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Servomex OxyExact (2210) Control Unit Installation Manual
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PROCESS ANALYSERS
SERVOTOUGH
OxyExact (2210)
Control Unit
Installation Manual
Part Number:
Revision:
Language:
02210/005A
10
UK English
This page intentionally blank
SERVOTOUGH OxyExact Installation Manual 02210005A_10
TABLE OF CONTENTS
1.
INTRODUCTION ....................................................................................................................... 1
1.1
SAFETY INFORMATION .............................................................................................................. 1
1.2
SCOPE OF THIS MANUAL ........................................................................................................... 1
1.3
EC DIRECTIVE COMPLIANCE ..................................................................................................... 1
1.4
GENERAL DESCRIPTION ........................................................................................................... 2
1.4.1 Standard Attributes............................................................................................................ 2
1.4.2 Optional Attributes ............................................................................................................. 2
1.5
HAZARDOUS AREA APPROVAL AND CERTIFICATION.................................................................... 3
2.
INSTALLATION ......................................................................................................................... 4
2.1
OVERVIEW OF THE INSTALLATION .............................................................................................. 4
2.2
CONTROL UNIT OPTION CARDS ................................................................................................ 5
2.3
INSTALLATION LOCATION .......................................................................................................... 6
2.4
ELECTRICAL SUPPLY REQUIREMENTS ....................................................................................... 7
2.5
SIGNAL OUTPUTS/INPUTS ......................................................................................................... 7
2.5.1 MODBUS Communications ............................................................................................... 7
2.5.2 Analog Output Board ......................................................................................................... 7
2.5.3 Relay Board ....................................................................................................................... 9
2.5.4 Digital Inputs Board ......................................................................................................... 10
2.6
TAG NUMBERS ....................................................................................................................... 10
3.
3.1
3.2
3.3
4.
MECHANICAL INSTALLATION ............................................................................................. 11
UNPACKING AND INSPECTION.................................................................................................. 11
CONTROL UNIT DESCRIPTION ................................................................................................. 11
FIXING CENTRES.................................................................................................................... 12
ELECTRICAL INSTALLATION ............................................................................................... 14
4.1
CE MARKINGS ....................................................................................................................... 14
4.2
GLANDS AND CABLE ENTRIES ................................................................................................. 15
4.3
IDENTIFICATION AND LOCATION OF COMPONENTS .................................................................... 15
4.4
EARTH/GROUND REQUIREMENTS ............................................................................................ 17
4.5
ELECTRICAL POWER SUPPLY CONNECTION ............................................................................. 17
4.6
TRANSMITTER UNIT TO CONTROL UNIT CONNECTION............................................................... 18
4.6.1 Cable Termination Link ................................................................................................... 19
4.7
SIGNAL AND OUTPUT/INPUT CONNECTIONS ............................................................................. 19
4.7.1 MODBUS® Connection ................................................................................................... 19
4.7.2 Analog Output Board ....................................................................................................... 21
4.7.3 Relay Board ..................................................................................................................... 21
4.7.4 Digital Inputs Board ......................................................................................................... 22
5.
AUTOCALIBRATION OPTIONS ............................................................................................. 23
6.
INSTALLATION CHECK LIST ................................................................................................ 28
7.
ROUTINE MAINTENANCE ..................................................................................................... 29
APPENDIX 1
TECHNICAL SPECIFICATION ............................................................................. 30
APPENDIX 2
MODBUS PROFILE .............................................................................................. 31
APPENDIX 3
CERTIFICATION ................................................................................................... 41
I
SERVOTOUGH OxyExact Installation Manual 02210005A_10
FIGURES
FIGURE 1-1: ATEX CERTIFICATION DETAILS ..................................................................................................... 3
FIGURE 1-2: IECEX CERTIFICATION DETAILS ..................................................................................................... 3
FIGURE 2-1: ANALYSER SYSTEM CONFIGURATIONS ............................................................................................ 5
FIGURE 3-1: FLUSH PANEL MOUNTING DETAILS ................................................................................................ 12
FIGURE 3-2: MECHANICAL ARRANGEMENT ....................................................................................................... 13
FIGURE 4-1: ELECTRICAL CONNECTIONS ........................................................................................................... 16
FIGURE 5-1: AUTOCALIBRATION CYCLE ........................................................................................................... 24
FIGURE 5-2: AUTOCALIBRATION CONFIGURATIONS .......................................................................................... 26
TABLES
TABLE 2-1: NAMUR NAS4 VS SYSTEM DISPLAY .............................................................................................. 9
TABLE 4-1: PATCH LEAD WIRE COLOURS .......................................................................................................... 20
TABLE 5-1: AUTOCALIBRATION LOGIC TABLE ................................................................................................... 25
TABLE 5-2: SOFTWARE CONFIGURATION OPTIONS ............................................................................................ 27
TABLE 6-1: INSTALLATION CHECKLIST ............................................................................................................. 28
II
SERVOTOUGH OxyExact Installation Manual 02210005A_10
1.
1.1
INTRODUCTION
Safety Information
This manual includes WARNINGS, CAUTIONS and NOTES which provide information
relating to the following
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
Laser monitor 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).
1.2
Scope of this Manual
This manual covers installation and routine maintenance of the SERVOTOUGH
OxyExact Control Unit.
For details of operation refer to the Operator manual, part number 02210/001A. For
technical specification refer to Appendix 1. Contacts for technical assistance and spares
are given at the back of this manual.
A service manual is available for use by qualified personnel, part number 02200002A.
About this manual
Ref: 02210/005A/10
Order as part number: 02210005A
1.3
EC Directive Compliance
The SERVOTOUGH OxyExact complies with the EMC Directive 89/336/EEC (as
amended by Directives 92/31/EEC and 93/68/EEC) and the ATEX Directive 94/9/EC.
INTRODUCTION
1
SERVOTOUGH OxyExact Installation Manual 02210005A_10
1.4
General Description
The SERVOTOUGH OxyExact Control Unit is designed to work with any of the
SERVOTOUGH OxyExact Transmitters. The simple graphical user interface allows for
simple operation and has multi-language capability as standard. In addition it offers:
Certification for hazardous areas, flammable dust and flammable gas
atmospheres
Simple two-wire connection to up to six transmitters
Digital communications
Configurable options for relays and mA outputs
Configurable options for digital (status/action) inputs
The control unit provides full access to set up such functions as autocalibration, alarms,
relays and faults. A full set of diagnostics information is available that can be used to
assist with predictive maintenance. The unit is compliant with the requirements of
NAMUR.
1.4.1
1.4.2
Standard Attributes
Graphics display and user interface
English, French and German languages
The ability to connect multiple transmitters to a single control unit
Digital communications ‘enabled’ with "Modbus"
Autocalibration software as standard (operation will need one of the relay option
cards)
Optional Attributes
Four option slots exist; any of the following may be fitted into each slot:
2
mA card - two 4 - 20 mA outputs and two relays
Relay card - four relays
Digital input card - eight channels
INTRODUCTION
SERVOTOUGH OxyExact Installation Manual 02210005A_10
1.5
Hazardous Area Approval and Certification
Copies of the Hazardous Area Certificates are held in Appendix 2. In summary, the
SERVOTOUGH OxyExact Control Unit is certified for use in Zone 2/Division 2 areas
(both gases and dusts) and is available with the following hazardous area approvals:
USA
FM Class I, Division 2, Groups A, B, C and D
FM Class II, Division 2, Groups F and G
FM Class III, Division 2
T4, ambient temperature 50°C maximum
Also American Class I, Zone 2 approval, IIC T4 (Ta = 50°C) with IS outputs
Canada
CSA Class I, Division 2, Groups A, B, C and D
CSA Class II, Division 2, Groups E, F and G
CSA Class III
Type 4X, T4, ambient temperature 50°C maximum
Also Canadian Class I, Zone 2 approval, IIC T4 (Ta = 50°C) with IS outputs
Europe
The control unit is ATEX approved as shown on the marking plate (see Figure 1-1). In
addition, the serial number and year of manufacture are marked on an external rating
label with duplicate details within the unit.
Figure 1-1: ATEX Certification Details
International
The control unit is IEC Ex approved non-incendive and intrinsically safe.
Code: Ex ic nA nC [ia Ga] IIC T4 Gc
-20°C10mA at
12Vdc.
When used as ‘Status' indicators, available functions are defined in accordance with
NAMUR recommendation NA64, i.e.:
NAMUR NAS4 Meaning
terminology
"Breakdown"
OxyExact 2200
system display
The measured signal is invalid due to Fault
a fault on the transmitter unit or its
peripheral equipment
"Check request" The measured signal is still valid but Maintenance
required
the "attrition reserves" will soon be
used up.
"In service"
Work is in progress on the transmitter Service in
progress
unit
Table 2-1: NAMUR NAS4 vs System Display
In addition, a ‘message’ status function may be assigned.
INSTALLATION
9
SERVOTOUGH OxyExact Installation Manual 02210005A_10
2.5.4
Digital Inputs Board
Each optional digital input board has eight input channels. These can be configured in
software for:
Range select
Initiate autocalibration routine
Inhibit autocalibration routine
External fault
External maintenance required
External service in progress
External message
Clear all alarms
Action functions (such as initiate autocalibration) are initiated by momentary (0.5 to 1.5
seconds) change of state of the required input. ‘Conditions’ (such as external fault) will
be maintained for as long as the signal is applied.
All inputs are configurable for:
volt-free contacts, or
24V (nominal) logic
Volt-free contact operation
The board has a 24Vdc supply available. This may be used for supplying volt-free
contacts.
24v Logic operation
2.6
Input voltage ON
Input voltage OFF
Nominal input current
Isolation voltage
-
13 to 33 Vdc
0 to 6 Vdc at 0 to 1mA
5 mA/channel at 24 Vdc
500 V minimum
Tag Numbers
The control unit enclosure must not be drilled or modified in any way. A tag number
may be written on the unit identification label on the side of the unit. The system can
also be configured to show transmitter tag numbers on the display.
10
INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02210005A_10
3.
MECHANICAL INSTALLATION
3.1
Unpacking and Inspection
WARNING
The control unit weighs approximately 12Kg (26lbs). Care
must be taken when handling it.
Remove the SERVOTOUGH OxyExact 2210 Control Unit and accessories from their
packing and inspect for any damage due to transit. (The enclosure has handholds on
both sides to facilitate lifting.)
If damage has occurred, inform Servomex or its agent immediately. Retain all packing
and shipping information.
Check that the supplied parts agree with the purchase specification. See also any
Instrument Modification Sheets which may form part of this manual.
Supplied parts:
One SERVOTOUGH OxyExact Control Unit
One accessories kit comprising:
o Spare fuses
o 1 x Allen key
o 1 x Installation manual
o 1 x Operator manual
(Other order specific items may also be included.)
3.2
Control Unit Description
The SERVOTOUGH OxyExact Control Unit is essentially an aluminium enclosure
finished with protective epoxy powder paint. A glass window facilitates viewing the
integral display and the user interface is via a polyester keypad. All weatherproof seals
are silicone rubber.
The internal electronics are of modular form and fit into seven positions within a card
frame, the minimum configuration being:
Interfaces board
Processor board
Power supply unit
Optional signal input/output boards, as defined in Section 2.5, may be fitted
The display and keypad are mounted on the rearside of the front door. Access to the
enclosure is made by removing the four screws securing the cover and opening the
hinged door.
MECHANICAL INSTALLATION
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SERVOTOUGH OxyExact Installation Manual 02210005A_10
3.3
Fixing Centres
The control unit must be mounted vertically (either surface or flush panel). See Figure
3-1 and Figure 3-2 for fixing centres and dimensions. Note that there should be
sufficient space at the base and sides of the enclosure for routing cables and opening
covers, etc.
Flush panel fixing screws are supplied to order and locate in the rear of the flange
around the enclosure.
Figure 3-1: Flush panel mounting details
12
MECHANICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02210005A_10
Figure 3-2: Mechanical arrangement
Key to Figure 3-2
1. Surface mount fixing hole
2. Display window
3. Keypad
4. Door, in open position
5. Power and signal cable entries
6. Functional (EMC) earth/ground terminal
7. Transmitter connection cable entries
MECHANICAL INSTALLATION
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SERVOTOUGH OxyExact Installation Manual 02210005A_10
4.
ELECTRICAL INSTALLATION
CAUTION
It is a condition of certification that the unit must be installed following the appropriate
national or international legislation or codes of practice. In particular, the correct glands
must be fitted to cable entries and the weatherproofing of the enclosure must not be
compromised.
To retain certification the unit must not be modified, mechanically or electrically.
Additional holes must not be drilled into any part of the unit's enclosure.
Insulation testing: to prevent damage to the control unit it is necessary to disconnect
cables being tested from the unit.
WARNING
The installation must conform to relevant safety
requirements, National Electrical Code and any local
regulations. The installation must be safe for any extremes of
operating conditions which may occur in the operating
environment of the analyser system.
4.1
CE Markings
The Servomex 2200 oxygen analyser system complies with the European Directives on
CE Marking (93/68/EEC) and Electromagnetic Compatibility (EMC 89/336/EEC).
CAUTION
To comply with the European Community Directives the interconnecting cables used for
all signal inputs and outputs must be screened/shielded or equivalent protection
provided.
To comply with EMC emissions and susceptibility standards the functional earth/ground
must always be connected to a local EMC ground.
14
ELECTRICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02210005A_10
4.2
Glands and Cable Entries
All cable entries must be fitted with appropriate glands or plugs to maintain the required
weatherproofing of the enclosures. Whilst the SERVOTOUGH OxyExact has been
tested to meet IP66 actual certification requirements are less onerous, however, as a
minimum:
All entries to the enclosure must be sealed to meet IP54.
When used in a hazardous dust area, all entries must be sealed to meet IP6X.
Reminder to maintain the full integrity of the control unit all entries to both
enclosures must be sealed to meet IP66.
Power supply cable entry:
Signal cable entries:
Transmitter connection entries:
1 x 3/4" NPT
4 x 3/4" NPT
2 x 1/2" NPT
Accessories are available to convert to M20 or PG 13.5 and are supplied if ordered.
4.3
Identification and Location of Components
See Figure 4-1 for location of terminal blocks, etc.
ELECTRICAL INSTALLATION
15
SERVOTOUGH OxyExact Installation Manual 02210005A_10
Figure 4-1: Electrical connections
Key to Figure 4-1
12345-
16
Interfaces board
Processor board
Option board - analog output
Option board - digital input
Option board - relay
6789-
Network (MODBUS) connector
Power supply terminals
Mains fuse
Transmitter connection block
ELECTRICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02210005A_10
4.4
Earth/ground Requirements
For compliance with EMC standards the external functional (EMC) earth/ground
terminal located on the external base of the unit (see Figure 3-2) must always be
connected to a local earth/ground.
The terminal is suitable for:
Flexible conductors Solid conductors
-
up to 10mm2
up to 10mm2
WARNING
The control unit contains intrinsically safe circuits. When the control
unit is installed in a hazardous area the safety earth/ground must
comply with relevant national or international standards to ensure a
safe installation, whether by the electrical supply or by a separate
connection.
4.5
Electrical Power Supply Connection
CAUTION
The unit is factory configured to operate on either 100V ac to 120V ac or 220V ac to
240V ac. Refer to Section 2.4 for additional installation rating details.
Specific voltage rating information is given on the label located on the right-hand side of
the unit. Ensure that the unit is configured to operate on the correct supply voltage.
The unit does not include an integral switch for disconnecting the electrical supply. The
installer must include a means of isolating electrical power by a switch or circuit breaker
located close to the control unit. It must be marked as the disconnecting device for the
equipment.
The branch circuit supplying power to the control unit should be installed with a suitable
fuse rated not greater than 15A or a suitable over current protection device set not
greater than 15A.
The electrical supply terminals are suitable for:
Flexible conductors Solid conductors
-
0.5 to 1.5mm2 (20 to 16 AWG)
0.5 to 2.5 mm2 (20 to 14 AWG)
Cables should be suitable for temperatures of at least 70°C.
ELECTRICAL INSTALLATION
17
SERVOTOUGH OxyExact Installation Manual 02210005A_10
Connection is made to the terminal block located on the power supply unit (identified
‘PSU'). Terminal order from the top is:
4.6
L
N
-
Live (AC)
Neutral (ACC)
Protective earth/ground
Transmitter Unit to Control Unit Connection
One or more transmitter units can be connected to a single control unit using a
two-wire, semi-duplex, bi-polar connection. The possible system configurations are
shown in Figure 2-1 earlier in this manual.
The maximum total cable length depends on cable parameters and certification
conditions (refer to Appendix). However, typically, a single transmitter/control unit
configuration may be separated by up to 1km of cable.
Cable is to be a screened/shielded, twisted pair with the screen/shield connected to the
control unit ground. The screen/shield must not be connected directly to the transmitter
unit ground.
The terminals are suitable for:
Flexible conductors Solid conductors
-
0.5 to 1.5mm2 (20 to 16 AWG)
0.5 to 1.0mm2 (20 to 18 AWG)
Cables should be suitable for temperatures of at least 70°C.
Connection is made to the terminal block on the interfaces board.
For a control unit at the ‘end’ of the data connection cable, connections are made to
terminal numbers:
1
‘A’ from the cable
2
‘B’ from the cable
For a control unit located in the ‘middle’ of the data connection cable, connections are
made to terminal numbers:
1
‘A’ from cable 1
2
‘B’ from cable 1
3
‘A’ from cable 2
4
‘B’ from cable 2
The cable screen/shield is connected to the terminal post adjacent to the gland hole.
In order to avoid ground loops, the screen/shield termination is not connected
directly to ground for this cable within the transmitter.
The screen/shield is directly connected to ground at the control unit.
The control unit features 1M ohm resistors from the ‘A' and ‘B' lines to ground to
discharge associated cable capacitance.
18
ELECTRICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02210005A_10
4.6.1
Cable Termination Link
A link exists within the control unit that configures the cable termination to either be a
‘mid-point’ or an ‘end’ (by definition an ‘end’ occurs when the second cable is not
installed).
The link is made across terminals 4 and 5 and must be fitted when the second cable is
not installed.
E.g., reference Figure 2-1; the link is required in configurations 1 and 2, but not 3.
4.7
Signal and Output/Input Connections
To comply with EMC standards, connections to signal outputs/inputs must use
screened/shielded or shielded cable. This may be either separately screened/ shielded
pairs or twisted pairs with an overall screen/shield.
The screens/shields or drain wire must be terminated at the terminal posts located on
the internal base of the enclosure.
All terminals are suitable for:
Flexible conductors Solid conductors
-
0.5 to 1.5mm2 (20 to 16 AWG)
0.5 to 1.0mm2 (20 to 18 AWG)
Cables should be suitable for temperatures of at least 70°C.
Connections are made with plugs and sockets. After assembly the socket must be
secured to the relevant board using the screws supplied, apart from the RJ45 Ethernet
connector which incorporates its own retaining tab.
Cables should be identified and labelled with their associated option board.
Cables should be dressed so that they do not cause a strain on the sockets and
boards.
4.7.1
MODBUS® Connection
Reference Section 2.5.1 and Figure 4-1.
Connection is made to the 'NETWORK' connector on the front panel of the
'PROCESSOR' board. Details of these connections depends on the network option
fitted as described below.
ELECTRICAL INSTALLATION
19
SERVOTOUGH OxyExact Installation Manual 02210005A_10
MODBUS Serial RS4S5 Interface
Connections are made to the designated terminals on the removable connector. For a
single-wire system (control unit as an 'end-node') connections are made to terminal
numbers:
Pin 1 ‘A’ from cable 1
Pin 2 ‘B’ from cable 1
For multiple configurations (control unit as 'mid-point node') the second cable should be
routed to:
Pin 3 ‘A’ from cable 2
Pin 4 ‘B’ from cable 2
The cable screen/shield is connected to the terminal post adjacent to the gland hole.
Cable termination link: A link exists within the control unit that configures the cable
termination to either be a 'mid-point' or an 'end' (by definition an 'end' occurs when the
second cable is not installed). The link is made across terminals 4 and 5 and must be
fitted when the second cable is not installed.
MODBUS TCP Ethernet Interface
Ethernet cabling should use shielded (STP) CAT 5 cable or better.
The cable should first be passed through the control unit gland and then assembled on
to a standard RJ45 connector. The cable screen/shield is connected to the terminal
post adjacent to the gland hole. The table below lists the functions of each connector
pin.
Pin 1
Transmit +
Pin 2
Transmit –
Pin 3
Receive +
Pin 6
Receive –
Pins 4, 5, 7, 8
Not used
For guidance, the tables below show the corresponding wire colours specified in
TIA/EIA-568A and TIA/EIA-568B for patch leads as viewed from the back of the plug
with the tab facing down. It is the responsibility of the installer to ensure the correct
connections are made.
TIA/EIA-568A
1
2
3
white/green
green
white/orange
2
3
4
5
6
7
8
7
8
orange
TIA/EIA-568B
1
white/orange orange
white/green
4
5
6
green
Table 4-1: Patch Lead wire colours
20
ELECTRICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02210005A_10
4.7.2
Analog Output Board
Reference Section 2.5.2 and Figure 4-1.
Connection is made to the connector on the front panel of the 'mA O/P' board.
4.7.3
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
-
Analog output 1 +ve
Analog output 1 -ve
Relay 1, N/C: closes on power fail
Relay 1, C: Common
Relay 1, N/O: opens on power fail
Relay 2, N/C: closes on power fail
Relay 2, C: Common
Relay 2, N/O: opens on power fail
Analog output 2 +ve
Analog output 2 -ve
Relay Board
Reference Section 2.5.3 and Figure 4-1.
Connection is made to the connector on the front panel of the 'RELAY' board.
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Pin 11
Pin 12
Pin 13
Pin 14
Pin 15
-
Relay 1, C: common
Relay 1, N/O: opens on power fail
Relay 1, N/C: closes on power fail
no connection
Relay 2, C: common
Relay 2, N/O: opens on power fail
Relay 2, N/C: closes on power fail
no connection
Relay 3, C: common
Relay 3, N/O: opens on power fail
Relay 3, N/C: closes on power fail
no connection
Relay 4, C: common
Relay 4, N/O: opens on power fail
Relay 4, N/C: closes on power fail
ELECTRICAL INSTALLATION
21
SERVOTOUGH OxyExact Installation Manual 02210005A_10
4.7.4
Digital Inputs Board
Reference Section 2.5.4 and Figure 4-1.
Connection to a DCS or similar system
Terminations 1 and 2 are at approximately ground/earth potential for a common
connection to the DCS.
Connection is made to the connector on the front panel of the 'DIGITAL I/P'
board.
22
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Pin 11
Pin 12
Pin 13
Pin 14
-
Input common
Input common
Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Channel 6
Channel 7
Channel 8
Switch supply
Switch supply
Switch supply
Switch supply
ELECTRICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02210005A_10
5.
AUTOCALIBRATION OPTIONS
Autocalibration is the function of automatically adjusting or checking the calibration
data held within a transmitter. However, the software routine that controls this
calibration does not reside within the transmitter.
Autocalibration (or ‘autocal') is achieved by subjecting the transmitter measuring system
to real live' conditions (i.e. by passing a number of calibration gases through the gas
sensor) and recording the effects of these conditions.
The autocalibration routines held within the SERVOTOUGH OxyExact Control Unit offer
the following as standard:
1. Initiation by:
direct access through the user interface
setting timer parameters within the control unit
digital input (requires installation of a digital input board or Modbus
network link)
2. The option to conduct full calibration (low and high) or one at either end point.
(i.e. just a low or just a high).
3. The ability to use two-way or three-way solenoid valves to control up to three
different gases to the transmitter:
Sample
Low calibration
High calibration
This enables the following optional configurations:
A. full zero and span autocal with three two-way solenoid valves.
B. full zero and span autocal with two three-way solenoid valves.
C. auto-zero (or span) using two two-way solenoid valves.
D. auto-zero (or span) using one three-way solenoid valve.
4. Optional sample inerting - to isolate the sample gas from one of the calibration
gases and/or to pass a safe' gas through the transmitter during warm up
conditions.
The ‘isolation’ of sample from a calibration gas (should the sample be
flammable) is achieved by adding an ‘inerting’ stage to the autocalibration
cycle. It does not, therefore, impact on the number of solenoid valves but the
contents of one of the calibration gases must be selected accordingly.
Complete gas shut off is not available with options B and D above and
flammable samples ‘isolation’ is not applicable to options B, C or D.
5. The ability to calibrate single transmitters or ‘groups’ of units at the same time.
6. The ability to adopt the ‘NAMUR’ users solenoid configuration.
AUTOCALIBRATION OPTIONS
23
SERVOTOUGH OxyExact Installation Manual 02210005A_10
When autocalibration is installed, any designated solenoid valves will also be
activated, as necessary, when manual calibration routines are invoked from the
control unit.
Full autocalibration cycle
The full cycle is best described pictorially, see Figure 5-1 below. The full cycle
includes the inerting stages and utilises a low calibration gas for this purpose.
Figure 5-1: Autocalibration cycle
Key to Figure 5-1
1.
2.
3.
4.
5.
6.
High calibration gas target concentration
Sample gas concentration
Low calibration gas target concentration
High calibration gas tolerance concentration
Low calibration gas tolerance concentration
Start of autocalibration, gas stream changes from sample to low calibration gas.
If configured accordingly, the mA output freeze is activated.
7. Customer configurable flush time
8. Gas stream changes from low to high calibration gas
9. Customer configurable flush time
10. Gas stream changes from high to low calibration gas
11. Low calibration gas left running for a customer configurable flush time
12. Gas stream changes from low calibration gas to sample
13. Customer defined flush time
14. End of autocalibration, if configured, the mA output freeze would be de-activated
and the new calibration figures utilised.
24
AUTOCALIBRATION OPTIONS
SERVOTOUGH OxyExact Installation Manual 02210005A_10
It is acceptable to ‘reverse’ this arrangement and utilise the high calibration gas
at the inerting stages. In such cases the solenoids would switch as follows:
6
Sample to high calibration gas
8
High to low calibration gas
10
Low to high calibration gas
12
High calibration gas to sample
Autocalibration logic table
It is possible, in software, to assign a relay to control each specific gas. This permits
direct wiring to two-way solenoid valves. The following table gives the logic:
Relay
(& nominal
designation)
No power to
control unit
Sample
'Zero' gas
'Span' gas
1 (Sample)
Off
On
Off
Off
2 (Low Cal)
Off
Off
On
Off
3 (Hi Cal)
Off
Off
Off
On
Table 5-1: Autocalibration logic table
The above permits various three-way valve configurations and inlet hardware
configured potentially as shown below in Figure 5-2.
Figure 5-2 is intended to demonstrate that there is no software change to the
autocalibration routines - there may be additional preferred arrangements.
AUTOCALIBRATION OPTIONS
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SERVOTOUGH OxyExact Installation Manual 02210005A_10
Figure 5-2: Autocalibration configurations
Key to Figure 5-2
1. Three-way valve configuration
2. Optional configuration
3. Example of NAMUR users configuration
4. Electrical connections to Relay 1
5. Electrical connections to Relay 2
6. Electrical connections to Relay 3
7. Gas connection to transmitter inlet
8. Gas connection - Low calibration gas
9. Gas connection - High calibration gas
10. Gas connection - Sample gas
26
AUTOCALIBRATION OPTIONS
SERVOTOUGH OxyExact Installation Manual 02210005A_10
Customer configuration (user interface):
Customers are offered full flexibility and the following overview is provided of software
configuration options. Refer to the Operator manual for further details.
A pair of autocalibration digital logic inputs may be defined (requires a digital input
option board):
1. Initiate an autocalibration - momentary contact
2. Disable timed autocalibration - whilst a contact is closed
Category
Gas Parameters
Time Parameters
Parameter
Units
(in 2200)
Target concentration for low calibration
% Oxygen
Target concentration for high calibration
% Oxygen
Tolerance associated with low calibration
% Oxygen
Tolerance associated with high calibration
% Oxygen
Time of first autocalibration
Date and
Time
Period between autocalibrations
Hrs/Days
Flush time for low calibration gas at stage 7
Flush time for high calibration gas at stage 9
(Stages associated
Flush time for low calibration gas at stage 11
with figure)
Flush time for final sample gas stage 13
Address' of relay assigned to sample gas (N/A
for three-way calibration valves)
Minutes
(decimals
allowed)
Text
Address' of relay assigned to low cal gas
Hardware
Parameters
Address' of relay assigned to high cal gas
Status of above relays under normal operation,
i.e. normally energised or de-energised
Transmitter mA output (if applicable) to Freeze
Control unit mA output (if applicable) to Freeze
‘Type'
Full, High only, Low only
Check or Calibrate
Table 5-2: Software configuration options
AUTOCALIBRATION OPTIONS
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SERVOTOUGH OxyExact Installation Manual 02210005A_10
6.
INSTALLATION CHECK LIST
Following completion of the installation procedure check:
Item
Checked
Unit is firmly mounted
Supply voltage agrees with unit supplied
The unit is correctly earthed/grounded
Connection is made to transmitter unit
Connection is made to analog outputs (as required)
Connection is made to digital outputs (as required)
Connection is made to alarm relays (as required)
Connection is made to digital inputs (as required)
Sockets are secured to their relevant boards
All wiring terminations are tightened
Screws in unused terminals are tightened
I/O cable screen connections are secure
Cable glands are secured and made weather-tight
Cables are dressed neatly within the control unit
Inner door is secured
Hazardous area safety requirements are complied with
External electrical connections are labelled
Covers are secured and weatherproof
Table 6-1: Installation checklist
It is now possible to apply power to the unit.
See the Operator manual for commissioning and operating the unit.
28
INSTALLATION CHECKLIST
SERVOTOUGH OxyExact Installation Manual 02210005A_10
7.
ROUTINE MAINTENANCE
The SERVOTOUGH OxyExact Control Unit requires minimal routine maintenance.
WARNING
The unit must only be cleaned with a damp cloth.
In very dusty environments, it will be prudent to occasionally clean off the outer
surfaces using a damp cloth.
Spares
The SERVOTOUGH OxyExact Control Unit contains no parts that require routine
service.
Refer to the Service manual for full service instructions.
ROUTINE MAINTENANCE
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SERVOTOUGH OxyExact Installation Manual 02210005A_10
APPENDIX 1
TECHNICAL SPECIFICATION
FUNCTIONAL
Power supply:
Either 100-120V ac 50/60Hz, -10% and +10%.
or
220-240V ac 50/60Hz, -15% and +10%.
Power required:
30VA
Physical:
Width:
Height:
Depth:
Weight:
280mm
242mm (300mm including mounting)
250mm
12kg
ENVIRONMENTAL
General:
Suitable for indoor and sheltered outdoor locations
Ingress protection:
IP66 and Type 4X (NEMA 250)
Operating temperature:
-10 to 50°C (14°F to 122°F), in sheltered location
Storage temperature:
-20 to 70°C (-4°F to 158°F)
Relative humidity:
95% RH maximum, non-condensing
Atmospheric pressure:
76 to 112 kPaa (11 to 16.2 psia)
Altitude:
3000m (10,000 feet) maximum
Installation category:
II - in accordance with IEC 664
Pollution degree:
2 - in accordance with IEC 664
Warm up time:
Not applicable
PERFORMANCE
No degradation of associated transmitter performance.
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APPENDIX 1 – TECHNICAL SPECIFICATION
SERVOTOUGH OxyExact Installation Manual 02210005A_10
APPENDIX 2
MODBUS PROFILE
The control unit supports the Modbus slave communication through the network
connector on the processor board.
The following facilities are provided:
Access to transmitter measurement data
Access to transmitter and control unit status information
Access to transmitter calibration information
Progress indication during autocalibration
Network inputs and outputs
Diagnostics
Error handling
These are described below.
Transmitter data
The measurement data from each registered transmitter is available in a block of input
registers that can be read using Modbus function code 04. The specific range of
registers used is related to the transmitter address as shown in the following table:
Register
Range
Transmitter
address
Comments
1 – 100
01
Measurements and data for each registered
transmitter.
101 – 200
02
All data is read-only.
201 – 300
…
…
03
…
…
1401 – 1500
15
The format of the data within each block of registers is shown in the following table. The
register offset values in that table should be added to the base value appropriate to the
Transmitter address in the table above. For example, the Measurement for the
Transmitter at address 02 can be read from registers 108-109.
Measurement data is in IEEE 754 floating point format.
Each value requires 2 registers as follows:
Register N
= High word
Register N + 1
= Low word
APPENDIX 2 – MODBUS PROFILE
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Register
offset
0-6
7-8
9 - 11
12 - 14
15 - 16
17 - 19
20 - 22
23 - 24
25 - 27
28 - 30
31 - 32
33 - 35
36 - 38
39 – 40
41 – 42
43 – 44
45 – 46
47 – 48
49 – 50
51
52
53 - 60
32
Name
Comments
A 13 character string denoting the user- entered
transmitter name/tag.
Final oxygen measurement in IEEE 754 floating
Oxygen measurement
point format.
Gas formula
Contains the text "O2 " (6 characters).
Oxygen units
A 5 character string containing the oxygen units.
Analog input 1
The measurement value at analog input 1 in
measurement
IEEE 754 floating point format.
A 6 character string containing the user- entered
Analog input 1 description
name of analog input 1.
A 5 character string containing the user entered
Analog input 1 units
units of analog input 1.
Analog input 2
The measurement value at analog input 2 in
measurement
IEEE 754 floating point format.
A 6 character string containing the user- entered
Analog input 2 description
name of analog input 2.
A 5 character string containing the user entered
Analog input 2 units
units of analog input 2.
Internal pressure
Internal pressure measurement in IEEE 754
measurement
floating point format.
Internal pressure
A 6 character string containing the user- entered
description
name of the internal pressure measurement.
A 5 character string containing the user- entered
Internal pressure units
internal pressure units.
Low calibration gas concentration (gas 1) in IEEE
Low target value
754 floating point format.
Low calibration tolerance in IEEE 754 floating
Low tolerance value
point format.
Low target compared
Oxygen measurement value immediately before
value
low calibration in IEEE 754 floating point format.
High calibration gas concentration (gas 2) in
High target value
IEEE 754 floating point format.
High calibration tolerance in IEEE 754 floating
High tolerance value
point format.
High target compared
Oxygen measurement value immediately before
value
high calibration in IEEE 754 floating point format.
Last low calibration action Indicates whether the last maintenance action
was a check or a calibrate.
Last high calibration
Integer value: 0=none 1=check 2=calibrate
action
Name
Transmitter software ID
A 16 character string containing the transmitter
software identity.
APPENDIX 2 – MODBUS PROFILE
SERVOTOUGH OxyExact Installation Manual 02210005A_10
Transmitter status information
Transmitter status information from each registered transmitter is available in a block of
discrete inputs that can be read with function code 02. The specific range of inputs
used is related to the transmitter address as shown in the following table:
Input Status
Range
Transmitter
address
1 – 100
01
101 – 200
02
201 – 300
…
…
401 – 500
03
…
…
15
Comments
Status information for each registered
transmitter. All data is read-only.
The format of the data within each block of inputs is shown in the following tables. A
data value of "1" indicates that the status condition is raised. Addresses are in the form
of an offset from the start of the block. For example, for a Transmitter at address 02, the
Discrete Input for the summary Message status flag would have the address 104 (=101
+ 3).
Status Conditions - Summary
Input Offset
0
1
2
3
4-7
Description
Transmitter Fault status raised
Transmitter Maintenance Required status raised
Transmitter Service In Progress status raised
Transmitter Message status raised
Unused (zero)
Status Conditions - Detail
Fault
Input Offset
8
9
10
11
12
13
14
15
16
17
Description
Transmitter not responding. If set, the Fault status will be set and
all other statuses will be zero.
Raw Oxygen Input Voltage Low Fault
Raw Oxygen Input Voltage High Fault
Cell Temperature Low Fault
Cell Temperature High Fault
Pressure Low Fault
Pressure High Fault
Not used (zero)
Cell Temperature Measurement Fault
Paramagnetic Cell Feedback Fault
APPENDIX 2 – MODBUS PROFILE
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SERVOTOUGH OxyExact Installation Manual 02210005A_10
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35-39
Paramagnetic Cell Photocell Fault
Low Flow Fault – internal flow sensor
High Flow Fault – internal flow sensor
Flow Sensor Fault – external flow sensor
Flow Fault – external flow sensor
Analog Input 1 Invalid – Fault 1
Analog Input 2 Invalid – Fault 1
Digital Input 1 Active – Fault 2
Digital Input 2 Active – Fault 2
Digital Input 3 Active – Fault 2
Digital Input 4 Active – Fault 2
Software Processing - Fail
Non-Volatile Memory Fail
Internal ADC Fail
External ADC Fail
System RAM Fail
Program Integrity Fail
Unused (zero)
Maintenance Required
Input Offset
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62 – 63
34
Description
Raw Oxygen Input Voltage Low Check
Raw Oxygen Input Voltage High Check
Pressure Low Check
Pressure High Check
Warmup Time Exceeded
Oven Temperature Measurement Check
Feedback Check
Photocell Check
Low Flow Check
High Flow Check
Analog Input 1 Invalid – Maintenance Required 1
Analog Input 2 Invalid – Maintenance Required 1
Low Calibration Fail
High Calibration Fail
Pressure Compensation Calibration Fail
Internal Pressure Transducer Calibration Fail
Internal Flow Alarm Calibration Fail
Digital Input 1 Active – Maintenance Required 2
Digital Input 2 Active – Maintenance Required 2
Digital Input 3 Active – Maintenance Required 2
Digital Input 4 Active – Maintenance Required 2
Using system Default Data
Unused (zero)
APPENDIX 2 – MODBUS PROFILE
SERVOTOUGH OxyExact Installation Manual 02210005A_10
Service In Progress
Input Offset
Description
Analog Input 1 Invalid - Service Mode 1
Analog Input 2 Invalid - Service Mode 1
Digital Input 1 Active - Service Mode 2
Digital Input 2 Active - Service Mode 2
Digital Input 3 Active - Service Mode 2
Digital Input 4 Active - Service Mode 2
Controller Requested Service Mode
Unused (zero)
64
65
66
67
68
69
70
71
Message
Input Offset
Description
Analog Input 1 Invalid – Message 1
Analog Input 2 Invalid – Message 1
Digital Input 1 Active – Message 2
Digital Input 2 Active – Message 2
Digital Input 3 Active – Message 2
Digital Input 4 Active – Message 2
Warming Up
Unused (zero)
72
73
74
75
76
77
78
79 to 99
Notes:
1. The status type that can be raised by the external mA inputs is user
configurable.
2. The status type that can be raised by the external digital inputs is user
configurable.
Control unit identity
Read only access to the Control Unit software identity is available in a block of holding
registers that can be read with function code 03.
Register
Name
101 - 108
Control unit software ID
APPENDIX 2 – MODBUS PROFILE
Comments
A 16 character string containing the control
unit software identity
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SERVOTOUGH OxyExact Installation Manual 02210005A_10
Control unit status information
Read-only access to control unit status information is available in the following block of
discrete inputs that can also be read with function code 02.
Status Conditions Summary
Discrete Input
Description
6001
Control unit Fault status raised
6002
Control unit Maintenance Required status raised
6003
Control unit Service In Progress status raised
6004
Control unit Message status raised
6005 - 6008
Unused (zero)
Status Conditions - Detail
Fault
Discrete Input
6009
6010
6011
6012
6013
6014
6015
6016
6017
6018
6019
6020
6021
6022
6023
6024
6025
6026
6027
6028
6029 to 6032
36
Description
System Data Defaults In Use
Watchdog Fault
Non-Volatile Memory Fail
Communications Failure
Software Processing Fail
RAM Fail
Program Integrity Fail
Display Card Reset
Option Card 1 Reset
Option Card 2 Reset
Option Card 3 Reset
Option Card 4 Reset
Option Card 5 Reset
Option Card 6 Reset
Option Card 7 Reset
Option Card 8 Reset
External Fault 1 1
External Fault 2 1
External Fault 3 1
External Fault 4 1
Unused (zero)
APPENDIX 2 – MODBUS PROFILE
SERVOTOUGH OxyExact Installation Manual 02210005A_10
Maintenance
Discrete Input
6033
6034
6035
6036
6037
6038
6039
6040
6041
6042
6043
6044
6045
6046 to 6048
Description
Option Card 1 Reset Override
Option Card 2 Reset Override
Option Card 3 Reset Override
Option Card 4 Reset Override
Option Card 5 Reset Override
Option Card 6 Reset Override
Option Card 7 Reset Override
Option Card 8 Reset Override
External Maintenance Required 1 1
External Maintenance Required 2 1
External Maintenance Required 3 1
External Maintenance Required 4 1
Invalid System Time/Date
Unused (zero)
Service In Progress
Discrete Input
6049
6050
6051
6052
6053
6054 to 6056
Description
External Service Mode 1 1
External Service Mode 2 1
External Service Mode 3 1
External Service Mode 4 1
Controller Requested Service Mode
Unused (zero)
Message
Discrete Input
6057
6058
6059
6060
6061
6062
6063
6064
6065
6066
6067
6068
6069
6070
6071
6072
Description
Auto Calibration Group 1 In Progress
Auto Calibration Group 2 In Progress
Auto Calibration Group 3 In Progress
Auto Calibration Group 4 In Progress
Auto Calibration Group 5 In Progress
Auto Calibration Group 6 In Progress
External Message 1 1
External Message 2 1
External Message 3 1
External Message 4 1
Alarm History 80% Full
Alarm History Full
Calibration History 80% Full
Calibration History Full
Status History 80% Full
Status History Full
APPENDIX 2 – MODBUS PROFILE
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SERVOTOUGH OxyExact Installation Manual 02210005A_10
Notes:
1
Any of the Control Unit digital inputs may be user-assigned to raise any of the
“External” statuses. The status type that is raised is also user-configurable.
Autocalibration progress
An indication of progress during autocalibration is available by reading holding
register 1 using function code 03.
The value returned will be one of the following:
Value
0
1*
2
3
4*
5
6*
7
8*
Meaning
No autocalibration in progress
Preparing for autocalibration
Flushing with calibration gas 1
Flushing with calibration gas 2
Capturing calibration point for gas 2
Flushing with calibration gas 1
Capturing calibration point for gas 1 and applying new calibration
Flushing with sample gas
Restoring normal operation
*These values are only present for very short times and are unlikely to be returned.
Network digital inputs
Network digital inputs are functionally identical to physical digital inputs such as those
provided by the digital inputs board. Modbus adds 8 network digital inputs to any
physical digital inputs and allow these to be selected and set up in the same way.
Network digital inputs will be identified as N:1 to N:8.
To a Modbus master these network digital inputs will appear as coils according to the
table below. Their state can be written using function codes 05 or 15 and read
back using function code 01.
Coil
00001
00002
00003
00004
00005
00006
00007
00008
38
Description
Network Digital Input 1
Network Digital Input 2
Network Digital Input 3
Network Digital Input 4
Network Digital Input 5
Network Digital Input 6
Network Digital Input 7
Network Digital Input 8
0 = open circuit,
0 = open circuit,
0 = open circuit,
0 = open circuit,
0 = open circuit,
0 = open circuit,
0 = open circuit,
0 = open circuit,
1 = closed circuit
1 = closed circuit
1 = closed circuit
1 = closed circuit
1 = closed circuit
1 = closed circuit
1 = closed circuit
1 = closed circuit
APPENDIX 2 – MODBUS PROFILE
SERVOTOUGH OxyExact Installation Manual 02210005A_10
Network relays
Network relays are functionally identical to physical relays such as those provided by
the relay board. Modbus adds 8 network relays to any physical relays and allow these
to be selected and set up in the same way. Network relays will be identified as N:1 to
N:8.
To a Modbus master these network relays will appear as discrete inputs according to
the table below. Their state will be read using function code 02.
Discrete Input Description
7001
7002
7003
7004
7005
7006
7007
7008
Network Relay 1
Network Relay 2
Network Relay 3
Network Relay 4
Network Relay 5
Network Relay 6
Network Relay 7
Network Relay 8
0 = De-energised,
0 = De-energised,
0 = De-energised,
0 = De-energised,
0 = De-energised,
0 = De-energised,
0 = De-energised,
0 = De-energised,
1 = Energised
1 = Energised
1 = Energised
1 = Energised
1 = Energised
1 = Energised
1 = Energised
1 = Energised
Network analog outputs
Network analog outputs are functionally identical to physical analog outputs such as
those provided by the analog output board. Modbus adds 8 network analog outputs to
any physical outputs and allow these to be selected and set up in the same way.
Network analog outputs will be identified as N:1 to N:8.
Read-only access will be provided to the mA values of these network analog outputs in
the holding registers listed in the table below. These will be read using function code
03.
Measurement data is in IEEE 754 floating point format.
Each value requires 2 registers as follows:
Register N
= High word
Register N + 1
= Low word
Registers
2-3
4-5
6-7
8-9
10 - 11
12 - 13
14 - 15
16 - 17
Description
Network Analog Output 1
Network Analog Output 2
Network Analog Output 3
Network Analog Output 4
Network Analog Output 5
Network Analog Output 6
Network Analog Output 7
Network Analog Output 8
APPENDIX 2 – MODBUS PROFILE
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SERVOTOUGH OxyExact Installation Manual 02210005A_10
Diagnostics
Modbus function code 08 provides a diagnostic capability for checking communication
between the master and the control unit. Following the function code is a 2-byte sub
function code that specifies the test to be performed, followed by 2 bytes of data.
The only supported sub function code is 00. This causes the query message, including
the 2 data bytes, to be copied back as the response.
Error handling
If a communications error (e.g. framing error, checksum error) is detected during the
receipt of a Modbus message, that message will be ignored and no response will be
generated.
All correctly received Modbus messages will be checked for a valid function code and
data address. If a problem is detected the following exception responses will be
returned.
Condition
Exception code
Requested function code is not supported
01
Register or coil address outside of supported range
02
40
APPENDIX 2 – MODBUS PROFILE
SERVOTOUGH OxyExact Installation Manual 02210005A_10
APPENDIX 3
CERTIFICATION
The following pages contain the ATEX certificate for this analyser. It details conditions
of safe use and important parameters that shall be followed for safe installation.
APPENDIX 3 – CERTIFICATES
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SERVOTOUGH OxyExact Installation Manual 02210005A_10
42
APPENDIX 3 – CERTIFICATES
SERVOTOUGH OxyExact Installation Manual 02210005A_10
APPENDIX 3 – CERTIFICATES
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APPENDIX 3 – CERTIFICATES
SERVOTOUGH OxyExact Installation Manual 02210005A_10
APPENDIX 3 – CERTIFICATES
45
SERVOTOUGH OxyExact Installation Manual 02210005A_10
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APPENDIX 3 – CERTIFICATES
SERVOTOUGH OxyExact Installation Manual 02210005A_10
APPENDIX 3 – CERTIFICATES
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