Servomex Servotough 1900 Operator's Manual

PROCESS ANALYSERS SERVOTOUGH Oxy Gas Analyser Operator Manual Part Number: Revision: Language: 01910001B 6 UK English This page intentionally blank SERVOTOUGH Oxy, Oxygen Gas Analyser LIST OF CONTENTS Section Page 1 DESCRIPTION AND DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 1.2 1.3 1.4 1.5 Scope of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Environmental limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Sample gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Corrosive Purge gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Calibration gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hazardous area certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3 UNPACK THE ANALYSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4 ANALYSER USER INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Start-up and measurement screens . . . . . . . . . . . . . . . . . . . . . . . . 19 Soft key legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 System and measurement status icons . . . . . . . . . . . . . . . . . . . . . 22 Scroll bars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Menu options/screens and password protection . . . . . . . . . . . . . . 23 The Menu screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 The Settings screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 The Information screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Editing on-screen data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5 INSTALLATION AND SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.4 5.5 5.6 5.7 5.8 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Remove the power/interface compartment cover . . . . . . . . . . . . . . 33 Electrical supply and interface signal connections . . . . . . . . . . . . . 34 Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Configure the cable entry holes . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Interface signal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Auto Validate/Calibrate connections (option) . . . . . . . . . . . . . . . . . 37 Modbus RS485 and ethernet connections (option. . . . . . . . . . . . . 39 Mains electrical supply connection . . . . . . . . . . . . . . . . . . . . . . . . . 40 Refit the power/interface compartment cover . . . . . . . . . . . . . . . . . 41 External earth (ground) connection . . . . . . . . . . . . . . . . . . . . . . . . 42 Connect the sample/calibration gas pipe(s) . . . . . . . . . . . . . . . . . . 43 Switch on/set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Selecting the security level and password(s) . . . . . . . . . . . . . . . . . 44 01910001B / Revision 6 1 1 1 2 3 i SERVOTOUGH Oxy, Oxygen Gas Analyser CONTENTS (CONTINUED) Section ii Page 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.15.1 5.15.2 5.15.3 5.15.4 5.15.5 5.15.6 5.15.7 5.16 5.16.1 5.16.2 5.16.3 5.16.4 5.17 5.17.1 5.17.2 5.18 5.18.1 5.18.2 5.19 5.20 5.20.1 5.20.2 5.20.3 5.20.4 5.20.5 5.21 Setting the security level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the backlight timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing regional settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting up automatic validation/calibration (option) . . . . . . . . . . . . Overview of automatic validation/calibration . . . . . . . . . . . . . . . . . Automatic validation/calibration sequence. . . . . . . . . . . . . . . . . . . Remote calibration or automatic validation/calibration . . . . . . . . . Automatic validation/calibration target and tolerance . . . . . . . . . . Automatic validation/calibration type and mode . . . . . . . . . . . . . . Automatic validation/calibration phases. . . . . . . . . . . . . . . . . . . . . Automatic validation/calibration timers . . . . . . . . . . . . . . . . . . . . . Configuring and using the mA outputs. . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction to the mA output parameters . . . . . . . . . . . . . . . . . . . Setting up the mA output parameters . . . . . . . . . . . . . . . . . . . . . . Calibrating the mA output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuring and using the relay outputs . . . . . . . . . . . . . . . . . . . . Overview relay default status settings . . . . . . . . . . . . . . . . . . . . . . Setting up the relay coil status . . . . . . . . . . . . . . . . . . . . . . . . . . . . Correcting O2 measurements for background gases . . . . . . . . . . Overview of measurement errors . . . . . . . . . . . . . . . . . . . . . . . . . Entering a cross-interference compensation . . . . . . . . . . . . . . . . Selecting display units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuring the measurement alarms . . . . . . . . . . . . . . . . . . . . . . Alarm modes and levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Latching/non-latching alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hysteresis levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing the measurement alarm status. . . . . . . . . . . . . . . . . . . . . Setting the Measurement Filter Level . . . . . . . . . . . . . . . . . . . . . . Setting up the Flowcube (F3) Flow Sensor (option) . . . . . . . . . . . 45 46 47 47 48 49 50 50 52 54 55 56 57 59 60 60 60 62 64 65 65 66 68 68 69 69 71 71 73 74 75 76 77 6 CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 6.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.3 Manual calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic validation/calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . Initiating an automatic validation/calibration . . . . . . . . . . . . . . . . . Automatic validation/calibration status indications. . . . . . . . . . . . . Stopping an automatic validation/calibration . . . . . . . . . . . . . . . . . Viewing validation/calibration history . . . . . . . . . . . . . . . . . . . . . . . Calibrating the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrating the Flowcube (F3) Flow Sensor (option) . . . . . . . . . . . 79 81 81 82 83 84 84 85 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser CONTENTS (CONTINUED) Section Page 7 GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 7.1 7.2 7.2.1 7.2.2 7.2.3 7.3 7.4 7.5 Checking the relay signal outputs. . . . . . . . . . . . . . . . . . . . . . . . . . 86 Pressure compensation (option). . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Switching pressure compensation on/off . . . . . . . . . . . . . . . . . . . . 87 Viewing pressure effected measurements . . . . . . . . . . . . . . . . . . . 87 Checking the mA output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Viewing flow levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Switching off the analyser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 8 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 8.1 8.2 8.3 8.4 8.5 8.6 Cleaning the analyser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Inspecting/replacing the fuse (when necessary). . . . . . . . . . . . . . . 92 Refit the power/interface compartment cover . . . . . . . . . . . . . . . . . 93 Use of the analyser with toxic gases . . . . . . . . . . . . . . . . . . . . . . . 94 Preventative maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 9 SAMPLE SYSTEM INTEGRATION . . . . . . . . . . . . . . . . . . . . . . . . 97 9.1 9.2 Sample Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Corrosive Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 10 FAULT FINDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 10.1 10.1.1 10.1.2 10.2 10.2.1 10.2.2 10.3 Fault, Maintenance Required and SIP Statuses. . . . . . . . . . . . . . . 99 Status definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Status Annunciations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Viewing messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Active messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 View history messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 General fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 11 STORAGE AND DISPOSAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 11.1 11.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 12 SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 01910001B / Revision 6 iii SERVOTOUGH Oxy, Oxygen Gas Analyser CONTENTS (CONTINUED) Section ® © iv Page A1 IMPLEMENTATION GUIDE FOR MODBUS COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7 A1.8 A1.9 A1.10 A1.11 A1.12 A1.13 A1.14 A1.15 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Modbus setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Supported function codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Exception codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Floating point numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 System data mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Transducer data mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 System fault mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Transducer fault and alarm mapping . . . . . . . . . . . . . . . . . . . . . . 117 System setup mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Transducer setup mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 System control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Transducer control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 A2 CONFIGURING THE MODBUS PARAMETERS . . . . . . . . . . . . . 127 A2.1 A2.2 RS485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 TCP (Ethernet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 A3 DISPLAY UNIT CONVERSION FACTORS . . . . . . . . . . . . . . . . . 131 A4 PARAMAGNETIC CORRECTION FACTORS . . . . . . . . . . . . . . . 133 A5 MATERIALS IN CONTACT WITH SAMPLE AND CALIBRATION GASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 A6 DISPOSAL IN ACCORDANCE WITH THE WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE) DIRECTIVE. . . . . . . . 139 A7 COMPLIANCE AND STANDARDS INFORMATION . . . . . . . . . . . 141 Viton are registered trademarks of Dupont. This manual is copyright, and no part of it may be reproduced without Servomex’s written approval. 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 1 DESCRIPTION AND DEFINITIONS 1.1 Scope of this manual This manual provides installation, operation and routine maintenance instructions for the Servomex SERVOTOUGH Oxy, Oxygen Gas Analyser, abbreviated to "analyser" in the remainder of this manual. 1.2 Safety information Read this manual and ensure that you fully understand its content before you attempt to install, use or maintain the analyser. Important safety information is highlighted in this manual as WARNINGs and CAUTIONs, which are used as follows: WARNING Warnings highlight specific hazards which, if not taken into account, may result in personal injury or death. CAUTION Cautions highlight hazards which, if not taken into account, can result in damage to the analyser or to other equipment or property. This manual also incorporates ‘Be aware of’ information, which is used as follows: This highlights information which it is useful for you to be aware of (for example, specific operating conditions, and so on). 1.3 Description The analyser is designed to provide stable, accurate and specific gas concentration measurements, and is suitable for use in hazardous areas. The analyser uses a paramagnetic transducer to determine the oxygen (O2) content of gas samples in concentrations of up to 21% in any background mixture, including continuously flammable backgrounds. The analyser is simple to operate, with an intuitive user interface. Gas sample measurements are shown on the analyser display, and are also provided as milliAmp (mA) outputs and via Modbus digital communication (RS485 and Ethernet). The analyser also provides fault, concentration, maintenance required and service in progress alarms and milliAmp (mA) range indication via 30Vdc 1A relay signal outputs. 01910001B / Revision 6 1 SERVOTOUGH Oxy, Oxygen Gas Analyser The analyser can also be equipped with an optional pressure sensor, Flowcube (F3) flow sensor technology, sample compartment heater and autovalidation 30Vdc 1A relay signal outputs. The analyser requires little routine maintenance, other than calibration (which is essential for the accuracy of sample gas measurements). 1.4 Construction The analyser comprises an aluminium enclosure, with Viton® and silicone rubber seals. Refer to Figure 1. The analyser has two internal compartments: • Sample/control compartment: This compartment is accessed through the hinged door, on which the display and soft keys are mounted. It contains intrinsically safe components such as the sample measurement transducer, pressure sensor and sample compartment heater. To ensure the stability of the measurement the transducer is maintained at approximately 65 oC (149oF). Where fitted the pressure sensor is directly after the sample measurement transducer and compensates for both barometric and other pressure changes, i.e back pressure variations when venting to flare stacks and vent headers. Where fitted the Flowcube (F3) flow sensor is directly after the sample measurement transducer, enabling accurate flow trending and alarm setting for many applications including safety critical applications. The flow sensor offers one high flow alarm and two low flow alarms which can be configured to be inactive or to indicate a fault or maintenance required status via the instrument relay ouputs or Modbus digital communication. Where fitted sample compartment heating allows samples with dew points of up to 50oC to be directly sampled by the analyser and give greater robustness of the analyser to sample system upsets and fluctuations. 2 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser The sample gas inlet and outlet connections on the base of the analyser (see Figure 2) are piped into/from this compartment and contain sintered stainless steel particulate filters, designed to give extra protection to the measurement transducer. They also form part of the analysers elevated sample pressure (124kPa (18psia)) hazardous area certification and the analyser should not be vented to pressures over 110 kPa (16psia) without these fitted. They are external to the analyser and simple to change in the case of contamination. When sample compartment heating is fitted these sintered elements are also heated to 70oC, giving further robustness to moisture droplets or aerosols carried over from the sample system. During normal operation, calibration and installation it is not required to access this side of the enclosure. • Power/signal compartment (Figure 1): This explosion-proof compartment contains the components which supply power to the rest of the analyser, and the components to interface the analyser to your control/monitoring system. These components include the mA outputs, Modbus digital communication (RS485 or Ethernet) and 30 Vdc 1A relay signal outputs which provide fault, concentration, maintenance required, service in progress alarms, mA range indication, and optional autovalidation control. The analyser electrical supply cable, and the communications cables to your control/monitoring system, must be connected (through the cable entry holes on the base of the analyser) to the terminals in this compartment. You must remove the threaded cover to access this compartment. 1.5 Ordering options For the latest ordering options please contact your local Servomex agent or visit www.servomex.com. 01910001B / Revision 6 3 SERVOTOUGH Oxy, Oxygen Gas Analyser Key 1. 2. 3. 4. 5. 6. 7. Description Key Description Hinged cover Display Sample gas label Locking screws (4 off) Locking screw * Identification/rating label † Threaded cover 8. 9. 10. 11. 12. 13. 14. Certification label Soft key 4 Soft key 3 Fault LED (red) Soft key 2 Alarm LED (yellow) Soft key 1 * The locking screw may be in a different orientation with respect to the cover (6), depending on how the cover has been fitted. † On the side of the analyser. Contains Servomex contact details, date of manufacture, analyser model and serial number, analyser inlet flow rate, mains voltage rating and optional Tag Number. Figure 1 - Front of the analyser 4 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Key 1. 2. 3. Description Key Cable entry holes (2 off) 1/2 inch NPT Cable entry holes (2 off) 3/4 inch NPT Functional Earth (ground) terminal 4. 5. 6. Description Sample gas inlet 1/4 inch NPT Sample gas outlet 1/4 inch NPT Corrosive purge inlet 1/4 inch NPT, or blank Figure 2 - Base of the analyser 01910001B / Revision 6 5 SERVOTOUGH Oxy, Oxygen Gas Analyser Key 1. 2. 3. Description Key Cable entry holes (2 off) 1/2 inch NPT Cable entry holes (2 off) 3/4 inch NPT Functional Earth (ground) terminal 4. 5. 6. 7. 8. Description Sample gas inlet 1/4 inch NPT female Sample gas outlet 1/4 inch NPT female Sample inlet/outlet insulation and cover plate Cover plate fixing screw, 4 x M4 Corrosive purge inlet 1/4 inch NPT female, or blank Figure 3 - Base of analyser, Sample Heating 6 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Key 1. 2. 3. Description Key Earth (ground) connection Relays P112, relay functions: mA range indication, Service in Progress and Maintenance Required Relays P102, relay functions: Concentration Alarms 1& 2 and Fault 4. 5. 6. 7. Description Fuse F101 Electrical Supply P101 mA output terminals P103 Modbus 485 (P109) or Ethernet (U152) connection Figure 4 - Inside Power / Signal Compartment 01910001B / Revision 6 7 SERVOTOUGH Oxy, Oxygen Gas Analyser Key 1. Description Relay P803, relay functions: Sample gas, low calibration gas and high calibration gas Key 2. Description Switch inputs P804, autovalidation, autocalibration, calibrate low, calibrate high and initiate service in progress Figure 5 - Inside Power / Signal Compartment - Autovalidation / Remote Calibration 8 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 2 SPECIFICATION WARNING You must install and use the analyser in accordance with the requirements of this and subsequent sections of the manual. If you do not, people may be injured, the protection facilities incorporated into the design of the analyser may not operate as intended, sample gas measurements may not be accurate, or the analyser may be damaged. 2.1 2.2 General Dimensions Analyser Standard mounting 235 x 448 x 227 mm (height x width x depth) See Figure 14 and Figure 15 Mass 26 kg Environmental limits WARNING The installation of the analyser in a hazardous area must comply with any ‘Special conditions for safe use’ and/or ‘Schedules of Limitations’ as specified in the safety certification. See Certification Supplement Manual Part Number: 01910008B WARNING The analyser is not suitable for use with oxygen enriched sample gases, that is gases over 21% O2, relative to atmospheric pressure. If used with gases containing over 21% O2 the hazardous area certification is invalidated. WARNING During operation the analyser is rated -10 to 55oC (14oF to 131oF), outside these temperature limits the measurement performance will be effected and outside -10 to 60oC (14oF to 140oF) the hazardous area certification is invalidated. If ambient temperatures are likely to exceed either of these temperature limits, actions must be taken to install the analyser within a temperature controlled environment. WARNING The analyser is not suitable for use with sample vent back pressures that cause pressurisation at the sample vent of greater than 124 kPa (18 psia). If used with gases at pressures over 124 kPa (18 psia) the hazardous area certification is invalidated. 01910001B / Revision 6 9 SERVOTOUGH Oxy, Oxygen Gas Analyser Ambient temperature range Operation -10 to 55oC (14oF to 131oF) Storage -20 to 60 oC (-4oF to 140oF) Operating ambient pressure range 79 to 110 kPa (11 to 16 psi absolute) Operating ambient humidity range 0 to 95% RH, non-condensing Operating altitude range -500 * to 2000 † meters Ingress protection IP66 / NEMA 4X * Below sea level. † Above sea level. 10 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 2.3 Electrical data Electrical supply Voltage 100 to 120 Vac or 220 to 240 Vac. * Frequency 50/60 Hz Maximum power consumption 50 VA Internal fuse rating 100 to 120 V supply T 2.0 A H 250 V 220 to 240 V supply T 1.0 A H 250 V Electrical supply terminals suitable for Flexible conductors 0.5 to 2.5 mm2 (20 to 14 AWG) Solid conductors 0.5 to 2.5 mm2 (20 to 14 AWG) Interface signal relay ratings ‡ 30 Vdc 1 A milliAmp output Maximum load resistance 600 Ω Minimum isolation voltage 500 V Output range Normal sample measurement 0 to 20 mA or 4 to 20 mA † Fault condition 0 mA or 21.5 mA † Under range # < 4 mA Switched Inputs Input Voltage and Current $ 12 to 24 Vdc; 5 to 15 mA Minimum operating time ~ 0.5 seconds (Momentary Inputs) Maximum operating time ~ Infinite Signal/milliAmp/RS485 output terminals suitable for: Flexible conductors 0.5 to 1.5 mm2 (20 to 16 AWG) Solid conductors 0.5 to 1.5 mm2 (20 to 16 AWG) * The analyser is supplied configured for operation with one of these voltage ranges. You must specify the voltage range when you order the analyser. ‡ The relay output signals are volt-free signals. † User selectable. # Only available when the 4 to 20 mA output range is selected. $ Switch contacts should be suitable for low current switching. ~ For Initiate and Stop of Autovalidation, Autocalibration, Calibrate Low and Calibrate High, a momentary input of 0.5 seconds or longer is required, i.e. momentary push button switch. To activate and deactivate Service in Progress, a latching action switch is required. 01910001B / Revision 6 11 SERVOTOUGH Oxy, Oxygen Gas Analyser 2.4 Sample gas WARNING The analyser is not suitable for use with oxygen enriched sample gases, that is gases over 21% O2, relative to atmospheric pressure. WARNING The analyser is not suitable for use with sample vent back pressures that cause pressurisation at the sample vent of 124 kPa (18 psia). CAUTION The analyser will be damaged if condensation is allowed to form within the measurement cell or pipe work. It is important that the sample gas dew points specified below are maintained at all times. The sample gases must be clean, non-corrosive, free from oil/condensates and compatible with the materials listed in Appendix A5. Flow rates Standard inlet/outlet † 150 to 250 ml min-1 (200 ml min-1 recommended) High flow bypass † 50 to 70 l h-1 (60 l h-1 recommended) Maximum sample vent pressure Standard inlet/outlet † 124.0 kPa (18.0 psia) High flow bypass † 122.8 kPa (17.8 psia) Maximum inlet pressure Standard inlet/outlet † 0.2kPa (0.03psi) relative to sample vent pressure High flow bypass † 1.4kPa (0.2psi) relative to sample vent pressure Sample dew point (without optional sample compartment heating) 5 oC (9oF) below ambient temperature (minimum) Sample dew point (with optional sample compartment heating) 50 oC (122oF) maximum Particulate size < 3 μm (3 micron) † The pressure and flow of sample gases must be externally regulated to meet the above requirements. 12 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 2.5 Corrosive Purge gas The purge gases must be clean, non-corrosive, free from oil/condensates . 2.6 Flow rate 40 to 60 ml min-1 Dew point 5 oC (9oF) below ambient temperature (minimum) Maximum purge pressure 110 kPa (16 psia) Recommended gas Instrument Grade Air Calibration gas The calibration gases must be clean, non-corrosive, free from oil/ condensates and compatible with the materials listed in Appendix A5. For optimum calibration results, the calibration gas flow rate/pressure should be the same as the flow rate/pressure of the gases to be sampled. O2 transducer calibration gases High calibration setpoint 0.5 to 20.95% O2 Low calibration setpoint 0 (99.5% zero grade nitrogen recommended) Minimum Difference 0.5% Low calibration tolerance level * Calibration gas < 5% O2 Calibration gas ≥ 5% O2 ± 0.5% O2 ± 10% Calibration target value High calibration tolerance level * Calibration gas < 5% O2 Calibration gas ≥ 5% O2 ± 0.5% O2 ± 10% Calibration target value * If the measurement is outside the specified range, a fault message is stored to indicate that there may be a problem (for example, the wrong calibration gas has been introduced, or the transducer has drifted excessively). The fault can be over-ridden to allow the calibration to take place. CAUTION It is recommended that sample/calibration gas flow is monitored to ensure a representative sample is being measured. 01910001B / Revision 6 13 SERVOTOUGH Oxy, Oxygen Gas Analyser 2.7 Performance The display indications given below are the default indications. You can configure the analyser to provide other display indications (see Section 5.19). Oxygen Measurement Display indication Measured volume % oxygen Measurement ranges from 0 to 1% to 0 to 21% oxygen Lower Detection Limit <±50ppm oxygen Linearity No measurable error Repeatability ±0.02% oxygen Intrinsic error (accuracy) <±0.05% oxygen (based on 95% confidence limits) Zero drift per week < 0.05% oxygen Span drift per week < 0.05% oxygen Output fluctuation (peak to peak) < 0.01% oxygen T90 response time < 6 seconds (at 200 ml min-1 and 1 l min-1) Sample flow effect: (50 - 250 ml min-1 or 12 - 70 l hr-1) zero < 0.1% oxygen span < 0.5% reading Zero temperature coefficient: <±0.03% oxygen per 10 oC (18oF) change in temperature Sample vent pressure effects: Pressure compensation not fitted 1% change in sample vent pressure corresponds to 1% change in reading Pressure compensation fitted 1% change in sample vent pressure corresponds to 0.05% change in reading. Flowcube (F3) Flow Sensor Intrinsic Error <±5% of full scale for 100% N2* (based on 95% confidence limits) Resolution 1% of full scale Span temperature coefficient: <±2% of full scale per 10 oC (18oF) change in temperature T90 response time < 15 seconds Recommended Calibration Interval 6 to 12 months * For gases with higher molecular weights than N2, the accuracy will be <±10% of full scale. 14 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 2.8 Hazardous area certification When correctly installed as described in this manual, the analyser is certified to operate in the following hazardous areas (as specified by the certification label fitted to the analyser, see Figure 6 and Figure 7): • Europe The analyser is ATEX approved to: II 2 GD Ex ia d IIC T4 Gb (-10 oC ≤ Ta ≤ +60 oC) Ex tb IIIC T90 oC Db (-10 oC ≤ Ta ≤ +60 oC) Certificate number: Baseefa 09ATEX0080X • International The analyser is IECEx approved to: Ex ia d IIC T4 Gb (-10 oC ≤ Ta ≤ +60 oC) Ex tb IIIC T90 oC Db (-10 oC ≤ Ta ≤ +60 oC) Certificate number: IECEx BAS 09.0029X Figure 6 - ATEX and IECEx Certification label 01910001B / Revision 6 15 SERVOTOUGH Oxy, Oxygen Gas Analyser • North America The analyser is CSA approved for use in North America in the following locations: Class I, Division 1, Groups A, B, C, D T4 (-10 oC ≤ Ta ≤ +60 oC) Class II, Division 1, Groups E,F,G (-10 oC ≤ Ta ≤ +60 oC) Class III, (-10 oC ≤ Ta ≤ +60 oC) Class I, Zone 1, Ex ia d IIC T4 (-10 oC ≤ Ta ≤ +60 oC) Class I, Zone 21, Ex tD T90 oC Class I, Zone 1, AEx ia d IIC T4 (-10 oC ≤ Ta ≤ +60 oC) Class I, Zone 21, AEx tD T90 oC Certificate number: CSA 08.1961540 Figure 7 - CSA Certification label 16 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 3 UNPACK THE ANALYSER WARNING The analyser is heavy (see Section 2.1). Care must be taken when handling. 1. Remove the analyser and any other equipment from its packaging. 2. Inspect the analyser and the other items supplied, and check that they are not damaged. If any item is damaged, immediately contact Servomex or your local Servomex agent. 3. Check that you have received all of the items that you ordered. If any item is missing, immediately contact Servomex or your local Servomex agent. 4. Check that you have also received an accessory kit, containing the following: Quantity Item Check (3) 1 2 mm hexagonal key o 1 5 mm hexagonal key o 2 Spare fuses o If the accessory kit is missing, or any item is missing from the kit, immediately contact Servomex or your local Servomex agent. . CAUTION Check that the electrical supply voltage (shown on the rating label) is correct for your electrical supply. If the incorrect voltage is shown, do not continue to install the analyser; instead, contact Servomex or your Servomex agent. CAUTION Check that the sample inlet gas flow rate (shown on the rating label) is correct, if not contact Servomex or your Servomex agent, as the measurement maybe damaged by excessive flow rates. Retain the shipping documentation and packaging for future use (for example, return of the analyser to Servomex for servicing or repair). 01910001B / Revision 6 17 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 18 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 4 ANALYSER USER INTERFACE Throughout this manual, reference is made to product ordering options (such as "Autovalidation" or "pressure compensation") which must be specified at the time of purchase. Associated menus and menu options will not be available if your analyser does not have the corresponding product options. 4.1 Introduction The analyser user interface comprises the following (shown on Figure 1): 4.2 Display Shows various screens: see Section 4.2 onwards. Soft keys The function of each of the soft keys depends on the screen currently being shown on the display: see Section 4.3. Alarm LED On when an alarm condition exists: see Section 5.20. Fault LED On when a fault condition exists: see Section 10. Start-up and measurement screens When you first switch on the analyser, a ’start-up screen’ is displayed while the analyser carries out a self-test. The start-up screen shows the Servomex name, a ‘self-test time elapsed/remaining’ indicator, and messages identifying the tasks being carried out as part of the self-test. The screen will initially display the "System Check" task message. The Measurement screen is then displayed, as shown in Figure 8 below. 01910001B / Revision 6 19 SERVOTOUGH Oxy, Oxygen Gas Analyser measurement screen: Gas being measured Measurement units Transducer number ("1" always shown) Pressure compensation indicator * Current measurement Flow icon # Maintenance required icon ~ Status icon bar Alarm icon Software health indicator mA Range Soft key legends * Only shown when unit is installed with pressure compensation installed and is on: see Section 7.2. # Only shown when unit is installed with flow senor option. ~ Measurement status, either Maintenance required, Service in Progress or Fault. Figure 8 - The Measurement screen During normal analyser operation, the software health indicator continuously moves from left to right and then back again, below the status icon bar. If the indicator stops moving, this means that the analyser is not operating correctly, and you must refer to Section 10. If no soft key is pressed for 10 minutes, the Measurement screen will be automatically displayed. You will also then have to enter the password again to access any password-protected screens. 20 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 4.3 Soft key legends The four soft key legends at the bottom of the Measurement screen (Figure 8) correspond to the four soft keys on the front of the analyser. (The first, left-most, legend corresponds to the function of soft key 1, the second legend corresponds to the function of soft key 2, and so on). On the Measurement screen, the soft key functions are as follows: Legend Meaning Function (when soft key pressed) Menu Displays the Menu screen Calibrate * Displays the Calibrate screen Alarm * Displays the Alarm option screen - None (no effect) * These soft keys are ‘shortcuts’ to the described functions, which are also accessible from the menu structure. Other soft key legends which are used on the various screens are as follows: Legend 01910001B / Revision 6 Meaning Function (when soft key pressed) Back Cancels the current screen and displays the previous screen in the menu structure Accept Accepts the currently selected option or data (A new screen may be displayed accordingly) Edit Allows the highlighted data to be edited Up Moves the cursor up a list (or increases a digit during editing). Down Moves the cursor down a list (or decreases a digit during editing) Left Moves the cursor left Right Moves the cursor right Stop Stops an automatic validation/calibration 21 SERVOTOUGH Oxy, Oxygen Gas Analyser 4.4 System and measurement status icons System status is on the status icon bar and can be shown with a fault icon or a maintenance required icon, see table below. Measurement status is on the right hand side of the measurement reading and can be shown with a fault icon, a maintenance required icon, a service in progress icon or a warming icon, see table below. Icon Meaning Indicates that a fault has been detected Indicates that maintenance is required Indicates that service is in progress Indicates that the analyser is warming up To determine the cause of these status icons, see Section 10.1.2 4.5 Scroll bars On some screens (for example, see Figure 10), there may be more options available than can be shown on the screen, and you have to scroll down the screen to view all of the options: this is identified by a scroll bar at the right-hand side of the screen. The height of the wide part of the scroll bar gives an indication of what proportion (of all the options) are currently shown on the screen. As you scroll up or down the options (using the and soft keys), the wide part of the scroll bar will also move on the screen, indicating approximately where the currently displayed options are, within the complete list of options. 22 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 4.6 Menu options/screens and password protection The menu structure of the analyser is shown in Figure 9, which indicates that some of the options/screens are password protected. When an option/screen is password protected, this means that the correct corresponding password has to be entered before the option/screen can be accessed. Password protection operates as follows: As supplied, the security level is set to ‘high’, the supervisor password is set to "2000" and the operator password is set to "1000". • The first time you try to access a password-protected option/screen, you will be prompted for the corresponding password. You must then enter the correct password before the option/screen can be displayed. • If you have already entered the corresponding password, you will gain access to all options/screens protected by that password immediately (you do not need to enter the password again). Once you have entered a password, it remains active until 10 minutes after the last soft key is pressed. After this, the password becomes inactive; you must re-enter the password to access password-protected options/screens again. To change the passwords see Section 5.10. 01910001B / Revision 6 23 SERVOTOUGH Oxy, Oxygen Gas Analyser View Pressure* View pressure compensated/ uncompensated measurements. Flow Alarm* Percentage of nominal flow Set Up mA output Filtering Comms type Unit selection X-interface Pressure* Flow Alarm* Auto val* Calibration Switch inputs* Relay Set up* Alarm short-cut Calibrate short-cut S S S S S S S S S S S Set mA ouput parameters. Set Measurement Filtering level. Set communication type. Select measurement display units/ factor. . Enter a cross-compensation error. Switch pressure comp on/off. Set flow alarm levels. Set auto val parameters. Set calibration link. Set switch input mode. Set relay parameters. Calibrate Calibrate View History O Calibrate the analyser. View the calibration history. Alarm View* Set up Calibrate Alarm Settings Service Status KEY A Option/screen is always protected by supervisor. S Option/screen can be protected by supervisor. O Option/screen can be protected by operator. * Menu may not be displayed (option) Unlatch View Set up O Unlatch a latched alarm View measurement alarm status. Set up measurement alarms. S Set up the comms parameters. A S S Change the password(s). Settings Comms parameters Password Clock Regional Backlight Contrast Security Information A S Set the time and date. Change the regional settings. Adjust the display backlight. Adjust the display contrast. Select the security level. View the system information. S S S Calibrate/override mA output. Override relay outputs. Calibrate flow alarm module. Service mA output Relay Flow Alarm* Status Active View history* View status. View status history. Figure 9 - The analyser menu structure 24 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 4.7 The Menu screen Some of the menu screens referenced below may not be available: refer to the note at the start of Section 4. The Menu screen provides access to other screens in the menu structure, and is displayed by pressing the soft key when the Measurement screen is displayed. Scroll bar: see Section 4.5 Figure 10 - The Menu screen Use the and soft keys to highlight the required screen option, then press the soft key to display the selected screen: Screen Use View Select this screen to view the O2 measurement pre and post pressure compensation readings and the percentage flow level. Set up Select this screen to select the communications type, configure the auto validation/calibration target range, enter a cross-interference compensation, switch pressure compensation on/off, select the display units, set up flow sensor parameters and trip levels, set up the mA output parameters and ranges and the relay energised or deenergised settings. Calibrate Select this screen to calibrate or validate the analyser and to view calibration history. Alarm Select this screen to set up the measurement alarms and set the alarm follow options, unlatch alarms and view the measurement alarm status. Settings Select this screen to change analyser settings (password, display language and so on). Service Select this screen to calibrate/check the mA outputs and check the relay signal outputs. Status Select this screen to view active and historical fault, maintenance required and service in progress (SIP) messages. Alternatively, press the 01910001B / Revision 6 soft key to display the Measurement screen again. 25 SERVOTOUGH Oxy, Oxygen Gas Analyser 4.8 The Settings screen Use the and soft keys to highlight the required screen option, then press the soft key to display the selected screen, as shown below: Figure 11 - The Settings screen Screen Use [refer to section] Comms Parameters Configuring the communications parameters [A2.1 or A2.2] Password Changing the password [5.10] Clock Setting the clock time and/or date [5.13] Regional Changing regional settings (language and so on) [5.14] Backlight Adjusting the backlight timer duration [5.12] Contrast Adjusting the contrast of the screen [5.11] Security Selecting the security level [5.9] Information Viewing analyser system information [4.9] Alternatively, press the 4.9 soft key to display the Menu screen again. The Information screen This screen shows information (such as the analyser serial number and the version of the operating software embedded in the analyser) which is useful to the Servomex support team. Figure 12 - Typical information screen Note that the information shown on the screen will vary, depending on the analyser model. After viewing (and if necessary recording) the information shown on the screen, press the soft key to display the Settings screen again, or press and hold the soft key to show the Measurement screen again. You may be asked to provide the information from this screen to the Servomex support team; for example, as an aid to fault diagnosis. 26 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 4.10 Editing on-screen data A common method is used for editing data shown on all of the different screens. When you press the soft key to edit an item of data, the screen changes to show the corresponding edit screen, with the first digit highlighted: Figure 13 - A typical edit screen When the first digit is highlighted, press the changing the data. soft key to exit the menu without Alternatively, use the soft keys to edit the data as follows: Soft key Function Increases the highlighted digit by 1 Decreases the highlighted digit by 1 Moves the cursor left to the previous digit Moves the cursor right to the next digit Note that the figures above and below the highlighted digit show the digits above and below the currently highlighted value. When the last digit is highlighted, press the soft key to enter the new data. When editing numerical values, the decimal point appears between digits "9" and "0". 01910001B / Revision 6 27 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 28 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5 INSTALLATION AND SET-UP WARNING You must not modify the analyser in any way (either mechanically or electrically). If you do, the certification of the analyser will be invalidated, and it may not operate safely. WARNING The analyser must be installed by a suitably skilled and competent technician or engineer in accordance with this manual and to the special conditions of installation contained within the Certification Supplement Manual, Part Number: 01910008B. 5.1 Mechanical installation WARNING The analyser is not suitable for use with oxygen enriched sample gases, that is gases over 21% O2, relative to atmospheric pressure. WARNING The analyser is not suitable for use with sample vent back pressures that cause pressurisation at the sample vent of 124 kPa (18 psia). WARNING You must ensure that, when the analyser is in its installation location: • The operating environment is within the limits specified in Section 2.2. • There is sufficient space around the analyser to install and connect the electrical supply and interface signal cables, and the sample inlet and outlet pipes. • There is sufficient space to access the internal compartments for maintenance. • The unit must be mounted so that dust may only form a layer on the top surface. • To avoid propagating brush discharges, the unit is not to be installed in a high velocity dust-laden atmosphere. 01910001B / Revision 6 29 SERVOTOUGH Oxy, Oxygen Gas Analyser CAUTION Do not install the analyser on a surface which is subject to high levels of vibration or sudden jolts. If you do, sample measurements may not be accurate, or the analyser may be damaged. You must mount the analyser on a suitable rigid vertical surface which is capable of supporting the mass of the analyser (refer to Section 2.1). Note the following when you install a sample conditioning system: • Locate the sample conditioning system below the analyser, to prevent the carryover of condensate into the analyser sample measurement transducer. • Ensure that the sample conditioning system will not impact on the environmental limits of the analyser (see Section 2.2). To mount the analyser on a rigid vertical surface, attach the fixing lugs on the analyser to suitable bolts or hooks to securely mount the analyser: refer to Figure 14 and Figure 15 for the fixing dimensions. 30 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser . Fixing lugs are suitable for M8 studs or bolts Figure 14 - Fixing dimensions (mm) 01910001B / Revision 6 31 SERVOTOUGH Oxy, Oxygen Gas Analyser Figure 15 - Fixing dimensions cont. (mm) 32 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.2 Remove the power/interface compartment cover WARNING The power/interface compartment cover is heavy. Ensure that you do not drop the cover once it is disengaged from the body of the analyser. If you do, you may injure yourself or damage other equipment. Any damage to the thread on the cover will compromise the analyser certification. CAUTION Place the cover carefully on a clean surface, resting on the exterior of the cover, so that the pregreased threads do not become contaminated. 1. Refer to Figure 1. Use the 2 mm hexagonal key supplied to loosen the locking screw which secures the cover. 2. Unscrew the cover; that is, turn it anticlockwise. If necessary, fit a suitable metal bar between the protruding fins on the front of the cover to provide additional leverage. 3. When the cover is fully disengaged from the body of the analyser, remove it and place it carefully on a clean surface: see the caution above. 01910001B / Revision 6 33 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.3 Electrical supply and interface signal connections 5.3.1 Electrical safety WARNING Ensure that the electrical installation of the analyser conforms with all applicable local and national hazardous area and electrical safety requirements. WARNING Obey the safety instructions given below when you install the analyser; if you do not, the analyser certification may be invalidated, the analyser may not operate correctly, or it may be damaged. • All cables connected to the power/signal compartment must be connected to equipment which is not supplied from, or contain in normal or abnormal operating conditions, a source of potential with respect to earth (ground) higher than 253 Vac or 253 Vdc. As such it is recommended that the analyser is connected to a "grounded neutral" supply. • The analyser does not incorporate an integral on/off switch. You must provide a means of externally isolating the electrical supply from the analyser: use a suitable switch or circuit breaker located close to the analyser, clearly marked as the disconnecting device for the analyser. • The electrical supply circuit must incorporate a suitable fuse or over-current protection device, set to or rated at no more than 10 A. • The analyser must be connected to an external protective earthing system, using the Protective Earth on terminal P101. • The analysers Earth (ground) connection located on the base of the analyser must be equipotentially bonded locally to the analyser. • Ensure that your electrical supply can provide the necessary maximum power consumption: refer to Section 2.3. • The volt-free relay contacts are isolated from the analyser mains circuits and from each other, only 30 Vdc 1A max signal voltage circuits can be connected to the contacts. • The mA output and RS485 terminals are separated from the analyser mains circuits by reinforced insulation. The terminals must only be connected to circuits that are themselves separated from mains voltages by at least reinforced insulation. • All signal and electrical supply cables must be rated for temperatures of 70oC (158oF) or higher. 34 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser • Ensure that the cables that you connect to the analyser are routed so that they do not present a trip hazard. • When you carry out insulation testing, disconnect all cables from the analyser. 5.3.2 Configure the cable entry holes WARNING If the analyser is installed in a hazardous area, all cable-glands, adaptors and blanking plugs must be suitably approved. ATEX approved analysers must be fitted with IP66 ATEX Ex d IIC approved components. IECEx approved analysers must be fitted with IP66 IECEx Ex d IIC approved components. CSA North American Approved analysers must be fitted with CSA/UL, cULus or cCSAus 4X, Class I, Groups A, B, C, D approved components. The analyser has two 3/4 inch and two 1/2 inch NPT cable entry holes. As supplied, three of these holes are fitted with blanking plugs (rated to IP66 / NEMA 4X). Configure the analyser so that the entry holes that you use for the electrical supply and signal connection cables have suitable cable-glands (and/or adaptors) fitted, and so that any unused entry hole has a blanking plug fitted. All cable-glands/adaptors and plugs used must provide ingress protection to IP66, NEMA 4X or better. It is recommended that the 1/2 inch NPT cable entry hole on the far right hand side of the enclosure is used for the power supply cable. 01910001B / Revision 6 35 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.3.3 Interface signal connections WARNING All of the analyser interface signal outputs are considered to be incendive and therefore must only be connected to safe area equipment. CAUTION To comply with EMC requirements, you must use a screened 4 to 20 mA cable to connect to the mA output. It is recommended that screens are terminated at the cable gland. Connect the wires in your cables to the appropriate terminals as described below and refer to Section 2.3 for detailed ratings and cable sizes. 1. Pass your signal cable(s) through one or two of the cable-glands fitted to the base of the power/interface compartment. 2. Refer to Figure 4. Connect the mA output wires in your cables to the corresponding terminal pins of the mA output, as follows: 3. Signal Terminal pin +ve P103 Pin 1 -ve P103 Pin 2 Refer to Figure 4. Connect the relay signal output wires in your cables to the appropriate terminals for the corresponding relay, as shown below. Note that both N/O (normally open) and N/C (normally closed) signals are available for each relay. The default relay configuration is shown below. The relays can either be set up to be energised or deenergised during normal operation. Refer to Section 5.17 for changing the relay set up and configuration and default states. Relay Signal Terminal pin Use Alarm 1 N/C COM N/O P102 Pin 1 P102 Pin 2 P102 Pin 3 Open indicates an alarm condition (Common) Closed indicates an alarm condition Alarm 2 N/C COM N/O P102 Pin 4 P102 Pin 5 P102 Pin 6 Open indicates an alarm condition (Common) Closed indicates an alarm condition Fault * N/C COM N/O P102 Pin 7 P102 Pin 8 P102 Pin 9 Closed indicates a fault condition (Common) Open indicates a fault condition * As default the Fault relay is configured "Fail Safe", i.e. is permanently energised in normal operation. 36 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Relay Signal mA Range indication N/C P112 Pin 1 COM N/O P112 Pin 2 P112 Pin 3 Service in progress (SIP) N/C COM N/O P112 Pin 4 P112 Pin 5 P112 Pin 6 Open indicates a SIP condition (Common) Closed indicates a SIP condition Maintenance Required N/C COM N/O P112 Pin 7 P112 Pin 8 P112 Pin 9 Open indicates a maintenance required (Common) Closed indicates a maintenance required 5.3.4 Terminal pin Use Closed indicates a Range 1 and open indicates Range 2 (Common) Open indicates a Range 1 and closed indicates Range 2 Auto Validate/Calibrate connections (option) WARNING The auto validate/calibrate board connections are separated from the analyser mains circuits by reinforced insulation. The terminals must only be connected to circuits that are themselves separated from mains voltages by at least reinforced insulation. The analyser can be supplied with auto-validate/calibrate relays and switched inputs. The relays can control solenoid valves in the gas supply system to perform validate or calibrate routines. Depending on whether you have chosen to do a Remote Validate/Calibrate routine or an Auto Validate/Calibrate (see Section 6 and Section 6.2) the pin assignments will have different functions. Unlike the relays detailed in Section 5.3.3, the autovalidate/calibrate relays cannot have their default configuration changed in any way. 01910001B / Revision 6 37 SERVOTOUGH Oxy, Oxygen Gas Analyser . Relay Signal Terminal pin Use Sample Gas* N/O COM N/C P803 Pin 1 P803 Pin 2 P803 Pin 3 Open to isolate sample gas flow (Common) Closed to isolate sample gas flow Low Calibration Gas N/O COM N/C P803 Pin 4 P803 Pin 5 P803 Pin 6 Closed to start low calibration gas flow (Common) Open to start low calibration gas flow High Calibration Gas N/O COM N/C P803 Pin 7 P803 Pin 8 P803 Pin 9 Closed to start high calibration gas flow (Common) Open to start high calibration gas flow * The Sample Gas relay is configured "Fail Safe", i.e. is permanently energised in normal operation. If there is a power supply failure to the analyser, then the relay state will change and the sample gas flow to the analyser will be isolated. This helps to protect the analyser against sample corrosion during power interruptions. Digital Input Signal Terminal pin Use Initiate Auto Validation / Auto Calibration / Calibrate Low +ve -ve Momentary Input P804 Pin 1 P804 Pin 2 +12V to 24V to start 0V Stop Auto Validation / Auto Calibration / Calibrate High +ve -ve Momentary Input P804 Pin 3 P804 Pin 4 +12V to 24V to start 0V Initiate Service in Progress Status +ve -ve Latching Input P804 Pin 5 P804 Pin 6 +12V to 24V to start 0V For Initiate and Stop of Autovalidation, Autocalibration and Calibrate Low and Calibrate High, a momentary input of 0.5 seconds or longer is required, i.e. momentary push button switch. To activate and deactivate Service in Progress, a latching action switch is required. Switch contacts should be suitable for low current switching. 38 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.3.5 Modbus RS485 and ethernet connections (option) WARNING The Digital communications terminals are separated from the analyser main circuit by reinforced insulation. The terminals must only be connected to circuits that are themselves separated from mains voltages by at least reinforced insulation. The analyser can be supplied with Modbus RS485/Ethernet digital communications. For a full list of what can be communicated over the Modbus communications see Appendix A1. If Modbus RS485 option is supplied: 1. The cable should not leave the building in which it is installed without suitable isolation. 2. The screen should be terminated at the cable gland. 3. Connect the wires in your cable to the screw terminals on the 5 pin interface connector provided. Refer to Section 2.3 for the cable electrical requirements, and refer to Figure 16 for the connection requirements. Terminal pin Signal P109 1 A P109 2 B P109 3 A P109 4 B P109 5 Termination Figure 16 - Modbus RS485 interface connector Link pins 4 and 5 if the analyser is at the end of the RS485 network. If Modbus Ethernet option is supplied: 1. The cable should not leave the building in which it is installed without suitable isolation. 2. The cable must be screened CAT5E with standard RJ45 connectors. 01910001B / Revision 6 39 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.3.6 Mains electrical supply connection CAUTION Ensure that the analyser as supplied is correctly configured for your mains electrical supply voltage. If the analyser is not correctly configured for your mains electrical supply voltage, the analyser may not operate correctly, or it may be damaged when you operate it. When you make your mains electrical supply cable, ensure that the earth (ground) conductor is longer than the live and neutral conductors. This will ensure that if the cable is accidentally dragged and the strain relief on the cable-gland fails, the earth (ground) conductor will be the last conductor to be pulled from the analyser. Connect your mains electrical supply cable to the analyser as follows: 1. Refer to Figure 4. Connect the wires in the supply cable to the appropriate electrical supply terminals P101, as follows: Signal Terminal pin Live P101 L Neutral P101 N Protective Earth (ground) P101 WARNING The analyser must be connected to an external protective earthing system, using the Protective Earth on terminal P101. It is recommended that the 1/2 inch NPT cable entry hole on the far right hand side of the enclosure is used for the power supply cable. 40 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.4 Refit the power/interface compartment cover WARNING The power/interface compartment cover is heavy. Ensure that you do not drop the cover when you refit it to the body of the analyser. If you do, you may injure yourself or damage other equipment. CAUTION Ensure that the pregreased threads of the cover do not become contaminated. The threads on the cover are pregreased. You do not need to add any grease or sealant to the threads before you refit the cover. 1. Tighten the strain relief on all of the cable-glands fitted to the base of the analyser. 2. Refer to Figure 1. Carefully refit the cover to the body of the analyser, so that the threads on the rear of the cover are correctly aligned with the threads in the analyser: pick the cover up by its exterior, and do not touch or contaminate the pregreased threads on the cover. 3. Screw on the cover (that is, turn the cover clockwise) to secure it to the analyser. It can help to turn the cover anticlockwise, up to one turn, till you feel or hear the threads align, before beginning to screw on the cover clockwise. 4. Fully tighten the cover. If necessary, fit a suitable metal bar between the protruding fins on the front of the cover to provide additional leverage. 5. Use the 2 mm hexagonal key supplied to tighten the locking screw which secures the cover. 6. Ensure that the certification label is in the correct orientation. If necessary, press and turn the label until it is in the correct orientation. 01910001B / Revision 6 41 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.5 External earth (ground) connection WARNING When the analyser is installed in a hazardous area, the analysers’ external earth (ground) connection located on the base of the analyser, Figure 2 or Figure 3, must be equipotentially bonded locally to the analyser. You must correctly connect it in compliance with all relevant local, national and international standards, to ensure that the installation is safe. Failure to do so will invalidate the hazardous area certification. CAUTION To comply with the EMC emissions and susceptibility standards, the external earth (ground) connection is also considered to be a Functional Earth and must always be connected to a local EMC earth (ground). The conductor that you use must not exceed 2 metres in length. Use a suitable conductor to connect the analyser external earth (ground) terminal to a local equipotential earth (ground) point: see warning and caution above. You can use flexible or solid conductors, up to 10 mm2 up to a maximum length of 2 metres. 42 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.6 Connect the sample/calibration gas pipe(s) WARNING Ensure that the pipes that you connect to the analyser are routed so that they do not present a trip hazard to people. WARNING Sample and calibration gases may be toxic, asphyxiant or flammable. Ensure that the external connections are leak free at full operating pressure before you use sample or calibration gases. WARNING Sample and calibration gases may be toxic, asphyxiant or flammable. Ensure that the sample outlet pipe is vented to an area where the gases will not be a hazard to people. WARNING Sample and calibration gases may be toxic, asphyxiant or flammable. To prevent the build-up of such gases, ensure that the analyser is used in a sufficiently well-ventilated environment. CAUTION When you carry out a leak test, do not exceed a maximum pressure of 34.5 kPa gauge (0.35 bar gauge, 5 psig) and do not introduce a sudden change of pressure into the analyser. If you do, you can damage it. CAUTION If you use a liquid to assist in leak testing, do not spill liquid onto any of the electrical components in the sample/control compartment. CAUTION If optional sample compartment heating is fitted the maximum gas dew point is 50oC. To prevent condensation reaching the analyser the gas should be maintained at a minimum of 55oC up to the inlet connection. Sample compartment heating is not designed to be a replacement for other sample conditioning systems used for high dew point gases. Connect your sample/calibration gas inlet and outlet pipes to the sample gas inlet and outlet on the base of the analyser (see Figure 2). The inlet/outlet fittings on the analyser are 1/4 inch NPT female. Refer to Section 2.4 for the sample gas requirements, and refer to Section 2.6 for the calibration gas requirements 01910001B / Revision 6 43 SERVOTOUGH Oxy, Oxygen Gas Analyser Locate your gas selection valves (to direct sample or calibration gas into the analyser) as close as possible to the analyser. Do not introduce calibration or sample gases into the analyser yet. You must switch on the electrical supply and leave the analyser for at least 4 hours before you allow calibration or sample gases into the analyser. Refer to the Caution at the start of Section 6. 5.7 Switch on/set-up When the electrical supply to the analyser is switched on, the Alarm LED and the Fault LED will both go on for 1 second to demonstrate that they are functioning correctly, and will then go off again. When you switch on the electrical supply to the analyser, a ‘start-up screen’ is first displayed, then the Measurement screen (Figure 8) is displayed. 5.8 Selecting the security level and password(s) You can configure the analyser to provide any of three levels of security: Security level Function Low None of the options/screens are password protected *. Standard Some of the options/screens are protected by a supervisor password. High Some of the options/screens are protected by a supervisor password and some of the options/screens are protected by an operator password †. * Except for the ‘change the password(s)’ and ‘select the security level’ options/screens: see notes below. † The supervisor password can also be used to access options/screens protected by the operator password: see notes below. The ‘change the password(s)’ and ‘select the security level’ screens/options are always protected by the supervisor password, regardless of the security level selected. This is to ensure that unauthorised personnel cannot change the security level and password(s) and so lock out the analyser from other users. 44 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser The supervisor password provides access to all password protected options/ screens. That is, if you have selected the ‘high’ security level and are prompted to enter the operator password, you can also access the option/ screen by entering the supervisor password. Password protection can be used to prevent adjustment of the clock by unauthorised persons, so ensuring the validity of measurement times and the ’time since last calibration’ history. Figure 9 shows the options/screens which can be password-protected within the menu structure. 5.9 Setting the security level As supplied, the security level is set to ‘high’, the supervisor password is set to "2000" and the operator password is set to "1000". Before the analyser is used for sample measurement, we recommend that you select the security level most suitable for the way in which the analyser will be used by you and/or your personnel. Use the following procedure to select the required security level: 1. Select 2. To change the security level, press the soft key. You will then be prompted to enter the supervisor password. 3. Once the supervisor password has been entered correctly, the Security select screen will be displayed (see Figure 17), with the currently selected security level highlighted. 4. Settings Security. Figure 17 - The Security level screen To change the security level, use the and soft keys to highlight the required level, then press the soft key. The Security level screen will then be displayed again, showing the newly selected security level. Figure 18 - The Security select screen 01910001B / Revision 6 45 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.10 Changing passwords If you change a password, ensure that you record the new password somewhere safe. Otherwise, if you cannot recall the new password, you will have to contact Servomex or your local Servomex agent for assistance. Use the following procedure to change the supervisor and operator passwords: 46 1. Select: Settings 2. To change the supervisor password, press the soft key, then enter the new password. 3. To change the operator password, press the soft key to display the edit operator password screen, press the soft key, then enter the new password. Password. Figure 19 - The Edit supervisor password screen 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.11 Adjusting the contrast 1. Select: Settings 2. Use the and soft keys to increase or decrease the contrast to the required level, then press the soft key. Contrast. Figure 20 - The Contrast screen Hold the 5.12 or soft key pressed in to adjust the contrast quickly. Adjusting the backlight timer When the analyser is first switched on, the backlight goes on to illuminate the screen. If no soft key is pressed, the backlight will remain on for the preset ‘backlight time’, and will then go off. The timer associated with the backlight time is restarted whenever a soft key is pressed (that is, the backlight remains on for the backlight time after the last soft key press). To adjust the backlight time: 1. Select Settings 2. Change the backlight time (Duration) setting as required, then press the soft key. Backlight. Figure 21 - The Backlight timer screen The backlight time (Duration) can be set between 0 and 999 seconds. Set the backlight time (Duration) to 0 seconds to leave the backlight permanently switched on. 01910001B / Revision 6 47 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.13 Setting the clock The time and date will remain set for approximately 1 week if the power supply to the analyser is switched off. Use the following procedure to set the date and time: 1. Select Settings 2. Edit the displayed time. Clock. Figure 22 - The Clock (time) screen 3. Edit the displayed date. 4. The date format can be set to your regional preference (‘day/ month/year’ or ‘month/day/ year’): refer to Section 5.14. Figure 23 - The Clock (date) screen 48 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.14 Changing regional settings You can configure the following analyser regional settings so that the information shown on the various screens is better suited to your local conventions: Setting Options available Language Various languages are supported Date format Day/Month/Year * or Month/Day/Year Decimal format Use of "."* (full stop) or "," (comma) as the decimal point * Default option. To change the regional settings: 1. Select Settings 2. This screen shows the first regional option (Language). Regional. Figure 24 - The Regional settings (Language) option screen 01910001B / Revision 6 49 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.15 Setting up automatic validation/calibration (option) 5.15.1 Overview of automatic validation/calibration Automatic validation operates in the same way as automatic calibration, except that the transducer is not calibrated when the low and high calibration gases have been passed through the transducer. Automatic validation therefore allows you to determine the drift of sample measurements over time. You can set tolerance levels, so that if the sample measurements fall outside acceptable limits, a ‘maintenance required’ status is raised ( ) to identify that a full calibration needs to be carried out. If your analyser supports auto validation/calibration you have the option to: • Configure the analyser so that automatic validation/calibration of a transducer is carried out once (at a preset time). • Configure the analyser so that automatic validation/calibration of a transducer is carried out repeatedly at a specified frequency. • Use the soft keys to manually start an automatic Validation/Calibration • Use a control input signal (on the RS485, Ethernet or digital input) to initiate an automatic validation/calibration. You can also perform a ‘remote calibration’ using the switched inputs on the calibration option pcb if they are configured accordingly. 50 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Automatic validation/calibration provides the following functionality: • During an automatic validation/calibration of a transducer, the analyser controls gas selection relays which can be used to control the flow of low and high calibration gases into the analyser. • The analyser checks that the resulting measurement is within the preset validate target range (validate target value ± validate tolerance value). • If the measurement is within the preset validate target range and mode is set to calibrate, the transducer is calibrated (as in manual calibration). • You can specify a pre-warning time, which will precede the automatic validation/ calibration. During this time, the ‘service in progress’ status output will be set; the automatic validation/calibration will then be carried out at the end of the pre-warning time. If automatic validation is cancelled during this time the gas selection control will not have changed state. • You can specify an inerting phase. This ensures that non-inert hazardous mixtures of calibration gas and sample gas cannot flow into the analyser one immediately after the other. During this phase, inert gas (the low or high calibration gas) will be introduced between the two gases for a preset time. • You can specify a flushing phase. This phase operates as a delay, after a different gas is routed into the analyser, before a validation/calibration is carried out. 01910001B / Revision 6 51 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.15.2 Automatic validation/calibration sequence Before you carry out an automatic validation/calibration, you must preset the following parameters: 52 Parameter Use/range Low target value Low measurement target value for validate/ calibrate. Low target tolerance Low measurement target tolerance. High target value High measurement target value for validate/ calibrate. High target tolerance High measurement target tolerance. Validation/Calibration type Low, High, Low & High or High & Low. Mode Calibration or Validation. Pre-warning On or Off. Pre-warning time Only applicable if Pre-warning is On. Specifies the length of the pre-warning period (0 min 1 sec to 59 min 59 sec). Inerting On or Off. Inert gas Only applicable if Inerting is On. Specifies the type of inert gas (High or Low). Inerting time Only applicable if Inerting is active. Specifies the inerting time (0 min 30 sec to 59 min 59 sec). Flushing time Specifies the flushing time (0 min 30 sec to 59 min 59 sec). Timer On (active) or Off (inactive). If active the calibration or validation can be carried out regularly at a specified frequency. Start time/date Only applicable if the timer is active. This specifies the time/date on which the first automatic validation/calibration will be carried out. Repeat time Only applicable if the timer is active. If set (in the range 1 hour to 999 days), specifies the interval between successive automatic calibrations/ validations. Select 0 hours and 0 days if repeat is not required. 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Figure 25 shows a typical automatic calibration sequence, where: • Pre-warning is on. • Automatic calibration has been initiated. • Validation/Calibration type has been set to Low & High. • Mode has been set to Calibration. • Inerting is set to On (active) and Inert gas has been set to Low Calibration Gas. Time Sample gas measurement Pre-warning period Inerting phase Initiate auto calibration Service in progress (SIP) status on Route calibration gas 1 into the analyser Flushing phase Auto calibration (low) Flushing phase Route calibration gas 2 into the analyser Auto calibration (high) Inerting phase Flushing phase Route calibration gas 1 into the analyser Route sample gas into the analyser Service in progress (SIP) status off Sample gas measurement Figure 25 - Typical automatic calibration sequence 01910001B / Revision 6 53 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.15.3 Remote calibration or automatic validation/calibration Switch inputs can be set to remote calibration mode (Remote cal), automatic validation/calibration mode (Auto val) or disabled so the inputs will have no function. In Remote cal mode, switch input pins P108 1 and 2 activate a transducer low calibration (as if the request had been selected from the user interface) and switch input pins P108 3 and 4 activate a transducer high calibration. Switch input pins P108 5 and 6 activate the transducer service in progress (SIP) status, which must be closed before either calibration can be executed. This is to ensure a calibration cannot be executed without a service in progress status being activated. For example, to carry out a remote low calibration: Close pins 5-6 Close pins 1-2 Open pins 5-6 Remote service in progress (SIP) on (latching switch) Activate low calibration (momentary switch) Remote service in progress (SIP) off A calibration will be successfully completed if the current measurement is equal to the target measurement +/- the auto validation tolerance values, See Figure 28. If this condition is not met a Maintenance required status will be raised. If the switch inputs are set to ‘Remote Cal’ mode the gas control relays will not be changed from ’sample’ during a remote low or high calibration. See Section 6 for instructions on Manual Calibration to ensure that your calibration procedure is correctly configured. 54 1. In Auto val mode, switch input pins 1-2 Initiate an Auto Validation/Calibration sequence and switch input pins 3-4 stop an Auto Validation/Calibration sequence. Select Set up Switch Inputs. 2. Use to soft key to select either Auto val, Remote cal or Disabled. 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.15.4 Automatic validation/calibration target and tolerance 1. Select Set up 2. Select Target, the Auto val/cal low target value screen will then be displayed. Auto val. Figure 26 - The Auto val/cal parameters screen 3. Edit the displayed low target value. Figure 27 - The Auto val/cal low target value screen 4. Edit the low tolerance value. Figure 28 - The Auto val/cal low tolerance screen 5. Scroll down to the High target value then repeat steps 3 and 4 to set the High target and High tolerance values. Figure 29 - The Auto val/cal high target value screen 01910001B / Revision 6 55 SERVOTOUGH Oxy, Oxygen Gas Analyser Figure 30 - The Auto val/cal high tolerance screen 5.15.5 Automatic validation/calibration type and mode 1. Return to the Auto val screen (Figure 26). Select ‘Control’. 2. Select required type: ‘Low’, ‘High’, ‘Low & High’, ‘High & Low’. Figure 31 - The Auto val/cal type screen 3. Select ‘Mode’. Select required type: ‘Validate’ or ‘Calibrate’. Figure 32 - The Auto val/cal mode screen 56 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.15.6 Automatic validation/calibration phases 1. Return to the Auto val screen (Figure 26). Select ’Phase’. 2. Select ’On’ or ’Off’ for Pre warning. Figure 33 - The Auto val/cal phase screen 3. If you changed the pre-warning setting from ’Off’ to ’On’, the Auto val/cal pre-warning timer screen will then be displayed (see Figure 34). Edit the displayed time. Figure 34 - The Auto val/cal prewarning timer screen 4. Select ‘On’ or ‘Off’ for Inerting. Figure 35 - The Auto val/cal inerting screen 5. If you have changed the Inerting setting from ‘On’ to ‘Off’, continue at Step 9, otherwise continue from step 6. 6. Select the correct inert gas: ‘Low’ or ‘High’. Figure 36 - The Auto val/cal inert gas screen 01910001B / Revision 6 57 SERVOTOUGH Oxy, Oxygen Gas Analyser 7. Scroll to the Auto val/cal inerting timer screen, showing the currently selected inerting time setting. 8. Edit the time. Figure 37 - The Auto val/cal inerting timer screen 9. Scroll to the Auto val/cal flushing screen, showing the currently selected flushing time setting. 10. Edit the time. Figure 38 - The Auto val/cal flushing screen 58 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.15.7 Automatic validation/calibration timers 1. Return to the Auto val screen (Figure 26). Select ‘Timer’. 2. Select ‘On’ or ‘Off’ for Timer. Figure 39 - The Auto val/cal timer screen 3. Scroll to the Auto val/cal start date screen. 4. Edit the displayed start date. Figure 40 - The Auto val/cal start date screen 5. Scroll to the Auto val/cal start time screen. 6. Edit the displayed start time. Figure 41 - The Auto val/cal start time screen 7. Scroll to the Auto val/cal repeat time screen. 8. Edit the displayed repeat time. Figure 42 - The Auto val/cal repeat time screen If you set the repeat time to "000:00" (0 days, 0 hours), the automatic validation/calibration will only be performed once, on the specified start date, at the specified start time. You will therefore need to initiate any subsequent automatic validation/calibration: see Section 6.2.1. 01910001B / Revision 6 59 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.16 Configuring and using the mA outputs 5.16.1 Overview The milliAmp output provides a constantly updated output, in which the current represents the value of gas sample measurement. The analyser allows you to specify two separate range configurations for the milliAmp output: Range 1 and Range 2. The current range is shown on the Measurement screen (see Figure 8): is shown if Range 1 is selected. is shown if Range 2 is selected. The mA output can be selected as: • 0 to 20 mA, where 0 mA represents the lowest sample measurement and 20 mA represents the highest sample measurement in the range you have specified. • 4 to 20 mA, where 4 mA represents the lowest sample measurement and 20 mA represents the highest sample measurement in the range you have specified. In addition to the above, you can specify how the milliAmp output will operate during calibration, during a fault condition, and during under range conditions. 5.16.2 Introduction to the mA output parameters WARNING For safety critical applications or applications were the fault relay is not being utilised, the mA output should be configured to 4-20mA and Jam Low (Default Settings). This will prevent analyser faults remaining undiagnosed and is the safest mode of operation. The milliAmp output parameters that you must set up are as follows: 60 Parameter Values/options Range The selected option determines the mA output range associated with a measurement: Range 1 The output is set to use range 1. Range 2 The output is set to use range 2. Auto The output will automatically switch between Range 1 and Range 2 depending on sample measurements. 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Parameter Values/options Range 1 low level The Range 1 lowest sample measurement. Range 1 high level The Range 1 highest sample measurement (span). Range 2 low level The Range 2 lowest sample measurement. Range 2 high level The Range 2 highest sample measurement (span). During calibration The selected option determines how the mA output will operate during calibration: Jam condition Freeze As soon as the calibration screen is displayed, the milliAmp output will ‘freeze’ at its last output value. The output will only be updated to reflect subsequent measurements when the calibration screen has been exited. Follow The milliAmp output value will reflect the measurement value, even during calibration. The selected option determines how the mA output will operate during a fault condition: High The output value will be held at 21.5 mA. Low* The output value will be held at 0 mA. None The output values will continue to be derived from the sample gas measurements, even though these output values may be erroneous. mA output range 0-20 mA or 4-20 mA. * Underrange Any value below 4 mA. # Range change point The range change point.† Hysteresis The range change hysteresis.† † Only available when Auto range is selected. * Default setting. Fail safe operation. # Only available if the 4-20mA output range is selected; this sets the lowest output current during normal operation, and allows negative gas concentrations to be monitored through the mA output. For example, with an underrange setting of 3.8 mA, the mA output can be less than 4 mA (which indicates a zero gas concentration), down to a minimum of 3.8 mA, where an output between 3.8 mA and 4 mA indicates a negative gas concentration. 01910001B / Revision 6 61 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.16.3 Setting up the mA output parameters If Auto ranging is selected, the way in which the output changes between the ranges depends on the values you have set for the range change point and the hysteresis. For example, if you set the range change point to 18% and set hysteresis to 1%, then: • The output value must be greater than 18% before changing from Range 1 to Range 2. • The output value must be less than 18% - 1% (17%) before changing from Range 2 to Range 1. Use the following procedure to select Auto Ranging or manually select the range: 1. Select Set up 2. Select the Range option. mA output. Figure 43 - The mA configuration screen 3. Select the Range option you want the output to use (Range 1, Range 2 or Auto). If you have selected Auto ranging, you must also set the range change and hysteresis values. Figure 44 - The mA range screen 4. Return to the mA configuration screen (Figure 43) and select ’Set up’ option. 5. Edit the Range high level and low level. Figure 45 - The mA output high level screen 62 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 6. You can select the during calibration option to ’Freeze’ or ‘Follow’ Figure 46 - The during calibration screen 7. You can then select the Jam condition to ‘High’, ‘Low’ or ‘None’ Figure 47 - The jam condition screen 8. You can then select the range that you would like to use: 0-20mA or 420mA. Figure 48 - The mA output range screen 9. You can then select the underrange value. Figure 49 - The mA underrange screen 10. If Auto Ranging is selected you will then need to set the Range change point and the Hysteresis. Figure 50 - The mA range change point screen. 01910001B / Revision 6 63 SERVOTOUGH Oxy, Oxygen Gas Analyser Figure 51 - The mA range change hysteresis screen 5.16.4 Calibrating the mA output Use the following procedure to calibrate the mA output: 1. Select Service 2. Select the required ‘Calibrate’ option. mA output. Figure 52 - The mA output service screen Figure 53 - The mA output calibrate screen 3. As soon as the mA output calibrate screen is shown, the nominal mA output value is set to 20 mA: • Use your control/monitoring equipment (connected to the analyser) to monitor the actual output value. • Use the and soft keys to increase or decrease the actual output value until your control/monitoring equipment indicates 20 mA output. 4. When the mA output has been correctly calibrated, press the soft key: the mA output service screen (Figure 52) will then be displayed again. The actual mA output value is controlled from the mA output calibrate screen as long as the screen is displayed. As soon as the mA service screen is no longer displayed, the mA output value will be updated to reflect the corresponding gas measurement. 64 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.17 Configuring and using the relay outputs 5.17.1 Overview relay default status settings As default the relays are set up as in the following table. For details on relay connections refer to Section 5.3.3. Relay Relay coil state in "active" status Definition of "active" status Fault Deenergised Measurement or analyser fault detected Alarm 1 Energised Alarm 1 active Alarm 2 Energised Alarm 2 active mA Range Indication Energised mA range has changed over from range 1 to range 2 Service in Progress (SIP) Energised Service in progress status enabled Maintenance Required Energised Measurement or analyser maintenance required detected The relay coil status, energised or deenergised, can be set up to meet any particular application requirements. Example: As default, the fault relay coil is deenergised during an "active" status. As defined above, this is when a measurement or analyser fault is detected. Therefore if the power to the analyser fails or the relay cable is disconnected, then this is transmitted as a fault, as electrically it has the same effect as if the fault relay is deenergised, this is often termed "fail safe". In some applications it is preferred that the fault relay is energised in an "active" status, if this is the case then the relay coil set up can be changed as detailed in Section 5.17.2. 01910001B / Revision 6 65 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.17.2 Setting up the relay coil status To define the "active" status of the relay coil, see Section 5.17.1 Select 1. Set up Relay Set Up. Edit fault relay coil sate that is required for the "active" status Figure 54 - Fault Relay 2. Edit Maintenance Required relay coil sate that is required for the "active" status Figure 55 - Maintenance Required 3. Edit Service in Progress (SIP) relay coil sate that is required for the "active" status Figure 56 - Service in Progress 4. Edit Alarm 1 relay coil sate that is required for the "active" status Figure 57 - Alarm 1 66 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5. Edit Alarm 2 relay coil sate that is required for the "active" status Figure 58 - Alarm 2 6. Edit mA Range Indication relay coil sate that is required for the "active" status Figure 59 - mA Range Indication 01910001B / Revision 6 67 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.18 Correcting O2 measurements for background gases If you are measuring O2 (oxygen) in a background of nitrogen or air, you do not need to correct the measurements. 5.18.1 Overview of measurement errors For a paramagnetic oxygen measurement, the composition of any typical background gas in the gas sample will have a minor effect on the analyser measurement. For an analyser which has been ’Lo’ calibrated with N2 (nitrogen) and ’Hi’ calibrated with O2, some examples of cross-interference errors (that is, O2 measurement errors) in gases which contain 100% of a background gas are shown below. See Appendix A4 for more corrections. Background gas Error Background gas Error Hydrogen 0.26% Methane -0.18% Carbon dioxide -0.30% Propane -0.87% The error is directly proportional to the concentration of the background gas in the sample being measured, and in many cases can be ignored. All corrections must be calculated using 60oC data from the tables in Appendix A4. If you cannot ignore the error, you can use the procedure in Section 5.18.2 to enter a compensation to correct for the error. Example corrections are shown below. Example: If you are measuring O2 (oxygen) in a background of Carbon dioxide -0.30 should be entered as the cross interference offset. Example: If you are measuring 10% Oxygen in a background of 70% Hydrogen and 20% Carbon Dioxide the correction factor would be: The correction factor assumes 100% of background gas, so you must firstly correct for the nominal process oxygen concentration: Total background concentration = 70% + 20% = 90% Correct background concentrations for 0% oxygen: (100% / 90%) x 70% = 77.8% Hydrogen (100% / 90%) x 20% = 22.2% Carbon Dioxide For 100% Hydrogen the correction is 0.26, so for 77.8% it is 0.202 For 100% Carbon Dioxide the correction is -0.30, so for 22.2% it is -0.067 So the total correction factor in this case is -0.067 + 0.202 = 0.135 68 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.18.2 Entering a cross-interference compensation Cross-interference compensation is disabled during calibration, and is not applied to the values shown in Figure 77. All other outputs (that is, serial or mA outputs) remain compensated. Use the following procedure to enter a compensation to correct for an O2 (oxygen) measurement error: 5.19 1. Select Set up X-Interference. 2. The offset value shown on the XInterference offset screen is the correction which will be applied to O2 (oxygen) sample measurements before they are displayed (or output). 3. Edit the displayed offset. Figure 60 - The X-Interference offset screen Selecting display units You can change the measurement units shown on the display (and output). The following display units are supported: Units Meaning % volume % ppm parts per million vpm volume parts per million mg/m3 mg m-3 (milligrams per normal cubic metre) mol/mol mols per mol (or moles per mole) % LEL volume % of the Lower Explosive Limit When you select display units other than the measurement default units, you must also enter the units conversion factor: refer to Appendix A3 to determine the units conversion factor for your specific application. If you select the "off" option on the units selection screen, the display units revert to the measurement default units as supplied. Converting from one measurement unit to a different display measurement unit may reduce the resolution of the displayed measurements. 01910001B / Revision 6 69 SERVOTOUGH Oxy, Oxygen Gas Analyser Use the following procedure to select the displayed units, and to change the units conversion factor: 1. Select Set up Unit selection. 2. If you want to change the currently displayed units, press the soft key: the Units selection screen will then be displayed. Figure 61 - The Currently selected units screen 3. If required scroll to the "Factor" screen to change the unit conversion factor. Figure 62 - The Units selection screen 4. Edit the displayed offset referring to Appendix A3 for the correct value. Figure 63 - The Units conversion factor screen 70 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.20 Configuring the measurement alarms 5.20.1 Alarm modes and levels Two separate measurement alarms are available for the gas measurement and you can configure each alarm to operate in one of three modes: Alarm mode Operation None The alarm is not used (that is, an alarm condition will not be activated under any circumstances). Low alarm An alarm condition will be activated when a sample measurement is lower than the preset alarm level. * High alarm An alarm condition will be activated when a sample measurement is higher than the preset alarm level. * * During a calibration, an alarm will only be activated if the alarm ‘Follow’ option is set to Yes. While a measurement alarm condition is activated: • An ‘alarm’ icon is shown on the measurement screen. The number ("1" or "2") in the icon will identify the alarm which has been triggered. • The alarm LED on the front of the analyser flashes on and off. • The appropriate alarm relay will be triggered. You can view the details of the activated alarm: see Section 5.20.4. Ensure that the measurement alarm and hysteresis levels are not too close to the expected sample measurements. (If there are minor and acceptable variations in your sample gas concentrations this will reduce spurious alarms). If you configure one measurement alarm as ‘low’ and configure the other alarm as ‘high’, ensure that the ‘high’ alarm and hysteresis levels are higher than the ‘low’ alarm and hysteresis levels. (If you do not, the analyser can be permanently in an alarm condition, until you correct the levels). 01910001B / Revision 6 71 SERVOTOUGH Oxy, Oxygen Gas Analyser 1. Select Set up. 2. Select the required transducer and alarm. Figure 64 - The Alarm set up screen 3. Select the required mode (none, low or high), then press the soft key. Figure 65 - The Alarm mode screen 4. Scroll up or down to edit the appropriate settings: • Latching (Section 5.20.2) • Level • Hysteresis (Section 5.20.3). ’Follow’ option: • If the ‘Follow’ option is set to ‘No’, the alarm will be inhibited during calibration. • If the ‘Follow’ option is set to ‘Yes’, the alarm will not be inhibited during cal. 1. Select Follow. 2. Select the required alarm. Figure 66 - The Alarm follow screen 3. Select the correct option: ‘Yes’ or ‘No’. Figure 67 - The Alarm follow options screen 72 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.20.2 Latching/non-latching alarms You can configure each of the two measurement alarms to be either latching or not latching: Alarm setting Meaning Latching Once the alarm condition has been activated, the alarm condition remains activated (even if subsequent sample measurements would not trigger the alarm) until the alarm is manually unlatched. Not latching Once the alarm condition has been activated, the alarm condition remains activated only until a subsequent sample measurement which would not trigger the alarm is made. The alarm condition is then deactivated. When necessary, use the following procedure to unlatch any ‘latched’ measurement alarm(s): 1. On the Measurement screen, press the (Figure 64) will then be displayed. 2. With the "Unlatch" option highlighted, press the soft key. All latched alarms will then be unlatched and the Measurement screen will be displayed again. 01910001B / Revision 6 soft key; the Alarm option screen 73 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.20.3 Hysteresis levels The hysteresis level associated with a measurement alarm determines when an alarm condition (once activated) is deactivated, and this depends on the alarm mode, as follows: Alarm mode Effect of hysteresis Low alarm Once the low alarm condition has been activated, the alarm condition will not be deactivated until a sample measurement is above (alarm level + hysteresis level). High alarm Once the high alarm condition has been activated, the alarm condition will not be deactivated until a sample measurement is below (alarm level - hysteresis level). For example: • If a ‘low’ alarm has an alarm level of 18% and a hysteresis level of 1%, the alarm will be activated when a sample measurement is < 18%, and the alarm will not be deactivated until a sample measurement is > 19%. • If a ‘high’ alarm has an alarm level of 20% and a hysteresis level of 2%, the alarm will be activated when a sample measurement is > 20%, and the alarm will not be deactivated until a sample measurement is < 18%. 74 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.20.4 Viewing the measurement alarm status 1. Select View. 2. In the Alarm status screen shown in Figure 68, both measurement alarms are shown as "Inactive"; that is, either the mode of each alarm is set to ‘none’, or no alarm condition currently exists. Figure 68 - The Alarm status screen If a measurement alarm condition exists when you view this screen, the screen will show: • The alarm number ("1" or "2"). • The sample reading which triggered the alarm condition. • The alarm mode (where "<" indicates a low alarm and ">" indicates a high alarm). • The alarm level. 01910001B / Revision 6 75 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.20.5 Setting the Measurement Filter Level Use the following procedure to set up the measurement filtering: 1. Select Set up 2. The current filter level is shown. Filtering. Figure 69 - Filter factor screen 3. Edit the filter factor to the desired level. Values must be between 001, no filtering, and 064. Figure 70 - Filter Factor Edit Screen The value relates to the number of readings that the filter averages over. i.e. 15 would mean a filter length of 15 readings. The measurement reading updates five times per second, therefore in this case the filter length is three seconds of measurement data. It is only recommended that the filter level is altered, default value of 8 readings, if excessive measurement fluctuations are experienced. This could be caused by high levels of vibration or sample system fluctuations, and we recommend that the root causes of the fluctuations are fully investigated before applying higher filter levels, as increasing filter length increases the response time of the analyser i.e. at a filter length of 064 the response time (T90) of the analyser is approximately 19 seconds. 76 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 5.21 Setting up the Flowcube (F3) Flow Sensor (option) The flow sensor option measures the sample flow through a measurement transducer and allows the user to configure two low flow alarms and one high flow alarm. The flow sensor allows preventative maintenance to be taken before the sample flow rate reduces to unacceptable levels Section 2.4. Configuration options and defaults for each flow sensor alarm level are given below: Alarm Default Alarm Levels Default Status Configurable Alarm Levels Low flow alarm 1 70% Maintenance required 25% to 90% Low flow alarm 2 50% Fault 25% to 90% High flow alarm 130% None 130% Status Options Maintenance required Fault None A zero and normal calibration must be performed on the flow sensor before the reading is accurate. See Section 6.3 for the calibration procedure. To prevent false fault status indications during the change over of gases during measurement calibration or validation (not flow calibration) the status level of each flow alarm level will be demoted. A Fault status will be reported as a Maintenance Required and a maintenance required status will not be reported at all. 1. Select Set up Flow alarm. 2. Scroll to the low flow level 1 screen and set the activation level for low flow alarm 1. Figure 71 - The low flow level 1 screen 01910001B / Revision 6 77 SERVOTOUGH Oxy, Oxygen Gas Analyser 3. Scroll to the low flow level 2 screen and set the activation level for low flow alarm 2. Figure 72 - The low flow level 2 screen 4. Scroll to the low flow 1 status screen and set the status type to be reported on low flow alarm 1 activation. Figure 73 - The low flow 1 status screen 5. Scroll to the low flow 2 status screen and set the status type to be reported on low flow alarm 2 activation. Figure 74 - The low flow 2 status screen 6. Scroll to the high flow status screen and set the status type to be reported on the high flow alarm activation (flow greater than 130%). Figure 75 - The high flow status screen 78 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 6 CALIBRATION CAUTION Sample and calibration gases must be as specified in Sections 2.4 and 2.6. If the gas pressures and/or flow rates are above those specified in Sections 2.4 and 2.6, you must regulate the gases externally, before they enter the analyser. CAUTION You must leave the analyser (with the electrical supply switched on) for at least 4 hours before you allow sample or calibration gases into the analyser. If you do not, the gas may condense inside the transducer. 6.1 Manual calibration The required frequency of calibration depends on the reliance that you place upon the accuracy and consistency of the measurements made by the analyser. Adjust the frequency according to your requirements/experience. You can carry out a manual calibration at any time unless an automatic validation/calibration is in progress. If the auto validation/calibration option is installed, the gas control relays (Section 5.3.4) will select the correct gas once the manual calibration screen is shown (Figure 76). Sample gas will be reselected once the screen is exited. For optimum measurement accuracy, perform Low and High calibrations. We recommend that you manually calibrate the analyser regularly during normal operation, and that you keep a record of the calibration errors. Use the errors to adjust the required calibration frequency You must manually calibrate the analyser as part of the initial set up, and whenever ambient conditions have changed. If the analyser is configured for automatic validation/calibration (see Section 6.2). 01910001B / Revision 6 79 SERVOTOUGH Oxy, Oxygen Gas Analyser Manually calibrate the analyser as follows: 1. Ensure that your equipment is configured to correctly route your calibration gas supply to the analyser sample gas inlet. 2. Select Calibrate Figure 76 - The Calibrate screen Note that the "9999d" field of the screen shown in Figure 76 will identify the period of time that has elapsed since the last calibration, and can be in any of the following forms: • 9999d specifying days • 9999m specifying minutes 3. Use the and • 9999h specifying hours • Any combination of these. soft keys to select the required calibration, that is: • ‘Lo’ (low calibration gas). • ‘Hi’ (high calibration gas). 4. Press the soft key. The Calibrate target value screen will then be shown, identifying the target value and the current reading. Figure 77 - The Calibrate target value screen 5. If the target value is not correct for the calibration gas which you are using, change the target value to the required value. Refer to Sections 2.4 and 2.6 for the required, flow rates and concentrations of the calibration gases. 80 6. When the current reading is stable, press the then carry out the specified calibration. soft key. The analyser will 7. Repeat steps 3 to 6 of this section for the second calibration. 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 6.2 Automatic validation/calibration 6.2.1 Initiating an automatic validation/calibration You must have set up the parameters/options as described in Section 5.15.2 before you initiate an automatic validation/calibration. If the timer is active and you have set the repeat option, an automatic validation/calibration will be initiated automatically at the specified times. When an automatic validation/calibration is in progress, all new initiation requests will be ignored (that is, initiation requests are not queued). Close the Start Auto val switch input on the appropriate interface connection (see Section 5.3.4) to initiate an automatic validation/calibration. Alternatively you can manually initiate an automatic validation/calibration as follows: 1. Press the soft key on the Measurement screen (or select the "Calibrate" option from the Menu screen). 2. Use the and soft keys to select the required automatic validation/calibration. 3. Press the 4. Note that the date/time of the last automatic validation/calibration is shown on the screen. ("-" will be shown if no automatic validation/ calibration has previously been run). 5. Press the 01910001B / Revision 6 Figure 78 - The Auto val/cal select screen soft key. soft key. Figure 79 - The Auto val/cal initiate screen 81 SERVOTOUGH Oxy, Oxygen Gas Analyser 6. Press the soft key to initiate the automatic validation/calibration. Figure 80 - The Auto val/cal confirm screen 6.2.2 Automatic validation/calibration status indications During an automatic validation/calibration: • A ‘service in progress’ icon ( ) is shown on the measurement screen, if displayed. • The calibration screen, if displayed, (pre-warning and inerting phase off) will be updated to show the current phase and the gas being used, as shown in Figure 81 to Figure 83. If the automatic validation/calibration fails: • A ‘maintenance required’ icon ( displayed. ) is shown on the measurement screen, if • A "failed" message will be shown on the calibration screen (if displayed), for example: see Figure 84. Figure 81 - The Auto val/cal status screen (flushing phase) Figure 82 - The Auto val/cal status screen (validating phase) 82 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Figure 83 - The Auto val/cal status screen (finishing phase) Figure 84 - The Auto val/cal failed screen 6.2.3 Stopping an automatic validation/calibration If you stop an automatic validation/calibration after the pre-warning phase, the inerting phase (if active) and the final flushing phase will always be completed. To stop an automatic validation/calibration which is in progress, close the stop Auto val switch input on the appropriate interface connection (see Section 5.3.4) or use modbus command see Appendix A1. Alternatively, whenever an automatic validation/ calibration is in progress and the (stop) icon is shown on the Auto val/cal status screen (see Figures 81 and 82), you can press the soft button to manually stop the automatic validation/calibration. When you press the soft button, the Auto val/cal stop confirmation screen is shown. Press the soft key to stop the automatic validation/calibration. The Measurement screen will then be displayed again. Press the 01910001B / Revision 6 Figure 85 - The Auto val/cal stop confirmation screen soft key to continue with the automatic validation/calibration. 83 SERVOTOUGH Oxy, Oxygen Gas Analyser 6.2.4 Viewing validation/calibration history You can use the following procedure to display the 100 most recent validation/ calibration points: 1. Select 2. This screen shows the target value (T) and the actual measurement reading (R) before val/cal was carried out. 3. It also shows whether the procedure performed was an Auto Calibration (Auto cal), Auto validation (Auto val), manual calibration (Man cal) and whether it was a Pass or a Fail. 4. Calibrate View history. Figure 86 - The validation/calibration history screen (initial view) Note also that the top line of the validation/calibration history screen will alternate between: • "Calibration /" (as in Figure 86 above), where is the number of the displayed calibration point and is the total number of calibration points stored. Figure 87 - The validation/calibration history screen (alternate view) • " " (as in Figure 87), specifying the date and time of the displayed calibration point. Use the and soft keys to scroll through and view the validation/calibration history screens for other validation/calibration points as required. 6.2.5 Calibrating the pressure sensor Every time a high calibration of the measurement transducer is carried out, the pressure sensor is calibrated automatically. No further calibration is necessary. 84 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 6.3 Calibrating the Flowcube (F3) Flow Sensor (option) If the flow sensor option has been fitted you must calibrate the flow sensor when you first calibrate the analyser and annually thereafter. Use the following procedure to calibrate the flow sensor: 1. Select Service Flow alarm 2. Select the zero calibration option and stop the flow of gas through through the analyser. Wait 3 minutes before pressing the soft key. Figure 88 - The flow calibrate zero screen 3. Select the normal calibration option and restore the sample flow through the analyser. Wait 3 minutes before pressing the soft key. Figure 89 - The flow calibrate normal screen 01910001B / Revision 6 85 SERVOTOUGH Oxy, Oxygen Gas Analyser 7 GENERAL OPERATION CAUTION Sample and calibration gases must be as specified in Sections 2.4 and 2.6. If the pressure/flow rates are outside the ranges specified in Sections 2.4 and 2.6, you must regulate the gases externally, before they enter the analyser. 7.1 Checking the relay signal outputs Gas selection relays (Sample, Cal lo, Cal hi) are not effected during the signal relay override as this could cause hazardous gas flows. If required, use the following procedure at any time to perform a check on the outputs of the signal relays fitted to the analyser: 1. Select Service 2. Figure 90 shows the relay state (Energised or Deenergised) that the relay signals outputs will be set to when the override is active. Edit if required. Relay. Figure 90 - The Relay override state screen When a relay is energised, the N/C-Common contacts will be open, and the N/O-Common contacts will be closed. The converse is true when the relay is deenergised. 3. Scroll to the relay override screen. 4. Select the "Yes" option, then press the soft key. The relay outputs will now be set to the selected override state, and you can use your control/monitoring equipment (connected to the analyser) to monitor the relay signal outputs Figure 91 - The Relay override action screen The relay signal outputs freeze at the selected override signal state as long as the ‘Override action’ screen is displayed. As soon as another screen is displayed, the relay signal outputs will be updated to reflect the corresponding alarm, fault and range states. 86 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 7.2 Pressure compensation (option) 7.2.1 Introduction When pressure compensation is on: • A Pressure Compensation indicator is displayed on the Measurement screen (see Figure 8). • The sample measurements shown on the Measurement screen (and provided as outputs) are pressure compensated measurements. • If required, you can view the pressure compensated and uncompensated sample measurements at any time: refer to Section 7.2.3. 7.2.2 Switching pressure compensation on/off To switch pressure compensation on/off, use the following procedure: 1. Select Set up Pressure. 2. The Pressure compensation select screen shows the current selection state: • "Yes" indicates that pressure compensation is on. • "No" indicates that pressure compensation is off. Figure 92 - The Pressure compensation select screen 7.2.3 Viewing pressure effected measurements When pressure compensation is on, use the following procedure to view simultaneous pressure compensated and uncompensated measurements: 1. Select 2. On this screen: View Pressure. • The "Pre comp" value is the sample measurement before pressure compensation. • The "Post comp" value is the pressure compensated sample measurement. 01910001B / Revision 6 Figure 93 - The Pressure view screen 87 SERVOTOUGH Oxy, Oxygen Gas Analyser 7.3 Checking the mA output If required, use the following procedure at any time to perform a check on a mA output: 1. Select 2. Select the option. 3. Edit the displayed override value. 4. Press the soft key: an acceptance screen showing "No" will then be displayed. Select "Yes" to apply the override. 5. Service required mA output. ‘Override’ Figure 94 - The mA output override screen The mA output will now be set to the override value you have selected. Use your control/monitoring equipment (connected to the analyser) to check that the output is correct. The mA output freezes at the override value as long as the ‘Override’ screen is displayed. As soon as another screen is displayed, the mA output value will be updated to reflect the gas measurement. 7.4 Viewing flow levels Select View Flow Alarm 1. The flow level shown at ‘A’ is indicating flow rate of 119% of nominal flow. 2. The flow level shown at ‘B’ is indicating flow rate of 35% of nominal flow. A B Figure 95 - Flow levels 7.5 Switching off the analyser After you have switched off the analyser, when required or as necessary (for example, if you need to carry out plant/factory maintenance and will not use the analyser for several days): 88 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser • Ensure the gas inlet and outlets are blocked off (closed valve or protective caps supplied). • Isolate/lockout the external electrical supply and disconnect the electrical supply cable from the analyser. 01910001B / Revision 6 89 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 90 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 8 ROUTINE MAINTENANCE WARNING The analyser must be maintained by a suitable skilled and competent person. WARNING Sample and calibration gases may be toxic, asphyxiant or flammable. Never inspect the inlet filter, open the front cover of the sample/control compartment, or service or repair the analyser while such gases are still connected to it. WARNING Sample and calibration gases may be toxic, asphyxiant or flammable and hazardous concentrations may accumulate within the analyser during use. Always open the front cover of the sample/control compartment in a force-ventilated enclosure with a minimum volume of 17 m3, or in another appropriate environment, in which any hazardous gases are directed away from you. 8.1 Cleaning the analyser When necessary, use a damp (but not wet) cloth to wipe clean the outer surfaces of the analyser, to prevent the entry of dust or other particulates into the breather vent or the interior of the analyser. 8.2 Inspection It is recommended that the analyser is inspected for signs of corrosion. Particular care is should be taken when inspecting the door seals, sample inlet and outlet entries, mounting plate and the gland entries. If a sample system or corrosive purge is being used, then the operation of these should be verified at regular intervals, no greater than annually. Failure of either the sample system or the corrosive purge can result in significant analyser damage and research has shown that sample system failures account for over 70% of analytical measurement field failures. The pressure drop across the analyser is low, less than 1.0kPa (0.15psi) in most cases, if excessive pressure is required to generate a flow through the analyser it is an indication that the inlet sintered filter is blocked or contaminated. If this is the case then this fitting can be removed and inspected or replaced. 01910001B / Revision 6 91 SERVOTOUGH Oxy, Oxygen Gas Analyser 8.3 Inspecting/replacing the fuse (when necessary) WARNING Ensure that the electrical supply is isolated/locked out from the analyser. If you do not, there will be a danger of injury or death from electric shock. WARNING Do not remove the cover of the power/signal compartment if an explosive atmosphere may be present. WARNING The power/interface compartment cover is heavy. Ensure that you do not drop the cover once it is disengaged from the body of the analyser. If you do, you may injure yourself or damage other equipment. Any damage to the thread on the cover will compromise the analyser certification. CAUTION Place the cover carefully on a clean surface, resting on the exterior of the cover, so that the pregreased threads do not become contaminated. If you suspect that the internal fuse has failed, use the following procedure to inspect it and replace if necessary: 1. Ensure that the external electrical supply is switched off and isolated/locked out from the analyser. 2. Refer to Figure 1. Use the 2 mm hexagonal key supplied to loosen the locking screw which secures the cover. 3. Unscrew the cover; that is, turn it anticlockwise. If necessary, fit a suitable metal bar between the protruding fins on the front of the cover to provide additional leverage. 4. When the cover is fully disengaged from the body of the analyser, remove it and place it carefully on a clean surface: see the caution above. 5. Refer to Figure 4. Remove the fuse (F101) and check the continuity across the fuse: • If there is continuity, the fuse has not failed: refit the fuse. • If there is no continuity, the fuse has failed: fit a new fuse of the correct type and rating. 92 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 8.4 Refit the power/interface compartment cover WARNING The power/interface compartment cover is heavy. Ensure that you do not drop the cover when you refit it to the body of the analyser. If you do, you may injure yourself or damage other equipment. CAUTION Ensure that the pregreased threads of the cover do not become contaminated. The threads on the cover are pregreased. You do not need to add any grease or sealant to the threads before you refit the cover. 1. Refer to Figure 1. Carefully refit the cover to the body of the analyser, so that the threads on the rear of the cover are correctly aligned with the threads in the analyser: pick the cover up by its exterior, and do not touch or contaminate the pregreased threads on the cover. 2. Screw on the cover (that is, turn the cover clockwise) to secure it to the analyser. It can help to turn the cover anticlockwise, up to one turn, till you feel or hear the threads align, before beginning to screw on the cover clockwise. 3. Fully tighten the cover. If necessary, fit a suitable metal bar between the protruding fins on the front of the cover to provide additional leverage. 4. Use the 2 mm hexagonal key supplied to tighten the locking screw which secures the cover. 5. Ensure that the certification label is in the correct orientation. If necessary, press and turn the label until it is in the correct orientation. If a new fuse fails immediately after you have fitted it, there may be an electrical fault in the analyser: contact Servomex or your Servomex agent. 01910001B / Revision 6 93 SERVOTOUGH Oxy, Oxygen Gas Analyser 8.5 Use of the analyser with toxic gases WARNING If you use the analyser to sample toxic gases, the concentrations of the gases sampled or used for calibration of the analyser may be above their respective threshold limit values. You must therefore regularly leak-test the analyser and associated equipment. If any leaks are found, do not continue to use the analyser or associated equipment until the leaks have been sealed. CAUTION When you carry out a leak test, do not exceed a maximum pressure of 34.5 kPa gauge (0.35 bar gauge, 5 psig) and do not introduce a sudden change of pressure into the analyser. If you do, you may damage it. CAUTION If you use a liquid to assist in leak testing, do not spill liquid onto any of the electrical components in the sample/control compartment. If you use the analyser for toxic gas sample measurements, you must regularly leaktest the analyser and the associated sample inlet and outlet pipelines or hoses. We recommend that you leak-test the analyser at least once every 6 months: • If there are leaks within the analyser, it must be returned to Servomex for repair. Do not continue to use the analyser. • You must seal any leaks in your sample pipelines or system. When you leak-test, ensure that you do not exceed the maximum pressure, and do not increase the pressure in the analyser too quickly (see the caution above): we recommend that you allow at least 30 seconds to fully pressurise the analyser to the maximum pressure. 94 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 8.6 Preventative maintenance To minimise unscheduled analyser downtime, ensure the proper operation of the analyser and to comply with the guidelines of applicable regulatory bodies, we recommend that you utilise the SERVOSURE annual preventative maintenance program for your analyser. The preventative maintenance program consists of a yearly inspection of the analyser, and repair of any faults, to ensure that the analyser meets its original factory specification. Once inspection and repair are complete, you will be provided with a full SERVOSURE report. Note that you will always be informed in advance if any repairs or new parts are required for your analyser. Contact Servomex or your local Servomex agent to arrange for a preventative maintenance contract. 01910001B / Revision 6 95 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 96 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 9 SAMPLE SYSTEM INTEGRATION CAUTION The SERVOTOUGH Oxy is a precision analytical device, suitable for a wide variety of industrial applications. Though every effort has been taken to ensure that the analyser is highly robust to differing sample stream compositions, it should be noted that if the requirements of Section 2.4 and Section 2.5 are not met then the analyser can be damaged and the measurement invalidated. 9.1 Sample Systems CAUTION The analyser will be damaged if condensation is allowed to form within the measurement cell or pipe work. It is important that the sample gas dew points specified in Section 2.4 are maintained at all times. It is recommended that sample systems contain a flow monitoring device on the outlet of the analyser, ideally with a status indication communicating back to the control room, or that the analyser is fitted with a Servomex Flowcube flow sensor option. Any failure in the sample flow can then be quickly diagnosed and corrective action taken. In the event of power failure to the analyser or the sample system, condensation can form within the sample pipework if the sample gas has a dew point below that of the ambient temperature. It is recommended that if there is a power failure that the sample system contains sufficient protection and interlocks on coolers and "hot" sample elements to prevent gas flow though the analyser until these are at working temperature. If the sample gas is considered corrosive, then it is recommended that during a power failure or while the sample system is not at operational conditions, that instrument air is used to purge the measurement pipework of the analyser. 01910001B / Revision 6 97 SERVOTOUGH Oxy, Oxygen Gas Analyser 9.2 Corrosive Purge CAUTION Failure of the corrosive purge could result in damage to the electronics within the sample/control compartment, which could result in an analyser failure. CAUTION The corrosive purge gas must comply with the requirements of Section 2.5. If the purge gas is not dry or contains other contaminates, i.e. oil vapours, then this can result in damage to the electronics within the sample/control compartment, which could result in an analyser failure. 98 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 10 FAULT FINDING 10.1 Fault, Maintenance Required and SIP Statuses 10.1.1 Status definitions • Fault - A serious fault has been detected. • Maintenance required - A maintenance required status has been raised, the analyser requires attention. • Service in Progress (SIP) - During service operations (calibration, auto validation, I/O overriding) a service in progress status will be raised. 10.1.2 Status Annunciations Condition LCD Icon LED Annunciation Relay Annunciation Fault Orange fault LED Fault relay deenergised Maintenance None Maintenance required relay energised Service in Progress (SIP) None Service in progress relay energised All status conditions are listed in alphabetical order on the next 4 pages. The LCD icons are displayed on the measurement screen only (see Figure 8). 01910001B / Revision 6 99 SERVOTOUGH Oxy, Oxygen Gas Analyser Message Measurement screen icon Recommended actions Auto cal high fail Check that the calibration gases are as specified in Section 2.4 and Section 2.6 and that the correct settings have been entered, then recalibrate the analyser again. Auto cal low fail Check that the calibration gases are as specified in Section 2.4 and Section 2.6 and that the correct settings have been entered, then recalibrate the analyser again. Auto cal low flow Flow has fallen below the Fault Level set for the flow sensor during a calibration routine (very low flow): Check that there is sufficient gas flow into the transducer (see Section 2.4) Auto val low flow Flow has fallen below the Fault Level set for the flow sensor during a validation routine: Check that there is sufficient gas flow into the transducer (see Section 2.4) Auto validate Raised during auto validation of the transducer (see Section 5.15) Auto val high fail Check that the calibration gases are as specified in Section 2.4 and Section 2.6 and that the correct settings have been entered, then revalidate the analyser again. Auto val low fail Check that the calibration gases are as specified in Section 2.4 and Section 2.6 and that the correct settings have been entered, then revalidate the analyser again. Calibration fault Recalibrate (both low and high) as described in Section 6. If the fault persists, contact Servomex or your local Servomex agent for assistance. Code fault Contact Servomex or your local Servomex agent for assistance. Communication fail Turn the analyser off, and then turn it on again. If the fault message is then displayed again, contact Servomex or your local Servomex agent for assistance. Messages (Sheet 1 of 5) 01910001B / Revision 6 100 SERVOTOUGH Oxy, Oxygen Gas Analyser Message Measurement screen icon Recommended actions Database fault Turn the analyser off, and then turn it on again. If the fault message is then displayed again, contact Servomex or your local Servomex agent for assistance. Date/Time invalid This usually occurs because the electrical supply to the analyser has been switched off for more than a week. Switch on the electrical supply, then set the date/ time as described in Section 5.13. If the fault persists, contact Servomex or your local Servomex agent for assistance. Fatal fault Contact Servomex or your local Servomex agent for assistance. Flow calibrate Raised during calibration of the Flowcube flow sensor. Flow H/W fault Contact Servomex or your local Servomex agent for assistance. Flow cal high diff The zero and normal calibration points are too far apart, check normal flow is within limits (see Section 2.4) and re-calibrate the Flowcube flow sensor. Flow cal low diff The zero and normal calibration points are too close, check normal flow is within limits (see Section 2.4) and there is no flow during zero calibration. Re-calibrate the Flowcube flow sensor. Flow temp fault Contact Servomex or your local Servomex agent for assistance. High flow alarm Configurable Flow risen above the set level for the Flowcube flow sensor: Check that there is not excessive gas flow into the transducer (see Section 2.4). Check that the level has been set correctly and that calibration has been performed (see Section 6.3). Check sample is clean and without contaminants. Messages (Sheet 2 of 5) 101 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Message Low flow alarm 1 / Low flow alarm 2 Measurement screen icon Configurable Recommended actions Flow has fallen below the set level for the Flowcube flow sensor: Check that there is sufficient gas flow into the transducer (see Section 2.4). Check that the level has been set correctly and that calibration has been performed (see Section 6.3). Heater fault Contact Servomex or your local Servomex agent for assistance. mA fault Ensure that the electrical cabling connected to the analyser is not open circuit. Turn the analyser off, and then turn it on again. If the fault persists, contact Servomex or your local Servomex agent for assistance. mA not detected Contact Servomex or your local Servomex agent for assistance. mA overridden Raised during checking of the mA output (see Section 7.3). mA reset Contact Servomex or your local Servomex agent for assistance. P calib fault Calibrate the pressure compensation transducer again. P high fault Adjust pressure. Contact Servomex or your local Servomex agent for assistance. P H/W fault Contact Servomex or your local Servomex agent for assistance. P low fault Adjust pressure. Contact Servomex or your local Servomex agent for assistance. Power config fault Contact Servomex or your local Servomex agent for assistance. Relay not detected Contact Servomex or your local Servomex agent for assistance. Relays overridden Raised when the alarm and status relays have been overridden (see Section 7.1). Messages (Sheet 3 of 5) 01910001B / Revision 6 102 SERVOTOUGH Oxy, Oxygen Gas Analyser Message Measurement screen icon Recommended actions Remote activation Raised when the Service in Progress status is remotely activated via the SIP digital inputs on the Calibration Card. Rem lo cal denied Raised when a remote low calibration cannot execute because the current reading is outside tolerances (see Section 5.15.4). Rem hi cal denied Raised when a remote high calibration cannot execute because the current reading is outside tolerances (see Section 5.15.4). Static RAM fault Turn the analyser off, and then turn it on again. If the fault message is then displayed again, contact Servomex or your local Servomex agent for assistance. Sw IP not detected Contact Servomex or your local Servomex agent for assistance. Temperature fault Reduce temperature to within environmental limits or contact Servomex or your local Servomex agent for assistance. Transducer error Ensure that you are using the analyser in the specified operating conditions (refer to Section 2). If the fault persists, contact Servomex or your local Servomex agent for assistance. Tx calibrate Raised during manual, remote or auto calibration of the transducer. Tx incorrect type Contact Servomex or your local Servomex agent for assistance. Tx maintenance Recalibrate (both low and high) as described in Section 6. If this does not clear the fault, turn the analyser off, and then turn it on again. If the fault message is then displayed again, contact Servomex or your local Servomex agent for assistance. Tx not detected Contact Servomex or your local Servomex agent for assistance. Messages (Sheet 4 of 5) 103 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Message Very low flow Measurement screen icon Recommended actions Flow has fallen below the Fault Level set for the Flowcube flow sensor: Check that there is sufficient gas flow into the transducer (see Section 2.4). Messages (Sheet 5 of 5) 01910001B / Revision 6 104 SERVOTOUGH Oxy, Oxygen Gas Analyser 10.2 Viewing messages 10.2.1 Active messages 1. Select Status 2. Each message shows: status Active. screen • Date and time of message. • The message type ("Fault", "Maintenance rqd" or "Service in Progress"). Figure 96 - The Message status screen • The message itself. 3. Refer to Section 10.1 for the recommended actions associated with the displayed messages. 10.2.2 View history messages 1. Select Status 2. Each message shows: View history • Date and time of message. • The message type ("Fault", "Maintenance rqd" or "Service in Progress"). • The message itself. Figure 97 - The Message status screen • The status of the entry ON or OFF. 3. Refer to Section 10.1 for the recommended actions associated with the displayed messages. A maximum of 100 status messages can be stored. 105 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 10.3 General fault finding For general analyser fault finding, refer to the table on the following pages. If you have read through the table and still cannot rectify a fault, or cannot identify the cause of a fault, contact Servomex or your local Servomex agent for assistance. Fault symptom Recommended actions The Fault LED is on. Check any current fault messages (see Section 10.2), and carry out the recommended actions (see Section 10.1). If there are no applicable fault messages stored, or if you cannot rectify the fault after you have carried out the recommended actions: • Switch off the analyser, then switch it on again. • If the fault persists, contact Servomex or your local Servomex agent for assistance. The software health indicator is not moving on the display. Carry out the recommended actions for the "The Fault LED is on" symptom above. " - - - - - " is displayed instead of a sample measurement. This indicates a possible measurement error, or a communications error between the transducer and the analyser controller. Check that the analyser is not being knocked, moved, or subjected to high levels of vibration during sample measurements. If the analyser is not being knocked, moved or subjected to vibration and the fault persists, contact Servomex or your local Servomex agent for assistance. Analyser response is slow. Check that the sample gas inlet is not blocked, and that the sample gas supply to the analyser is not restricted. Check that the sample gas outlet is not blocked, and that any pipes connected to the outlet are not restricted. Check that the inlet and outlet sintered filters are not blocked or show signs of moisture or particle contamination. Check that the sample gas supply pressure is correct: refer to Section 2.4. General fault finding (Sheet 1 of 3) 01910001B / Revision 6 106 SERVOTOUGH Oxy, Oxygen Gas Analyser Fault symptom Recommended actions Analyser measurements are not as expected. Check that the correct display units have been selected, and that the units conversion factor has been correctly entered (see Section 5.19). If you are using pressure compensation, check that the pressure transducer is switched on (see Section 7.2.2). Ensure there are no leaks in the pipework. Analyser measurements are unstable. Check that the sample gas supply pressure is correct: see Section 2.4. Check that the analyser is not being subjected to high levels of vibration and ensure there are no leaks. Check that the sample gas inlet is not blocked, and that the sample gas supply to the analyser is not restricted. Ensure there are no leaks in the pipework. The analyser will not calibrate. Check that the correct low and high calibration gases are being used: see Section 2.6. Check that the sample gas inlet is not blocked, and that the sample gas supply to the analyser is not restricted. Check that the sample gas outlet is not blocked, and that any pipes connected to the outlet are not restricted. The analyser will not switch on. Check that the external supply is switched on, and that no fuse or over-current device in the external supply has operated to switch off the supply. If the external electrical supply is correct, switch off and isolate the supply and check that the supply is correctly connected to the analyser. If the supply is correctly connected, the operating fuse may have failed; inspect and replace the fuse if necessary: refer to Section 8.3. General fault finding (Sheet 2 of 3) 107 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Fault symptom Recommended actions The analyser display is blank or is too dark. Check that the ambient temperature is within the valid analyser operating temperature range: refer to Section 2.2. Check that the display contrast adjustment has been correctly set (refer to Section 5.11), and has not been altered. The measurement alarms are activating more often than expected. Check that the analyser is not being knocked, moved, or subjected to high levels of vibration during sample measurements. Check that the alarm modes, alarm levels and hysteresis levels have been correctly set: refer to Section 5.20. The mA output is at 0 or 21.5 mA. If you have configured the milliAmp output to jam high or jam low, check whether a fault condition exists (see Section 5.16). Otherwise, contact Servomex or your local Servomex agent for assistance. The mA output is not as expected. Ensure that the electrical cabling connected to the analyser is not open circuit. Check that the milliAmp output is calibrated correctly (see Section 5.16.4). Check that you have selected the correct Range (see Section 5.16.3). A relay signal output is not as expected. Check that the signal cable is correctly connected to the analyser: refer to Section 5.3.3, Section 5.3.4 or Section 5.3.4 General fault finding (Sheet 3 of 3) 01910001B / Revision 6 108 SERVOTOUGH Oxy, Oxygen Gas Analyser 11 STORAGE AND DISPOSAL 11.1 Storage Refit any protective plastic covers (see Section 3) and place the analyser and any associated equipment in its original packaging before storage. Alternatively, seal it inside a waterproof plastic bag, sack, or storage box. Store the analyser and any associated equipment in a clean, dry area. Do not subject it to excessively hot, cold, or humid conditions: see Section 2.2. 11.2 Disposal Dispose of the analyser and any associated equipment safely, and in accordance with all of your local and national safety and environmental requirements. The analyser is not suitable for disposal in municipal waste streams (such as landfill sites, domestic recycling centres and so on). Refer to Appendix A6 for disposal requirements in accordance with the WEEE Directive within the EC. If you send the analyser to Servomex or your local Servomex agent for disposal, it must be accompanied by a correctly completed decontamination certificate. 109 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 01910001B / Revision 6 110 SERVOTOUGH Oxy, Oxygen Gas Analyser 12 SPARES WARNING Do not use spares other than those specified below, and do not attempt to carry out any maintenance procedures other than those specified in this manual. If you do, you can damage the analyser and invalidate its certification, and use of the analyser in a hazardous area may result in a risk of fire or explosion. The standard spares available for the analyser are shown below. You can order these spares from Servomex or your Servomex agent. Spare Part Number Fuse F101: 2 A for 100-120 V operation 204629 Fuse F101: 1 A for 220-240 V operation 2531-2630 Inlet & Outlet filter / resticter kit standard, viton orings S1910982 Inlet & Outlet filter / resticter kit solvent resistant, chemraz orings S1910983 Spare insulation kit - cover for inlet / outlet (sample heating only) S1910981 01910001B / Revision 6 111 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 112 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser APPENDIX A1 IMPLEMENTATION GUIDE FOR MODBUS COMMUNICATIONS A1.1 Introduction This appendix details the implementation and use of the Modbus protocol in the SERVOTOUGH Oxy Analyser. A1.2 References Document “MODBUS over Serial Line Specification & Implementation guide V1.0 Nov 02” Modbus web site modbus.org. A1.3 Modbus setup The Modbus setup form will allow the user to configure the following parameters: Default values are in Bold. A1.4 Parameters Options Comments Address 1 to 247 Slave address of unit. Mode ASCII or RTU Select serial transmission mode. Baud rate 2400, 4800, 9600, 19200, 38400 Parity Odd, Even, None. Supported function codes For simplicity, only the following function codes will be supported. Function Description Usage 01 Read coils Read calibration status, pump state, etc. 02 Read discrete inputs Read faults and alarm states. 03 Read holding registers Read settings. 04 Read input registers Read measurements, units, etc. 05 Write single coil Change modes, perform calibration etc. 06 Write single register Change single setting. 08 Sub Function 00= Return query data Diagnostic to test communications. 01910001B / Revision 6 113 SERVOTOUGH Oxy, Oxygen Gas Analyser A1.5 Function Description Usage 16 Write multiple registers Change multiple settings. Exception codes If an error should occur while processing a message one of the following exception codes will be returned by the instrument. A1.6 Code Condition Meaning 01 Illegal function Requested function code is not supported. 02 Illegal data address The combination of data address and transfer length is invalid for this function. 03 Illegal data value A value contained in the query data field is not an allowable value. This indicates a fault in the structure of the remainder of a complex request. This does NOT mean that a value to be stored in a register is incorrect as Modbus has no means of determining what is legal for any particular register. 04 Slave device failure An unrecoverable error occurred while the unit was attempting to perform the requested action. Addressing Addresses in Modbus ADU (application data unit), run from 1—N, whereas addresses in the Modbus PDU (protocol data unit) run from 0—N. This appendix gives addresses in the ADU model. Depending on the particular Modbus master, addresses may have to be entered as they are given or have 1 subtracted from them. For example to read register 101 an address of 100 may be needed. A1.7 Floating point numbers Floating point numbers (e.g. 12.34, -1012.32, etc.), are digitally represented using the IEEE-754 format. Single precision floating point numbers are used throughout and they require 32 bits of data. Since a Modbus register holds 16 bits it takes 2 registers to represent a floating point number. We default to having the most significant word of the float, bits 16-31, in the first register, and the least significant word, bits 0-15, in the next register. This order can be reversed by setting a coil. 114 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser A1.8 System data mapping Read-only access to system data will be provided in a block of 100 registers. These can be accessed as input registers using function code 04. A1.9 Register Name Comments 1-7 Serial Number ASCII text, 14 characters max, terminated by a zero. 8 - 15 Software Version ASCII text, 16 characters max, terminated by a zero. Transducer data mapping The transducer will provide read-only access to its measurements and associated data in blocks of input registers that can be read with function code 04. A block of 100 registers is allocated for the transducer to provide the means of supplying the measurement and other transducer related data as follows: Register Name Comments 101 - 200 Transducer Measurements and data for each transducer 01910001B / Revision 6 115 SERVOTOUGH Oxy, Oxygen Gas Analyser The following table shows the assignment for the transducer. Each register provides 2 bytes of data. Register Name Comments 101 - 102 Measurement As seen on the measurement display. Floating point number. 103 - 104 Filtered measurement Basic measurement, filtered. Floating point number. 105 - 106 Pressure compensated measurement Filtered and pressure compensated measurement. Floating point number. 107 - 108 PMR Primary measurement range 109 Warming state 0 = Not warming, 1 = Warming 110 - 112 Formula Gas formula. ASCII text, 5 characters max, terminated by a zero. 113 - 116 Units Measurement units. ASCII text, 7 characters max, terminated by a zero. 117 Auto val state 0 = Idle, 1 = Pre-warning, 2 = Inerting, 3 = Flushing, 4= Validating/Calibrating 118 Auto val gas 0 = Low gas, 1 = High gas, 2 = Sample gas 119 Auto val finishing 0 = Not finishing, 1 = Finishing 120 Auto val fail state 0 = Auto validation OK, 1 = Auto validation failed 121 Active analogue output range 0 = Range 1, 1 = Range 2 122 Flow Current flow through the transducer in percent A1.10 System fault mapping Read-only access to system fault information will be provided in a block of 100 registers. These can be accessed as discrete inputs using function code 02 or as input registers using function code 04. Reading them as discrete inputs provides a simple bit result for each, 0 for off and 1 for on. Reading them as input registers provides information on their NAMUR status, as follows: • 0 = off, • 1 = fault, • 2 = maintenance required, • 3 = service in progress. 116 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser The fault, maintenance required, and service in progress faults provide a summary of the other states and can only be off or on. The registers are assigned as follows: Register Name Comments 1001 Fault If any system fault exists. 1002 Maintenance required If any system maintenance required status exists. 1003 Service in progress If any system service in progress status exists. 1005 Date/Time invalid System clock needs setting. 1006 Code fault the programmed software has become corrupted. 1007 Database fault A fault occurred when using the database. 1012 Static RAM fault A fault in the internal memory has been detected. A1.11 Transducer fault and alarm mapping Read-only access to transducer fault and alarm information will be provided in a block of 100 registers and coils. These can be accessed as discrete inputs using function code 02 or as input registers using function code 04. Reading them as discrete inputs provides a simple bit result for each, 0 for off and 1 for on. Reading them as input registers provides information on their NAMUR status, as follows: • 0 = off, • 1 = fault, • 2 = maintenance required, • 3 = service in progress. Alarm 1 and alarm 2 are not faults and can only be off or on. The fault, maintenance required, and service in progress faults provide a summary of the other states and can only be off or on. The registers are assigned as follows: Register Name Comments 11011200 Measurements and data for each transducer Transducer 01910001B / Revision 6 117 SERVOTOUGH Oxy, Oxygen Gas Analyser Each input within the block for the transducer is assigned as follows: 118 Register Name Comments 1101 Alarm 1 Alarm 1 is active or latched. 1102 Alarm 2 Alarm 2 is active or latched. 1103 Fault If any transducer fault exists. 1104 Maintenance required If any maintenance required status exists. 1105 Service in progress If any service in progress status exists. 1106 Transducer maintenance fault Internal transducer fault. 1107 Transducer error Internal transducer fault. 1108 Transducer fatal fault Internal transducer fault. 1109 Heater fault Transducer heating has failed. 1110 Sample heater fault Transducer sample heating has failed. 1111 Calibration fault Transducer needs calibrating. 1112 Communication fail Transducer not responding. 1113 Incorrect transducer type Incorrect type of transducer fitted. 1114 Transducer not detected Transducer is unplugged or broken. 1115 Low calibration fail Auto cal low failed. 1116 High calibration fail Auto cal high failed. 1117 Low validation fail Auto val low failed. 1118 High validation fail Auto val high failed. 1119 Remote low cal denied Remote low calibration denied. 1120 Remote high cal denied Remote high calibration denied. 1121 Milliamp fault Hardware fault detected. 1122 Milliamp not detected Card is missing or the incorrect type has been fitted. 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Register Name Comments 1123 mA reset A time out occurred on the mA card. 1124 Volt fault Hardware fault detected. 1125 Volt not detected Card missing or the incorrect type has been fitted. 1126 Volt reset A time out occurred on the volt card. 1127 Pressure calibration Pressure needs calibrating. 1128 Pressure fail Hardware fault detected. 1129 Pressure low Pressure low fault. 1130 Pressure high Pressure high fault. 1131 Relay not detected Card missing or incorrect type has been fitted. 1132 Switch input not detected Card missing or incorrect type has been fitted. 1133 Flow fail Hardware fault detected. 1134 Low flow alarm 1 Flow has fallen below flow alarm level 1 1135 Low flow alarm 2 Flow has fallen below flow alarm level 2 1136 Remote service in progress Switch input has activated service in progress. 1137 Transducer calibration mode Calibration mode is active. 1138 Auto Sequence is in progress validation/calibration. 1139 Milliamp service in progress Calibration or override in progress. 1140 Volt service in progress Calibration or override in progress. 1141 Pressure service in progress Calibration in progress. 1142 Relay service in progress Override in progress. 1143 Flow service in progress Calibration in progress. 1145 High Flow Alarm Flow has risen above the high flow alarm level 1146 Flow temperature fault Flow hardware has a temperature fault 01910001B / Revision 6 119 SERVOTOUGH Oxy, Oxygen Gas Analyser Register Name Comments 1147 Flow cal high diff Zero and normal flow calibration points are too far apart 1148 Flow cal low diff Zero and normal flow calibration points are too close together 1149 Flow temp fault Temperature fault on flow sensor A1.12 System setup mapping System data will be available with read-write access in blocks of holding registers. This data can be read with function code 03 and written with function codes 06 and 16. Register Name Comments Clock 1 Year 0-99 2 Month 1-12 3 Date 1-31 4 Hour 0-23 5 Minute 0-59 6 Second 0-59 Calibration set up 7 Linked 0=No, 1=Yes. Switch input 8 Switch input function 0=Disabled, 1=Remote cal, 2=Auto val. A1.13 Transducer setup mapping The transducer will provide read-write access to various setup data in blocks of holding registers that can be read with function code 03 and written with function codes 06 and 16. Each register provides 2 bytes of data so it takes 2 registers each to store a 4 byte floating point measurement value. A block of 100 registers is allocated for each transducer to provide the means of supplying the transducer related setup data as follows: 120 Register Name Comments 101 - 200 Transducer Transducer related data. 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser The following table shows the assignment for the transducer. Each register provides 2 bytes of data. Register Name Comments Analogue Output 101-102 Range 1 low Float. 103-104 Range 1 high Float. 105-106 Range 2 low Float. 107-108 Range 2 high Float. 109 Range mode 0=Range 1, 1=Range 2, 2=Auto range. 110 Freeze 0=Follow, 1=Freeze. 111 Jam 0=None, 1=low, 2=high. 112 Output range 0=0-20mA, (0-10V), 1=4-20mA. 113-114 Under range Float. 115-116 Change over point Float. 117-118 Hysteresis Float. Cross Interference 119-120 Offset Float. Auto validation 121-122 Low target Float. Also calibration target. 123-124 Low tolerance Float. 125-126 High target Float. Also calibration target. 127-128 High tolerance Float. 129 Type 0=low, 1=high, 2=low and high, 3=high and low. 130 Mode 0=validate, 1=calibrate. 131 Pre-warning phase 0=No, 1=Yes. 132 Pre-warning seconds Integer. 133 Inerting phase 0=No, 1=Yes. 134 Inert gas 0=low, 1=high. 135 Inert seconds Integer. 136 Flush seconds Integer. 137 Timer 0=Off, 1=On. 138 Start year 0-99. 01910001B / Revision 6 121 SERVOTOUGH Oxy, Oxygen Gas Analyser Register Name Comments 139 Start month 1-12. 140 Start date 1-31. 141 Start hour 0-23. 142 Start minute 0-59. 143 Repeat hour Integer. Compensating 0=No, 1=Yes. Pressure 144 Alarm set up 145 Alarm 1 mode 0=None, 1=low, 2=high. 146 Alarm 1 latching 0=No, 1=Yes. 147-148 Alarm 1 level Float. 149-150 Alarm 1 hysteresis Float. 151 Alarm 2 mode 0=None, 1=low, 2=high. 152 Alarm 2 latching 0=No, 1=Yes. 153-154 Alarm 2 level Float. 155-156 Alarm 2 hysteresis Float. Flowcube Flow Sensor 157 Low flow 1 level A status will be raised if flow falls to this level 158 Low flow 2 level A status will be raised if flow falls to this level 159 Low flow 1 status type The type of status to use for the low flow 1 alarm 0=None, 1=Fault, 2=Maintenance Required. 160 Low flow 2 status type The type of status to use for the low flow 2 alarm 0=None, 1=Fault, 2=Maintenance Required. 161 High flow status type The type of status to use for the high flow alarm 0=None, 1=Fault, 2=Maintenance Required. 162 Fault relay active state Relay state when fault is raised 0=deenergised, 1=Energised 163 Maintenance Relay state when maintenance required is required relay active raised state 0=deenergised, 1=Energised 164 Service in progress relay active state Relays 122 Relay state when service in progress is raised 0=deenergised, 1=Energised 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Register Name Comments 165 Alarm 1 relay active Relay state when measurement alarm 1 is state active 0=deenergised, 1=Energised 166 Alarm 2 relay active Relay state when measurement alarm 2 is state active 0=deenergised, 1=Energised 167 Range relay active state Relay state when mA range 2 is selected 0=deenergised, 1=Energised A1.14 System control System control will be provided using a block of coils that can be written to using function code 05. Reading the same coils with function code 01 provides status information. Coil Name Comments 1 Floating point order Changes the order of the Modbus registers when dealing with 32-bit floating point numbers. 0=Big-endian, e.g. 40001=high word, 40002=low word (default). 1=Little-endian, e.g. 40001=low word, 40002=high word. 2 User interface busy 0=Idle (on main screen), 1=Busy, user interface is in use. Write 1 to stop the user interface (keys) being used. A1.15 Transducer control Transducer control will be provided using a block of coils that can be written to using function code 05. Reading the same coils with function code 01 provides status information. A block of 100 coils is reserved for each transducer as follows: Coil Name 101-200 Transducer 1 01910001B / Revision 6 Comments 123 SERVOTOUGH Oxy, Oxygen Gas Analyser The coils for transducer 1 are shown in the following table: Coil Name Comments Measurement 101 Calibration mode on/off 0=off (normal), 1=On (alarms masked, jamming etc). Write 1 to turn calibration mode on. 102 Low calibration gas 0=Sample gas, 1=low calibration gas. 103 High calibration gas 0=sample gas, 1=High calibration gas. 104 Low calibrate 0=Idle, 1=low calibration in progress. Write 1 to initiate low calibration. 105 High calibrate 0=Idle, 1=high calibration in progress. Write 1 to initiate a high calibration. 106 Start auto val 0=Idle, 1=Auto val in progress. Write 1 to start an auto validation/ calibration. 107 Stop auto val 0=Auto val in progress and can be stopped, 1=Stop N/A. Write 1 to stop an auto validation/ calibration. Flowcube Flow Sensor 111 Calibrate flow mode 0= Normal, 1= Calibrate mode. 112 Calibrate zero flow 1=Calibrate at 0% flow. 113 Calibrate nominal 1=Calibrate at 100% flow. span flow Analogue Output 114 Calibration mode 0= Normal, 1= Calibration mode. 115 Decrease output level 1= Step down. 116 Increase output level 1= Step up. 117 Service mode 0= Normal, 1= Service mode. 118 Relay state during service 0= De-energised, 1= Energised. Relays 124 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Coil Name Comments Remote Service in Progress 119 Remote service in progress 0= Inactive, 1= Active. Autovalidation 120 Autovalidation mode 01910001B / Revision 6 0= Validate, 1= Calibrate. 125 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 126 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser APPENDIX A2 CONFIGURING THE MODBUS PARAMETERS If your analyser has the Modbus output (either RS485 or Ethernet), you must configure the communications parameters to suit the requirements of the network to which you have connected the analyser. The cable connections are shown in Section 5.3.5. All screen shots show the default setting. These values are supervisor password protected. Your network administrator will advise you of the necessary parameters that will be required to be entered. A2.1 RS485 1. Select Settings 2. The first screen (see Figure A98) requests the communication mode. This can be RTU or ASCII. 3. Press the the value. Comms parameters. softkey to change Figure A98 - Comms Parameters Mode Screen Use 8 bits for RTU and 7 bits for ASCII. 4. Use the softkey to select the next parameter: 5. Node address, this can be anything from 1 to 247. Use the and soft keys to select the correct value. Figure A99 - Comms Parameters Node address screen 01910001B / Revision 6 127 SERVOTOUGH Oxy, Oxygen Gas Analyser 6. Use the and soft keys to select the next parameter: 7. Baud Rate, this can be anything 2400, 4800, 9600, 19200 or 38400. Use the and soft keys to select the correct value. Figure A100 - Comms Parameters Baud rate screen 8. Use the and soft keys to select the next parameter. 9. Parity, this can be none, even or odd. Use the and soft keys to select the correct value. Figure A101 - Comms Parameters Parity screen A2.2 TCP (Ethernet) Each parameter consists of a 4-octet address in the form xxx.xxx.xxx.xxx where x represents a digit, each xxx octet can be in the range 000 to 255. 1. Select Settings 2. The first screen requests the IP address, (always communicates in RTU mode). Use the and soft keys to select the correct value. Comms parameters. Figure A102 - Comms Parameters IP Address screen The IP address must be set to a unique value in the network. 128 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser 3. Use the and soft keys to select the next parameter: 4. Subnet mask, sets the subnet mask for the network. A provisional mask is generated automatically by the control unit whenever a new IP address is entered that falls into a different class. The mask may then Figure A103 - Comms Parameters Subnet mask screen be altered manually if required by clicking soft key. 5. Use the and soft keys to select the next parameter: 6. Gateway address, or router, allows communication to other LAN segments. The gateway address should be the IP address of the router connected to the same LAN segment as the unit. The gateway address must be within the local network. 01910001B / Revision 6 Figure A104 - Comms Parameters Gateway address screen 129 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 130 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser APPENDIX A3 DISPLAY UNIT CONVERSION FACTORS When you select display units as described in Section 5.19, you must ensure that you also enter the correct units conversion factor, as shown in the table below: To convert from * to † use the units conversion factor % ppm 10000 ppm % 0.0001 ppm vpm 1 ppm mg/m3 1.4277 % mg/m3 14277 % mol/mol 0.01 ppm mol/mol # * Measurement default units. † Selected display units. # This conversion is not supported. To return to the measurement default units, select the "off" units selection option and set the units conversion factor to "1": see Section 5.19. 01910001B / Revision 6 131 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 132 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser APPENDIX A4 PARAMAGNETIC CORRECTION FACTORS For a paramagnetic oxygen measurement, the composition of any typical background gas in the gas sample will have a minor effect on the analyser measurement. For an analyser which has been ’Lo’ calibrated with N2 (nitrogen) and ’Hi’ calibrated with O2, some examples of cross-interference errors (that is, O2 measurement errors) in gases which contain 100% of a background gas are shown below. Background gas Error Background gas Error Hydrogen 0.26% Methane -0.18% Carbon dioxide -0.30% Propane -0.87% The correction is directly proportional to the concentration of the background gas in the sample being measured, and in many cases can be ignored. All corrections must be calculated using 60oC data from the tables below. If you cannot ignore the error, you can use the procedure in Section 5.18.2 to enter a compensation to correct for the error. Example corrections are shown below. Example: If you are measuring O2 (oxygen) in a background of Carbon dioxide -0.30 should be entered as the cross interference offset. Example: If you are measuring 10% Oxygen in a background of 70% Hydrogen and 20% Carbon Dioxide the correction factor would be: The correction factor assumes 100% of background gas, so you must firstly correct for the nominal process oxygen concentration: Total background concentration = 70% + 20% = 90% Correct background concentrations for 0% oxygen: (100% / 90%) x 70% = 77.8% Hydrogen (100% / 90%) x 20% = 22.2% Carbon Dioxide For 100% Hydrogen the correction is 0.26, so for 77.8% it is 0.202 For 100% Carbon Dioxide the correction is -0.30, so for 22.2% it is -0.067 So the total correction factor in this case is -0.067 + 0.202 = 0.135 01910001B / Revision 6 133 SERVOTOUGH Oxy, Oxygen Gas Analyser Pure Gas Formula Molar mag.susc x 10-6 Zero offset 20oC 50oC 60oC 110oC Acetaldehyde Acetic acid Acetone Acetylene Acrylonitrile Allyl alcohol Ammonia Argon CH2CHO CH3CO2H CH3COCH3 HCCH CH2=CHCN CH2CHCH2OH NH3 Ar -22.70 -31.50 -33.70 -20.80 -24.10 -36.70 -18.00 -19.60 -0.31 -0.56 -0.63 -0.25 -0.35 -0.71 -0.17 -0.22 -0.34 -0.62 -0.69 -0.28 -0.39 -0.79 -0.19 -0.24 -0.35 -0.64 -0.71 -0.29 -0.40 -0.81 -0.20 -0.25 -0.40 -0.74 -0.82 -0.33 -0.46 -0.93 -0.23 -0.29 Benzene Boron chloride Boron trifluoride Bromine 1,2 Butadiene 1,3 Butadiene N-Butane iso-Butane 1 Butene N-Butyl acetate iso-Butylene 1 Butyne (Ethylacetylene) C6H6 BCl3 BF3 Br2 C4H6 C4H6 C4H10 (CH3)2CHCH2 CH3CH2CH=CH2 CH3COOC4H9 (CH3)2CH=CH2 CH3C3H2 -54.84 -59.90 -19.00 -73.50 -35.60 -30.60 -50.30 -51.70 -41.10 -77.50 -44.40 -43.50 -1.24 -1.38 -0.20 -1.78 -0.68 -0.54 -1.11 -1.15 -0.84 -1.89 -0.94 -0.91 -1.36 -1.53 -0.22 -1.96 -0.75 -0.59 -1.22 -1.26 -0.93 -2.09 -1.03 -1.00 -1.41 -1.57 -0.23 -2.02 -0.77 -0.61 -1.26 -1.30 -0.96 -2.15 -1.06 -1.03 -1.62 -1.81 -0.26 -2.32 -0.89 -0.70 -1.45 -1.50 -1.10 -2.47 -1.22 -1.19 Carbon dioxide Carbon disulphide Carbon monoxide Carbon tetrachloride Carbon tetrafluoride Chlorine Chloro ethanol Chloroform Cumene Cyclohexane Cyclopentane Cyclopropane CO2 CS2 CO CCl4 CF4 Cl2 ClCH2CH2OH CHCl3 (CH3)2CHC6H5 C6H12 C5H10 C3H6 -21.00 -42.20 -9.80 -66.60 -31.20 -40.50 -51.40 -59.30 -89.53 -68.13 -59.18 -39.90 -0.26 -0.87 0.06 -1.58 -0.55 -0.82 -1.14 -1.37 -2.24 -1.62 -1.36 -0.81 -0.29 -0.96 0.07 -1.74 -0.61 -0.91 -1.25 -1.51 -2.47 -1.79 -1.50 -0.89 -0.30 -0.99 0.07 -1.79 -0.63 -0.94 -1.29 -1.55 -2.55 -1.84 -1.55 -0.92 -0.34 -1.14 0.08 -2.06 -0.72 -1.08 -1.49 -1.78 -2.93 -2.12 -1.70 -1.05 Diacetylene Dichloroethylene Diethyl ether 2,2 Difluoro 1 chloroethane 1,2 Difluoro 1,2 dichloroethylene Difluoro dichloro methane (Freon 12) Dimethoxy methane Dimethylamine Dimethylether Dimethylethylamine C4H2 (CHCl)2 (C2H5)2O CClH2CHF2 CFCl=CFCl CCl2F2 -37.50 -49.20 -55.10 -52.40 -60.00 -52.20 -0.74 -1.07 -1.25 -1.17 -1.39 -1.16 -0.81 -1.18 -1.37 -1.29 -1.53 -1.28 -0.84 -1.22 -1.41 -1.33 -1.58 -1.32 -0.96 -1.40 -1.63 -1.52 -1.81 -1.5 CH2(OCH3)2 (CH3)2NH CH3OCH3 (CH3)2NC2H5 -47.30 -39.90 -26.30 -63.60 -1.02 -0.81 -0.41 -1.49 -1.12 -0.89 -0.46 -1.64 -1.16 -0.92 -0.47 -1.69 -1.33 -1.05 -0.54 -1.95 Enflurane (Ethrane) Ethane Ethanol C3H2F5ClO C2H6 C2H5OH -80.10 -26.80 -33.60 -1.97 -0.43 -0.62 -2.17 -0.47 -0.69 -2.24 -0.49 -0.71 -2.57 -0.56 -0.82 Ethyl acetate Ethyl amine Ethyl benzene Ethyl bromide CH3COOC2H5 C2H5NH2 C6H5C2H5 C2H5Br -54.20 -39.90 -77.20 -54.70 -1.22 -0.81 -1.88 -1.23 -1.34 -0.89 -2.08 -1.36 -1.39 -0.92 -2.14 -1.40 -1.59 -1.05 -2.46 -1.61 134 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser Pure Gas Formula Molar mag.susc x Zero offset 50oC 20oC 60oC 110oC 10-6 Ethyl chloride Ethylene Ethylene glycol Ethylene oxide Ethyl mercaptan C2H5Cl C2H 4 (CH2OH)2 (CH2)2O C2H5OSO3H -46.00 -18.80 -38.80 -30.70 -47.00 -0.98 -0.20 -0.77 -0.54 -1.01 -1.08 -0.22 -0.85 -0.60 -1.11 -1.12 -0.22 -0.88 -0.61 -1.15 -1.28 -0.26 -1.01 -0.71 -1.32 Fluorochlorobromomethane Fluorodichloromethane (Freon 21) Fluroxene Freon 114 Furan CFClBr CHCl2F CF3CH2OCHCH2 C2Cl2F4 C4H 4O -58.00 -48.80 -56.70 -77.40 -43.09 -1.33 -1.06 -1.29 -1.89 -0.90 -1.46 -1.17 -1.42 -2.08 -0.99 -1.51 -1.21 -1.47 -2.15 -1.02 -1.74 -1.39 -1.69 -2.47 -1.17 Germanium tetrachloride GeCl4 -72.00 -1.73 -1.91 -1.97 -2.26 Halothane Helium N-Heptane N-Hexane Hydrogen Hydrogen bromide C2HBrClF3 He C7H16 C6H14 H2 Br -78.80 -1.88 -85.24 -73.60 -3.98 -35.30 -1.93 0.29 -2.12 -1.78 0.23 -0.67 -2.13 0.32 -2.33 -1.96 0.26 -0.74 -2.19 0.33 -2.40 -2.02 0.26 -0.76 -2.52 0.38 -2.76 -2.32 0.30 -0.88 Hydrogen chloride Hydrogen cyanide Hydrogen iodide Hydrogen selenide Hydrogen sulphide HCl HCN HI H2Se H 2S -22.60 -14.50 -48.20 -39.20 -25.50 -0.31 -0.07 -1.05 -0.79 -0.39 -0.34 -0.08 -1.15 -0.87 -0.43 -0.35 -0.08 -1.19 -0.89 -0.44 -0.40 -0.09 -1.37 -1.03 -0.51 Isoflurane (Forane) Isoprene C3H2F5ClO C5H 8 -80.10 -44.80 -1.97 -0.95 -2.17 -1.04 -2.24 -1.08 -2.57 -1.24 Ketene Krypton CH2CO Kr -15.70 -28.80 -0.11 -0.49 -0.12 -0.54 -0.12 -0.55 -0.14 -0.63 Methane Methanol Methoxyfluorane Methyl acetate Methyl cyclopentane Methylene chloride Methylethlyketone Methyl fluoride Methyl formate Methyl iodide Methyl iso-butyl ketone (MIBK) Methyl mercaptan Molybdenum hexafluoride Monochlorobenzene CH4 CH3OH CHCl2CF2OCH3 CH3COCH3 C6H12 CH2Cl2 CH3COCH2CH3 CH3F HCOOCH3 CH3I C4H9COCH3 CH3SH MoF6 C6H5Cl -17.40 -21.40 -87.10 -42.60 -70.20 -46.60 -45.50 -25.50 -32.00 -57.20 -69.30 -35.30 -26.00 -70.00 -0.16 -0.27 -2.17 -0.88 -1.68 -1.00 -0.97 -0.39 -0.58 -1.31 -1.66 -0.67 -0.40 -1.68 -0.17 -0.30 -2.39 -0.97 -1.85 -1.10 -1.07 -0.43 -0.64 -1.44 -1.82 -0.74 -0.45 -1.85 -0.18 -0.31 -2.47 -1.00 -1.91 -1.14 -1.10 -0.44 -0.66 -1.48 -1.88 -0.76 -0.46 -1.90 -0.20 -0.35 -2.83 -1.15 -2.20 -1.31 -1.26 -0.51 -0.75 -1.71 -2.16 -0.88 -0.53 -2.19 Neon Nitric oxide Nitrobenzene Nitrogen Nitrogen dioxide Ortho-Nitrotoluene para-Nitrotoluene Nitrous oxide Ne NO C6H5NO2 N2 NO2 C6H4CH3NO2 C6H4CH3NO2 N 2O -6.70 1461.00 -61.80 -12.00 150.00 -72.30 -76.90 -18.90 0.15 42.56 -1.44 0.00 5.00 -1.74 -1.88 -0.20 0.17 42.96 -1.59 0.00 16.00 -1.92 -2.07 -0.22 0.17 42.94 -1.63 0.00 20.00 -1.98 -2.13 -0.23 0.20 41.62 -1.88 0.00 35.00 -2.28 -2.45 -0.26 01910001B / Revision 6 135 SERVOTOUGH Oxy, Oxygen Gas Analyser Pure Gas Formula Molar mag.susc x Zero offset 50oC 20oC 60oC 110oC 10-6 N-Nonane N-Octane C9H20 C8H18 -108.13 -96.63 -2.78 -2.45 -3.06 -2.70 -3.16 -2.78 -3.63 -3.19 Oxygen Ozone O2 O3 3449.00 6.70 100.0 0.54 100.0 0.60 100.0 0.61 100.0 0.71 iso-Pentane N-Pentane 0.01%Phenol C5H12 C5H12 C6H5OH -64.40 -63.10 -60.21 -1.51 -1.48 -1.39 -1.67 -1.63 -1.54 -1.72 -1.68 -1.58 -1.98 -1.93 -1.82 Phosphine Phosphorous oxychloride Propane iso-Propanol Propene N-Propyl acetate Propyl amine Propyl chloride Propylene Propylene oxide iso-Propyl ether Propyl fluoride Pyridine PH3 POCl3 C3H8 (CH3)2CHOH CH3CH=CH2 CH3COOC3H7 C3H7NH2 C3H7Cl C3H6 OCH2CHCH3 (CH3)4CHOCH C3H7F N(CH)5 -26.00 -69.00 -38.60 -47.60 -31.50 -65.90 -52.40 -56.10 -31.50 -42.50 -79.40 -52.20 -49.21 -0.40 -1.65 -0.77 -1.03 -0.56 -1.56 -1.17 -1.27 -0.56 -0.88 -1.95 -1.16 -1.08 -0.45 -1.82 -0.85 -1.13 -0.62 -1.72 -1.29 -1.40 -0.62 -0.97 -2.15 -1.28 -1.19 -0.46 -1.87 -0.87 -1.17 -0.64 -1.77 -1.33 -1.45 -0.64 -1.00 -2.21 -1.32 -1.22 -0.53 -2.15 -1.00 -1.34 -0.74 -2.03 -1.52 -1.66 -0.74 -1.15 -2.54 -1.52 -1.40 Silane Silicon tetrachloride Styrene Sulphur dioxide Sulphur hexafluoride SiH4 SiCl4 C6H5CH=CH2 SO2 SF6 -20.50 -88.30 -68.20 -18.20 -44.00 -0.25 -2.20 -1.62 -0.18 -0.92 -0.27 -2.43 -1.79 -0.20 -1.02 -0.28 -2.50 -1.85 -0.20 -1.05 -0.32 -2.88 -2.12 -0.23 -1.21 Tetrachoroethylene Tetrahydrofuran Toluene 1,1,2 Trichloroethane (Freon 113) Trichloroethylene Trifluorochloroethylene Trimethylamine Tungsten fluoride Cl2C=CCl2 C4H8O C6H5CH3 CHCl2CH2Cl -81.60 -52.00 -66.11 -66.20 -2.01 -1.16 -1.56 -1.57 -2.22 -1.27 -1.72 -1.73 -2.28 -1.31 -1.78 -1.78 -2.63 -1.51 -2.04 -2.05 CHCl=CCl2 C2F3Cl (CH3)3N WF6 -65.80 -49.10 -51.70 -40.00 -1.55 -1.07 -1.15 -0.81 -1.71 -1.18 -1.26 -0.89 -1.77 -1.22 -1.30 -0.92 -2.03 -1.40 -1.50 -1.06 Urethane CO(NH2)OC2H5 -57.00 -1.30 -1.43 -1.48 -1.70 Vacuum Vinyl bromide Vinyl chloride Vinyl fluoride CH2=CHBr CH2=CHCl CH2=CHF 0.00 -44.80 -35.60 -28.80 0.35 -0.95 -0.68 -0.49 0.38 -1.04 -0.75 -0.54 0.39 -1.08 -0.77 -0.55 0.45 -1.24 -0.89 -0.63 Water H2O -13.00 -0.03 -0.03 -0.03 -0.04 Xenon Xylene Xe (CH3)2C6H4 -43.90 -77.78 -0.92 -1.90 -1.02 -2.09 -1.05 -2.16 -1.20 -2.48 136 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser APPENDIX A5 MATERIALS IN CONTACT WITH SAMPLE AND CALIBRATION GASES The materials of the parts of the analyser in contact with the sample and calibration gases are listed below. These materials have a wide range of chemical compatibility and corrosion resistance. Analyser with standard transducer: 304 St Steel Viton Borosilicate glass* 316 stainless steel Platinum Platinum / Iridium Alloy Electroless Nickel Analyser with solvent resistant transducer: 304 St Steel Chemraz® 555 PTFE Borosilicate glass* 316 stainless steel Platinum Platinum / Iridium Alloy Electroless Nickel Pressure Sensor (Extra to above): None Flowcube Flow Sensor (Extra to above): Zirconia Aluminia Silicate Glass 01910001B / Revision 6 137 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 138 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser A6 DISPOSAL IN ACCORDANCE WITH THE WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE) DIRECTIVE The analyser is not considered to be within the scope of the Waste Electrical and Electronic Equipment (WEEE) Directive. The analyser is not intended for disposal in a municipal waste stream, but shall be submitted for material recovery and recycling in accordance with any appropriate local regulations. For additional information and advice on the disposal of the analyser, contact Servomex: Servomex Group Limited, Jarvis Brook, Crowborough, East Sussex, TN6 3DU, England Tel: Fax: Global email: (44) 1892 652181 (44) 1892 662253 info@servomex.com If you send the analyser to Servomex or your local Servomex agent for disposal, it must be accompanied by a correctly completed decontamination certificate. 01910001B / Revision 6 139 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 140 01910001B / Revision 6 SERVOTOUGH Oxy, Oxygen Gas Analyser APPENDIX A7 COMPLIANCE AND STANDARDS INFORMATION • The analyser complies with the European Community "Electromagnetic Compatibility Directive". To comply with the above directive, the analyser must not be used in residential areas. • The analyser complies with the European Community "ATEX Directive". • The analyser is rated in accordance to Overvoltage Category II, Pollution Degree 2. • The analyser complies with the Class A digital apparatus requirements of ICES-003 of Canada through the application of EN 55011:2007. • L'analyseur est conforme aux Conditions A numériques d'appareillage de classe de NMB-003 du Canada par l’application du EN 55011:2007. • This analyser complies with Part 15 of the US FCC Rules for Class A equipment. It is not suitable for operation when connected to a public utility power supply that also supplies residential environments. 01910001B / Revision 6 141 SERVOTOUGH Oxy, Oxygen Gas Analyser This page is blank 142 01910001B / Revision 6