Neutronics NTRON Mini-ICS Manuale utente

Process Instruments

Engineered Solutions for Gas Detection and

nalysis

MODEL Mini-ICS

OXYGEN ANALYZER / CONTROLLER – PERCENT RANGE

OPERATIONS MANUAL

MODE

NORMAL FAULT LOW FLOW O2ALARM

20.9

PERCENTOXYGEN

MODEL Mini-ICS O2Controller

Neutronics

Reference Manual for

Installation and

Operation Instructions

Manual Part Number: 5-06-4900-53-0

Document Control Number: MN-A-0031

Revision Level: B – ECO 7822

Revision Date: April 14, 2006

A DIVISION OF

456 Creamery Way, Exton, PA 19341

Phone: 610.524.8800 • Fax: 610.524.8807 • Email: [email protected]

www.neutronicsinc.com

Table of Contents

TABLE OF CONTENTS....................................................... III

FOR YOUR SAFETY:........................................................ VII

WELCOME

1CHAPTER 1 – INTRODUCTION AND OVERVIEW......................... 1-1

................................................................ VIII

1.1 GENERAL ........................................................... 1-1

1.2 FEATURES .......................................................... 1-2

1.3 SYSTEM HARDWARE OVERVIEW ............................................. 1-3

1.3.1 Main Board.................................................... 1-3

1.3.2 Relay Board................................................... 1-3

1.3.3 Power Supply.................................................. 1-3

1.3.4 Display Board................................................. 1-3

1.3.5 Control Panel................................................. 1-4

1.3.6 Chassis....................................................... 1-4

1.4 SYSTEM INPUTS AND OUTPUTS ............................................ 1-6

1.4.1 Oxygen Sensor Input........................................... 1-6

1.4.2 Flow Switch Status Input...................................... 1-6

1.4.3 O2Alarm Relay Output ......................................... 1-6

1.4.4 Inert Gas Control Relay Output................................ 1-6

1.4.5 Fault Relay Output............................................ 1-7

1.4.6 Remote Calibration Relay Output............................... 1-7

1.4.7 Analog Voltage Output......................................... 1-7

1.4.8 Analog Current Output:........................................ 1-7

1.4.9 Range ID Output............................................... 1-8

1.4.10 Service Port.................................................. 1-8

1.5 FRONT PANEL USER INTERFACE ........................................... 1-1

1.5.1 The “UP” Pushbutton........................................... 1-1

1.5.2 The “DOWN” Pushbutton......................................... 1-1

1.5.3 The “MODE” Pushbutton......................................... 1-1

1.5.4 7-Segment Alphanumeric Display................................ 1-1

1.5.5 Normal Indicator LED.......................................... 1-1

1.5.6 O2Alarm Indicator LED ........................................ 1-1

1.5.

2CHAPTER 2 – SYSTEM INSTALLATION AND START-UP.................. 2-3

7Low Flow Indicator LED........................................ 1-1

8Fault Indicator LED........................................... 1-2

2.1 INSTALLING THE ANALYZER .............................................. 2-3

2.1.1 Step 1 – Locate and Mount the Analyzer unit................... 2-4

2.1.2 Step 2 – Install the Oxygen Sensor............................ 2-5

2.1.3 Step 3 – Install the Analyzer................................. 2-5

2.1.3.1 Oxygen Sensor Input....................................... 2-8

2.1.3.2 Flow Switch Status Input.................................. 2-8

2.1.3.3 Oxygen Alarm Relay Outputs................................ 2-8

2.1.3.4 Inert Gas Control Relay Outputs........................... 2-9

2.1.3.5 Fault Relay Outputs....................................... 2-9

2.1.3.6 Remote Calibration Relay Outputs.......................... 2-9

2.1.3.7 Analog Voltage Output.................................... 2-10

2.1.3.8 Analog Current Output.................................... 2-10

2.1.3.9 Range ID Output.......................................... 2-10

2.1.3.10 RS-232 Service Port..................................... 2-11

2.1.3.11 Battery Backup.......................................... 2-11

2.1.3.12 Mains Power............................................. 2-12

2.2 STARTING UP AND COMMISSIONING THE SYSTEM ............................... 2-13

2.2.1 STEP 1 – Power Up the unit................................... 2-13

2.2.2 STEP 2 – Calibrate the Unit.................................. 2-15

2.2.3 STEP 3 –Set Alarms, and Inert Gas Control Limits............. 2-15

2.2.3.1 Set Oxygen Alarm Level................................... 2-15

2.2

3CHAPTER 3 – ANALYZER OPERATION................................ 3-1

.3.2 Set High Inert Gas Control limit......................... 2-15

.3.3 Set Low Inert Gas Control limit.......................... 2-15

3.1 SYSTEM ORGANIZATION ................................................. 3-1

3.2 USER MODES ........................................................ 3-1

3.2.1 CALIBRATE Mode................................................ 3-1

3.2.1.1 When to calibrate......................................... 3-1

3.2.1.2 What gases to use......................................... 3-1

3.2.1.3 Procedure for calibrating the Model Mini-ICS.............. 3-2

3.2.2 SET O2ALARM Mode ............................................. 3-3

3.2.3 SET HIGH INERT GAS CONTROL LIMIT Mode......................... 3-3

3.2.4 SET LOW INERT GAS CONTROL LIMIT Mode.......................... 3-3

3.2.5 VIEW ACTIVE FAULTS Mode....................................... 3-3

3.3 RUN MODES ......................................................... 3-5

3.3.1 NORMAL Mode................................................... 3-5

3.3.2 O2ALARM ACTIVE Mode .......................................... 3-5

3.3.

4CHAPTER 4 – MAINTENANCE AND TROUBLESHOOTING................... 4-1

3INERTING CONTROL ACTIVE Mode.................................. 3-6

4FAULT ACTIVE Mode............................................. 3-7

4.1 SYSTEM SETUP ....................................................... 4-1

4.1.1 System Setup via Front Panel Keypad........................... 4-1

4.1.1.1 User Setup 1: ICS and O2 Alarm Relays Failsafe/Non Failsafe.4-2

4.1.1.2 User Setup 2: O2 Alarm Relays Ascending Trip.............. 4-2

4.1.1.3 User Setup 3: Analog Voltage Output Setting............... 4-2

4.1.1.4 User Setup 4: Analog Current Output Setting............... 4-2

4.1.1.5 User Setup 5: Display Range Setup......................... 4-2

4.1.1.6 User Setup 6: RS-232 Baud Rate............................ 4-2

4.1.1.7 User Setup 7: Serial Output Format........................ 4-2

4.1.1.8 User Setup 8: Sensor Disconnect Detection Test............ 4-3

4.1.1.9 User Setup 9: Minimum Analog Output Voltage Concentration. 4-3

4.1.1.10 User Setup 10: Maximum Analog Output Voltage Concentration4-3

4.1.1.11 User Setup 11: Minimum Analog Output Current Concentration4-3

4.1.1.12 User Setup 12: Analog Current Full Scale................. 4-3

4.1.1.13 User Setup 13: Set Current Year. ** NOT ACTIVE FOR THIS

RELEASE** 4-4

4.1.1.14 User Setup 14: Set Current Month. ** NOT ACTIVE FOR THIS

RELEASE** 4-4

4.1.1.15 User Setup 15: Set Current Day. ** NOT ACTIVE FOR THIS RELEASE**

4-4

4.1.1.16 User Setup 16: Set Current Hour. ** NOT ACTIVE FOR THIS

RELEASE** 4-4

4.1.1.17 User Setup 17: Set Current Minute. ** NOT ACTIVE FOR THIS

RELEASE** 4-4

4.1.1.18 User Setup 18: Factory Setup Restore..................... 4-4

4.1.2 System Setup via Service Port................................. 4-4

4.1.2.1 RS-232 Service Port Interfacing with HyperTerminal in Microsoft

Windows 95 or later................................................ 4-4

4.1.2.2 Troubleshooting Your HyperTerminal Interface.............. 4-5

4.1.2.3 Organization of RS-232 Serial Data........................ 4-5

4.1.2.4 Standard Level Access..................................... 4-6

4.1.2.5 Advanced Level 1 Access................................... 4-9

4.1.2.6 Advanced Level-2 Access................................... 4-9

4.1.2.7 SETTING UP THE MODEL Mini-ICS – The RS-232 User Setup Menu4-10

4.1.2.8 System Information Display............................... 4-10

4.1.2.9 (U20) Alarm and Relay Setup Menu......................... 4-10

4.1.2.10 (U30) Analog Output Setup Menu.......................... 4-12

4.1.2.11 (U04) Display/Analog Output Range....................... 4-15

4.1.2.12 (U50) RS-232 Serial Setup Menu.......................... 4-15

4.1.2.13 (U60) Front Panel Locks Menu............................ 4-16

4.1.2.14 (U70) Auto Calibration Setup Menu....................... 4-17

4.1.2.15 Sensor Disconnect Test.................................. 4-18

4.1.2.16 Set Time-of-Day and Date ** NOT ACTIVE FOR THIS RELEASE**4-19

4.1.2.17 Averaging Window Size................................... 4-19

4.1.2.18 Auto Return to Run Mode Time............................ 4-19

4.1.2.19 Return all Settings to Factory Delivered Settings....... 4-19

4.1.3 Change factory settings via Hardware Jumpers................. 4-20

4.1.3.1 Analog Voltage Output.................................... 4-20

4.2 ROUTINE PERIODIC MAINTENANCE ......................................... 4-22

4.3 TROUBLESHOOTING .................................................... 4-23

4.3.1 Fault Codes.................................................. 4-23

4.3.1.1 Fault Code 0 – Constant Memory Error..................... 4-23

4.3.1.2 Fault Code 1 – Low Flow.................................. 4-23

4.3.1.3 Fault Code 2 – Sensor disconnected....................... 4-23

4.3.1.4 Fault Code 4 – Low Sensor Limit higher than Low ICS Limit 4-23

4.3.1.5 Fault Code 5 – High ICS Limit lower than Low ICS Limit... 4-24

4.3.1.6 Fault Code 6 – Unstable Calibration Sample............... 4-24

4.3.1.7 Fault Code 7 – Sensor Calibration signal high............ 4-24

4.3.1.8 Fault Code 8– Sensor Calibration Signal Low.............. 4-24

4.3.1.9 Fault Code 9 – Sensor Analog-to-Digital Converter Time-Out4-24

4.3.1.10 Fault Code 10 – Sensor Operating Signal Low............. 4-25

4.3.1.11 Fault Code 11 – Calibration Period too Short............ 4-25

4.3.1.12 Fault Code 17 – Bad cell Calibration Coefficient........ 4-25

4.3.1.13 Fault Code 18 – Main-board EEPROM corrupted............. 4-25

4.3.1.14 Fault Code 27 – Auto Calibration Mode active............ 4-25

3.1.15 Fault Code 28 – Calibration Mode active................. 4-25 
3.1.16 Fault Code 29 – Manual Relay Control active............. 4-25 
3.1.17 Fault Code 30 – User Setup Mode active.................. 4-26 
3
3
5CHAPTER 5 – APPENDICES........................................ 5-1 
.1.18 Fault Code 31 – Factory Setup Mode active............... 4-26 
.1.19 Fault Code 32 – Program Starting........................ 4-26 
1 APPENDIX A – SPARE PARTS LIST ........................................ 5-1 
2 APPENDIX B - SPECIFICATIONS .......................................... 5-2 
3 APPENDIX C – ANALYZER FACTORY CONFIGURATION SETTINGS5-5 
4 APPENDIX D – FRONT PANEL HOT-KEY FUNCTIONS............................ 5-7 
5 APPENDIX E – WARRANTY ............................................. 5-8 
INTENDED USE FOR THE MODEL MINI-ICS....................... 5-8 
6 APPENDIX F – REFERENCE DRAWINGS ..................................... 5-9 
7 APPENDIX G – MOUNTING CONFIGURATIONS ................................ 5-10 
7.1 Wall Mount Enclosure......................................... 5-10 
7.2 Rack Mount Enclosure......................................... 5-11 
7.3 Explosion Proof Enclosure.................................... 5-12 

For Your Safety:

PLEASE READ THIS MANUAL IN ITS ENTIRETY BEFORE ATTEMPTING

INSTALLATION OR OPERATION! Attempting to operate the

Model 1100 without fully understanding its features and

functions may result in unsafe conditions

• Always use protective eye wear and observe proper safety procedures

when working with pressurized gases.

• Properly dispose of the Oxygen sensor according to the MSDS and local

policies when it has expired.

• Ensure the MODEL Mini-ICS has been properly calibrated before use.

• Never expose the analyzer chassis or sensor to water, high humidity or

moisture. The analyzer chassis is not watertight.

• Never expose the MODEL Mini-ICS to flame or high temperatures. Never

expose the Model Mini-ICS analyzer to flammable gases or vapors. The

Mini-ICS is not rated Intrinsically Safe.

• Ensure the analyzer unit is mounted in an area with free airflow to

prevent the chassis from exceeding the operating temperature

specifications. Do not mount the analyzer or sensor against hot

surfaces. Do not block the ventilation louver on the analyzer

chassis.

WELCOME

Thank you for purchasing the Model Mini-ICS

Analyzer for percent range Oxygen measurement.

The Model Mini-ICS Compact Analyzer is a user friendly, microprocessor

controlled Oxygen measuring instrument. It has many features to offer the

user, which will be described in this manual. We recommend that all

personnel who use this instrument read this manual to become more familiar

with its proper operation.

For further detail regarding the maintenance and in-field service of the

Model Mini-ICS analyzer, please contact the Neutronics Inc. Application

Engineering Department. If you have questions or comments, we would like

to hear from you.

Neutronics Inc. Customer Service Department

456 Creamery Way

Exton, PA 19341

Tel: 610) 524-8800 ext 136

Toll Free: (800) 378-2287 ext 136 (US only)

Fax: (610) 524-8807

EMAIL: [email protected]

Visit us at www.neutronicsinc.com

Equipment Serial Number:

(For faster service, please have this number ready if for any reason you need to contact

us about your instrument)

This work is protected under Title 17 of the US Code and is the sole property of

Neutronics Inc. No part of this document may be copied or otherwise reproduced, or

stored in any electronic information retrieval system, except as specifically permitted

under US copyright law, without the prior written consent of Neutronics Inc.

1 CHAPTER 1 – INTRODUCTION AND OVERVIEW

sensor

1.1 General

The Model Mini-ICS [Inert Gas Control System] analyzer by Neutronics

offers a cost effective solution in a small package for industrial

process Oxygen measurement and inert gas control applications for flash-

fire/explosion prevention, or product quality. The Model Mini-ICS is a

custom analytical instrument, designed to accurately measure 0.1 to

50.0% Oxygen, and provide direct control of Oxygen levels in your

process by controlling inert gas purging.

At the heart of the analyzer is a remote-mounted Neutronics zero-

maintenance, disposable galvanic Oxygen sensor. Remote mounting allows

the sensor to be installed close to a process sampling point for the

fastest response time possible. Neutronics also offers a variety of

process sampling and sample conditioning solutions for

reliability and longevity.

Pre-Filter

Sample Conditioning

Package

O2 Sensor

Loss of Sample

Sensor

Inert Gas Input

(Nitrogen)

Vent

Analyzer (Control Module)

Safety Barriers

SAFE AREAHAZARDOUS AREA

Inert Gas

Control Valve

Remote

Cal

Solenoid

Valve

1100-ICS

Gas Head-Space

Industrial Mixer,

Centrifuge, Reactor,

Blender, etc.

Figure 1

–

Complete process Oxygen

onitor and control system example

Manual Part Number:

5-06-4900-53-0 Revision Level: B

ECO 7822 Revision Date:

April 14, 2006 Page

1-1

System Installation and Startup

1.2 Features

The Model Mini-ICS analyzer module is designed to be flush mounted to a

panel or console. Packaging options available from Neutronics Inc.

include General Purpose and Explosion Proof surface-mount enclosures,

and custom rack-mount designs. Because of the small size of the Model

Mini-ICS analyzer, the basic panel-mount unit can be integrated into a

variety of equipment or control panels.

Figure 2 – analyzer

MODE

NORMAL FAULT Low Flow O2 Alarm

20.9

PERCENTOXYGEN

MODEL Mini-ICS O2Analyzer

Neutronics

Color Coded LED’s:

NORMAL = Green

FAULT = Yellow

Low Flow = Red

O2 Alarm = Red Large Buttons

for Ramp Up and

Ramp Down for

Display and

Mode Control

Large Mode Select

Button for easy

scrolling through

menu options

Large LED

Digital Display

Reference Manual for

Installation and

Operation Instructions

Other Features Include:

• User-adjustable Oxygen Alarm with relay output for process control use

• User-adjustable Inert Gas Control function with relay output for

process control use. Inert Gas Control features user-adjustable high

and low set point hysteresis

• Loss of Flow indication for extractive process sampling applications

• Double Redundant system configuration backup file, with automatic

repair function

• Convenient Remote calibration relay output for “one-man” calibration

in applications where the Oxygen sensor is a long distance from the

Mini-ICS Analyzer

• Two Analog Outputs: 4-20 mA AND 0-1, 0-5, or 0-10 VDC

• Auto Ranging or Fixed Range Oxygen Measurement (VDC output provided

for auto-range identification)

• Bi-directional RS-232 Serial Interface for connection to a PC,

terminal, or printer

Indice

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