SST OXY-Flex Manuale utente

UG-014 Rev 1

O2SENSORS – Zirconium Dioxide (ZrO2)

OXY-Flex Oxygen Analyser User’s Guide

This document describes the installation, operation and maintenance of the OXY-Flex oxygen

analyser.

The OXY-Flex analyser designed to determine the oxygen concentration in air or inert gas mixtures in

areas that are not easily accessible, or in closed systems, such as ventilation pipes, flues and

containers:

•OXY-Flex-X Series standard temperature oxygen analyser is designed for use in air or inert

gas mixtures with temperatures of -100 to +250°C maximum.

•OXY-Flex-X-H Series high temperature oxygen analyser is designed for use in air or inert gas

mixtures with temperatures of -100 to +400°C maximum.

The actual oxygen sensor is mounted in the tip of the stainless-steel probe and is protected by a

stainless-steel sintered cap which acts as both a large particulate filter and also as a flame trap. The

die-cast aluminium housing accommodates the electronics and is mechanically connected to the

sensor probe.

UG-014 Rev 1

Contents

1 DEFINITIONS.................................................................................................................................1-1

2 SAFETY INSTRUCTIONS.................................................................................................................2-1

3 TECHNICAL SPECIFICATIONS ........................................................................................................3-1

4 PRODUCT OVERVIEW...................................................................................................................4-1

4.1 Main Components................................................................................................................4-1

4.2 External Dimensions ............................................................................................................4-1

5 INSTALLATION ..............................................................................................................................5-1

5.1 Mounting Instructions .........................................................................................................5-1

5.2 Electrical Connections..........................................................................................................5-2

5.3 System Block Diagram..........................................................................................................5-3

5.4 PCB Layout ...........................................................................................................................5-3

6 INITIAL STARTUP ..........................................................................................................................6-1

6.1 Commissioning Checks.........................................................................................................6-1

6.2 Switching ON........................................................................................................................6-1

6.3 First-time Calibration ...........................................................................................................6-1

7 SYSTEM CONFIGURATION............................................................................................................7-1

7.1 Setting the Output Type.......................................................................................................7-1

7.2 Setting the Calibration Type and Measurement Range.......................................................7-2

7.3 Digital Variant – RS232 Output ............................................................................................7-3

7.4 Analogue Variants – 0-10VDC and 4-20mA Output Values...................................................7-6

8 OPERATION ..................................................................................................................................8-1

8.1 Operating Tips......................................................................................................................8-1

8.2 RS232 Operation ..................................................................................................................8-1

9 MAINTENANCE.............................................................................................................................9-1

9.1 Cleaning................................................................................................................................9-1

9.2 Calibrating ............................................................................................................................9-1

9.3 Error Conditions ...................................................................................................................9-3

9.4 Disposal ................................................................................................................................9-3

APPENDIX A – MENU STRUCTURE ...................................................................................................... A-1

UG-014 Rev 1 Page | 1-1

1DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS and NOTES used throughout this manual.

WARNING:

The warning symbol is used to indicate instructions that, if they are not followed, can result in minor,

serious or even fatal injuries to personnel.

CAUTION:

The caution symbol is used to indicate instructions that, if they are not followed, can result in

damage to the equipment (hardware and/or software), or a system failure occurring.

NOTE: Highlights an essential operating procedure, condition or statement.

UG-014 Rev 1 Page | 2-1

2SAFETY INSTRUCTIONS

•This equipment may only be installed by a suitably qualified technician in accordance with

the instructions in this manual and any applicable standards associated with the country or

industry.

•Failure to correctly adhere to these instructions may result in serious injury or death and in

this regard the manufacturer will not be held liable.

•This equipment may only be operated and maintained by trained technical personnel. The

technical personnel must strictly adhere to the instructions given in this manual, and any

prevailing standards/certificates (depending on application).

•Where instructed, you must read the User Guides and Datasheets referenced within this

manual. There, you can find detailed information on the equipment.

•The operator may only perform modifications and repairs to the equipment/system with

written approval of the manufacturer.

•Do NOT operate damaged equipment.

•If faults cannot be rectified, the equipment must be taken out of service and secured against

unintentional commissioning.

UG-014 Rev 1 Page | 3-1

3TECHNICAL SPECIFICATIONS

Electrical Specifications

•Supply voltage; 24VDC ±10%

•Current consumption; 500mA maximum at 24VDC

Output

•Digital output; RS232

•Analogue output;

o0 – 10 VDC; load 10kΩminimum

and

o4 – 20mA; load 600Ωmaximum

Performance Specifications

•Measurement range;

oRS232 output; 0.1 and 100% O2

oAnalogue outputa;

0.1 – 25% O2

0.1 – 100% O2

•Accuracy after factory calibration; 1% vol. O2b

•Repeatability after calibration; 0.5% vol. O2

•Resolution;

oRS232 output; 0.01% vol. O2

oAnalogue output;

0 – 10VDC; 0.01V

4 – 20mA; 0.01mA

•Response time (10—90% step); < 15s

•Warmup time (prior to sensor operation); 60s

•Output stabilisation time; 5 – 10mins

Environmental Specifications

•Temperature limits (housing);

oStorage; -10 to +85°C

oOperating; -10 to +85°C

•Temperature limits (permissible gas temperature at probe tip);

oStandard temperature; -100 to +250°C

oHigh temperature; -100 to +400°C

•Gas flow rate; 0 to 10m/s

Mechanical Specifications

•Dimensions; refer to 4.2 External Dimensions on page 4-1.

•Weight; <450g

aStandard ranges shown, however analogue output measurement range is user selectable also.

bAccuracy valid for measurements at Standard Barometric Pressure (SBP) in ambient gas temperatures of

-30°C to +60°C.

UG-014 Rev 1 Page | 4-1

4PRODUCT OVERVIEW

The OXY-Flex analyser is housed in a sealed, die-cast aluminium enclosure with attached oxygen

sensor probe and amphenol ecomate connector.

4.1 Main Components

4.2 External Dimensions

Dimensions in mm unless otherwise stated; tolerance ±0.5mm.

Figure 4-2 - External Dimensions

Enclosure

Figure 4-1 - Main Components

Amphenol Ecomate

connector

Probe type sensor;

available in three lengths –

220mm, 400mm & 600mm

UG-014 Rev 1 Page | 5-1

5INSTALLATION

To ensure the best performance from your equipment, it must be installed correctly.

CAUTION: Protect the device from accidental shocks or vibrations as this may damage the

board.

5.1 Mounting Instructions

Dimensions in mm unless otherwise stated; tolerance ±0.5mm.

Figure 5-1 – Mounting Hole Positions

Figure 5-2 – Probe Mounting Details

UG-014 Rev 1 Page | 5-2

5.2 Electrical Connections

WARNINGS:

All wiring MUST be in accordance with the National Electrical Code and any local codes,

ordinances, and regulations.

Disconnect and lock out power before connecting the equipment to the power supply.

The device wiring should be in a separate conduit. Do NOT install wiring in any conduit or

junction boxes with high voltage wiring.

CAUTION:

•Do NOT install the device suspended from the cable.

•Avoid exerting excessive tensile force on the cable (e.g. tugging).

NOTE: Electrical connections shown in Figure 5-3.

Housing: Amphenol Ecomate C016 30C006 100 12

Mating Connector: Binder 99-4218-00-07

NOTE: Mating connector also supplied.

PINOUT:

Pin 1: 24VDC ± 10%

Pin 2: 0VDC

Pin 3: Calibrate

Pin 4: Cycle

Pin 5: 4 – 20mA / RS232 Tx

Pin 6: 0 – 10VDC / RS232 Rx

Centre: Housing / Probe Earth

NOTES:

•Output pins 5 and 6 are both referenced to the power supply 0VDC (pin 2). Due to high current

flow in the supply GND, when monitoring the 0 – 10VDC output (pin 6) it is recommended that a

separate GND wire for the measurement system is taken from pin 2. This removes errors due to

voltage drops in the power supply connections.

•Assignment of output pins 5 and 6 selectable by altering the position of the jumper links on the

PCB; refer to 5.4 PCB Layout on page 5-3 for details.

Figure 5-3 - Electrical Connections

UG-014 Rev 1 Page | 5-3

5.3 System Block Diagram

Figure 5-4 - Block Diagram

5.4 PCB Layout

Figure 5-5 - PCB Layout

UG-014 Rev 1 Page | 6-1

6INITIAL STARTUP

6.1 Commissioning Checks

Before commissioning the equipment read 2 SAFETY INSTRUCTIONS on page 2-1 of this document.

Complete the following essential tasks BEFORE switching the system ON for the first time:

•Ensure compliance with permissible installation position.

•Verify the device is mounted securely correctly.

•Verify the device and wiring are all undamaged.

•Ensure the cables are strain-free.

•Ensure the device is connected properly, with all its inputs and outputs complete. All screw

terminals are properly tightened. All connectors seated correctly.

CAUTION: Test the power supply to ensure it is “24VDC ± 10%” before wiring to the board.

CAUTION: Failure to test the suitability of the power supply BEFORE first power on could

result in irreversible product damage that is NOT covered by warranty.

6.2 Switching ON

When the device is initially powered ON, the:

Red LED illuminates solid to indicate power is being supplied to the

interface.

Green LED blinks rapidly then goes OFF to indicate that the microprocessor

is operational.

NOTE: LEDs are only visible when the lid is removed from the analyser housing.

NOTE: If a fault is detected, an error is displayed (RS232 variant), or the analogue output will remain

at 4mA or 0V. Refer to 9.3 Error Conditions on page 9-3.

If the error condition persists, switch the device OFF and contact technical@sstsensing.com.

6.3 First-time Calibration

Calibration, or re-referencing, is required when the product is powered ON in the process

application for the first time. Refer to 9.2 Calibrating starting on page 9-1.

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