Delta F Platinum Series User manual

Platinum Series
Process Oxygen Analyzer
Instruction Manual
P/N 99000001
DELTA F CORPORATION
4 Constitution Way !Woburn, Massachusetts 01801-1087
Telephone: [phone] !FAX: [phone]

Platinum Series
Process Oxygen Analyzer
Instruction Manual
P/N 99000001
Revision G
Covers Firmware
Version 2.82 And Higher
DELTA F CORPORATION
4 Constitution Way
Woburn, MA 01801-1087
Telephone: [phone]
FAX: [phone]
Service Dept.: 781-935-5808
Service FAX: [phone]

Copyright 1992-2000 by Delta F Corporation. All rights reserved except as follows:
This entire publication and/or its' PDF version may be reproduced, transmitted, and
stored electronically. Note that this manual must only be reproduced, transmitted or
stored in its’ entirety. Extraction of a portion of the printed or the PDF document, for
any use, requires written permission from Delta F Corporation.
Stablex, Bi-Strata, and NanoTrace are trademarks of Delta F Corporation. VCR®is a
registered trademark of the Cajon Company. Waferpure™ is a trademark of Millipore
Corporation. Nanochem®is a registered trademark of Semigas Corporation. Snoop®is
a registered trademark of Nupro Company. MicroTorr™ is a registered trademark of
SAES.

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Platinum Series Process Oxygen Analyzer Instruction Manual
Table Of Contents iii
TABLE OF CONTENTS
1.0 Overview Of This Manual .......................................1-1
1.1 Introduction ................................................1-2
1.2 Definitions And Warnings .....................................1-2
1.2.1 Explanation Of Graphic Symbols .........................1-2
1.2.2 Definitions ..........................................1-5
1.3 Unpacking .................................................1-6
1.4 Verify Operating Voltage ......................................1-7
2.0 Quick Set-up Procedure ........................................2-1
2.1 Tools Required ..............................................2-1
2.2 Adding The Electrolyte ........................................2-1
2.3 Sample Gas Connections .....................................2-3
2.4 Electrical Connections ........................................2-3
2.5 Standard Outputs ............................................2-3
2.6 Powering Up ...............................................2-4
2.7 Operational Recommendations .................................2-6
3.0 Beyond The Basic Analyzer - The Options .........................3-1
3.1 High-Resolution Model ........................................3-2
3.2 STAB-EL ..................................................3-3
3.3 Pump .....................................................3-3
3.4 Heater ....................................................3-4
3.5 Installation Of The Filter .......................................3-6
3.6 Installation Of The Pressure Regulator ...........................3-7
3.7 Installation Of Both Filter And Pressure Regulator ..................3-8
3.8 Supplemental Ni-Cd Battery Power ..............................3-9
3.9 Key Lock ..................................................3-9
3.10 Stainless Steel Outlet Line ...................................3-10
3.11 Welded Gas Delivery System With VCR®Metal Face-Seal Inlet
Connections ............................................3-10
3.12 4-20 mA Fully Isolated Output ................................3-11
3.13 Quick Start ...............................................3-12
3.14 Password Protection .......................................3-12
3.15 Gas Scale Factor ..........................................3-12
3.16 Alarms ..................................................3-12
3.16.1 Oxygen Alarms .....................................3-12
3.16.2 Temperature Alarm .................................3-13
3.16.3 Low Flow Alarm ....................................3-13
3.16.4 Electrolyte Condition Alarm ...........................3-13

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3.17 Expanded Range Scale Output ...............................3-13
3.18 Relay Contact Closures .....................................3-14
3.19 Panel/Rack Mount .........................................3-14
3.20 Comm Ports ..............................................3-14
4.0 Connecting To External Devices .................................4-1
4.1 Introduction ................................................4-1
4.2 The Comm Port .............................................4-1
4.3 Relay Ports ................................................4-2
4.4 Sensor Port ................................................4-3
4.5 Option Ports ................................................4-4
4.6 Changing The Analog Voltage Output Selection ....................4-5
4.7 Proper Grounding & Cable Shielding For External Equipment .........4-7
4.7.1 Output Signal Grounding ...............................4-7
4.7.2 Cable Shielding ......................................4-9
4.7.3 Hook-up For Specific Analyzer Configurations ..............4-11
4.7.3.1 Standard Analyzer With No RS-232, RS-485, Or
Isolated 4-20 mA Options .......................4-11
4.7.3.2 Analyzer With Optional 4-20 mA, But No RS-232 Or
RS-485 ......................................4-12
4.7.3.3 Analyzer With Optional RS-232 ..................4-13
4.7.3.4 Analyzer With Optional RS-485 ..................4-14
5.0 Gas Sample Preparation And Delivery .............................5-1
5.1 Sample Flow Rate And Pressure ................................5-1
5.1.1 Flow Rate Effects On Sensor Performance .................5-1
5.1.2 Background Gas Effects On Indicated Flow Rate ............5-2
5.1.2.1 Indicated Flow Corrections For H2Or He ............5-2
5.1.3 Positive Pressure Operation .............................5-3
5.1.4 Negative Pressure Operation ............................5-4
5.1.5 Pressure Effects On Sensor Performance ..................5-5
5.2 Gas Sample Compatibility .....................................5-5
5.2.1 Condensation / Liquid Slugs ............................5-6
5.2.2 Gas Solubility In Aqueous KOH Solution ...................5-7
5.2.3 Reactivity With KOH Electrolyte ..........................5-7
5.2.4 Sample Gas Flammability ..............................5-7
5.2.5 Abnormal Process Condition Or Maintenance Operation ......5-8
5.2.6 Capability Of The STAB-EL System ......................5-8
5.3 Normal Installation And Operation Considerations .................5-10
5.3.1 Normal Operating Conditions ...........................5-10
5.3.2 Sample Gas Temperature Control .......................5-11
5.3.3 Back Pressure/Sample Outlet Vent ......................5-11
5.3.4 Checking For Plumbing Leaks ..........................5-12

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5.4 Sampling Considerations During Calibration ......................5-12
5.4.1 Calibration Standards .................................5-13
5.4.2 Cylinder Regulators ..................................5-13
5.4.3 Process Conditions During Calibration ....................5-15
5.4.3.1 Delivery And Vent Pressure During Calibration ......5-15
5.4.3.2 Background Gas Effects On Calibration ............5-15
6.0 User Interface .................................................6-1
6.1 Introduction ................................................6-1
6.2 The Main Menu .............................................6-4
6.2.1 Programming Protocol .................................6-5
6.3 Controls ...................................................6-7
6.3.1 Quick St(art) .........................................6-7
6.3.2 Pump ..............................................6-8
6.3.3 Heater .............................................6-8
6.3.4 Sensor Polarization ...................................6-8
6.3.5 SensOFF Relay ......................................6-9
6.3.6 P(o)w(e)r UP .......................................6-10
6.3.7 ESC ..............................................6-10
6.4 Set-Up ...................................................6-10
6.4.1 Alarms ............................................6-11
6.4.1.1 O2Alarms ...................................6-12
6.4.1.2 Temperature Alarm ...........................6-14
6.4.1.3 Low Flow Alarm ..............................6-14
6.4.1.4 Electrolyte Condition Alarm .....................6-15
6.4.2 Analog Outputs .....................................6-15
6.4.2.1 Scaling Analog Output Range On High-Resolution
Analyzers ....................................6-16
6.4.2.2 Expanded Range Scale Operation And Setup .......6-19
6.4.2.3 ExpRng Relay ................................6-20
6.4.2.4 CAL FREEZE ................................6-20
6.4.2.5 IN-CAL RELAY ...............................6-20
6.4.3 Comm Port .........................................6-20
6.4.3.1 Port ........................................6-21
6.4.3.2 Device ID:xxx ................................6-21
6.4.3.3 Baud .......................................6-21
6.4.3.4 Update And Quit ..............................6-22
6.4.4 GSF ..............................................6-22
6.4.5 Oxygen Calibration ...................................6-22
6.4.5.1 Background Gas Correction .....................6-22
6.4.5.2 Check/Adj Span ..............................6-26
6.4.5.3 Reset Orig(inal) Span ..........................6-29
6.4.5.4 New Sensor .................................6-30

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6.5 The Password Menu ........................................6-30
6.6 Diagnostics ...............................................6-33
6.6.1 Prescaler ..........................................6-33
6.6.2 Sensor Temperature .................................6-33
6.6.3 Sensor Zero ........................................6-34
6.6.3.1 ZERO REF ..................................6-35
6.6.3.2 Reset Orig(inal) Zero ..........................6-35
6.6.3.3 Zero Cal(ibration) .............................6-35
6.6.4 Test Output ........................................6-38
6.6.5 Test Relays ........................................6-38
6.6.6 Memory Test .......................................6-39
6.6.7 Screen Test ........................................6-39
7.0 Theory Of Operation ...........................................7-1
7.1 The Sensor ................................................7-1
7.2 The STAB-EL Electrolyte System ...............................7-1
7.2.1 STAB-EL And Carbon Dioxide ...........................7-3
7.2.2 STAB-EL And Gases In The Halogen Family ...............7-3
7.2.3 STAB-EL With Organic, Nitrogen, Or Sulfur Containing Acid
Gases .............................................7-3
7.3 The Gas Scale Factor ........................................7-3
7.4 Effects Of Gas Sample Flow Rate On Sensor Performance ...........7-5
7.5 Pressure Effects On Sensor Performance .........................7-5
7.6 Temperature Effects On Sensor Performance .....................7-6
7.6.1 Determining Maximum Temperature Effects On Analyzer
Readings ..........................................7-6
8.0 Service ......................................................8-1
8.1 Maintenance ...............................................8-1
8.1.1 Calibration ..........................................8-1
8.1.2 Storage Temperature ..................................8-2
8.1.3 Sensor Maintenance ..................................8-2
8.1.4 Replacing The Filter ...................................8-4
8.2 Troubleshooting .............................................8-4
8.2.1 Sample System Leak Test (Low Flow Sensitivity) ............8-4
8.2.2 Basic Troubleshooting .................................8-6
8.3 Shipping ..................................................8-10
9.0 Safety .......................................................9-1
9.1 General Warnings ...........................................9-1
9.2 Electrolyte Material Safety Data Sheet (MSDS) .....................9-3

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10.0 Specifications ................................................10-1
11.0 Warranty ....................................................11-1
Appendix A - Replaceable Spare Parts List ............................. A-1
Index ............................................................. I-1

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LIST OF FIGURES
Figure 1-1: Delta F Platinum Series Process Oxygen Analyzer ...............1-3
Figure 1-2: Major Internal Components ..................................1-4
Figure 2-1: Quick Disconnect Fitting At Rotameter Outlet ....................2-2
Figure 2-2: Pinouts At Enclosure Rear ..................................2-4
Figure 2-3: Front Panel Display, Main Menu ..............................2-5
Figure 3-1: Plumbing Configurations ....................................3-5
Figure 3-2: Filter Installation ..........................................3-6
Figure 3-3: Regulator Installation ......................................3-7
Figure 3-4: Filter And Regulator Installation ..............................3-8
Figure 3-5: Rack Mount Configuration ..................................3-15
Figure 3-6: Panel Mount Configuration .................................3-15
Figure 3-7: Cutout Dimensions For Panel Mount .........................3-16
Figure 4-1: Ground Loop Example .....................................4-8
Figure 4-2: Analyzer Internal Grounding .................................4-9
Figure 4-3: Analyzer With Relay Outputs ...............................4-10
Figure 4-4: Standard Analyzer Outputs (No RS-232, RS-485, Or Isolated
4-20 mA Option ..........................................4-11
Figure 4-5: Analyzer With Optional Isolated 4-20 mA (No RS-232 Or RS-485
Option) ................................................4-12
Figure 4-6: Analyzer With Optional RS-232 And Optional Isolated 4-20 mA,
If Equipped .............................................4-13
Figure 4-7: Analyzer With Optional RS-485 And Optional Isolated 4-20 mA,
If Equipped .............................................4-14
Figure 6-1: Data Display Screen .......................................6-1
Figure 6-2: Main Menu ..............................................6-4
Figure 6-3: Menu Tree - Operator Interface ..............................6-6
Figure 6-4: Control Menu ...........................................6-7
Figure 6-5: Set-Up Menu ..........................................6-11
Figure 6-6: Alarm Selection Menu ...................................6-11
Figure 6-7: Oxygen Alarm Selection Menu .............................6-12
Figure 6-8: Alarm Set-Up Screen (Alarm Not Used) ......................6-12
Figure 6-9: Alarm Set-Up Screen (Alarm Used) .........................6-13
Figure 6-10: Recorder Output Set-Up Menu ............................6-15
Figure 6-11: Recorder Output Scaling For High-Resolution Analyzers ..........6-17
Figure 6-12: Comm Port Set-Up Menu .................................6-21
Figure 6-13: Oxygen Cal Menu .......................................6-22
Figure 6-14: Gas Scale Factor Menu .................................6-23
Figure 6-15: Gas Scale Factor Menu (cont.) ............................6-24
Figure 6-16: Span Check Menu ......................................6-26
Figure 6-17: Calibration Converging Screen ............................6-28
Figure 6-18: Oxygen Cal Menu After User’s Calibration ....................6-29

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Figure 6-19: Password Menu ........................................6-31
Figure 6-20: Password Entry Screen ..................................6-32
Figure 6-21: Diagnostics Menu .......................................6-33
Figure 6-22: Sensor Zero Menu ......................................6-34
Figure 6-23: Zero Cal Warning Screen .................................6-35
Figure 6-24: Zero Cal Screen ........................................6-36
Figure 6-25: Zero Cal, Not Stable Yet Screen ...........................6-37
Figure 6-26: Output Test Screen .....................................6-38
Figure 6-27: Relay Test Screen ......................................6-38
Figure 6-28: Memory Test Screen ....................................6-39
Figure 7-1: Diagram Of The Sensor Configuration .........................7-3

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LIST OF TABLES
Table 3-1: Instrument Resolution ......................................3-3
Table 5-1: Maximum Allowable Acid Gas Limits Using The STAB-EL Sensor ....5-9
Table 5-2: Normal Operating Conditions ...............................5-11
Table 6-1: Approximate Trip Point For Flow Switch .......................6-14
Table 7-1: Supported Gases For Gas Scale Factor ........................7-4
Table 7-2: Temperature Effects .......................................7-7

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SPECIAL WARNINGS
DANGER
Line voltage exists in the Oxygen Analyzer Enclosure. If the
enclosure door is open, DO NOT REACH INTO THE ENCLOSURE
when the Analyzer is connected to AC power.
CAUTION
Do not operate the Platinum Series Process Oxygen Analyzer at
oxygen concentrations that are over-range for extended periods
of time. Trace and low percent range sensors may be damaged if
exposed to high levels of oxygen, e.g., air, for periods of time
>15 minutes while on power.
If an exposure is unavoidable, turn off power to the instrument, or
deactivate the sensor polarization voltage (See Section 6.3.4).

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Platinum Series Process Oxygen Analyzer Instruction Manual
Overview Of This Manual 1-1
1.0 Overview Of This Manual
This manual is organized in sections that will provide progressively more detailed
information. This section provides information about this manual, introduces the Delta
F Platinum Series Process Oxygen Analyzer, and defines some terms that will occur
throughout the manual.
The Analyzer is a sophisticated instrument with many features that need to be
discussed in detail. However, Section 2 of this manual will describe a procedure to get
the Analyzer up-and-running quickly without going through all of the detail. Later
sections will delve into the details of the Analyzer's features to help customize its
operation.
Section 2 assumes that the user has an instrument that does not include options. If the
instrument has any of the options listed below, some minor changes to the Quick Set-
Up Procedure in Section 2.0 will be necessary. The changes that are necessary can be
found in Section 3, under the selected option.
Option Section Change To Quick
Start-up Procedure
Filter 3.5 Plumbing Filter for Particulates or Mists
Filter and Regulator 3.7 Plumbing Filter for Particulates or Mists
Stainless Steel Outlet 3.10 Removal of Sensor Assembly
Welded Gas Delivery 3.11 Removal of Sensor Assembly
Panel/Rack Mount 3.19 Enclosure Mounting
Section 3 discusses optional equipment and features. Useful information about specific
options for the Analyzer can be found in this section.
Section 4 describes how the Analyzer is connected to external devices through the
connectors at the back of the Analyzer. Details about communication ports, relay ports
and other optional ports can be found in this section of the manual.
Section 5 covers gas sample preparation and delivery. This section discusses sample
flow, pressure, and gas quality, for both normal sampling and calibration.
Section 6 describes how to do normal operation and program the Analyzer for specific
requirements. The user will be taken step-by-step through the screen menus to
customize the Analyzer's set-up.

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Platinum Series Process Oxygen Analyzer Instruction Manual
Overview Of This Manual1-2
The remainder of the manual covers Theory of Operation (Section 7.0), Service
(Section 8.0), Safety (Section 9.0), Specifications (Section 10.0) and Warranty (Section
11.0). Appendix A lists replacement parts and part numbers.
1.1 Introduction
Many factory options are available for the Analyzer. For simplicity, it is assumed that
the user has a basic Analyzer without options. Therefore, this section will not cover
operation of Analyzers equipped with the high-resolution feature, pump, flow switch,
heater, regulator, filter, alarms, etc.
Every Analyzer can measure and display oxygen, and can output the signal to an
external device. The analog output range can be scaled for specific needs. Standard
outputs are non-isolated 4-20 mA and 0-10 VDC.
Figure 1-1 shows the basic Analyzer. Figure 1-2 shows some of the major internal
components.
Before setting-up the Analyzer, some definitions and warnings need to be stated.
1.2 Definitions And Warnings
1.2.1 Explanation Of Graphic Symbols
This symbol alerts the user to the presence of “dangerous
voltage” within the Analyzer’s enclosure or to the possibility of
physical danger to personnel or permanent damage to the
equipment.
This symbol alerts the user to the presence of important
operations and/or maintenance instructions in this manual.

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Platinum Series Process Oxygen Analyzer Instruction Manual
Overview Of This Manual 1-5
1.2.2 Definitions
DANGER: Indicates that the information is provided to alert the user to a potential
personal hazard or the potential of damage to the product.
CAUTION: Indicates that the information is provided to alert the user to the potential
of damage to the instrument, or an incorrect result if the directions are not
followed.
NOTE: Indicates that the information is provided to increase the efficiency,
accuracy or reliability of the Analyzer.
DANGER
Potentially hazardous AC voltages are present within this instrument.
Leave all servicing to qualified personnel. Disconnect all AC power at
the source when installing or removing AC power connections, or data
signal connections, as well as when installing or removing the sensor
or the electronics or charging or draining electrolyte. Do not connect
this Analyzer to a power source until all electrical connections within
the instrument are complete.
CAUTION
Do not set-up or operate the Oxygen Analyzer without a complete
understanding of the instructions in this manual. Chapter 9.0, Safety,
contains safety instructions and the electrolyte Material Safety Data
Sheet (MSDS). To protect yourself and the instrument, please read
Chapter 9.
RF DISCLAIMER
This instrument generates, uses, and can radiate 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 instrument
to determine if the interference disappears. If it does, try one or more of the following
methods to correct the problem:

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Platinum Series Process Oxygen Analyzer Instruction Manual
Overview Of This Manual1-6
1. Reorient or relocate the receiving antenna.
2. Move the instrument further away from the receiver.
3. Plug the instrument or receiver into a different AC outlet so the instrument
and receiver are on different circuits.
CAUTION
Do not use hand-held radios with greater than 0.5 Watt power within
fifteen feet of this instrument. Otherwise, significant spikes in O2
readings may occur when the radio is transmitting.
1.3 Unpacking
When unpacking the instrument, notice the condition of the package and its contents. If
any damage is apparent, immediately notify the carrier and the Delta F Customer
Support Services Department at 781-935-5808. Do not proceed with the installation.
Check the contents against the packing slip to make sure that the shipment is
complete. Unattached equipment may be included with the Analyzer in supplemental
packaging.
All Analyzers are shipped with the following parts:
Two Bottles of EO5 Electrolyte P/N DF-E05
Power Cord w/Connector (115 VAC only) P/N 59017300
Wash Bottle P/N 67002401
This Manual P/N 99000001
Note: Any damage claims and shortage reports must be reported to Delta F
Corporation within 10 days after receipt of the shipment.
Keep the packing carton for future use. The carton is designed to protect the Analyzer
and should be used if shipping becomes necessary.

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Platinum Series Process Oxygen Analyzer Instruction Manual
Overview Of This Manual 1-7
Open the Analyzer door and inspect the inside of the unit to be sure that no
components have become loosened or dislodged. Remove any shipping materials.
CAUTION
Check the printed circuit boards (PCBs) to be sure they are seated
properly.
1.4 Verify Operating Voltage
The Platinum Series Process Oxygen Analyzer is configured at the factory to operate
on 100-120 VAC or 220-250 VAC as specified on the purchase order. The factory
setting can be verified by noting the red mark in the box imprinted on the back panel of
the Analyzer near the power receptacle, and by looking at the voltage selector switch on
the internal power panel, Figure 1-2. Analyzers that are ordered to operate on 220-250
VAC are not supplied with a power cord, due to the variety of plug styles used
throughout North America and the world. The Analyzer has an IEC 60320 C13 inlet on
the rear panel that will accept a customer supplied power cord having the appropriate
local 220-250 VAC plug on one end and the standard IEC 60320 C13 connector on the
other end.
CAUTION
On units with a pump and/or heater, the Voltage Selector switch must
not be moved from the factory-set position or the pump and/or heater
may be damaged. The pump and heater are voltage specific. If it is
necessary to operate these Analyzers on a voltage, different from the
factory-set voltage, contact the Delta F Customer Support Services
Department at 781-935-5808.
To change the operating voltage on units without a heater and/or pump, simply move
the voltage selector switch to the appropriate position and replace the main fuse. For
115 V operation a 0.5 Amp fuse (P/N 45002361) is required, while for 230 V operation,
a 0.25 Amp fuse (P/N 45002301) is required. The basic Analyzer uses less than 25
watts of power, and is compatible with both 50 and 60 Hz.