Model D200 & D400 OxyProbe Series Manual

®
Manufacturers of Sensors and Process Control Automation
19 Thomas, Irvine, California 92618 USA
Phone: (949) 829-5555 Toll-Free: (800) 288-2833 Fax: (949) 829-5560
E-Mail: sales@broadleyjames.com Website: broadleyjames.com
Copyright © 2001-2014 Broadley-James Corporation. All rights reserved.
P1431O 10/2006
P1431O
12/2012
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
This product has been designed, manufactured, and tested to meet many national and
international standards. Because these sensors are sophisticated technical products, proper installation, use, and maintenance ensures they continue to operate within their normal specifications. The following instructions are provided for integration into your safety
program when installing, using, and maintaining these products. Failure to follow the
proper instructions may cause any one of the following situations to occur: Loss of life;
personal injury; property damage; damage to this sensor and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product. If this
instruction manual is not the correct manual, telephone (949) 829-5555 and the
requested manual will be provided. Save this manual for future reference.
• If you do not understand any of the instructions, contact Broadley-James for
clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the
product.
• Inform and educate your personnel in the proper installation, operation, and
maintenance of the product.
• Install your equipment as specified in the installation instructions of the appropriate
instruction manual and per applicable local and national codes.
• To ensure proper performance, use qualified personnel to install, operate, update,
calibrate, and maintain the product.
• When replacement parts are required, ensure that qualified people use replacement
parts specified by Broadley-James. Unauthorized parts and procedures can affect the
product’s performance and place the safe operation of your process at risk. Look
alike substitutions may result in improper operation.
OxyProbe® is a registered trademark of Broadley Technologies
Measurement and Control Products for Science and Industry
19 Thomas, Irvine, California 92618 USA Phone: (949) 829-5555
Fax: (949) 829-5560
Website: broadleyjames.com
1
P1806O 4/2006
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Contents
1.0 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.0 OxyProbe® Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Sensor Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.0 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Sensor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 Remote Recording & Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.0 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 Calibration Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Transmitter Zero Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Sensor Zero Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 Calibration at Air Saturation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5 Measurement with and without Temperature Compensation . . . . . . . . . . . . . . . . . 19
4.6 Calibration: % of Atmospheric Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.7 Calibration: mg O2 / L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.0 Functional Check / Maintenance / Trouble Shooting . . . . . . . . . . . . . . . . . . . . 21
5.1 Functional Check of Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 Functional Check of DO Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Replacement of Membrane Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.0 Effects on Oxygen Sensor Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Flow Dependence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Oxygen Partial Pressure vs. Oxygen Concentration . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.0 Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1 Insertion of the OxyProbe DO Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.0 Replacement and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.0 Return of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.2 Warranty Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.3 Non-Warranty Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Contents–Figures
Figure
Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
1
2
3
4
5
6
7
8
8b
9
10
11
12
13
14
15
Principle Sensor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OxyProbe® Protective Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Membrane Cartridge Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Membrane Cartridge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Stainless Steel Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Sensor Cap Nut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Sensor Polarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AX-5000 Cable Connection to Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AX-5100 Cable Connection to Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OxyProbe® Sensor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OxyProbe® Sensor Wiring for Model 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OxyProbe® Sensor Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OxyProbe® Sensor Typical Installation Diagrams . . . . . . . . . . . . . . . . . . . . . . 28
D200 and D205 OxyProbe® Sensor Exploded View . . . . . . . . . . . . . . . . . . . . . 29
D400/D405-B070 OxyProbe Sensor Exploded View . . . . . . . . . . . . . . . . . . . . 31
D400/D405-B150 OxyProbe Sensor Exploded View . . . . . . . . . . . . . . . . . . . . 33
Tables
1
Oxygen Solubility in air-saturated pure water in mg 02/L at an overall
pressure of a water-vapor saturated atmosphere of 760 mm Hg . . . . . . . . . 18
3
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Chapter 1: Technical Data
1.0 Technical Data
Sensor body:
Membrane:
Membrane cartridge:
Cathode:
Anode:
Electrolyte:
316L stainless steel
Teflon / silicone (steel-mesh reinforced)
High-temperature resistant plastic (PPS)
Platinum (Pt)
Silver (Ag)
KOH / KCl solution, pH 13
Response time:
@25°C
@37°C
98% of readout in
60 seconds
20 seconds
Stability:
In water, under constant pressure and at a
constant temperature drift amounts to less
than 2% per week
Flow dependence:
Readings in stirred and unstirred solutions
differ by approximately, 3 – 5 %.
Polarization voltage:
675 mV
Electrode current in ambient air:
Approximately 60 x 10-9 amps
Electrode current in N2:
< 1% of current in ambient air
Temperature coefficient of membrane
at constant O2 partial pressure:
Approximately 2.3% / K at 25°C
Temperature range:
Operation: 0 – 80°C
Sterilization: maximum 130°C
Temperature compensation:
Automatic with built-in thermistor,
22K @ 25°C
Linearity:
< 0.3% of readout
Maximum pressure:
58 psig, 4 bar (atm)
Cable connection:
Standard 4-pin
Wetted materials:
All metal parts in contact with sample solution
are made of 316L stainless steel.
O-ring seal:
Silicone Rubber
4
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Chapter 2: OxyProbe Features
sensor performance, no attempt should be
made to modify them. A silver anode tube is
positioned over the glass tube. A thermistor
for the temperature compensation of sensor
current is also incorporated within the glass
tube. The tube is then mounted and sealed
into a stainless steel threaded holder. This
comprises the anode/cathode assembly,
which is easily threaded into the sensor
housing with a simple tool.
2.1 Sensor Construction
The principle components of the oxygen
sensor are shown in Figure 1. All parts are
made of heat resistant materials.
The sensing element is comprised of a glass
tube that is sealed at one end with a fused
Pt wire. This sealed end is ground to a precise hemispherical curve. Since the geometrical configuration and roughness of the
ground surface have an important effect on
The membrane cartridge, when filled with
electrolyte, is gripped by the thumb and
forefinger slots (which forces out any
trapped air) and is slid over the end of the
anode/cathode assembly. It is sealed at the
lower end with a fixed, reinforced, gas-permeable membrane, and is surrounded by a
flexible silicone sleeve. This enables the
electrolyte to expand during sterilization
operations. The stainless steel sensor sleeve
forces the membrane cartridge against the
conical silicone washer. At the same time
optimum pressure of the gas-permeable
membrane against the cathode is obtained.
Figure 1
Principle Sensor Components
4 - pin plug
hermetically sealed
Sensor body
316L stainless steel
Silicone rubber o-ring
size AS-014
Silicone rubber o-ring
size AS-014
conical gasket
IMPORTANT: EVEN AFTER ASSEMBLY,
THE GLASS ROD EXTENDS A SLIGHT
DEGREE BEYOND THE ENDCAP.
THOUGH COVERED BY THE MEMBRANE, IT CAN BE DAMAGED BY SHARP
BLOWS.
Silver anode
Glass stem with
built-in 22K thermistor
Platinum cathode
OXYPROBE
Ryton (PPS) cartridge with composite
Teflon/silcone rubber membrane
reinforced with steel mesh
Sensor sleeve
316L stainless steel
Silicone rubber o-ring
size AS-209
Silicone rubber o-ring
size AS-015
5
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Chapter 3: Preparation
3.0 PREPARATION
Figures 2 through figure 7 inclusive.
3.1 Sensor
After performing the steps for the removal
of the protective caps, as shown in Figure 2,
proceed with the MEMBRANE CARTRIDGE
REFILL and INSTALLATION instructions as
shown in Figure 3 and Figure 4.
The sensor is shipped with a removable
boot that protects the anode/cathode
assembly and membrane cartridge during
shipment and during long term storage. A
moisture proof dust cap is also provided to
protect the 4-pin connector. See Figure 2 for
removal procedures for these protective
caps.
NOTE: Save the moisture proof dust
cap to protect the 4-pin connector during autoclave or out of service conditions.
Begin the sensor preparation by following
the step by step procedures as shown in
The OxyProbe sensor is now ready to reassemble by replacing the stainless steel
sensor sleeve as shown in Figure 5.
Continue with the final assembly step of the
OxyProbe sensor by installing the cap nut as
shown in Figure 6.
The final step in the sensor preparation
involves the POLARIZATION of the sensor
which is accomplished as shown in Fig. 7.
6
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Figure 2
®
OxyProbe Protective Cap Removal
Step 1
Step 2
Remove moisture proof dust cap
from 4-pin connector by applying
a quarter-turn twist in the direction
of the arrow as shown.
Remove the protective boot
from sensor body by twisting
and pulling in the direction of
the arrows as shown.
Cathode/Anode
Protective Boot
Step 3
Remove the optional moisture proof
dust cap from cable connector by
applying a quarter-turn twist in the
direction of the arrows as shown.
7
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Figure 3
Membrane Cartridge Refill
Electrolyte
Opening
Refill
Spout
Membrane
Cartridge
Assembly
Electrolyte
25 ml Bottle
Membrane
Surface
CAUTION
The use of protective gloves
and eyewear is recommended
throughout the membrane
cartridge refill and installation
procedures.
Step 4
While holding the membrane cartridge upright (with opening up)
in one hand, carefully pour the electrolyte from the bottle into the
cartridge until approximately 75% full. Remove any trapped air
bubbles by tapping on the side of the membrane housing. Try
not to spill any of the electrolyte and wipe off any excess electrolyte
with a clean tissue from the outside surfaces of the cartridge.
8
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Figure 4
Membrane Cartridge Installation
Step 5
Grip the membrane cartridge,
which has been properly filled
with electrolyte, by the thumb and
forefinger slots in one hand while
holding the sensor body with the
other hand as shown.
Step 6
While compressing the
membrane cartridge with the
thumb and forefinger, slide the
cartridge over the anode /
cathode assembly until the
cartridge seats against the
conical gasket. Release the
pressure from the thumb and
forefinger. Rinse lower portion
of this sub-assembly with D.I.
water to remove any excess
electrolyte and blot dry with a
clean tissue.
Step 7
The sensor body subassembly
with the membrane cartridge in
place is now ready for the
installation of the stainless steel
sensor sleeve .
9
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Figure 5
Stainless Steel Sensor Sleeve Installation
Step 8
Slide the stainless steel sensor sleeve over the membrane
cartridge, being careful not to knick the o-rings. Be certain
that the mating threads of the sleeve and sensor body are
free of any dirt or debris.
Step 9
Thread the stainless steel sensor sleeve onto the sensor
body in the direction shown by the arrow. Be certain that
the sleeve is flush with the sensor body so that no o-rings
are visible. Do not overtighten. Hand tight is all that is
necessary.
Flush Fit
Note:
Carefully inspect all O-rings and the
conical gasket for any physical damage
or excessive wear. Replace these items
as needed or if there is any doubt as to
their condition.
10
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
F
Sensor Polarization
Step 11
Insert the AM-9221
OxyProbe Polarizing Unit
into the 4-pin connector
of the sensor.
Step 12
Twist-lock the
connector of
the OxyProbe
Polarizing Unit in
the direction of the
arrow as shown
NOTE: SENSOR POLARIZATION MAY
ALSO BE ACHIEVED BY CONNECTING
THE SENSOR TO THE HOST DO
TRANSMITTER WHICH IS POWERED.
11
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Figure 8
AX-5000 Cable Connection to Sensor
Step 13
Insert the 4-pin cable
connector into the
mating 4-pin connector
of the sensor.
Step 14
Twist-lock the cable
connector in the
direction of the arrow
as shown.
12
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Figure 8
AX-5000 Cable Connection to Sensor
Step 13
Insert the 4-pin cable
connector into the
mating 4-pin connector
of the sensor.
Step 14
Twist-lock the cable
connector in the
direction of the arrow
as shown.
13
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
14
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
When the transmitter is switched on, a
polarization voltage is applied between the
anode and cathode. The sensor current is
initially very high, but then falls off exponentially and settles down to steady state
after a few hours. Since this polarization
period is relatively long, the sensor should
be kept connected to a powered transmitter
or polarizing unit (Part Number: AM-9221)
when not in use. Owing to the very small
current flowing through the sensor under
these conditions, its life will not be shortened. If for any reason the sensor has to be
disconnected (or the transmitter power
switched off) for an extended period, it will
have to be repolarized before it is ready for
further use.
During the polarization period, the sensor current will also fall off even in oxygenfree solutions. For this reason, an excessive
zero current (See Section 4.2) may indicate
incomplete polarization.
3.2 Sensor Cable
The oxygen sensor cable is provided in two
configurations: (1) the AX-5100 with a protective connector boot; or (2) the AX-5000
without the boot. See Figures 6 – 8 for cable
to sensor connections and descriptions.
Refer to the wiring diagram of the DO transmitter selected for use with the OxyProbe
for proper connection of the sensor.
15
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
3.3 Transmitter
The transmitter to be used with OxyProbe
DO sensors must be properly matched with
the sensor. Oxygen sensors differ in regard
to output current, polarization voltage, and
temperature compensation technique.
Therefore, the sterilizable DO sensor
requires a transmitter with precisely defined
characteristics. The transmitter specifications must be carefully examined to verify
compatibility. If there is any question regarding sensor and transmitter compatibility,
contact your Broadley-James representative
or call 949-829-5555 for factory assistance.
3.4 Remote Recording and Control
Devices
The signal circuits of all such remote instruments must be isolated from ground. If this
cannot be accomplished, an isolation device
must be placed between the oxygen transmitter and the remote instrument. For safety reasons the chassis of all component units
must be well grounded. We recommend that
the ground terminals of all ancillary instruments be connected together and taken to a
known good ground point.
16
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Chapter 4: Calibration
4.1 Calibration Comments
Zero point calibration may be carried out
in both pure nitrogen or in water saturated
The dissolved oxygen measuring system with nitrogen. A further alternative is the use
should be recalibrated prior to each fermenta- of a freshly-prepared 2% bisulfite solution.
tion. If work is performed under sterile conditions, the system can be calibrated with the The complete saturation of water with nitrosensor in place after sterilization, but prior to gen takes approximately 30 minutes.
inoculation. If the sensor is employed to mon- Calibration with pure nitrogen gas is faster and
itor a fermentation process that extends over more reliable. The zero point can be read after
several days (or weeks) with no possibility of 5 minutes.
changing it, the electrical zero point of the sensor should be checked before insertion. The 4.4 Calibration at Air Calibration
sensor should be fitted into the fermenter only
if the zero point of the sensor is less than the Zero point adjustment (Section 4.3) must predesired measuring accuracy (i.e. 2–5% of full cede calibration at air saturation. In compariscale ). If the zero point of the sensor is greater son to zero point calibration, the aqueous
than this threshold consult the recommenda- phase is preferred for saturation calibraiton.
tions in Section 5.4 (Troubleshooting) for cor- The following problems arise with calibration
rective action.
air:
4.2 Transmitter Zero Point
Calibration in a fermenter should be performed only after sterilization as sterilization
may alter the sensor’s membrance tension.
This alteration may be comparatively large,
particularly when a membrane cartridge is
used for the first time.
The electrical zero point of the transmitter
should first be set to correct for the non-zero
background of the oxygen sensor (see the
operating instructions for the host DO transmitter). It is critical that the sensor zero point
be checked and corrective actions taken if the After cooling, the fermenter is aerated.
sensor zero current exceeds the desired meas- Depending on the host instrument’s calibrauring accuracy (i.e. 2–5% of full scale).
tion method, the calculated oxygen concentration is set in units of mg 02 /L (ppm), or %
4.3 Sensor Zero Point
saturation.
The zero current of the D.O. sensor (reading at
0% saturation) is usually negligibly small and
almost identical with the transmitter zero
point. Nonetheless the sensor zero point
should be periodically checked as some sensor faults, which may compromise sensor performance, are detectable as an excessive zero
current.
Calibration is usually performed at air saturation since it is convenient and simple. If this
method is chosen, the reading is adjusted to
100% saturation. As partial pressure of oxygen
is dependent on total applied pressure, the
100% adjustment should be done under actual operating pressure.
17
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
See Figures 13 through 15 for exploded-view
drawings and itemized parts lists of the
OxyProbe 12 mm sensors.
4.5 Measurement with and without
Temperature Compensation
The NTC thermistor incorporated within the
glass tube of the anode/cathode assembly can
automatically provide for temperature compensation relating to the effect of temperature
on membrane permeability. This temperature
measurement provides the necessary input
for the algorithm calculation of the ppm readout.
4.6 Calibration: % of Atmospheric Oxygen
A solution saturated with air is defined as
100% saturated. In large-size aerated fermenters the sensor should be calibrated in
place after sterilization. Calibration should be
carried out under flow, aeration and pressure
conditions approximating as closely as possible those conditions expected to be encountered during the required measurement period. During measurement, the temperature
and pressure in the fermenter should remain
constant.
4.7 Calibration : mg O2 / L
TABLE 1
Oxygen solubility in air-saturated pure
water in mg 02 /L at an overall pressure of
a water-vapor saturated atmosphere of
760 mm Hg
Temp.
°C
Solubility
in mg O2 /L
0
2
4
6
8
10
12
14
16
18
14.57
13.79
13.08
12.42
11.81
11.26
10.74
10.27
9.83
9.43
Temp. Solubility
°C
in mg O2 /L
20
22
24
26
28
30
32
34
36
38
40
18
9.06
8.71
8.39
8.09
7.81
7.55
7.30
7.07
6.84
6.63
6.42
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
In determining oxygen concentration, the O2
content of the calibrating solution must be
accurately known. The values applying to pure
water are known and shown in Table 1. These
solubilities need only be adjusted to the prevailing barometric pressure PB.
PB / 760
This calibration is reliable only if measurements are affected by dilute aqueous solutions. In concentrated solutions the oxygen
solubility must first be determined by a
Winkler titration.
Solubility(PB) = solubility(at 760 mm Hg) x
19
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Chapter 5: Functional Check/
Maintenance/Trouble Shooting
5.1 Functional Check of Transmitter
The DO Simulator (Part number AM-9222) is
suitable for checking the transmitter and
connecting cable for proper operation.
5.2 Functional Check of DO Sensor
a) Place sensor in air-saturated water and set
transmitter reading to 100% saturation.
b) Place sensor in an oxygen-free atmosphere (e.g. pure nitrogen). After approximately 5 minutes the reading should drop
below 2–5% of the “air value” previously set.
Failing this test indicates that the zero current
is too high. See Section 5.4 for troubleshooting such a problem.
c) Response time: when changing from
nitrogen to ambient air, 98% of the reading
should be obtained within 45 to 90 seconds.
If this is not the case, consult Section 5.4 for
appropriate action.
5.3 Replacement of Membrane
Cartridge
OxyProbe DO sensors are supplied with an
installed membrane cartridge which has
been checked for proper function at the factory. Should sensors with fitted membrane
cartridges be stored for several months after
delivery, the electrolyte should be renewed
before use and the proper sensor operation
verified by checking the sensor zero point
and calibration in room air. Failure to pass
these steps may indicate that a change of the
membrane cartridge is needed.
If the membrane fails to operate (sluggish
response, mechanical damage, etc.) it must
be replaced. In so doing, observe the following instructions (Refer to Figures 3 through
Fig. 5 inclusive):
a) Unscrew the stainless steel cartridge sleeve
from sensor body and carefully pull it away
from the sensor body.
b) Compress thumb and forefinger recesses
of the membrane cartridge carefully pulling it
with a slight twisting action from the
anode/cathode and sensor body assembly. (If
the membrane cartridge remains in the
stainless steel sensor sleeve, it may be dislodged by pressing on the end of the membrane. Use a tissue to avoid direct contact
with the membrane surface).
c) Rinse the anode/cathode assembly with
deionized water and dry with a clean piece of
tissue paper.
d) Check all o-rings and the conical gasket
visually for mechanical defects and replace if
necessary.
e) Fill the new membrane cartridge to 75%
full with dissolved oxygen electrolyte solution
(P/N: AS-3140-C30-0025). Gently tap the cap
until the remaining air bubbles have been
removed from the electrolyte. Remove all
excess air from the membrane cartridge by
20
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
compressing the thumb and forefinder
recesses of the membrane cartridge. Slide the
cartridge over the anode/cathode assembly
until the cartridge seats against the conical
gasket. Release the pressure from thumb and
forefinger to draw electrolyte into the space
between the body of the membrance cartridge
and the silicone sleeve.
f) Rinse all parts with DI water and wipe dry
with a clean paper towel or tissue.
CAUTION: The DO electrolyte is an alkaline
solution with a pH of 13. Avoid contact of electrolyte with skin, mucous membrane, or eyes.
If contact occurs flush all affected areas with
plenty of water. Use of eye protection and rubber gloves is recommended.
g) Carefully slip the stainless steel sensor
sleeve over the fitted membrane cartridge and
thread it back onto the anode/cathode and
sensor body assembly. Be certain that the
mating threads are clean and free of any
debris.
h) Perform a functional check as per Section
5.2 after each membrane replacement.
5.4 Troubleshooting
A) CONDITION – Sensor is non-responsive,
i.e. sensor current equals zero.
POSSIBLE CAUSES
• Cable Interruption:
See functional check Section 5.1. Subsequently check measuring cable for continuity using an ohmmeter.
• Heavily contaminated or defective
membrane:
Gently clean membrane surface with a clean
tissue wetted with distilled or DI water or
replace membrane cartridge.
• No internal electrolyte:
Disassemble and refill with fresh electrolyte.
B) CONDITION – Zero current of sensor too
high:
POSSIBLE CAUSES
• Partial short-circuit in sensor cable:
Disconnect cable from sensor and set the
transmitter in the nA mode, the reading
should be < 1.0 nA. If not, there is either a
short-circuit in the sensor cable, in which
case the cable must be replaced.
• Partial short-circuit or moisture in
interior of sensor body:
Remove the stainless steel membrane cartridge assembly from the sensor housing.
Carefully clean the anode/cathode area of the
inner sensor body with acetone and allow to
dry. Do not allow the acetone to come in contact with the o-rings.
Connect sensor to the cable and the cable to
the transmitter and set the transmitter in the
nA mode. The reading should be < 1.0 nA. If
not, there is either a short-circuit in the
anode/cathode subassembly or in the sensor
connector. The defective component must be
replaced.
C) CONDITION – Excessive response time:
21
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
POSSIBLE CAUSE
• Deposits on membrane:
Perform a careful mechanical cleaning using
moist tissue or soft cloth, or change membrane.
D) CONDITION – Reading is much too high
in all measuring ranges:
POSSIBLE CAUSES
• Interruption of temperature compensating
measurement circuit:
Remove thermistor leads (black & brown)
from the transmitter and test with ohmmeter.
The resistance across these leads at room
temperature should be between 20 and 30 K
ohms.
• In case of large and rapid pressure changes
(or total pressure above 58 psig, 4 bar) the
pressure of the gas-permeable membrane
against the glass body may affect the thin
electrolyte film behind the membrane and
consequently the sensor output current. This
often generates a high and unstable current
which settles down again after a matter of
hours. Avoid large and rapid pressure
changes, particularly after sterilization.
22
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Chapter 6: Effects on Oxygen
Sensor Performance
6.1 Flow Dependence
With most oxygen sensors the sensor current
level is smaller in a stagnant solution than in
agitated ones. The consumption of oxygen by
the sensor results in extraction of oxygen
from the test solution in the close proximity
of the cathode. The oxygen is replaced
through diffusion. If the sensor current is
large the solution cannot fully restore the oxygen by diffusion. This results in a sensor current weaker than would correspond to conditions in the solution. In agitated solutions the
oxygen is transported to the surface membrane not only by diffusion but additionally by
the flow (convection). In that case no oxygen
depletion occurs at the membrane surface.
A high degree of flow dependence occurs
mainly with large cathodes or thin and highly permeable membranes (i.e. where sensor
current levels are large).
The problem of flow dependence is often
solved by specifying a minimum flow rate.
In OxyProbe® DO sensors, the thin Teflon
Medium
saturated
with air
Water
4 mol/KCl
50% Methanolwater
membrane which determines the sensor current (i.e. the actual measuring signal) is separated from the sample solution by a relatively thick reinforced silicone membrane. This
layer is highly permeable to oxygen molecules
and thus acts as an oxygen reservoir. The
double Teflon/silicone membrane therefore
acts as an effective buffer against disturbances due to hydrodynamic flow. Combined
with the OxyProbe sensor’s small cathode
surface area and resulting low oxygen consumption rate, the membrane configuration
makes this system ideal for use in variable
flow conditions or applications of extended
duration.
6.2 Oxygen Partial Pressure vs. Oxygen
Concentration
The sensor current depends on the oxygen
partial pressure and the O2 permeability of
the membrane — but not on the O2 solubility in the solution of interest. Without a prior
knowledge of the oxygen solubility in the
solution of interest, the oxygen concentration
in mg O2 / L (CL) cannot be determined
directly with a sensor.
Solubility at 20°C
760 mm Hg (ppm)
%
Saturation
9.1 mg O2 / L
2.0 mg O2 / L
21.9 mg O2 / L
100%
100%
100%
23
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
position of the solution.
According to Henry’s law the oxygen concentration is proportional to its partial pressure
(PO2).
CL = (PO2) (a)
a = solubility factor
If a is constant and either CL or a values are
known, the oxygen concentration can be
determined by means of the sensor. This
methodology only applies at constant temperature and with dilute aqueous solutions such
as drinking water.
Although the solubilities vary widely, the oxygen sensor gives the same reading in all three
solutions.
This determination of the oxygen concentration is only possible with constant and known
solubility factors a.
Solubility may be determined by a Winkler
titration or the method developed by Kappeli
and Fiechter.
The solubility factor is strongly influenced not
only by the temperature, but also by the com-
24
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Chapter 7: Sensor
Installation & Maintenance
7.1 Insertion of the OxyProbe DO
Sensors
liquid level is less than 75% full, flush with
DI water and refill with fresh electrolyte.
Most fermentation vessels and bioreactors
are fitted with either 19mm or 25mm ports
for installation of dissolved oxygen sensors.
Insert and secure the oxygen sensor as
shown in Figure 11 and Figure 12.
With a 40x power scope, closely inspect the
surface of the membrane for any scratches
or perforations. If found, replace the membrane cartridge.
Carefully inspect the large o-ring on the sensor sleeve for any physical damage or excessive wear. Replace as needed or if there is
any doubt about the condition of this o-ring.
The cost of o-ring replacement is usually
quite small when compared to the cost of
the media in the vessel.
7.2 Preventative Maintenance
The OxyProbe sensors are designed to provide a proper seal with the mating weld-in
port on the vessel/reactor when the cap nut
is hand tightened. Over-tightening of the cap
nut with tools will not improve this seal and
may in fact damage the sensor and/or the
weld-in port. The perceived need for over
tightening is usually a good indication that
there is a problem with the concentricity,
roundness, or surface finish of the ID surface of the mating weld-in port.
The OxyProbe sensors are designed for easy
maintenance. Remove the membrane cartridge sleeve and observe the condition and
amount of electrolyte liquid. If dirty or the
Inspect the large surface area Ag anode. If a
large portion of it is tarnished or discolored;
e.g. grey, purple/grey, or black; clean with 12
MICRON 3M IMPERIAL® LAPPING FILM
(aluminum oxide sheets) or toothpaste and
soft paper towel until the Ag surface is free
of most discoloration.
Visually inspect the tip of the cathode with a
10x power (or better) loop for the presence
of any organic/inorganic contamination/
coating.
In the case of an organic deposit, clean the
tip of the cathode with tooth-paste and a soft
paper towel.
If a grease film is observed, clean with acetone. In the event of an inorganic deposit,
clean by suspending the tip portion only of
the cathode in 0.1M H2SO4 for up to 24
hours.
The cathode tip should be free of any deposit
or film before being returned to service.
25
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Figure 11
OxyProbe ® Sensor Typical Installation Diagrams
SIGNAL CABLE
TO INSTRUMENT
PROCESS
D400 Installation
MODEL D400
DISSOLVED
OXYGEN
SENSOR
CAP NUT
25 mm SIDE ENTRY PORT
VESSEL WALL
PROCESS
MODEL D405
DISSOLVED
OXYGEN
SENSOR
D405 Installation
(90° Connector )
CAP NUT
25 mm SIDE
ENTRY PORT
VESSEL WALL
SIGNAL CABLE
TO INSTRUMENT
26
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
27
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Chapter 8:
Replacement and Spare Parts
28
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
D200/D205 OxyProbe® Sensor Assembly
EXPLODED VIEW, ITEMIZED PART NUMBER & DESCRIPTIONS
Item
Part Number
Description
1
2
AM-9230
AM-9203
3
AM-9316
4a
AM-9341
4b
AM-9342
4c
AM-9343
4d
AM-9344
5
6
7
8a
AM-9345
AM-9231
AM-9231
CT25-PT-130MP
8b
CT25-PT-130MP
8c
CT25-PT-130MP
8d
CT25-PT-130MP
9
10
AM-9307
AM-9210
11
12
13
14
15
AM-9233
AM-9234
AM-9239
AM-9236
AM-9230
16
AM-9347
17
18
AM-9315
AM-9348
M2.5 x 0.45 x 1/4” Stainless Steel Screw, set of 3
4-Pin Connector, glass to metal seal with ribbon/micro
cable disconnect
O-ring, EPDM, size: 10.4 x 1.0 for use w/AM-9203
4-Pin Connector
Sensor Body, 316L stainless steel, for B=150 mm
D200/205 sensors
Sensor Body, 316L stainless steel, for B=220 mm
D200/205 sensors
Sensor Body, 316L stainless steel, for B=320 mm
D200/205 sensors
Sensor Body, 316L stainless steel, for B=420 mm
D200/205 sensors
O-ring, Silicone, size: AS-016
O-ring, Silicone, size: AS-014
O-ring, Silicone, size: AS-014
Cathode/Anode ass’y w/dual EPDM, AS-011 O-rings for
B=150 mm D200/205 sensors
Cathode/Anode ass’y w/dual EPDM, AS-011 O-rings for
B=220 mm D200/205 sensors
Cathode/Anode ass’y w/dual EPDM, AS-011 O-rings for
B=230 mm D200/205 sensors
Cathode/Anode ass’y w/dual EPDM, AS-011 O-rings for
B=420 mm D200/205 sensors
O-ring, EPDM, size: AS-011
Retainer Ring Nut, 316L SST for CT25 Cathode/Anode
assembly
Conical Gasket, silicone
Membrane Cartridge for D200 and D400 Series sensors
Sensor Sleeve, 316L SST, D200 / D205 sensors
O-ring, Silicone, size: AS-015
M2.5 x 0.45 x 1/4” Stainless Steel Screw, set of 3
(2 sets required)
4-Pin Connector, glass to metal seal w/ribbon/micro
cable disconnect
O-ring, EPDM, size: AS-014
Right Angle connector / Adapter assembly
29
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Figure 15
D400-B150 & D405-B150 OxyProbe® Sensor Assembly
See Itemized List for Part Number & Description
1
NOTE:
These items are
required for the
Model D400
3 REQUIRED
2
3
4
NOTE:
These items are required for the Model D405
in lieu of item nos. 1 & 2 above.
15
6
REQUIRED
8
16
17
18
9
5
10
6
11
7
12
13
14
30
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
D100/D105 OxyProbe® Sensor Assembly
ITEMIZED PART NUMBER & DESCRIPTIONS
Item
Part Number
Description
1
AM-9230
M2.5 x 0.45 x 1/4” Stainless Steel Screw, set of 3
2
AM-9202
4-Pin Connector, glass to metal seal with
ribbon/micro cable disconnect
3
AM-9315
O-ring, EPDM, size: AS-014
4
AM-9232
Sensor Body, 316L stainless steel, for B=070 mm
D400/405 sensors
5
AM-9231
O-ring, Silicone, size: AS-014
5
AM-9231
O-ring, Silicone, size: AS-014
7
CT25-PT-050MP
Cathode/Anode ass’y w/dual EPDM, AS-011 O-rings for
B=070 mm D400/405
8
AM-9307
O-ring, EPDM, size: AS-011
9
AM-9210
Retainer Ring Nut, 316L SST for CT25 Cathode/Anode assembly
10
AM-9233
Conical Gasket, silicone
11
AM-9234
Membrane Cartridge for D200 and D400 Series sensors
12
AM-9235
Sensor Sleeve, 316L SST, for B=070 mm D400/405 sensors
13
AM-9237
O-ring, Silicone, size: AS-209
14
AM-9236
O-ring, Silicone, size: AS-015
15
AM-9230
M2.5 x 0.45 x 1/4” Stainless Steel Screw, set of 3
(2 sets required)
16
AM-9349
4-Pin Connector, glass to metal seal with ribbon/micro
cable disconnect
17
AM-9315
O-ring, EPDM, size: AS-014
18
AM-9238
Right Angle Connector/Adapter assembly for D405 Sensors
31
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
32
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
D400-B105 & D405-B150 OxyProbe® Sensor Assembly
EXPLODED VIEW, ITEMIZED PART NUMBER & DESCRIPTIONS
Item
Part Number
Description
1
AM-9230
M2.5 x 0.45 x 1/4” Stainless Steel Screw, set of 3
2
AM-9202
4-Pin Connector, glass to metal seal with
ribbon/micro cable disconnect
3
AM-9315
O-ring, EPDM, size: AS-014
4
AM-9346
Sensor Body, 316L stainless steel, for B=150 mm
D400/405 sensors
5
AM-9237
O-ring, Silicone, size: AS-209
6
AM-9231
O-ring, Silicone, size: AS-014
8
CT25-PT-130MP
Cathode/Anode ass’y w/dual EPDM, AS-011 O-rings for
B=150 mm D400/405
9
AM-9307
O-ring, EPDM, size: AS-011
10
AM-9210
Retainer Ring Nut, 316L SST for CT25 Cathode/Anode assembly
11
AM-9233
Conical Gasket, silicone
12
AM-9234
Membrane Cartridge for D200 and D400 Series sensors
13
AM-9239
Sensor Sleeve, 316L SST, for B=150 mm D400/405 sensors
14
AM-9236
O-ring, Silicone, size: AS-015
15
AM-9230
M2.5 x 0.45 x 1/4” Stainless Steel Screw, set of 3
(2 sets required)
16
AM-9349
4-Pin Connector, glass to metal seal with ribbon/micro
cable disconnect
17
AM-9315
O-ring, EPDM, size: AS-014
18
AM-9238
Right Angle Connector/Adapter assembly for D405 Sensors
33
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Chapter 9: Return of Materials
9.1 GENERAL
To expedite the repair and return of sensors,
proper communication between the customer and the factory is important. A return
material authorization (RGM number) is
required. Call (949) 829-5555, (800) 2882833 or FAX (949) 829-5560. The “Return
Goods Memo” form is provided for you to
copy and use in case the situation arises.
The accuracy and completeness of this form
will help to expedite the processing time of
your materials.
Goods Memo” form. Compliance to the
OSHA requirements is mandatory for the
safety of all personnel. MSDS forms and a
certification that the sensors have been disinfected or detoxified are requested.
5. Send the package prepaid to:
Broadley-James Corporation
19 Thomas
Irvine, CA 92618
Attn: Factory Repair
Mark the package:
Returned for Repair RGM
No.___________
Model No. ___________
9.2 WARRANTY REPAIR
The following is the procedure for returning
products still under warranty.
9.3 NON-WARRANTY REPAIR
1. Contact the factory for authorization.
1. Contact the factory for authorization.
2. Complete a copy of the “Return Goods
Memo” form as completely and accurately
as possible.
2. Fill out a copy of the “Return Goods
Memo” form as completely and accurately
as possible.
3. To verify warranty, supply the factory
sales ordernumber or the original purchase
order number.
3. Include a purchase order number and
make sure to include the name and telephone number of the right individual to be
contacted should additional information be
needed.
4. Carefully package the materials and
enclose thecompleted copy of the “Return
Goods Memo” form. If possible, pack the
materials in the same manner as received.
IMPORTANT
Please see second section of the “Return
4. Perform Steps 4 and 5 of Section 9.2.
NOTE:
Consult the factory for additional information regarding service or repair.
34
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Return of Materials Request
NOTICE TO SENDER
CUSTOMER/USER MUST SUBMIT MATERIAL SAFETY SHEET (MSDS) OR COMPLETE STREAM
COMPOSITION, AND/OR LETTER CERTIFYING THE MATERIALS HAVE BEEN DISINFECTED
AND/OR DETOXIFIED WHEN RETURNING ANY PRODUCT, SAMPLE OR MATERIAL THAT HAS
BEEN EXPOSED TO OR USED IN AN ENVIRONMENT OR PROCESS THAT CONTAINS A HAZARDOUS MATERIAL. ANY OF THE BELOW THAT IS SUBMITTED TO BROADLEY-JAMES CORPORATION WITHOUT THE MSDS WILL BE RETURNED TO SENDER C.O.D. FOR THE SAFETY AND
HEALTH OF OUR EMPLOYEES. WE THANK YOU IN ADVANCE FOR COMPLIANCE WITH THIS
SUBJECT.
CUSTOMER CONTACT INFORMATION
Name:
Phone:
Ship to:
REASON FOR RETURN — PLEASE CHECK APPROPRIATE BOX(ES):
Wrong part received
Duplicate shipment
Repair and calibrate
Evaluation
Replacement Required
Warranty request
Non-warranty
(Customer PO# ____________)
❏ Other (Explain)
❏
❏
❏
❏
❏
❏
❏
Description of Problem:
RETURN TO:
Broadley-James Corporation
19 Thomas, Irvine, CA 92618 USA
Tel: (949) 829-5555 (800) 288-2833 Fax: (949) 829-5560
Call for RGM NUMBER before sending (RGM #)
35
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
36
D200, D400 & D405 OxyProbe® Dissolved Oxygen Sensors
Chapter 10: Warranty
Subject to the limitations contained in
Section 6 of Seller’s (Broadley-James
Corporation) Terms & Conditions of Sale,
and except as otherwise expressly provided
herein, Seller warrants that the licensed
firmware will execute the programming
instructions provided by Seller, and that the
Goods manufactured or Services provided
by Seller will be free from defects in materials or workmanship under normal use and
care until the expiration of the applicable
warranty period.
Goods are warranted for twelve (12)
months from the date of initial installation
or eighteen (18) months from the date of
shipment by Seller, whichever period
expires first.
Dissolved Oxygen sensors are warranted
for (24) months from the date of shipment
by Seller.
Consumables and Services are warranted for a period of 90 days from the date of
shipment or completion of the Services.
Products produced by Seller from a third
party for resale to Buyer (“Resale Products”) shall carry only the warranty extended by the original manufacturer. Buyer
agrees that Seller has no liability for Resale
Products beyond making a reasonable commercial effort to arrange for procurement
and shipping of the Resale Products.
If Buyer discovers any warranty defects
and notifies Seller thereof in writing during
the applicable warranty period, Seller shall,
at its option, promptly correct any errors
that are found by Seller in the firmware or
Services, or repair or replace F.O.B. point of
manufacture that portion of the Goods or
firmware found by Seller to be defective, or
refund the purchase price of the defective
portion of the Goods/Services.
All replacements or repairs necessitated
by inadequate maintenance, normal wear
and usage, unsuitable power sources,
unsuitable environmental conditions, accident, misuse, improper installation, modification, repair, storage or handling, or any
other cause not the fault of Seller are not
covered by this limited warranty, and shall
be at Buyer’s expense.
Seller shall not be obligated to pay any
costs or charges incurred by Buyer or any
other party except as may be agreed upon in
writing in advance by an Officer of BroadleyJames Corporation. All costs of dismantling,
reinstallation and freight and the time and
expenses of Seller’s personnel for site travel
and diagnosis under this warranty clause
shall be borne by Buyer unless accepted in
writing by Seller.
Goods repaired and parts replaced during the warranty period shall be in warranty
for the remainder of the original warranty
period or ninety (90) days, whichever is
longer.
This limited warranty is the only warranty made by Seller and can be amended
only in writing signed by an Officer of
Broadley-James Corporation. Except as otherwise expressly provided in this Agreement,
THERE ARE NO REPRESENTATIONS OR
WARRANTIES OF ANY KIND, EXPRESS OR
IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, OR ANY
OTHER MATTER WITH RESPECT TO ANY OF
THE GOODS OR SERVICES.
37