OPERATING INSTRUCTIONS FOR
Model 3300TB
Trace Oxygen Analyzer
DANGER
HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING
SYSTEM.
PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.
HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST
FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.
P/NM70362
06/22/00
ECO#00-0228
ONLYAUTHORIZEDPERSONNELSHOULDCONDUCTMAINTENANCEAND/ORSERVICING. BEFORE
CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/
MANAGER.
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Contents
Introduction
1.1 Overview........................................................................ 1-1
1.2 Main Features of the Analyzer ....................................... 1-1
1.3 Front Panel Description.................................................. 1-2
1.4 Rear Panel Description .................................................. 1-3
OperationalTheory
2.1 Introduction .................................................................... 2-1
2.2 Micro-Fuel Cell Sensor .................................................. 2-1
2.2.1 Principles of Operation .......................................... 2-1
2.2.2 Anatomy of a Micro-Fuel Cell................................. 2-2
2.2.3 Electrochemical Reactions .................................... 2-3
2.2.4 The Effect of Pressure............................................ 2-3
2.2.5 Calibration Characteristics ...................................... 2-4
2.3 Electronics ..................................................................... 2-5
2.3.1 General .................................................................. 2-5
2.3.2 Signal Processing.................................................. 2-5
Installation
3.1 Unpacking the Analyzer................................................. 3-1
3.2 Location and Mounting .................................................. 3-2
3.2.1 Control Unit Installation.......................................... 3-2
3.2.2 External Probe Installation ..................................... 3-2
3.2.3 Installing the Micro-Fuel Cell ................................. 3-2
3.3 Electrical Connections ................................................... 3-3
3.4 Gas Connections ........................................................... 3-6
3.5 Installation Checklist ...................................................... 3-6
Operation
4.1 Introduction .................................................................... 4-1
4.2 Using the Function and Data Entry Buttons ................... 4-2
4.3 Setting the Analysis Ranges.......................................... 4-2
4.3.1 HI Range ............................................................... 4-2
4.3.2 LO Range .............................................................. 4-3
4.4 Setting the Alarm Setpoints............................................ 4-3
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4.4.1 Alarm 1 .................................................................. 4-3
4.4.2 Alarm 2 .................................................................. 4-3
4.4.3 Sensor Fail Alarm .................................................. 4-4
4.5 Selecting a Fixed Range or Autoranging ....................... 4-4
4.6 Calibration ..................................................................... 4-4
Maintenance
5.1 Replacing the Fuse........................................................ 5-1
5.2 Sensor Installation or Replacement ............................... 5-2
5.2.1 When to Replace a Sensor .................................... 5-2
5.2.2 Ordering and Handling of Spare Sensors .............. 5-3
5.2.3 Removing the Micro-Fuel Cell ............................... 5-3
5.2.4 Installing a Micro-Fuel Cell .................................... 5-3
5.2.5 Cell Warranty Conditions ....................................... 5-4
Appendix
A.1 Specifications ................................................................ A-1
A.2 Spare Parts List ............................................................. A-2
A.3 Reference Drawing ........................................................ A-3
A.4 Miscellaneous................................................................ A-3
A.5 Material Safety Data Sheet ............................................ A-3
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Model 3300TB complies with all of the requirements of the
Commonwealth of Europe (CE) for Radio Frequency Interference,
Electromagnetic Interference (RFI/EMI), and Low Voltage Directive
(LVD).
The following International Symbols are used throughout the Instruc-
tion Manual for your visual and immediate warnings and when you
have to attend CAUTION while operating the instrument:
STAND-BY, Instrument is on Stand-by,
but circuit is active
GROUND
Protective Earth
CAUTION, The operator needs to refer to the manual
for further information. Failure to do so may
compromise the safe operation of the equipment.
CAUTION, Risk of Electric Shock
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DANGER
COMBUSTIBLE GAS USAGE WARNING
This is a general purpose instrument, the Control Unit is de-
signed for usage in a nonhazardous area. It is the customer's
responsibility to ensure safety especially when combustible
gases are being analyzed since the potential of gas leaks al-
ways exist.
The customer should ensure that the principles of operating of
this equipment is well understood by the user. Misuse of this
product in any manner, tampering with its components, or unau-
thorized substitution of any component may adversely affect
the safety of this instrument.
Since the use of this instrument is beyond the control of
Teledyne, no responsibility byTeledyne, its affiliates, and agents
for damage or injury from misuse or neglect of this equipment is
implied or assumed.
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Trace Oxygen Analyzer
Introduction 1
Introduction
1.1 Overview
TheTeledyneElectronicTechnologiesAnalyticalInstruments(TET/AI)
Model3300TBisamicroprocessor-basedtraceoxygenanalyzerforreal-time
measurementofthepartspermillionofoxygenininertgases,orinawidevariety
ofgasmixtures.Itfeaturessimpleoperation,fastresponse,andacompact,
ruggedconstruction.TypicalapplicationsoftheModel3300TBaremonitoring
nitrogengeneratorsandinertgasblanketingapplications.
1.2 Main Features of the Analyzer
Themainfeaturesoftheanalyzerinclude:
•
Highresolution,accuratereadingsofoxygencontentfrom0-10ppm
through9999ppm Large,bright,LEDmeterreadout.
•
•
•
Simplepushbuttoncontrols.
Nyloncellholder.
AdvancedMicro-FuelCell,fortraceanalysis,hassixmonths
warrantyandanexpectedlifetimeofeightmonths.
•
•
•
Unaffectedbyoxidizablegases.
Fastresponseandrecoverytime.
Microprocessorbasedelectronics:8-bitCMOSmicroprocessor
with on-board RAM and 16 KB ROM.
•
•
Twouserselectableranges(from0-10 ppmthrough0-9999 ppm)
allowbestmatchtousersprocessandequipment.
OperatorcanselectAutoranging,whichallowstheanalyzerto
automaticallyselecttheproperpresetrangefor agiven
measurement,orhecanlocktheanalyzerontoasinglerange.
•
•
•
•
Twoconcentrationalarmswithadjustablesetpoints.
Panelmountflowmeter.
ControlvalvefortheselectionofSpangasorSamplegas.
Sensorfailurealarm.
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1 Introduction
Model 3300TB
•
Threeanalogoutputs:twoformeasurement(0–10V dc,and
negativeground4–20mA dc)andoneforrangeidentification
(0-10 V dc).
•
•
•
CompactandruggedControlUnit,wallmountedNEMA-4rated
enclosure.
RS-232SerialDigitalportforoutputof concentrationanddatatoa
computerterminals,orotherdigitaldevices.
ASampleflowcontrolvalve.
1.3 Front Panel Description
Allcontrolsexceptthepowerswitchareaccessiblefromthedoorandgas
panel.SeeFigure1-1.Thefrontpanelhassevenpushbuttonmembrane
switches,adigitalmeter,andanalarmindicatorLEDforoperatingtheanalyzer.
ThesefeaturesaredescribedbrieflyhereandingreaterdetailinChapter4,
Operation.
Figure 1-1: Front Panel
FunctionKeys:Sevenpushbuttonmembraneswitchesareusedtoselect
thefunctionperformedbytheanalyzer:
•
•
Set Alarm 1
Set Alarm 2
SetAlarm1HiorLow,andtheconcentrationat
whichalarm1activates.
Set the Alarm 2 Hi or Low, and the
concentrationtowhichalarm2activates.
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Trace Oxygen Analyzer
Introduction 1
•
•
•
Set HI Range
Setthehighanalysisrangefortheinstrument(up
to 0-9999ppm).
Set LO Range
Setthelowanalysisrangefortheinstrument
(downto0-10ppm).
Span
Spancalibratetheanalyzer.
DataEntryKeys:Twopushbuttonmembraneswitchesareusedto
manuallychangemeasurementparametersoftheinstrumentastheyaredisplayed
ontheLEDmeterreadout:
•
UpArrow
Incrementvaluesofparametersupwardsasthey
aredisplayedontheLEDreadout.
•
DownArrow
Incrementvaluesofparametersdownwardsas
theyaredisplayedontheLEDreadout.
Digital LED Readout: ThedigitaldisplayisaLEDdevicethat
produceslarge,bright,7-segmentnumbersthatarelegibleinanylighting
environment.Ithastwofunctions:
•
MeterReadout: Asthemeterreadout,itdisplaystheoxygen
concentrationcurrentlybeingmeasured.
•
MeasurementParametersReadout: Italsodisplaysuser-
definablealarmsetpoints,ranges,andspancalibrationpointwhen
theyarebeingcheckedorchanged.
1.4 Rear Panel Description
Therearpanelcontainstheelectricalinputandoutputconnectors. The
connectorsaredescribedbrieflyhereandindetailintheInstallationchapterof
thismanual.
Figure 1-2 Rear Panel
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1 Introduction
Model 3300TB
•
•
PowerConnection
AC version: 100–240 VAC, at 50/60Hz.
Theconnectorhousingincludesthefuse
holderandthepowerswitch.
FuseHolder:Replacingthefuseis
describedinChapter5,Maintenance.
I/OPowerSwitch:Turnstheinstrument
power ON (1) or OFF (0).
AnalogOutputs
0–10 V dcconcentrationoutput.
0–10 V dcrangeID(oroptionaloverrange)
output.
4–20 mA dcconcentrationoutput,negative
ground.
•
•
•
AlarmConnections Alarm1,Alarm2,andSensorFailureAlarm
connections.
SensorConnector
RS-232Port
InternalSamplingSystem,Sensor
Connector.
SerialDigitalOutputofconcentrationand
rangesignals.
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Trace Oxygen Analyzer
Operational Theory 2
Operational Theory
2.1 Introduction
Theanalyzeriscomposedoftwosubsystems:
1. AnalysisUnitwithMicro-FuelCellSensor
2. ControlUnitwithSignalProcessing,DisplayandControls
TheAnalysisUnitisdesignedtoacceptthesamplegasanddirectittothe
sensitivesurfaceoftheMicro-FuelCellsensor.TheMicro-FuelCellisan
electrochemicalgalvanicdevicethattranslatestheamountofoxygenpresentin
thesampleintoanelectricalcurrent.
TheControlUnitprocessesthesensoroutputandtranslatesitintoelectrical
concentration,range,andalarmoutputs,andapercentoxygenmeterreadout.It
containsamicrocontrollerthatmanagesallsignalprocessing,input/output,and
displayfunctionsfortheanalyzer.
2.2 Micro-Fuel Cell Sensor
2.2.1 Principles of Operation
TheoxygensensorusedintheModel3300TBisaMicro-FuelCellde-
signedandmanufacturedbyTAI.Itisasealed,disposableelectrochemical
transducer.
TheactivecomponentsoftheMicro-FuelCellareacathode,ananode,
andtheaqueousKOHelectrolyteinwhichtheyareimmersed.Thecellconverts
theenergyfromachemicalreactionintoanelectricalpotentialthatcanproducea
currentinanexternalelectricalcircuit.Itsactionissimilartothatofabattery.
Thereis,however,animportantdifferenceintheoperationofabatteryas
comparedtotheMicro-FuelCell:Inthebattery,allreactantsarestoredwithin
thecell,whereasintheMicro-FuelCell,oneofthereactants(oxygen)comes
fromoutsidethedeviceasaconstituentofthesamplegasbeinganalyzed.The
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2 Operational Theory
Model 3300TB
Micro-FuelCellisthereforeahybridbetweenabatteryandatruefuelcell.(All
ofthereactantsarestoredexternallyinatruefuelcell.)
2.2.2 Anatomy of a Micro-Fuel Cell
TheMicro-FuelCellismadeofextremelyinertplastic(whichcanbe
placedconfidentlyinpracticallyanyenvironmentorsamplestream).Itiseffec-
tivelysealed,thoughoneendispermeabletooxygeninthesamplegas.Atthe
permeableendascreenretainsadiffusionmembranethroughwhichtheoxygen
passesintothecell.Attheotherendofthecellisaconnectorandtemperature
compensationnetwork(restrictorsandthermistor)onaprintedcircuitboard.
RefertoFigure2-1, BasicElementsofaMicro-FuelCell, whichillus-
tratesthefollowinginternaldescription.
Electrical C onnector
Circuit Board
with tem perature com pensation network.
Anode
Cathode
Teflon M embrane
Screen
Clam p
Figure 2-1. Basic Elements of a Micro-Fuel Cell (not to scale)
Atthesensingendofthecellisadiffusionmembrane,whosethicknessis
veryaccuratelycontrolled.Nearthediffusionmembraneliestheoxygensensing
element—thecathode.
Theanodestructureislargerthanthecathode.Itismadeofleadandis
designedtomaximizetheamountofmetalavailableforchemicalreaction.
Thespacebetweentheactiveelementsisfilledbyastructuresaturatedwith
electrolyte.Cathodeandanodearewetbythiscommonpool.Theyeachhavea
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Trace Oxygen Analyzer
Operational Theory 2
conductorconnectingthem,throughsomeelectricalcircuitry,tooneofthe
externalcontactsintheconnectorreceptacle,whichisonthetopofthecell.
2.2.3 Electrochemical Reactions
ThesamplegasdiffusesthroughtheTeflonmembrane.Anyoxygeninthe
samplegasisreducedonthesurfaceofthecathodebythefollowingHALF
REACTION:
O2 + 2H2O + 4e– → 4OH–
(cathode)
(Fourelectronscombinewithoneoxygenmolecule—inthepresenceof
waterfromtheelectrolyte—toproducefourhydroxylions.)
Whentheoxygenisreducedatthecathode,leadissimultaneouslyoxidized
attheanodebythefollowingHALFREACTION:
2(Pb + 2OH–) → 2(Pb+2 + H2O) + 4e–
(anode)
(Twoelectronsaretransferredforeachatomofleadthatisoxidized.TWO
ANODEREACTIONSbalanceonecathodereactiontotransferfourelec-
trons.)
Theelectronsreleasedatthesurfaceoftheanodeflowtothecathode
surfacewhenanexternalelectricalpathisprovided.Thecurrentisproportional
totheamountofoxygenreachingthecathode.Itismeasuredandusedto
determinetheoxygenconcentrationinthegasmixture.
TheoverallreactionforthefuelcellistheSUMofthehalfreactionsabove,
or:
2Pb + O2 → 2PbO
(Thesereactionswillholdaslongasnogaseouscomponentscapableof
oxidizingleadarepresentinthesample. Theonlylikelycomponentsarethe
halogens—iodine,bromine,chlorineandfluorine.)
Theoutputofthefuelcellislimitedby(1)theamountofoxygeninthecell
atthetimeand(2)theamountofstoredanodematerial.
Intheabsenceofoxygen,nocurrentisgenerated.
2.2.4 The Effect of Pressure
Inordertostatetheamountofoxygenpresentinthesampleasapercent-
ageofthegasmixture,itisnecessarythatthesamplediffuseintothecellunder
constantpressure.
Ifthepressurechanges,theratethatoxygenreachesthecathodethrough
thediffusingmembranewillalsoincrease.Theelectrontransfer,andthereforethe
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2 Operational Theory
Model 3300TB
externalcurrent,willincrease,eventhoughtheproportionofoxygenhasnot
changed.
Fortunately,Dalton'sLawconfirmsthateverygasinamixturecontributes
thesamepressuretothemixturethatitwouldexertifitwerealoneinthesame
amountinthatsamevolume.Thismeansthataslongasthetotalpressureofthe
sampleremainsconstant,themixturecanchange,butthediffusionoftheoxygen
willbeaffectedonlybytheconcentrationoftheoxygen.
Forthisreason,thesamplesystemsupplyingsamplegastothecellshould
bedesignedtokeepthepressureonthediffusionmembraneconstant.
2.2.5 Calibration Characteristics
GiventhatthetotalpressureofthesamplegasatthesurfaceoftheMicro-
FuelCellinputisconstant,aconvenientcharacteristicofthecellisthatthe
currentproducedinanexternalcircuitofconstantimpedanceisdirectlypropor-
tionaltotherateatwhichoxygenmoleculesreachthecathode,andthisrateis
directlyproportionaltotheconcentrationofoxygeninthegaseousmixture.In
otherwordsithasalinearcharacteristiccurve,asshowninFigure2-2.Measur-
ingcircuitsdonothavetocompensatefornonlinearities.
Figure 2-2. Characteristic Input/Output Curve for a Micro-Fuel Cell
Inaddition,sincethereiszerooutputintheabsenceoxygen,thecharacter-
isticcurvehasanabsolutezero.Thecellitselfdoesnotneedtobezeroed.
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Trace Oxygen Analyzer
Operational Theory 2
2.3 Electronics
2.3.1 General
ThesignalprocessingusesanIntel microcontrollerwithon-boardRAM
andROMtocontrolallsignalprocessing,input/output,anddisplayfunctionsfor
theanalyzer.Systempowerissuppliedfromauniversalpowersupplymodule
designedtobecompatiblewithmostinternationalpowersources.
ThepowersupplycircuitryisonthePowerSupplyPCB,whichismounted
vertically,justbehindtherearpaneloftheControlUnit.
Thesignalprocessingelectronicsincludingthesensoramplifier,
microcontroller,analogtodigital,anddigitaltoanalogconvertersarelocatedon
theMainPCB,whichismountedvertically,justbehindthefrontpanelofthe
ControlUnit.
2.3.2 Signal Processing
Figure2-3isablockdiagramofthesignalprocessingelectronicsdescribed
below.
Millivolt
Potput
TEMPERATURE
COMPENSATION
NETWORK ON
SENSOR PCB
SENSOR
AMPLIFIER
MFC
A D C
E–I CONV
4–20 mA dc
Microamp
Output
Concentration
0–10 V dc
RANGE ID
B-2C Sensor
D A C
MICRO-
CONTROL-
LER
KEYBOARD
DISPLAY
RELAYS
RELAYS
ALARMS
ALARMS
Figure 2-3: Block Diagram of the Signal Processing Electronics
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2 Operational Theory
Model 3300TB
Inthepresenceofoxygenthecellgeneratesacurrent.Thesensorhasan
internalthermistorcompensationnetwork.
Theoutputofthesensorisconvertedtovoltagemillivoltrange. Thisoutput
isfedtoavoltageamplifier. Theinternalthermistornetworkprovidestempera-
turecompensationofthesensoroutput. Theresistanceofthenetworkchanges
withtemperature,compensatingforthechangesofthemicrofuelcelloutputto
temperature.
Theoutputfromthetemperaturecompensationamplifierissenttoan
analogtodigitalconverter(ADC),andtheresultingdigitalconcentrationsignalis
senttothemicrocontroller.
Thedigitalconcentrationsignalalongwithinputfromthefrontpanelbuttons
(KEYBOARD)isprocessedbythemicrocontroller,andappropriateoutput
signalsaredirectedtothedisplayandalarmrelays. Thesamedigitalinformation
isalsosenttoa12-bitdigitaltoanalogconverter(DAC)thatproducesthe0-10
V dcanalogconcentrationsignalandthe0-10V dcanalograngeIDoutput.A
voltagecurrentconverter(E–ICONV)producesthe4-20mA dcanalog
concentrationsignal.
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Trace Oxygen Analyzer
Installation 3
Installation
Installationoftheanalyzerincludes:
1. Unpacking the system.
2. Mounting the Control Unit to a wall
3. InstallingtheMicro-FuelCell
4. Makingtheelectricalconnections.
5. Making the gas connections.
6. Testingtheinstallation.
CAUTIONS:
Read this chapter in its entirety before installing the units.
The Sample must be free of entrained solids or water. How-
ever, a high humidity sample is ideal, since it will prevent
water loss from the cell electrolyte.
The Micro-Fuel Cell sensor electrolyte is caustic. Do not
attempt to open it. Leaking or exhausted cells should be
disposed of in accordance with local regulations. Refer to the
Material Safety Data Sheet in the Appendix.
Any damage or scarring of the delicate permeable membrane
on the sensing end of the cell will require cell replacement.
Prevent contact with membrane by any solid object.
3.1 Unpacking the Analyzer
As soon as you receive the instrument, carefully unpack and inspect the
Unit, and any included accessories for damage. Immediately report any
damage to the shipping agent. The analyzer is shipped with all the materials
you need to install and prepare the system for operation.
CAUTION: Do not disturb the integrity of the cell package until the cell is to
actually be used. If the cell package is punctured and air is
permitted to enter, cell-life will be compromised.
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3 Installation
Model 3300TB
3.2 Location and Mounting
3.2.1 Control Unit Installation
The 3300TB Control Unit is designed to be wall-mounted, in a general
purpose, area. The unit should be installed at viewing level in a sheltered
area.
Refer to the Outline diagram D-70361 for the physical dimensions of
theanalyzer.
3.2.2 InstallingtheMicro-FuelCell/CellBlockOrientation
A Micro-Fuel Cell is included as a separate item. It must be installed
prior to instrument use.
Also, once it is expended, or if the instrument has been idle for a
lengthy period, the Micro-Fuel Cell will need to be replaced.
Important Installation Note!
Membrane
side of MFC
-MUST FACE DOWNWARD-
Contact side
of MFC
During the Installation and/or Replacement of the MFC, Membrane
surface MUST ALLWAYS FACE DOWNWARD, and the Contact side of
the Membrane, MUST be placed FIRST into Analysis Unit.
The reason for proper Installation/Replacement is, if any bubble that
develops as the electrolyte dries out will be directed by the gravity away
fromthemembrane.
To install or replace the Micro-Fuel Cell, follow the procedures in
Chapter 5, Maintenance.
3-2
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Trace Oxygen Analyzer
Installation 3
3.3 Electrical Connections
Figure 3-1 shows the Model 3300TB rear panel of the control unit.
For detailed pinouts, see the wiring/interconnection drawings in the Draw-
ings section at the rear of this manual. To gain access to the terminal blocks,
the analyzer door screws must be lossened, and the door opened.
Figure 3-1 Electrical Connectors for AC Control Unit
Primary Input Power: The power strip supplied inside the analyzer.
Connect ground to terminal 1, neutral to terminal 3, and hot to terminal 2.
Make sure female plug end is inserted in the control unit power receptacle.
The universal power supply allows direct connection to any 100-240
VAC, 50/60Hz power source. The fuse block, to the right of the power cord
receptacle, accepts two 5x20mm 0.5 A, 250V, IEC time-lag (T) fuse. (See
Fuse Replacement in chapter 5, Maintenance.)
The Power switch is located on the right-hand end of the power source
inputreceptacleassembly.
AC Power Terminal Strip
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3 Installation
Model 3300TB
Analog Outputs: There are three DC output signal connectors with
screw terminals on the panel. There are two wires per output with the polar-
ity noted. See Figure 3-3. The outputs are:
0–10 V % Range:
Voltage rises with increasing oxygen concentration,
from 0 V at 0 percent oxygen to 10 V at full scale
percent oxygen. (Full scale = 100% of programmed
range.)
0–10 V Range ID:
03.33 V = Low Range, 06.66 V = High Range,
10 V = Air Cal Range.
4–20 mA % Range: Current increases with increasing oxygen concentra-
tion, from 4 mA at 0 percent oxygen to 20 mA at full
scale percent oxygen. (Full scale = 100% of pro-
grammedrange.)
Alarm Relays: The three alarm-circuit connectors are screw terminals
for making connections to internal alarm relay contacts. There is one set of
contacts for each type of alarm. Contacts are Form C, with normally open
and normally closed contact connections capable of switching up to 0.5
ampere at 125 VAC into a resistive load (2A for 30 VDC).
The alarm relay circuits are designed for failsafe operation, meaning the
relays are energized during normal operation. If power fails the relays de-
energize(alarmsactivated).
The contact connections are indicated diagrammatically on the rear
panel as Normally Closed, Common, and Normally Open. Figure 3-2
explains how these act in failsafe operation.
Alarm 1 and Alarm 2 can both be configured as either HI or LO. A
HI alarm will activate when concentration is above treshold, while a LO
alarm will activate concentration is below treshhold.
Figure 3-2: Contact ID for FAILSAFE Relay Operation
3-4
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Trace Oxygen Analyzer
Installation 3
The specific descriptions for each type of alarm are as follows:
Alarm #1
Programmable as high or low alarm (actuates when
concentration is above threshold). Can be set anywhere
between 0 and 9999ppm, but must be set ABOVE the
threshold set for the LO Alarm.
Alarm #2
Programmable as high or low alarm (actuates when
concentration is below threshold). Can be set anywhere
from 0 to 9999ppm.
Sensor Fail
Actuates when the output of the Micro-Fuel Cell sensor
falls below the acceptable level.
CAUTION:
There could be hazardous voltage at the alarms termi-
nals, even when power is removed from the instrument.
3.4 Gas Connections
The standard Model 3300TB has two inlets and one outlet fixture only.
Calibration gasses can be connected into the "Span" inlet. All of the gas
connections are 1/4 inch brass fittings.
A switching valve is provided to feed the analysis unit with either
sample or gas.
A flowmwter and flow controller valve are part of the system and will
assist in setting the flow of the gas.
Sample flow should be adjusted to 2 SCFH. The sample vent connec-
tion should not restrict the sample flow. The sensor is designed to operate at
atmospheric pressure. Restricting the sample vent line will result in pressur-
izing the sensor and altering the O2 reading.
The pressure required will depend on the sampling system. When
venting into a constant pressure, such as the atmosphere, controlling input
pressure is simple. If you are venting into a system of varying pressure, then
some form of pressure regulation is required to maintain a constant pressure
across the sensor.
The Sample and Span pressure is not to exceed 50 psig (345 kPa).
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3 Installation
Model 3300TB
3.4.1 Vacuum Service Option
For vacuum service pluming reference figure 3-4. The vacuum service
option is recommended for applications in which the sample source is not
pressurized. The customer must supply a pump and by-pass system to
complete the sample system. The sample inlet and outlet pressure must be
maintained at a constant pressure for proper performance. If the sample inlet
or vent pressure will not be held constant during the process, a pressure
regulator must be used to regulate the pressure across the cell.
Adjust the flow rate on a vacuum service system as follows:
Select Sample with the three-way control valve and open the flow
control valve on the analyzer to full flow (located on the analyzer flow
meter). Open the pump by-pass valve, and turn on the pump. Readjust the
pump by-pass valve to limit the maximum flow rate to full scale on the
flowmeter with the flowmeter valve fully open. Adjust the analyzer flow
control valve (flowmeter valve) to a flow-rate of approximately 2 SCFH).
Select Span and verify that the span and Sample gas are at different pres-
sures. The calibration accuracy will be adversely affected if the Span and
Sample gases are at differing pressures.
If the span gas is provided from pressurized source, a control valve
must be added between the analyzer and the span gas source. This valve is
used to adjust the span flow rate to match the sample flow rate. Do not
adjust the span flow rate with the flow control valve located on the analyzer
for units with vacuum service options.
Customer Supplied Parts
Figure 3-4: Piping Diagram for Vacuum Service Option
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Trace Oxygen Analyzer
Installation 3
3.5 Installation Checklist
Before connecting the instrument to the power source and turning it on,
make sure you have:
•
•
•
Correctly installed the Sample and Exhaust gas lines
Checked for leaks
Set the sample pressure to 5–10 psig (34.5 - 68.9 kPa), nominal
(fornon-vacuumserviceunits)
•
Set the flow
Once the above checks have been made, you can connect to the power
source. The instrument is now ready for operation.
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3 Installation
Model 3300TB
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Trace Oxygen Analyzer
Operation 4
Operation
4.1 Introduction
Once the analyzer has been mounted, the gas lines connected and the
electrical connections made, the Analyzer can be configured for your appli-
cation. This involves setting the system parameters:
•
•
•
Defining the user selectable analysis ranges.
Settingalarmsetpoints.
Calibratingtheinstrument.
All of these functions are performed via the front panel controls, shown
in Figure 4-1.
Analyzing for the trace oxygen level in the gas passing through the cell
block is the default mode of operation. As long as no front panel buttons are
being pressed the Unit is analyzing.
Figure 4-1: Front Panel Controls and Indicators
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4.2 Using the Function and Data Entry
Buttons
When no buttons on the Analyzer are being pressed, the instrument is in
the Analyze mode. It is monitoring the anount of oxygen in the sample gas
that is flowing through the sampling system.
When one of the Function Buttons is being pressed, the Analyzer is in
the Setup mode or the Calibration mode.
The 4 Setup function buttons on the analyzer are:
•
•
•
•
SET ALARM 1
SET ALARM 2
SET HI RANGE
SET LO RANGE
The Calibration mode button is:
SPAN
•
The Data Entry buttons (∆ and ∇) increment the values displayed on
the TRACE OXYGEN meter while one of the Function buttons is being
held down.
•
•
∆: Incrementsthedisplayedvalueupwards.
∇: Incrementsthedisplayedvaluedownwards.
Any of the functions can be selected at any time by holding down the
appropriatebutton.
Each function will be described in the following sections. Although the
operator can use any function at any time, the order chosen in this manual is
appropriate for an initial setup.
4.3 Setting the Analysis Ranges
The two user definable analysis ranges are both capable of being
adjusted for from 0-10ppm to 0-9999ppm oxygen concentration. Whatever
values are selected, the analyzer automatically switches from the LO range to
the HI range when the oxygen concentration reaches the LO range fullscale
value, and it switches back to the LO range when the oxygen concentration
falls below of the LO range fullscale value
Note: The HI Range setpoint MUST be set at a higher concentration percent-
age than the LO Range setpoint.
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Operation 4
4.3.1 HI Range
Setting the HI Range fullscale value defines the LEAST sensitive
analysis range to be used. To set the HI Range:
1. Press the SET HI RANGE Function button once.
2. Immediately (within 5 seconds) press either the ∆ or ∇ button to
raise or lower the displayed value, as required, until the display
readsthedesiredfullscalepercentconcentration.
4.3.2 LO Range
Setting the LO Range fullscale value defines the MOST sensitive range
to be used. To set the LO Range:
1. Press the SET LO RANGE Function button once.
2. Immediately (within 5 seconds) press either the ∆ or ∇ button to
raise or lower the displayed value, as required, until the display
readsthedesiredfullscalepercentconcentration.
4.4 Setting the Alarm Setpoints
The alarm setpoints can be adjusted over the full range of the analyzer
(0-9999ppm oxygen content). The set point values are expressed in ppm
only.
4.4.1 Set Alarm 1
Alarm 1 can be set either as a high or low alarm. To configure this
alarm to your preferences:
1. Press the SET ALARM 1 function button once.
2. The display will flash either HI or LO depending on what the
alarm was configured in the last time. If the alarm configuration
must be changed, use the Up or Down keys to toggle the alarm
from HI to LO or viceversa (if within 5 seconds no key is
pressed, the instrument will return to the sample mode and
displayoxygenconcentration).
3. To change the setting at which the alarm will be actuated, press
the SET ALARM 1 function button once more. The alarm
setpoint will flash on the LED display. Press either the Up or
Down keys to raise or lower the displayed value, as required,
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4 Operation
Model 3300TB
until the display reads the desired percent concentration. (if
within 5 seconds no key is pressed, the instrument will return to
the sample mode and display oxygen concentration).
After setting the value wait for the unit to time out of this mode (ap-
proximately 5 seconds) and return to displaying oxygen concentration.
4.4.2 Set Alarm 2
Alarm 2 can be set either as a high or low alarm. To configure this
alarm to your preferences:
1. Press the SET ALARM 2 function button once.
2. The display will flash either HI or LO depending on what the
alarm was configured in the last time. If the alarm configuration
must be changed, use the Up or Down keys to toggle the alarm
from HI to LO or viceversa (if within 5 seconds no key is
pressed, the instrument will return to the sample mode and
displayoxygenconcentration).
3. To change the setting at which the alarm will be actuated, press
the SET ALARM 2 function button once more. The alarm
setpoint will flash on the LED display. Press either the Up or
Down keys to raise or lower the displayed value, as required,
until the display reads the desired percent concentration. (if
within 5 seconds no key is pressed, the instrument will return to
the sample mode and display oxygen concentration)
After setting the value wait for the unit to time out of this mode (ap-
proximately 5 seconds) and return to displaying oxygen concentration.
4.4.3 Sensor Fail Alarm
The SENSOR FAIL alarm triggers if, during calibration, the raw cell
output for the given oxygen level is too low. (See Calibration Characteris-
tics in Chapter 2.). Should this alarm trigger, the ALARM indicator below
the SET function buttons will start blinking. Replace the cell before pro-
ceeding.
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Trace Oxygen Analyzer
Operation 4
4.5 Selecting a Fixed Range or Autoranging
The Model 3300TB can operate in fixed high, fixed low, or
autoranging mode. To change modes:
1. Press and then release the SET HI RANGE and the SET LO
RANGE buttons simultaneously.
2. Within 5 seconds, press either the ∆ or ∇ button until Auto, Lo,
or Hi displays on the LCD, as desired.
After about three seconds, the analyzer resumes monitoring in the
selected range mode.
NOTE: If the concentration exceeds 9999 ppm oxygen, the analyzer will
automatically switch to the Calibration Range, EVEN THOUGH IN-
STRUMENT IS IN THE FIXED RANGE MODE.
4.6 Calibration
Preliminary—If not already done: Power up the Analyzer and
allow the LED reading to stabilize. Set the Alarm setpoints and
the fullscale ranges to the desired values.
Procedure:
1. Expose the sensor to ambient air or instrument grade air (20.9 %
oxygen). Allow time for the sampling system to purge and the
analyzertoachieveequilibrium.
Note: If the analyzer output goes above the high alarm setpoint or below the
low alarm setpoint, the display will go blank and the front panel
ALARM Indicator, beneath the SET Function buttons, will blink. Hold
down the SPAN button until the ALARM Indicator stops blinking.
2. Press the SPAN button once.
3. Within 5 seconds press either the ∆ or ∇ button until the display
is stable and reads 20.9 %.
The unit is now calibrated.
Note: If you use a span gas other than air, do not span in the 0-10 ppm
range. Calibration at this level is not dependable.
Note: If you use a span gas other than air, and the span gas oxygen concen-
tration is less than 10,000 ppm, the analyzer could take up to 65
seconds to to settle. The lag is caused by a digital filter that is active
only below 10,000 ppm (1%) oxygen.
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4 Operation
Model 3300TB
4.7 Displaying Percent & PPM on the LED
Display
The analyzer displays the concentration in percent whenever the read-
ing is over 9999 ppm. When the reading changes to percent, the LED
display will alternate between flashing “PC” and the oxygen concentration.
On the other hand, if the instrument is displaying ppm, only the concentra-
tion reading will be shown.
Supplementary Information
If, during the Span Procedure, you pressed the SPAN button by mis-
take, you must wait five minutes for the analyzer to resume analisis or you
can press the UP button and then the DOWN button. (Pressing the UP and
DOWN buttons causes the analyzer to time-out in five seconds instead of
fiveminutes).
If during the span procedure, you press the RANGE or ALARM
buttons:
- either the range or alarm routine will be activated.
- any changes to span will be rejected.
- the 60 second alarm delay will not occur, i.e., the alarms will be
responsive immediately.
CAUTION: TET/AI considers the action of pressing the ALARM or RANGE
buttons to be at your (the user’s) discretion. The user should be
aware that the alarms will become active within 5 (five) seconds if
the Range or Alarm bottons are pressed during Span. This may
result in false alarms if the Span gas has not been fully purged
from the Cell and Sample lines.
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Maintenance 5
Maintenance
Asidefromnormalcleaningandcheckingforleaksatthegasconnections,
theModel3300TBshouldnotrequireanymaintenancebeyondreplacementof
expendedMicro-FuelCells,andperhapsablownfuse.Routinemaintenance
includesoccasionalrecalibration,asdescribedinchapter4,Operation.
5.1 Replacing the Fuse
Remove Power to Unit before replacing the fuse.
Whenafuseblows,checkfirsttodeterminethecause,thenreplacethe
fuseusingthefollowingprocedure:
1. DisconnecttheACpowerandplacethepowerswitchlocatedon
therearpanelintheOposition.Removethepowercordfromthe
receptacle.
2. Thefusereceptacleislocatedinthepowercordreceptacle
assemblyintheupperleft-handcorneroftherearpanel.SeeFigure
5-1.
FUSE
Figure 5-1: AC Fuse Replacement
3. Insertasmallflat-bladescrewdriverintotheslotinthereceptacle
wallnearestthefuseandgentlypryopenthefusereceptacle.The
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5 Maintenance
Model 3300TB
fuseholderwillslideout.Therearetwofusesinuseandarevisiblein
theclip.
4. Removethebadfuseandreplaceitwitha5x20mm0.5 A,
250 VAC, IECtimelag(T)fuse(P/NF1128).
5. Replacethefuseholderintoitsreceptacle,pushinginfirmlyuntilit
clicks.
5.2 Sensor Installation or Replacement
5.2.1 When to Replace a Sensor
Onthetraceanalyzers,theMicro-fuelCellwilltypicallyfailduetoexces-
sivezerooffsetcausedbylossofwater. Largezerooffsetswillresultininaccu-
rateSPANsettings. Totestforthiscondition,purgethesensorandsample
systemwithZEROgas(typicallynitrogenwithlessthan1ppmO2). Itmaytake
severalhoursforthesamplesystemandcelltoreturntoastablelowlevelofO2
ifithasbeenexposedtohigherlevelsofO2. Iftheinstrumentwillnotcome
downtoanacceptablylowreadingonzerogas,thenadepletedcellorasample
systemleakshouldbesuspected. Typicallyoffsetsof1.0ppmorlessare
acceptable. ACellfailuremayalsobeindicatedbyaninabilitytoSPAN,or
slowresponsetochangesinO2 concentrationatlevelsbelow100ppm.
CAUTION: Read the section Cell Warranty Conditions, below, before replac-
ing the cell.
CAUTION:
After replacing the Micro-Fuel Cell, the analyzer must be
recalibrated. See Calibration in chapter 4.
5.2.2 Ordering and Handling of Spare Sensors
Tohaveareplacementcellavailablewhenitisneeded,TAIrecommends
thatonesparecellbepurchasedwhenthecurrentcell'swarrantyperiodis
approximatelytwothirdsover.
CAUTION: Do not stockpile cells. The warranty period starts on the day of
shipment. For best results, do not order a new spare cell to soon.
Thesparecellshouldbecarefullystoredinanareathatisnotsubjectto
largevariationsinambienttemperature(75 °Fnominal),andinsuchawayasto
eliminatethepossibilityofincurringdamage.
CAUTION: Do not disturb the integrity of the cell package until the cell is to
actually be used. If the cell package is punctured and air is permit-
ted to enter, cell-life will be compromised.
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Trace Oxygen Analyzer
Maintenance 5
WARNING: THE SENSOR USED IN THE MODEL 3300TB CON-
TAINS AN ELECTROLYTE WHICH INCLUDES
SUBSTANCES THAT ARE EXTREMELY HARMFUL
IF TOUCHED, SWALLOWED, OR INHALED. AVOID
CONTACT WITH ANY FLUID OR POWDER IN OR
AROUND THE UNIT. WHAT MAY APPEAR TO BE
PLAIN WATER COULD CONTAIN ONE OF THESE
TOXIC SUBSTANCES. IN CASE OF EYE CONTACT,
IMMEDIATELY FLUSH EYES WITH WATER FOR AT
LEAST 15 MINUTES. CALL A PHYSICIAN. (SEE
APPENDIX, Material Safety Data Sheet—MSDS).
5.2.3 Removing the Micro-Fuel Cell
RefertoFigure5-2foranexplodedviewofthecellblockandcell.To
removeaspentordamagedMicro-FuelCell:
1. DisconnectthePowerSourcefromtheControlUnit.
2. Opentheanalyzerdoor.
3. Unscrewthecell-retainercapfromthecellblockbyturningit
counterclockwiseuntilitisfree.
Figure 5-2: Exploded View of MFC and Cell Block
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4. Slowly withdraw the cap from the block. The cell should come out
with the cap.
5. Carefullypullthecelloffofthecap.DONOTTOUCHTHE
SCREENED END OF THE CELL OR ANY FLUID THAT MAY
BE LEAKING FROM IT.
6. Disposeofthecellinasafemanner,inaccordancewithall
applicableENVIRONMENTALANDSAFETYlaws.
5.2.4 Installing a Micro-Fuel Cell
ToinstallanewMicro-FuelCell:
CAUTION: Do not scratch, puncture, or otherwise damage the sensing
membrane of the Micro-Fuel Cell. If the membrane is damaged,
the cell must be replaced.
1. DisconnectthePowerSourcefromtheControlUnit.
2. RemovethenewMicro-FuelCellfromitsprotectivebag.
3. ExaminetheO-ringatthebaseofthethreadedportionofthecell-
retainercap,andreplaceitifitiswornofdamaged.
4. Replacethecellontheendofcell-retainercap,whichisdesignedto
fitsnuglyintotherimonthescreensideofthecell.
5. Carefulinsertthecapandcellintotheblock,andscrewthecap
clockwiseintothecellblockuntilitisheldfirmlyinthecell.
6. Reconnectthecellblockelectricalconnectorplug.
5.2.5 Cell Warranty Conditions
TheB-2CClassMicro-FuelcellisusedintheModel3300TB.Thesecells
arewarrantedfor6months,withanexpectedlifeof8monthsfromthedateof
shipment(underspecifiedoperatingconditions—seeAppendix).Noteany
Addendaattachedtothefrontofthismanualforspecialinformationapplyingto
yourinstrument.
Notethatthewarrantyperiodbeginsonthedateofshipment.Thecus-
tomershouldstockonlyonesparecellperinstrumentatatime.Donotattempt
tostockpilesparecells.
Ifacellwasworkingsatisfactorily,butceasestofunctionbeforethe
warrantyperiodexpires,thecustomerwillreceivecredittowardthepurchaseof
anewcell.
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Maintenance 5
Ifyouhaveawarrantyclaim,youmustreturnthecellinquestiontothe
factoryforevaluation.Ifitisdeterminedthatfailureisduetofaultyworkmanship
ormaterial,thecellwillbereplacedatnocosttoyou.
Note: Evidence of damage due to tampering or mishandling will render the
cell warranty null and void.
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Trace Oxygen Analyzer
Appendix
Appendix
A.1 Specifications
Ranges:
Twouserselectablerangescanbeset
between 0-10 ppm and 0-9999 ppm
oxygen,anda0-25 %(nominal)AirCali-
brationRange.
SignalOutput:
Voltage: 0–10 V dc,negativeground
Current: 4-20mA,negativeground
Range ID: 0-10 V dc.
Display:
Lightemittingdiode(LED)display.
Alarms:
Onehighalarmrelay,adjustable;onelow
alarmrelay,adjustable;onesensorfailure
relay.(Allarefailsafe.)
SystemOperatingTemp:
0-50 °C
Accuracy:
±2 %offullscaleatconstanttemperature
±5 %offullscalethroughoperatingtem-
peraturerange(At100ppmandhigheruser
definedranges)oncetemperatureequilib-
riumisreached.
±1 ppmfor10 ppmrangeunderabove
conditions.
Response Time:
SystemPowerRequirement:
SystemEnclosure:
90 % in less than 65 seconds at 25 °C
(68 °F).
AC (100-240 VAC, 50/60Hz), or
DC(10-36 VDC);userspecified.
Wall Mount, NEMA -4 Enclosure:
16.40" H × 8.0" W × 6.0" D (416.56 mm×
203.2 mm×152.40 mm).
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Appendix
Model 3300TB
A.2 Spare Parts List
QTY P/N DESCRIPTION
1
1
1
2
C-65220-A
C-64586
C-6689-B-2C
F-1130
PC Board, Main
PC Board, Power Supply
Micro-Fuel Cell, class B-2C
Fuse (AC), ½A, 250 VAC Type "T" (IEC),
5 x 20mm
IMPORTANT: Orders for replacement parts should include the part number
and the model and serial number of the system for which the
partsareintended.
Send orders to:
TELEDYNE ELECTRONIC TECHNOLOGIES
Analytical Instruments
16830 Chestnut Street
City of Industry, CA 91749-1580
Telephone: (626) 934-1500
TWX: (910) 584-1887 TDYANYL COID
Fax: (626) 961-2538
or your local representative.
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Trace Oxygen Analyzer
Appendix
A.3 Reference Drawing
D-70361 OutlineDiagram
D-70362 FinalAssembly
A.4 Miscellaneous
The symbol: ~ is used on the rear panel of the model 3300TB to signify
volts alternating current (VAC).
NOTE: The MSDS on this material is available upon request
through the Teledyne Environmental, Health and
Safety Coordinator. Contact at (626) 934-1592
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Appendix
Model 3300TB
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Trace Oxygen Analyzer
Appendix
A.5 Material Safety Data Sheet
Section I – Product Identification
Product Name:
Micro-FuelCells
Mini-Micro-FuelCells,allclasses
Super Cells, all classes except T–5F
Electrochemical Oxygen Sensors, all classes.
Manufacturer:
Address:
TeledyneElectronicTechnologies/AnalyticalInstruments
16830 Chestnut Street, City of Industry, CA 91749
Phone: (626) 961-9221
Technical Support: (626) 934-1673
Environment,Health
and Safety:
Date Prepared :
(626) 934-1592
11/23/98
Section II – Physical and Chemical Data
Chemical and Common Names: Potassium Hydroxide (KOH), 15% (w/v)
Lead (Pb), pure
CAS Number:
KOH 1310–58–3
Pb 7439–92–1
KOH (15% w/v)
–10 to 0 °C
Boiling Point/Range: 100 to 115 °C
Pb (pure)
328 °C
1744 °C
11.34
Melting Point/Range:
Specific Gravity:
pH:
1.09 @ 20 °C
>14
N/A
Solubility in Water:
Percent Volatiles by Volume: None
Completely soluble
Insoluble
N/A
Appearance and Odor: Colorless, odorless solution
Grey metal,
odorless
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Appendix
Model 3300TB
Section III – Physical Hazards
Potential for fire and explosion: The electrolyte in the Micro-Fuel Cells
is not flammable. There are no fire or explosion hazards associated with
Micro-Fuel Cells.
Potential for reactivity: The sensors are stable under normal conditions of
use. Avoid contact between the sensor electrolyte and strong acids.
Section IV – Health Hazard Data
Primary route of entry:
Ingestion, eye/skin contact
Exposure limits:OSHA PEL: .05 mg/cu.m. (Pb)
ACGIH TLV:
2 mg/cu.m. (KOH)
Effects of overexposure
Ingestion:
The electrolyte could be harmful or fatal
if swallowed.
Oral LD50 (RAT) = 3650 mg/kg
Eye: The electrolyte is corrosive; eye contact
could result in permanent loss of vision.
Dermal: The electrolyte is corrosive; skin contact
could result in a chemical burn.
Inhalation: Liquid inhalation is unlikely.
Signs/symptoms of exposure: Contact with skin or eyes will cause a
burning sensation and/or feel soapy or
slippery to touch.
Medical conditions
aggravated by exposure:
Carcinogenicity:
None
NTP Annual Report on Carcinogens: Not
listed
LARC Monographs: Not listed
OSHA: Not listed
Other health hazards:
Lead is listed as a chemical known to the
State of California to cause birth defects
or other reproductive harm.
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Trace Oxygen Analyzer
Appendix
Section V – Emergency and First Aid Procedures
Eye Contact:
Flush eyes with water for at least 15 minutes and get im-
mediate medical attention.
Skin Contact:
Ingestion:
Wash affected area with plenty of water and remove
contaminated clothing. If burning persists, seek medical
attention.
Give plenty of cold water. Do not induce vomiting.
Seek medical attention. Do not administer liquids to an
unconscious person.
Inhalation:
Liquid inhalation is unlikely.
Section VI – Handling Information
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.
Protective clothing:
Rubber gloves, chemical splash goggles.
Clean-up procedures: Wipe down the area several times with a wet pa-
per towel. Use a fresh towel each time.
Protective measures
during cell replacement:Before opening the bag containing the sensor
cell, check the sensor cell for leakage. If the sen-
sor cell leaks, do not open the bag. If there is
liquid around the cell while in the instrument,
put on gloves and eye protection before remov-
ing the cell.
Disposal:
Should be in accordance with all applicable
state, local and federal regulations.
NOTE: The above information is derived from the MSDS provided by the
manufacturer. The information is believed to be correct but does
not purport to be all inclusive and shall be used only as a guide.
Teledyne Analytical Instruments shall not be held liable for any
damage resulting from handling or from contact with the above
product.
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