222  
16830 Chestnut Street, City of Industry, CA 91749  
Environmental Health  
and Safety: Extension 230  
Date Prepared : 04/26/95  
Section II – Hazardous Ingredients/Composition  
Material or  
Component  
TLV  
C.A.S. #  
Quantity  
OSHA PEL ACGIH  
Lead (Pb)  
7439-92-1  
1310-58-3  
3–20 gms  
1–5 ml  
0.05 mg/m3 0.15 mg/m3  
Potassium Hydroxide  
Solution 15% (KOH)  
None  
2 mg/m3  
Section III – Physical/Chemical Characteristics  
Material  
Appearance  
or Compo-  
nent  
Vapor  
Pres-  
sure  
Odor  
Specific  
Gravity  
Solubility  
in Water  
Melting DensityEvap.  
Boiling  
Point (°C)  
Point  
(°C)  
Rate  
Solid, silver  
gray, odorless  
11.34  
2.04  
Insoluble  
na na  
1744  
1320  
na  
na  
328  
360  
Lead  
White or  
slightly  
yellow,  
no odor  
Complete  
na na  
Potassium  
Hydroxide  
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319R  
Appendix  
Section IV – Fire and Explosion Hazard Data  
Flash Point:  
na  
Flammable Limits:  
na  
LEL: na  
UEL:  
na  
Extinguishing Media:  
Use extinguishing media appropriate to surrounding fire  
conditions. No specific agents recommended.  
Special Fire Fighting  
Equipment:  
Wear NIOSH/OSHA approved self-contained breathing  
apparatus and protective clothing to prevent contact with  
skin and eyes.  
Unusual Fire and Explosion  
Hazards:  
Emits toxic fumes under fire conditions.  
Section V – Reactivity Data  
Stability:  
Stable  
Incompatibilities:  
Aluminum, organic materials, acid chlorides, acid  
anhydrides, magnesium, copper. Avoid contact with acids  
and hydrogen peroxide > 52%.  
Hazardous Decomposition of  
Byproducts:  
Toxic fumes  
Hazardous Polymerization:  
Will not occur.  
Section VI – Health Hazard Data  
Routes of Entry:  
Inhalation:  
Ingestion:  
Highly unlikely  
May be fatal if swallowed.  
Skin:  
The electrolyte (potassium hydroxide) is corrosive; skin  
contact may cause irritation or chemical burns.  
Eyes:  
The electrolyte (potassium hydroxide) is corrosive; eye  
contact may cause irritation or severe chemical burns.  
Acute Effects:  
The electrolyte is harmful if swallowed, inhaled or  
adsorbed through the skin. It is extremely destructive to  
tissue of the mucous membranes, stomach, mouth, upper  
respiratory tract, eyes and skin.  
Chronic Effects:  
Prolonged exposure with the electrolyte has a destructive  
effect on tissue.  
Chronic exposure to lead may cause disease of the blood  
and blood forming organs, kidneys and liver, damage to  
the reproductive systems and decrease in fertility in men  
and women, and damage to the fetus of a pregnant  
woman. Chronic exposure from the lead contained in  
this product is extremely unlikely.  
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Appendix  
319R  
Signs and Symptoms of  
Exposure:  
Contact of electrolyte with skin or eyes will cause a  
burning sensation and/or feel soapy or slippery to touch.  
Other symptoms of exposure to lead include loss of  
sleep, loss of appetite, metallic taste and fatigue.  
Carcinogenicity:  
OSHA:  
Lead is classified by the IARC as a class 2B carcinogen  
(possibly carcinogenic to humans)  
Where airborne lead exposures exceed the OSHA action  
level, refer to OSHA Lead Standard 1910.1025.  
NTP:  
na  
Lead exposure may aggravate disease of the blood and  
blood forming organs, hypertension, kidneys, nervous  
and possibly reproductive systems. Those with preexist-  
ing skin disorders or eye problems may be more suscep-  
tible to the effects of the electrolyte.  
Medical Conditions Generally  
Aggravated by Exposure:  
Emergency First Aid Procedures:  
In case of contact with the skin or eyes, immediately  
flush with plenty of water for at least 15 minutes and  
remove all contaminated clothing. Get medical attention  
immediately.  
If ingested, give large amounts of water and DO NOT  
INDUCE VOMITING. Obtain medical attention imme-  
diately.  
If inhaled, remove to fresh air and obtain medical  
attention immediately.  
Section VII – Precautions for Safe Handling and Use  
NOTE: The oxygen sensors are sealed, and under normal circumstances,  
the contents of the sensors do not present a health hazard. The  
following information is given as a guide in the event that a cell  
leaks.  
Before opening the bag containing the sensor cell, check  
Protective measures  
during cell replacement:  
the sensor cell for leakage. If the sensor cell leaks, do  
not open the bag. If there is liquid around the cell while  
in the instrument, wear eye and hand protection.  
Cleanup Procedures:  
Wipe down the area several times with a wet paper  
towel. Use a fresh towel each time. Contaminated paper  
towels are considered hazardous waste.  
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319R  
Appendix  
Section VIII – Control Measures  
Eye Protection:  
Hand Protection:  
Chemical splash goggles  
Rubber gloves  
Other Protective Clothing:  
Ventilation:  
Apron, face shield  
na  
Section IX – Disposal  
Both lead and potassium hydroxide are considered poisonous substances and are regulated under  
TSCA and SARA Title III.  
EPA Waste Number:  
California Waste Number:  
DOT Information:  
D008  
181  
RQ Hazardous Waste Solid N.O.S. (Lead), 9, UN3077,  
PG III  
Follow all Federal, State and Local regulations.  
Section X – References  
Material Safety Data Sheets from J.T. Baker Chemical, Aldrich, Malinckrodt, ASARCO  
U.S. Department of Labor form OMB No. 1218-0072  
Title 8 California Code of Regulations  
TSCA  
SARA Title III  
CFR 49  
CFR 29  
CFR 40  
NOTE: The above information is believed to be correct and is offered for your  
information, consideration, and investigation. It should be used as a  
guide. Teledyne Brown Engineering Analytical Instruments shall not be  
held liable for any damage resulting from handling or from contact with  
the above product.  
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19  
 

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