model 1100 - On Site Gas Systems

Engineered Solutions for Gas Detection and Analysis
High Purity Instruments
MODEL 1100
OXYGEN ANALYZER / CONTROLLER – PERCENT RANGE
OPERATIONS MANUAL
NTRON
MODEL 1100 O2 Analyzer
PERCENT OXYGEN
REMOTE
SENSOR
20.9
RUN
FAULT
ALM 1
ALM 2
MODE
Manual Part Number: C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
A DIVISION OF
456 Creamery Way, Exton, PA 19341
Phone: 610.524.8800 • Fax: 610.524.8807 • Email: info@neutronicsinc.com
www.neutronicsinc.com
Installation and Operations Manual
Table of Contents
TABLE OF CONTENTS ...........................................................................................................................................................III
FOR YOUR SAFETY: ............................................................................................................................................................... V
WELCOME ............................................................................................................................................................................. VI
CHAPTER 1 – INTRODUCTION AND OVERVIEW............................................................................................................... 1-1
1.1
GENERAL ...................................................................................................................................................................1-1
1.2
FEATURES ..................................................................................................................................................................1-1
1.3
SYSTEM HARDWARE OVERVIEW ...................................................................................................................................1-3
1.3.1
Main Board ...........................................................................................................................................1-3
1.3.2
Relay Board ..........................................................................................................................................1-3
1.3.3
Power Supply ........................................................................................................................................1-3
1.3.4
Display Board........................................................................................................................................1-3
1.3.5
Control Panel ........................................................................................................................................1-3
1.3.6
Sensor ...................................................................................................................................................1-3
1.3.7
Sensor Flow-Through Head....................................................................................................................1-4
1.3.8
Chassis..................................................................................................................................................1-4
1.4
ANALYZER INPUTS AND OUTPUTS ................................................................................................................................1-6
1.4.1
The Oxygen Sensor Input .......................................................................................................................1-6
1.4.2
Alarm-1 Relay Output...........................................................................................................................1-6
1.4.3
Alarm-2 Relay Output...........................................................................................................................1-6
1.4.4
Fault Relay Output................................................................................................................................1-6
1.4.5
Analog Voltage Output...........................................................................................................................1-6
1.4.6
Analog Current Output ..........................................................................................................................1-7
1.4.7
Range ID Output....................................................................................................................................1-7
1.4.8
Service Port ...........................................................................................................................................1-7
1.5
CONTROL PANEL USER INTERFACE ..............................................................................................................................1-7
1.5.1
The “UP” Pushbutton ............................................................................................................................1-7
1.5.2
The “DOWN” Pushbutton .....................................................................................................................1-7
1.5.3
The “MODE” Pushbutton ......................................................................................................................1-7
1.5.4
7-Segment Alphanumeric Display ..........................................................................................................1-8
1.5.5
RUN Indicator LED ...............................................................................................................................1-8
1.5.6
Alarm-1 Indicator LED..........................................................................................................................1-8
1.5.7
Alarm-2 Indicator LED..........................................................................................................................1-8
1.5.8
Fault Indicator LED...............................................................................................................................1-8
CHAPTER 2 – SYSTEM INSTALLATION AND START-UP................................................................................................. 2-1
2.1
INSTALLING THE ANALYZER .........................................................................................................................................2-1
2.1.1
Step 1 – Locate and Mount the Analyzer unit..........................................................................................2-2
2.1.2
Step 2 – Install the Remote Sensor .........................................................................................................2-3
2.1.3
Step 3 – Install the Analyzer ..................................................................................................................2-5
2.2
STARTING UP AND COMMISSIONING THE SYSTEM ........................................................................................................2-10
2.2.1
STEP 1 – Power Up the unit ............................................................................................................... 2-10
2.2.2
STEP 2 – Calibrate the Unit ................................................................................................................ 2-11
2.2.3
STEP 3 –Set Alarm-1 and Alarm-2..................................................................................................... 2-11
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page iii
Installation and Operations Manual
CHAPTER 3 – ANALYZER OPERATION ............................................................................................................................. 3-1
3.1
SYSTEM ORGANIZATION ...............................................................................................................................................3-1
3.2
USER MODES ............................................................................................................................................................3-1
3.2.1
CALIBRATE Mode & Calibration Procedure...........................................................................................3-1
3.2.2
SET/VIEW ALARM-1 Mode .................................................................................................................3-3
3.2.3
SET/VIEW ALARM-2 Mode .................................................................................................................3-4
3.2.4
VIEW ACTIVE FAULTS Mode ..............................................................................................................3-4
3.2.5
Return to RUN Mode.............................................................................................................................3-4
3.3
SYSTEM MODES ..........................................................................................................................................................3-4
3.3.1
Self-Test & Warm-up Mode ...................................................................................................................3-4
3.3.2
RUN Mode............................................................................................................................................3-4
3.3.3
ALARM-1 ACTIVE Mode......................................................................................................................3-5
3.3.4
ALARM-2 ACTIVE Mode......................................................................................................................3-5
3.3.5
FAULT ACTIVE Mode...........................................................................................................................3-5
CHAPTER 4 – MAINTENANCE AND TROUBLESHOOTING............................................................................................... 4-1
4.1
SYSTEM SETUP ...........................................................................................................................................................4-1
4.1.1
System Setup via Control panel Keypad ..................................................................................................4-1
4.1.2
System Setup via Service Port ................................................................................................................4-3
4.1.3
Change factory settings via Hardware Jumpers .................................................................................... 4-11
4.2
ROUTINE PERIODIC MAINTENANCE .............................................................................................................................4-13
4.3
TROUBLESHOOTING ...................................................................................................................................................4-14
4.3.1
Fault Codes ........................................................................................................................................ 4-14
CHAPTER 5 – APPENDICES............................................................................................................................................... 5-1
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
APPENDIX A – SPARE PARTS LIST ..............................................................................................................................5-1
APPENDIX B – SPECIFICATIONS ...................................................................................................................................5-2
APPENDIX C – ANALYZER FACTORY CONFIGURATION SETTINGS ....................................................................................5-4
APPENDIX D – CONTROL PANEL HOT-KEY FUNCTIONS ................................................................................................5-5
APPENDIX E – RANGE / OUTPUT CHART ......................................................................................................................5-6
APPENDIX F – ZERO CALIBRATION RANGE SETTINGS ...................................................................................................5-6
APPENDIX G – MSDS MATERIAL SAFETY DATA SHEET..................................................................................................5-7
APPENDIX H – WARRANTY ........................................................................................................................................5-10
INTENDED USE FOR THE MODEL 1100 .......................................................................................................................... 5-10
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page iv
Installation and Operations Manual
For Your Safety:
PLEASE READ THIS MANUAL IN ITS ENTIRETY BEFORE ATTEMPTING
INSTALLATION OR OPERATION! Attempting to operate the Model 1100 without
fully understanding its features and functions may result in unsafe conditions
•
Always use protective eye wear and observe proper safety procedures when working with pressurized
gases.
•
Always remove the freshness seal from the CAG-250E sensor before using.
•
Always assure the pressure of gas entering the model 1100 is 1-3 psig.
•
Always calibrate the model 1100 at an equivalent pressure and flow rate to the measured gas.
•
Always calibrate the model 1100 whenever the point of use elevation changes more than 500 feet.
•
Properly dispose of the oxygen sensor when it has expired.
•
Ensure the protective freshness seal has been removed from the sensor before use.
•
Ensure the model 1100 has been properly calibrated before use.
•
Never expose the model 1100 analyzer chassis or sensor to water, high humidity or moisture. The
units are not watertight.
•
Never expose the model 1100 to flame or high temperatures.
•
Never expose the model 1100 analyzer to flammable gases or vapors. The unit is not rated Explosion
Proof, or Intrinsically Safe.
•
Never expose the model 1100 directly to unregulated gas lines, cylinder gas. High gas pressures may
cause the oxygen sensor to rupture.
•
Ensure the analyzer unit is mounted in an area of free airflow to prevent the chassis from exceeding
the operating temperature specifications. Do not mount the analyzer or sensor against hot surfaces.
Do not block the ventilation louver on the analyzer chassis.
•
The Model CAG-250 Oxygen Sensor is housed in a PVC casing. Please consult appropriate material
compatibility references to ensure the sensor is not damaged by background gases in process
monitoring applications.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page v
Installation and Operations Manual
WELCOME
Thank you for purchasing the Model 1100 Analyzer for zero to 100 %
range Oxygen measurement.
The Model 1100 Compact Analyzer is a user friendly, microprocessor controlled Oxygen measuring
instrument. It has many features to offer the user, which will be described in this manual. We recommend
that all personnel who use the instrument read this manual to become more familiar with its proper
operation.
For further detail regarding the maintenance and in-field service of the Model 1100 analyzer, please contact
the Neutronics Inc. Customer Service Department. If you have questions or comments, we would like to hear
from you.
Neutronics Inc. Customer Service Department
456 Creamery Way
Exton, PA 19341
Tel: (610) 524-8800 ext 118
Toll Free: (800) 378-2287 ext 118 (US only)
Fax: (610) 524-8807
EMAIL: info@neutronicsinc.com
Visit us at www.neutronicsinc.com
Equipment Serial Number: ________________
(For faster service, please have this number ready if for any reason you need to contact us about your instrument)
Copyright 2003 Neutronics Inc.
This work is protected under Title 17 of the US Code and is the sole property of Neutronics Inc. No part of this document may be
copied or otherwise reproduced, or stored in any electronic information retrieval system, except as specifically permitted under
US copyright law, without the prior written consent of Neutronics Inc.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page vi
1
1.1
CHAPTER 1 – INTRODUCTION AND OVERVIEW
General
The model 1100 Compact Series analyzer by Neutronics offers an efficient solution in a small package for
oxygen measurement and control applications. The Model 1100 is a microprocessor-based instrument
for measuring zero to 100 % oxygen. The system is supplied with a model CAG-250E oxygen sensor, a
flow through head, and a 6-foot sensor interface cable.
At the heart of the analyzer is the model CAG-250E oxygen sensor. This sensor assures reliability and
fast response for critical measurements from zero to 100 %. It utilizes a unique weak acid electrolyte
which offers long life and is unaffected by CO2 and other acid gases. When used with the model 1100,
the CAG-250E is remote mounted to allow the sensor to be installed close to a sampling point for the
fastest response time possible for process monitoring and control applications. A flow-through mounting
head is supplied for use with all Neutronics Inc. process gas sampling systems.
1.2
Features
The Compact Series analyzers are designed to be flush mounted to a panel or console. Because of the small
size of the Model 1100 analyzer, it can be integrated into a variety of equipment or control panels. The
Remote Sensor Module can be mounted close to the sampling point to assure the fastest response
possible.
Other Features Include:
•
Low-cost disposable Galvanic sensor
•
Two User-adjustable Oxygen Alarms with configurable relay outputs for process control use
•
Two Analog Outputs: 4-20 mA AND 0-1, 0-5, or 0-10 VDC
•
Auto Ranging or Fixed Range Oxygen Measurement (VDC output provided for auto-range
identification)
•
Double Redundant Operating System, with automatic repair function
•
Bi-directional RS-232 Serial Interface for connection to a PC, terminal, or printer
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 1-1
MODEL 1100 – Introduction and Overview
Oversized LED Display
NEMA 4 Front Panel
Neutronics
Mounting Studs
MODEL 1100 O2 Analyzer
PERCENT OXYGEN
Remote
Sensor
NEMA 4 Panel-mounting Gasket
RISK OF
ELECTRICAL
SHOCK.
SERVICE BY
AUTHORIZED
TECHNICIAN
ONLY.
20.9
RUN
FAULT
ALM 1
ALM 2
MODE
Large Menu-driven Pushbutton Operators for:
Increment
Decrement
Mode-Select
Color-coded Status
indicators:
RUN = Green
Fault = Yellow
ALM-1 = Red
ALM-2 = Red
Front view
Removeable Terminal Blocks
Plug-in Style Sensor
Connection
Rear view
Figure 1 – Model 1100 oxygen analyzer
front and rear view
Control
Panel
Power Supply Board
Relay Board
Chassis
Main Board
Display
Board
Figure 2 – Basic internal analyzer components
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 1-2
System Hardware Overview
1.3
System Hardware Overview
1.3.1
Main Board
The main board houses the microprocessor, and supporting electronics for controlling the operation of
the Model 1100 Analyzer. The main board receives the sensor input, and provides the control and
display functions of the analyzer.
1.3.2
Relay Board
The Relay Board houses relay contacts for all of the Alarm and Control features of the 1100. The relays
are mapped discretely to each alarm to provide electrical outputs for reporting, and process control use.
1.3.3
Power Supply
The power supply board is designed to take 110/220 VAC, 50/60 Hz mains power input. The supply is
fused directly on the board. Optional 12 VDC and 24 VDC power supplies are available for installations
where a DC voltage is required to power the Model 1100. A 12 VDC battery-backup power input (battery
not provided) is also provided to act as an emergency back up in case of mains power failure.
1.3.4
Display Board
The Display board is designed to generate a digital indication of the concentration of oxygen (Appendix E
– range / output chart), and fault codes (section 4.3.1). The display is a 7-segment, ¾” alphanumeric
LED.
1.3.5
Control Panel
The Control Panel serves as the main user interface. The Control Panel features the keypad (ramp-UP,
ramp-DOWN, and MODE keys) and the status LED’s. The control panel is designed to be splash and
water-resistant. There are #8-32 threaded mounting studs at each of the four corners for flush
mounting of the model 1100 to a stationary control or equipment panel. The gasketed panel is suitable
for NEMA type 4 / IP20 environments when properly installed.
1.3.6
Sensor
The sensor is an electrochemical cell, which measures partial pressure of oxygen. Sample gas is passed
by the face of the sensor and an electrical output is generated, which is directly proportional and linear to
the partial pressure of oxygen in the gas sample. It is similar in operation to a battery, except that one of
the reactants, oxygen is supplied externally to the cell.
The CAG-250E Oxygen sensor consists of a lead anode, oxygen cathode, and weak acid electrolyte.
Oxygen permeates a plastic membrane on the face of the sensor. The oxygen is electrochemically
reduced at the cathode. The current generated is directly proportional to the partial pressure of oxygen
at the sensing surface of the cell.
The CAG-250E sensor is a sealed disposable device with a serviceable life of 2 to 3 years. It does not
require any periodic maintenance. When the sensor has expired, the entire device is disposed of and
replaced easily and safely.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 1-3
MODEL 1100 – Introduction and Overview
1.3.7
Sensor Flow-Through Head
The sensor mounting-base allows the model CAG-250 sensor to be used for process monitoring. It serves
as both the receptacle for the sensor and the delivery system for a gas sample from a process vessel or
stream. It includes a sample inlet, a flow-through chamber a sample exhaust, and a screw-in receptacle
for the oxygen sensor.
1.3.7.1
Sample Gas Inlet
Gas must be directed from the measured process to the sample inlet port via positive pressure from the
source, or an external pump. The model CAG-250E sensor and flow-through head combination can be
installed in any Neutronics Inc. Process Sampling System.
1.3.7.2
Sample Gas Exhaust
A sample gas exhaust port is provided for installation with a process oxygen sampling system. Gas must
be directed from the sample exhaust port to a suitable vent source that does not apply significant
backpressure on the sampling system. The unit can be installed in-line with any Neutronics Inc. Process
Sampling System.
1.3.7.3
In-Situ Mounting
The model CAG-250 sensor may be mounted directly to a contained process gas stream via a userinstalled threaded port. In-situ sampling is appropriate for clean dry applications, where there is not
significant pressure / vacuum, or fluctuation in pressure / flow.
Sensor screws in here
Figure 3 –
Sensor flowthrough head
Sample Input
1.3.8
Sample Exhaust
Chassis
The chassis is manufactured of specially coated steel. It is designed to provide a general level of
protection against mechanical damage from the local environment. It is also an important component of
the electrostatic discharge (ESD) shielding design. Since the model 1100 is a flush mounted system, the
portion of the instrument housed in the chassis will be located behind the control panel or embedded
within the customer equipment enclosure. The enclosure is general purpose and is not watertight.
Figure 4 –
Analyzer chassis
Analyzer
Electronics
Package is
inserted here
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 1-4
System Hardware Overview
4-20 mA Output
RS-232 COM Line
Analog Voltage Output
Range ID Output
Fault Relay Outputs
Alarm 1 & 2 Relay Outputs
Relay Board
Line
Filter
Power
Supply
Main Board
Remote
Sensor
Display
Board
Mains Power
Input
Control
Panel
Figure 5 – Analyzer system configuration
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 1-5
MODEL 1100 – Introduction and Overview
1.4
Analyzer Inputs and Outputs
1.4.1
The Oxygen Sensor Input
The oxygen sensor electrical input to the model 1100 is used to indicate the oxygen concentration
measured by the model CAG-250E oxygen sensor. It is proportional to the oxygen present in the
measured gas at the sensor membrane. The oxygen sensor input is a female 3-pin 180° DIN connector to
mate with the supplied sensor interface cable connector.
1.4.2
Alarm-1 Relay Output
The Alarm-1 relay is mapped to the Alarm-1 setpoint, and is provided for process control use. The user
may set the oxygen level at which Alarm-1 activates (section 3.2.2). Alarm-1 may be configured as
ascending (highest oxygen level allowable) or descending (lowest oxygen level allowable) action. The
relay output may be configured for fail-safe (relay coil de-energized in alarm state) or non fail-safe (relay
coil energized in alarm state) action. Factory default settings are ascending, and fail-safe (Appendix C,
Factory Configuration). The Alarm-1 relay contacts are form C (DPDT), voltage-free.
1.4.3
Alarm-2 Relay Output
The Alarm-2 relay is mapped to the Alarm-2 setpoint, and is provided for process control use. The user
may set the oxygen level at which Alarm-2 activates (section 3.2.3). Alarm-2 may be configured as
ascending (highest oxygen level allowable) or descending (lowest oxygen level allowable) action. The
relay output may be configured for fail-safe (relay coil de-energized in alarm state) or non fail-safe (relay
coil energized in alarm state) action. Factory default settings are ascending, and fail-safe (Appendix C,
Factory Configuration). The Alarm-2 relay contacts are form C (DPDT), voltage-free.
1.4.4
Fault Relay Output
The Fault relay output is used to indicate that there is at least one system fault active on the Model 1100
analyzer (section 4.3.1 – fault codes and definitions). The relay output action is non fail-safe, and is not
configurable. The Fault relay contacts are Form B (SPST), voltage-free.
1.4.5
Analog Voltage Output
The Analog Voltage output is a dynamic potential used to indicate to a remote device the displayed
oxygen concentration during normal analyzer operation and system maintenance. The Analog voltage
output follows the oxygen readout displayed on the 7-segment LED display during all system and user
modes except for user setup. For a complete listing of available output levels by analyzer range, refer to
Appendix E – range / output chart.
The Analog voltage range can be adjusted by the user (section 4.1 – system setup). Available settings are
0-VDC for minimum-scale-deflection, to 1, 5 or 10-VDC full-scale. The factory default setting is 0-1 VDC
(Appendix C, Factory Configuration). The Analog voltage output is scaled according to the analyzer’s
selected range, and must be used in conjunction with the Range ID voltage when the Analyzer is
configured for auto-ranging (section 1.4.8).
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 1-6
Control Panel User Interface
1.4.6
Analog Current Output
The Analog Current output is a dynamic current flow used to indicate to a remote device the displayed
oxygen concentration during normal analyzer operation and system maintenance. The Analog current
output follows the oxygen readout displayed on the 7-segment LED display during all system and user
modes except for user setup. For a complete listing of output levels by analyzer range, refer to Appendix E
– range / output chart.
The minimum scale deflection may be set to either 0 mA or 4 mA. Full-scale is fixed at 20 mA. The
Analog current output is scaled according to the analyzer’s selected range, and must be used in
conjunction with the Range ID voltage when the Analyzer is configured for auto-ranging (section 1.4.8).
1.4.7
Range ID Output
The model 1100 can be configured by the user to automatically switch its measurement range, based on
the concentration of oxygen measured while in-service, to provide the most accurate, and highest
resolution outputs at all times. For a complete listing of analyzer ranges, refer to Appendix E – range /
output chart.
Remote auxiliary devices designed to interpret the model 1100 Analog outputs over multiple output
range scales require an indication of the analyzer’s selected range at all times for accurate scaling. The
model 1100 features a 0-10 VDC Auto-Range Identification output. The range ID output is used in
conjunction with the Analog voltage and Analog current outputs when auto-ranging is used. It provides
an indication of the Analog outputs’ selected full-scale. There are five range ID voltage levels used in the
1100 to correspond with its five output ranges (Appendix E – range / output chart).
1.4.8
Service Port
The Service port provides a user-friendly means of digital communications with the model 1100
Analyzer. Through this port, the unit may be configured, calibrated, and queried for most functions. The
RS-232 port may also be programmed to send out information on a timed basis for users who prefer to
use Digital instead of Analog interfacing with the analyzer. In addition, the service port may be used
with a PC based computer (such as a portable notebook computer) over a standard bi-directional RS-232
serial interface.
1.5
Control panel User Interface
1.5.1
The “UP” Pushbutton
The “UP” pushbutton can be used to program the 1100 Analyzer via the control panel. This momentary
push-button soft key is used to enter incremental information. Its function is menu-driven.
1.5.2
The “DOWN” Pushbutton
The “DOWN” pushbutton can be used to program the 1100 Analyzer via the control panel. This
momentary push-button soft key is used to enter decremental information. Its function is menu-driven.
1.5.3
The “MODE” Pushbutton
The “MODE” pushbutton can be used to program the model 1100 via the control panel. This momentary
push-button soft key is used to navigate the operational modes available through the control panel. Its
function is menu-driven.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 1-7
MODEL 1100 – Introduction and Overview
1.5.4
7-Segment Alphanumeric Display
The 7-Segment alphanumeric display feeds back information from the model 1100 to the user via the
control panel. The primary purpose of the 7-Segment display is to show the oxygen concentration
readout. It is also used for feedback of operational status, fault codes, and other information necessary to
perform system setup and maintenance.
1.5.5
RUN Indicator LED
The purpose of the RUN Indicator LED is to inform the user via the control panel that the model 1100 is
measuring the concentration of the sample gas and updating the display and outputs accordingly, and
has not detected any alarm, or fault conditions.
1.5.6
Alarm-1 Indicator LED
The purpose of the Alarm-1 Indicator LED is to inform the user via the control panel that the measured
oxygen concentration has exceeded the alarm-1 threshold; alarm-1 and its associated relay are in active
mode.
1.5.7
Alarm-2 Indicator LED
The purpose of the Alarm-2 Indicator LED is to inform the user via the control panel that the measured
oxygen concentration has exceeded the Alarm-2 threshold; alarm-2 and its associated relay are in active
mode.
1.5.8
Fault Indicator LED
The purpose if the Fault Indicator LED is to inform the user via the control panel that at least one system
fault is active. Note that when the fault Indicator LED is active, the fault relay will also be active.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 1-8
2
2.1
CHAPTER 2 – SYSTEM INSTALLATION AND START-UP
Installing the Analyzer
S TE P 1:
L O C A TE TH E A N A L YZER ...
PA N EL CU TO U T
S TE P 2:
IN S TA LL TH E S EN S O R …
P rocess S am pling System
S TE P 3:
IN S TA LL TH E A N A L YZER
Figure 6 – Installation outline
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 2-1
System Installation and Startup
2.1.1
Step 1 – Locate and Mount the Analyzer unit
The model 1100 is designed to be mounted flush to the surface of a stationary equipment control panel.
Select a suitable location for the analyzer unit where the digital display and status LED’s will be easy to
read, and the interface buttons on the display panel will be easy to access.
Cut/drill the mounting panel to the specifications in figure-7. Clearance holes for the #8-32 threaded
mounting studs do not need to be tapped. Hex nuts are included for securing the unit to a panel. Trim all
burrs or sharp edges in the cutout or mounting-holes, which would interfere with or damage the gasket
on the analyzer control panel.
Slide the analyzer unit into the cutout, rear-chassis first, and seat the control panel gasket on the
mounting surface. The gasket on the analyzer control panel ensures a watertight seal around the control
panel cutout. Secure the threaded mounting studs with the supplied hex-nuts, and internal-tooth lockwashers. The analyzer control panel is suitable for NEMA Type 4, IP20 environments when properly
installed. The rear electronics chassis is suitable for NEMA Type 1, IP 20 environments.
The analyzer should not be exposed to water, adverse temperature, or shock. Ensure the analyzer unit is
mounted in an area of free airflow to prevent the chassis from exceeding the operating temperature
specifications. Do not mount the analyzer or sensor against hot surfaces. Do not block the ventilation
louver on the analyzer chassis.
6.62"
6.20"
2.91"
PANEL CUTOUT & DRILL PATTERN
2.75"
.169 DIA. HOLE
4 PLACES
Figure 7 – Analyzer cutout
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 2-2
Installing the Analyzer
2.1.2
Step 2 – Install the Remote Sensor
The model 1100 is supplied with a model CAG-250E oxygen sensor, and sensor flow-through head for
connection to a sampled process gas stream, and a sensor interface cable with a rubberized sheath to
protect the sensor and the sensor electrical connector from dust and liquid spray.
The model 1100 can also be supplied with a Neutronics Inc. process Sampling system, built-toapplication. For detailed instructions on remote sensor installation with a Neutronics Inc. Process
Sampling System, please refer to the equipment manual.
CAUTION:
The remote mounted sensor contains a weak acid electrolyte
(concentrated acetic acid). Do not attempt to disassemble the sensor. Any sensor
found leaking electrolyte should be disposed of according to local regulations. See
material safety data supplied in the Appendix of this manual. Any damaged
sensor should be replaced with a new unit.
2.1.2.1
Flow-through Head
Surface-mount the flow through head horizontally (as shown in figure 8) or vertically on a stationary
panel. The sensor flow-through head is 1.25” diameter Delrin plastic or optional stainless steel, and is
machined to accommodate two # 6-32 machine-type mounting screws (1-inch on center). Be careful
not to over tighten the mounting screws. Allow sufficient space to screw the model CAG-250E oxygen
sensor into the top threaded port of the flow through head, and for the sample lines and sample inlet and
exhaust fittings.
Switchcraft #712A plug
MAX- 250E
Oxygen
Sensor
1.25
90.00°
O-ring top seal
M16 x 1 threaded
connector
Sensor
Receptacle
Flow Through
Head body
#6-32 thread, 2 places,
mounting holes
CL
Gasket
1/8" FNPT
Sample Exhaust
1/8" FNPT
Sample Input
CL
Mounting screws #6-32
2.1.2.2
Figure 8 – Sensor
and flow-through
head mounting
1.0
Sample Inlet Port
Pneumatic connection to the measured process for sample extraction is made at either of the two
interchangeable 1/8” FNPT fitting around the side of the flow-through head. For connecting the flowthrough head to the measured process, use 1/8” or 1/4” rigid tubing, and 1/8” MNPT fittings of a
material compatible with process gas composition. Ensure that no grease, particulate, or solvent is
present in the tubing during installation. Use thread-tape to seal connections, and prevent gauling. Fix
all sample tubing and connectors.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 2-3
System Installation and Startup
A fixed calibration port may be implemented in the process sampling line by installing a 1/8” or 1/4” 3way manual ball valve into the sampling line as in figure-9. Use 1/8” or 1/4” rigid tubing and 1/8”
MNPT fittings of a material compatible with process gas composition. Ensure that no grease, particulate,
or solvent is present in the tubing during installation. Use thread-tape to seal connections, and prevent
gauling. Fix all sample tubing and connectors.
SAMPLING POSITION
Sample Flow
Remote Sensor
Module
Sample Gas
Calibration Gas
CALIBRATE POSITION
Remote Sensor
Module
Sample Gas
Sample
Flow
Calibration Gas
Figure 9 – Calibration gas fixture configuration
2.1.2.3
Sample Exhaust Port
Pneumatic connection to the measured process for sample extraction is made at either of the two
interchangeable 1/8” FNPT fitting around the side of the flow-through head, but opposite the installed
sample inlet port (section 2.1.2.2). For connecting the sample exhaust to vent, use 1/8” or 1/4” rigid
tubing and 1/8” MNPT fittings of a material compatible with process gas composition. Select a vent
location that is known to be at atmospheric pressure at all times. Use a minimum 2-meters of tubing to
prevent back-flow of vent gas to the sensor. Ensure that no grease, particulate, or solvent is present in
the tubing during installation. Use thread-tape to seal connections, and prevent gauling. Fix all sample
tubing and connectors.
2.1.2.4
Sensor
The CAG-250E sensor pneumatic connection to the process gas stream is made at the M16x1 threaded
flow-through head connection with a supplied top seal o-ring and receptacle gasket. Electrical
connection to the model 1100 is made at the female SwitchCraft type #712A connector.
Connect the sensor to the flow-through head. Verify the supplied o-ring is in place at the base of the
sensor, over the M16x1 threaded connector. Do not lubricate the o-ring. Verify the supplied gasket is
seated in the bottom of the flow-through head sensor receptacle. Screw the sensor into the flow-through
head sensor receptacle, and hand-tighten. Do not over-tighten. The o-ring and gasket should be slightly
compressed. Match the sensor threaded flow-through head connection against the mating receptacle in
the sensor flow-through head.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 2-4
Installing the Analyzer
Attach the supplied sensor cable to the model CAG-250 oxygen sensor using the female SwitchCraft type
#712A connector. Hand-tighten the capture-ring to secure the connection. Match the sensor electrical
connection against the mating connector on the sensor interface cable. Slide the protective sheath over
the sensor. Fix all wiring and connectors.
Sampled process gas may be applied to the sensor flow-through head any time after the sensor is attached
to the flow-through head. Regulate sample gas to 1 to 3 psig at 1-SLPM flow rate. Do not exceed 3-psig
at the sample inlet port. Never apply an unregulated gas source to the sensor flow-through head.
2.1.3
Step 3 – Install the Analyzer
DANGER:
Electrical connections on the rear of the Model 1100 Oxygen analyzer may
have hazardous voltages present once power has been applied to the unit. High voltages
may remain present for a short time even after power has been disconnected from the
analyzer. Take care in observing standard electrical practices when making electrical
connections to the Model 1100 Oxygen analyzer.
DANGER: The model 1100 analyzer is not rated intrinsically safe or explosion proof.
Be certain that
no flammable gases are present in the area where the Model 1100 analyzer will be installed.
CAUTION: The model 1100 housing is not rated waterproof.
Do not mount the analyzer or the sensor
in an area where it may contact water or other liquid elements.
WARNING: Be certain that all power is OFF to the analyzer and associated wiring (cables) before
attempting installation. DO NOT WORK WITH LIVE WIRES! Do not leave any exposed wire at the terminal
blocks. Before applying power, ensure terminal blocks are fully inserted into the mating connector at the
analyzer.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 2-5
System Installation and Startup
A label depicting the terminal block arrangement is affixed to the top of the chassis for easy reference
during installation and maintenance (VAC configuration shown below). The terminal blocks feature
screwed terminals. The terminal blocks are also removable for ease of wiring or removal of the analyzer
module.
NTRON
PROCESS ANALYZER DIVISION
POWER INPUT
*
TB1
1
2
3
*
LINE
4
5
SENSOR
CABLE
FAULT
C
NO
C
1
3
5
2
TB3
4
*
*
1
2
ALARM 2
NC
NO
6
8
7
TB1
I-OUT
+
-
3
5
7
4
6
GND
no
connection
1
2
no
connection
TB2
TB3
1
2
*
12
TX
8
13
RS-232
RX RTN
9
10
11
Alarm 2
Alarm 1
NO
C
NC
NO
C
NC
NO
3
4
5
6
7
8
9
10
Bat.
BU
3
4
NO CONNECTION
VAC POW ER INPUT,
90-264 VAC, 47-63 Hz
C
-
*
- or -
5
Fault
+
14
SERVICE PORT
ANALOG
AC-L
AC-N
*
11
VDC POW ER INPUT,
11-24 VDC
4
3
10
V-OUT
+
-
VDC+
2
1
9
BAT. BU
+
12V DC
GND COM
ALARM 1
NC
NO
C
V
Out
+
5
6
no
connection
TB2
TEMP
C
NO
RANGE
V-OUT
+
-
mA
Out
11
-
TX
7
8
9
RX
10
+
-
13
14
NO = Normally Open
NC = Normally Closed
C = Common
RS-232
+
12
Range
V-Out
RTN
11
Service
Port
12
VDC
Figure 10 – Analyzer chassis electrical connections
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 2-6
Installing the Analyzer
2.1.3.1
Sensor Input
Electrical connection to the model CAG-250E oxygen sensor is made by connecting the supplied sensor
interface cable between the analyzer and the sensor. Attach the sensor interface cable to the model 1100
analyzer female 180° 3-pin DIN cable connector. Match the sensor input connector against the mating
connector on the sensor interface cable. Fix all wiring and connectors.
2.1.3.2
Alarm-1 Relay Output
Connections from the Alarm-1 relay contacts to the user’s process control equipment are made at
terminal block TB2 on the rear of the analyzer chassis. The oxygen alarm relay contacts are voltage-free
Form C relay contacts, SPDT, 5A @ 250 VAC, 5A @ 30 VDC. Be certain to match the terminal pins
against the terminal ID label on the top of the analyzer chassis.
2.1.3.3
Alarm-2 Relay Output
Connections from the Alarm-2 relay contacts to the user’s process control equipment are made at
terminal block TB2 on the rear of the analyzer chassis. The oxygen alarm relay contacts are voltage-free
Form C relay contacts, SPDT, 5A @ 250 VAC, 5A @ 30 VDC. Be certain to match the terminal pins
against the terminal ID label on the top of the analyzer chassis.
2.1.3.4
Fault Relay Output
Connections from the Fault relay contacts to the user’s process control equipment are made at terminal
block TB2 on the rear of the analyzer chassis. The fault relay contacts are voltage-free Form B relay
contacts, SPST, 5A @ 250 VAC, 5A @ 30 VDC. Be certain to match the terminal pins against the
terminal ID label on the top of the analyzer chassis.
2.1.3.5
Range ID Output
Connections from the Range ID output to the user’s auxiliary equipment are made at terminal block TB2
on the rear of the analyzer chassis. Be certain to match the terminal pins against the terminal ID label on
the top of the analyzer chassis.
TB2
1
Manual Part Number:
C5-06-4900-01-0
2
Fault
Alarm 2
Alarm 1
C
NO
C
NC
NO
C
NC
NO
3
4
5
6
7
8
9
10
Revision Level: A
no
connection
no
connection
Use 20-AWG, 2-conductor, stranded-wire, twisted pairs for the connections. It is not necessary to use
shielded cable for the Range ID output, with or without electrical barriers. If shielded cable is used, it
should be drained to dc ground at the auxiliary equipment.
11
12
Range
V-Out
+
-
13
14
Revision Date: January 19, 2004
Page 2-7
System Installation and Startup
2.1.3.6
Analog Voltage Output
Connections from the Analog Voltage output to the user’s auxiliary equipment are made at terminal
block TB3 on the rear of the analyzer chassis. Be certain to match the terminal pins against the terminal
ID label on the top of the analyzer chassis.
Use 20-AWG, 2-conductor, stranded-wire, twisted pairs for the connections. It is not necessary to use
shielded cable for the Analog voltage output, with or without electrical barriers. If shielded cable is used,
it should be drained to dc ground at the auxiliary equipment.
2.1.3.7
Analog Current Output
Connections from the Analog Current output to the user’s auxiliary equipment are made at terminal
block TB3 on the rear of the analyzer chassis. The Analog current output is a negative ground, nonisolated 0-20mA, or 4-20 mA current loop. 12 VDC Power is supplied by the model 1100 analyzer.
Maximum electrical loading is 250 Ohms. Be certain to match the terminal pins against the terminal ID
label on the top of the analyzer chassis.
Use 20-AWG, 2-conductor, stranded-wire, twisted pairs for the connections. It is not necessary to use
shielded cable for the Analog current output, with or without electrical barriers. If shielded cable is used,
it should be drained to dc ground at the auxiliary equipment.
2.1.3.8
Battery Backup
12-volt DC Battery Backup terminals are provided at terminal block TB3 on the rear of the analyzer
chassis. These terminals may be connected to a fixed 12 VDC power source to act as a back up in case
mains power has been lost. The circuit will detect loss of the mains power and the VDC battery backup
will maintain power to the system.
no
connection
Connection to the battery backup is not required for normal operation of the analyzer. Be certain to
match the terminal pins against the terminal ID label on the top of the analyzer chassis.
TB3
1
2
Bat.
BU
+
3
-
4
12
VDC
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
V
Out
+
5
6
mA
Out
RS-232
+
-
TX
7
8
9
RX RTN
10
11
Service
Port
Revision Date: January 19, 2004
Page 2-8
Installing the Analyzer
2.1.3.9
RS-232 Service Port
Connections from the Range ID output to the user’s auxiliary equipment are made at terminal block TB3
on the rear of the analyzer chassis. Be certain to match the terminal pins against the terminal ID label on
the top of the analyzer chassis.
For interfacing with any standard PC computer via serial port, use 20-AWG, 3-conductor, shielded,
stranded-wire, jacketed cable, terminated on one end with a female DB9 connector. The shielding should
be drained to dc ground at the computer.
SIGNAL
DESIGNATION AT
ANALYZER
RX
TX
RTN
2.1.3.10
ANALYZER TB2
CONNECTION
SIGNAL
DESIGNATION AT
COMPUTER
TX
RX
RTN
Pin 9
Pin 10
Pin 11
COMPUTER DB9
SERIAL PORT
CONNECTION
Pin 2
Pin 3
Pin 5
Mains Power
Connections for Mains Power input are made at terminal block TB1 on the rear of the analyzer chassis.
Be certain to match the terminal pins against the terminal ID label on the top of the analyzer chassis.
For VAC versions, use minimum 16-AWG, 3-conductor, stranded-wire, for the connections. Supply
single-phase 110/220 VAC, 50/60Hz to the unit. For VDC versions, use 18-AWG, 3-conductor,
stranded-wire, for the connections. Supply 12/24 VDC to the unit. Refer to Appendix B for detailed
power specifications.
GND COM
TB1
1
GND
Manual Part Number:
C5-06-4900-01-0
2
VDC POWER INPUT,
11-24 VDC
VDC+
3
AC-N
4
5
AC-L
Revision Level: A
- or VAC POWER INPUT,
90-264 VAC, 47-63 Hz
Revision Date: January 19, 2004
Page 2-9
System Installation and Startup
2.2
Starting up and Commissioning the System
STEP 1:
POWER UP
STEP 2:
IN ITIA L C A LIB R A TIO N
STEP 3:
S ET A LA R M 1 & 2
Figure 11 – Start-up outline
The Model 1100 is shipped ready to use, right from the carton. Factory default configuration settings are
listed in Appendix C for your information. Those settings will be suitable for most applications. Review
the factory default configuration settings before commissioning your system. If you wish to change any
of the factory default settings, refer to sections 4.1.1 and 4.1.2.
POWER UP CHECK LIST
Have you:
•
Mounted the analyzer and sensor in areas where there are no flammable vapors?
•
Mounted the system away from exposure to rain, dripping water, or hose down?
•
Correctly installed all of the wiring?
•
Connected the sensor interface cable at both the sensor and analyzer?
•
Ensured gas tight plumbing at the sensor flow-through head?
•
Regulated the sample pressure as instructed in section 2.1.2.4?
•
Read this manual in its entirety?
2.2.1
STEP 1 – Power Up the unit
When the Model 1100 is powered-up, it will go through a 5-second self-test. The 7-segment
alphanumeric display will show “8.8.8.8.”, then XXXX (software build), and the Power Supply voltage
setting. The Run, Alarm-1, Alarm-2 and Fault LED indicators will go through a display test sequence
(Lamp Test). The unit will then check the sensor signal and update the digital display and status LED’s,
and enter into the appropriate system mode according to programmed parameters (Appendix C – system
configuration).
Once the analyzer reading has stabilized, the user may apply an instrument air source to the sensor to
check the system. Allow the new reading to stabilize. It should take about 30-seconds for the gas to
sweep out the sample lines, depending on the length.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 2-10
Starting up and Commissioning the System
2.2.2
STEP 2 – Calibrate the Unit
All units are calibrated at the Neutronics factory before shipping. However, it is recommended that the
model 1100 be calibrated at commissioning, under ambient and process conditions similar to those
encountered while in-service. Refer to section 3.2.1 for detailed analyzer calibration instructions.
Helpful hint The model 1100 is configured-to-order, as specified by the user per the application. If the
application has changed, some adjustments in the system configuration may be necessary to optimize the
model 1100 performance for the application. After reviewing the calibration instructions, review
Appendix C – Factory Configuration Settings. Verify that the current settings are suitable for the
application. Refer to Appendices E and F for all valid range and output settings available on the model
1100. If any changes are necessary, they can be performed via the control panel (section 4.1.1) or the
service port (section 4.1.2).
2.2.3
STEP 3 –Set Alarm-1 and Alarm-2
After the unit has been calibrated on a known gas source, set the alarm points according to process
control requirements. Refer to Appendix C for factory settings.
2.2.3.1
Set Alarm-1
For process control applications, alarm-1 is used normally as the “primary” oxygen-level alarm, and is
set to the highest or lowest level of oxygen allowable in your process, according to the application. Refer
to section 3.2.2 for information about setting the alarm-1 level.
2.2.3.2
Set Alarm-2
For process control applications, alarm-2 is used normally as the “secondary”, or “warning” oxygenlevel alarm, and is set just below to the highest, or just above the lowest level of oxygen allowable in your
process, according to the application. Refer to section 3.2.3 for information about setting the alarm-2
level.
The Model 1100 should now be ready for commissioning. Neutronics Inc. offers commissioning, and
Factory Acceptance Testing services by our qualified technicians. You may contact the Neutronics
factory toll-free at (800) 278-2287 in the continental United States. Elsewhere, call (610) 524-8800) and
ask an Ntron Division Service Technician to schedule a service call.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 2-11
3.1
System Organization
3
CHAPTER 3 – ANALYZER OPERATION
The Model 1100 has two types of operational modes – User-type, and System-type. User modes are
initiated and controlled by the user, and are used to setup and maintain the analyzer. The User modes
are: Calibration, Set/View Alarm-1, Set/View Alarm-2, View Active Faults, and Setup. Operating modes
are accessed automatically by the Model 1100 during normal operation, according to its programming,
and its configuration parameters. The Operating modes are: Self-Test & Warm-up, Run, Alarm-1 Active,
Alarm-2 Active, and Fault Active.
3.2
USER Modes
At any time, the user can initiate any of the user modes either from the control panel or through the
service port. Control panel access of the Calibration, Set/View Alarm-1, Set/View Alarm-2 and View
Active Faults modes will be covered in this chapter. System setup mode and user access via the service
port will be covered in section 4.1.
The user modes Calibration, Set/View Alarm-1, Set/View Alarm-2 and View Active Faults are accessed
serially via the control panel, in the aforementioned order by repeatedly pressing and releasing the
“MODE” key. When a user mode is accessed via the control panel, the model 1100 aborts any system
mode active, and holds the state of Alarm-1, Alarm-2, Fault, and Heater OK relay outputs until the user
returns the unit to Run mode.
3.2.1
CALIBRATE Mode & Calibration Procedure
Calibration mode allows the oxygen sensor and analyzer to be aligned to gases of known oxygen
concentration for the most accurate on-line readings. For best accuracy in most ranges, the model 1100
requires single-gas calibration with ambient-level oxygen (20.9 %) at system commissioning, and at
regular monthly intervals during the normal service life of the oxygen sensor (2-3 years). The simple
procedure requires the user only to apply gas, and adjust the reading on the analyzer control panel. The
model 1100 does the rest.
When a new sensor is put into service, the analyzer is calibrated with two gases, 20.9 % and 1 – 4 %, to
ensure full range accuracy throughout the normal service life of the sensor. The analyzer will recognize
the two calibration gases automatically. The user just applies gas, adjusts the reading on the analyzer
control panel, and repeats the same simple steps with another gas. The model 1100 automatically sets
up the new sensor for best accuracy throughout its service life.
Calibration should be performed at the following times:
•
During commissioning 1
•
Once per 30-days of normal operation 1
•
When replacing an oxygen sensor 2
As required while troubleshooting the system 1
2
1
Single gas calibration 20.9 % O2
Two-gas calibration 20.9 % and 1 – 4 % O2
•
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 3-1
Analyzer Operation
3.2.1.1
Step-1;
Select Calibration gases
The following calibration gas sources can be used to calibrate the model 1100:
For normal calibration – use Instrument grade compressed air (Dew-point < 35°, particulates < 3micron, condensable hydrocarbons < 1-part-per-million), or Certified Standard grade bottled gas at 20.9
% oxygen concentration.
Additional gas for new sensor – use Certified Standard grade bottled calibration gas – 1.5 % O2
WARNING Do not calibrate the model 1100 on zero gas. If the unit is calibrated on zero-gas, it will not
operate properly.
3.2.1.2
Step-2;
Remove the Oxygen Sensor from Online Service
The oxygen sensor requires removal from on-line service to perform calibration. Calibration or other
maintenance of the model 1100 analyzer and sensor should be performed when the measured process is
not operating. If the unit has been installed with a Neutronics Inc process sampling system, please refer
to the equipment manual for detailed instructions.
Warning Before opening any part of the sampling system to air, make sure that the sampling
lines are not pressurized, and are clear of any gas that may create a personnel or
environmental hazard.
Disconnect the measured process from the sensor by completely removing the installed 1/8” MNPT
fittings from the sensor flow-through head sample inlet port (this step is not necessary if using a fixed gas
manifold – section 2.3.1). If it is necessary to exhaust to an alternate path during calibration, completely
remove the installed 1/8” MNPT fittings from the sensor flow-through head sample exhaust port.
Connect the oxygen sensor to an alternate exhaust location as in section 2.1.2.3.
3.2.1.3
Step-3;
Normal Calibration – Apply calibration gas to the Oxygen Sensor
Attach a calibration gas source at 20.9 % oxygen concentration to the model 1100 sensor flow through
head. The user may attach the regulated gas source to the sensor head sample inlet port directly, or
through a fixed gas manifold. The latter method will help to prevent premature wear of tube-ends and
fittings, and increase long-term sampling system integrity. Where a calibration manifold has not been
installed, connect the calibration gas source to the oxygen sensor similar to section 2.1.2.2.
Apply calibration gas to the oxygen sensor. Adjust the regulated calibration gas pressure to match the
pressure of the in-service sample gas, within the sensor pressure specification of 1-10psig (Appendix B).
Be sure to flow calibration gas to the sensor until the analyzer display has stabilized to allow calibration
gas to sweep out the sample lines.
Warning: Never apply an unregulated gas supply to the oxygen sensor.
High or uncontrolled
pressures may damage the oxygen sensor, and/or sampling system components.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 3-2
USER Modes
3.2.1.4
Step-4;
Normal Calibration – Calibrate the Model 1100
After a regulated stream of calibration gas has been applied to the sensor, press and release the “MODE”
key once. The 7-segment alphanumeric display will show “CAL”, then an oxygen concentration value.
Adjust the displayed oxygen concentration value to read “20.9” by pressing the “UP” or “DOWN” arrow
key as required. Press and release the “MODE” key four times to return to Run mode.
Note For normal monthly sensor calibration, skip to step-7, section 3.2.1.8 “Return the Oxygen Sensor to
Online Service”. The normal calibration procedure is complete. When replacing the oxygen sensor, the
model 1100 must be calibrated to an additional gas 1.5 % oxygen. Continue on to Step-5, section
3.2.1.6 “New Sensor Calibration”.
3.2.1.5
Step-5;
New Sensor Calibration – Apply calibration gas to the Oxygen Sensor
Attach a calibration gas source at 1.5 % oxygen concentration to the model 1100 sensor flow through
head. The user may attach the regulated gas source to the sensor head sample inlet directly, or through
a fixed gas manifold (section 2.3.1). The latter method will help to prevent premature wear of tube-ends
and fittings, and increase long-term sampling system integrity. Where a calibration manifold has not
been installed, connect the calibration gas source to the oxygen sensor similar to section 2.1.2.2.
Apply calibration gas to the oxygen sensor. Adjust the regulated calibration gas pressure to match the
pressure of the in-service sample gas, within the sensor pressure specification of 1-10psig (Appendix B).
Be sure to flow calibration gas to the sensor until the analyzer display has stabilized to allow calibration
gas to sweep out the sample lines.
Warning: Never apply an unregulated gas supply to the oxygen sensor.
High or uncontrolled
pressures may damage the oxygen sensor, and/or sampling system components.
3.2.1.6
Step-6;
New Sensor Calibration – Calibrate the Model 1100
After a regulated stream of calibration gas has been applied to the sensor, press and release the “MODE”
key once. The 7-segment alphanumeric display will show “CAL”, then an oxygen concentration value.
Adjust the displayed oxygen concentration to read “1.5” by pressing the “UP” or “DOWN” arrow key as
required. Press and release the “MODE” key four times to return to Run mode.
3.2.1.7
Step-7;
Return the Oxygen Sensor to Online Service
When calibration procedures are complete, the model 1100 is ready to return to service. Disconnect
calibration gas from the oxygen sensor by completely removing the installed 1/8” FNPT fitting from the
sensor flow-through head sample inlet port. Where a calibration manifold has not been installed,
reconnect the sample inlet port to the process for in-service oxygen measurement (section 2.1.2.2). If an
alternate vent connection has been made, reconnect the sensor flow-through head sample exhaust port
to the primary vent source (section 2.1.2.3). Be sure to flow sample gas to the sensor until the analyzer
display has stabilized to allow time to sweep the sample lines clear of calibration gas.
3.2.2
SET/VIEW ALARM-1 Mode
To enter Set Alarm-1 mode from run mode using the keypad; scroll through the user mode menu by
pressing momentarily the “MODE” key two (2) times, until the 7-segment alphanumeric display reads
“AL1” (set alarm-1 level), and the “RUN” and “ALM1” indicator LED’s flash. The display will show
momentarily “AL1” and then the current alarm-1 threshold level (an O2 concentration). Use the “UP”
and “DOWN” keys to adjust the alarm-1 setpoint level. Changed settings are automatically saved when
the “MODE” key is pressed to enter the next mode.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 3-3
Analyzer Operation
3.2.3
SET/VIEW ALARM-2 Mode
To enter Set Alarm-2 mode from run mode using the keypad; scroll through the user mode menu by
pressing momentarily the “MODE” key three (3) times, until the 7-segment alphanumeric display reads
“AL2” (set alarm-2 level) and the “RUN” and “ALM2” indicator LED’s flash. The display will show
momentarily “AL2” and then the current alarm-2 threshold level (an O2 concentration). Use the “UP”
and “DOWN” keys to adjust the alarm-2 setpoint level. Changed settings are automatically saved when
the “MODE” key is pressed to enter the next mode.
3.2.4
VIEW ACTIVE FAULTS Mode
To enter View Active Faults mode from run mode using the keypad; scroll through the user mode menu
by pressing momentarily the “MODE” key four (4) times until the 7-segment alphanumeric display reads
“FL”, and the “RUN” and “FAULT” indicator LED’s flash. The display will show momentarily “FL” and
then the highest priority active system fault. Press and release the “UP” or “DOWN key to scroll through
all active system faults. Refer to section 4.3.1 for a complete fault code listing, and troubleshooting
guide. To exit, press and release the “MODE” key.
3.2.5
Return to RUN Mode
To exit to run mode from any user mode, using the keypad; scroll through the control panel user mode
menu by pressing repeatedly the “MODE” key until the 7-segment alphanumeric display shows ”run”.
The display will then show an oxygen concentration. The “RUN”, “ALM1”, “ALM2”, and “FAULT”
LED’s will flash for 120 seconds to indicate that the analyzer is in a stabilization period. This is to allow
time to sweep the sample lines with sample gas before returning the unit to on-line service. During the
stabilization period, alarm-1, alarm-2, and fault, relays remain inactive, and held to their last state before
the control panel user mode menu was accessed.
3.3
System Modes
The model 1100 has five System modes – Self-Test & warm-up, Run, Alarm-1 Active, Alarm-2 Active, or
Fault Active. Self-test & warm-up are fixed routines that are initiated upon each start-up. The remaining
system modes, provided no valid manual input is received at the control panel or service port, are
initiated automatically by the analyzer according to setup parameters entered by the user in setup mode,
compared against monitored inputs and other monitored system hardware in real time.
3.3.1
Self-Test & Warm-up Mode
When the model 1100 is started up, it enters into Self-Test & Warm-up mode automatically (section
2.2.1). When the analyzer self-test is complete, the unit checks the current sensor signal, updates the 7segment LED display, status LED’s, and Analog outputs, then enters into the appropriate system mode
according to its programmed parameters.
3.3.2
RUN Mode
The model 1100 initiates Run mode when it is continuously measuring the oxygen concentration of the
in-service sample gas, and updating the display and outputs accordingly, and it has not detected any
valid user input. A solid lit or flashing “RUN” indicator LED indicates to the user that the instrument is
on-line, and the system is operating properly.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 3-4
SYSTEM Modes
When the measured process oxygen concentration falls outside of programmed alarm parameters,
and/or the system experiences a fault condition, the model 1100 analyzer enters into Alarm-1 Active,
Alarm-2 Active, and/or Fault Active mode accordingly. The system does not abort Run mode, and the
“RUN” indicator LED stays lit. The appropriate indicator LED will light in addition to the “RUN” indicator
LED.
When programmed alarm setpoints and/or fault conditions are cleared, the model 1100 analyzer aborts
Alarm-1 Active, Alarm-2 Active, and/or Fault Active mode accordingly. The system does not abort Run
mode, and the “RUN” indicator LED stays lit. Indicator LED’s mapped to aborted modes go out.
When the model 1100 analyzer detects valid user-input, it enters into one of the user modes accordingly
– Calibration, Set/View Alarm-1, Set/View Alarm-2, View Active Faults, or User Setup. The analyzer
aborts Run mode and holds the state of Alarm-1, Alarm-2, and Fault. The “RUN” indicator LED goes out,
except in Calibrate mode, where it flashes.
When the user manually aborts all user modes by returning the system to Run mode, or no valid user
input is detected for 120-seconds, the model 1100 checks the current sensor signal, updates the 7segment LED display, status LED’s, and Analog outputs, then enters into the appropriate system mode
according to its programmed parameters. Alarm-1, Alarm-2, and Fault relay outputs are released and
the “RUN” indicator LED is lit.
3.3.3
ALARM-1 ACTIVE Mode
The model 1100 initiates Alarm-1 Active mode when it has detected that the measured oxygen
concentration has exceed the set threshold value of Alarm-1 (section 3.2.2). The “ALM1” indicator LED
will light, The “RUN” indicator LED will remain lit. The Alarm-1 relay will change state according to the
analyzer configuration (Appendix C, Factory Setup). The Alarm status will be cleared automatically
when the measured oxygen concentration is within the set threshold value of Alarm-1. The “ALM1”
indicator LED will go out, and the Alarm-1 relay will return to its non-active state according to the
analyzer configuration. The Alarm-1 Active mode held to its last state during manual access to the user
mode menu.
3.3.4
ALARM-2 ACTIVE Mode
The model 1100 initiates Alarm-2 Active mode when it has detected that the measured oxygen
concentration has exceed the set threshold value of Alarm-2 (section 3.2.3). The “ALM2” indicator LED
will light, The “RUN” indicator LED will remain lit. The Alarm-2 relay will change state according to the
analyzer configuration (Appendix C, Factory Setup). The Alarm status will be cleared automatically
when the measured oxygen concentration is within the set threshold value of Alarm-2. The “ALM2”
indicator LED will go out, and the Alarm-2 relay will return to its non-active state according to the
analyzer configuration. The Alarm-2 Active mode is held to its last state during manual access to the
user mode menu.
3.3.5
FAULT ACTIVE Mode
The model 1100 initiates Fault Active mode when it has detected that one or more Fault criterion have
been satisfied (section 4.3.1). The “FAULT” indicator LED will light and the Fault relay will change state.
The Fault status will be cleared automatically when no Fault criterion have been satisfied. The “FAULT”
indicator LED will go out and the Fault relay will return to its non-active state. The user may view active
faults at any time from the control panel (section 3.2.4).
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 3-5
4
4.1
CHAPTER 4 – MAINTENANCE AND TROUBLESHOOTING
System Setup
The model 1100 is shipped ready to install and operate with complete factory configuration already
programmed and tested. The user may however wish to change the system configuration to suit the
application of the analyzer. Some setup parameters may be changed by the user via the control panel
keypad. All configuration parameters may be changed by the user via the Service Port.
Important: Before changing any of the model 1100 settings, refer to Appendix C – Factory Setup for
reference. If the user has any questions before proceeding with changing analyzer settings, please
contact the Neutronics Ntron division Service Department for assistance.
4.1.1
System Setup via Control panel Keypad
The control panel user setup menu may be accessed from the model 1100 control panel by pressing and
holding the “MODE” key for at least 10-seconds until the 7-segment alphanumeric display shows“---“ to
indicate that the analyzer has accessed setup mode. Release the “MODE” key to activate setup mode.
Once in setup mode, the user can access adjustable parameters sequentially by continuing to press and
release the “MODE” key to scroll through the setup menu.
When you reach the mode that you wish to change, use the “UP” and “DOWN” keys to adjust the
displayed setting. The modes are numerically identified by the number on the left side of the display. The
current mode setting is identified by the number on the right side of the display. The new settings are
automatically saved when the user advances to the next mode by pressing and releasing the “MODE”
key. The user may exit the Setup menu at any time by pressing simultaneously the “UP” and “DOWN”
keys (Appendix D, Control panel Hot-Key functions).
NTRON
MODEL 1100 O2 Analyzer
MODE
PERCENT OXYGEN
REMOTE
SENSOR
2
RUN
FAULT
l
ALM 1
SETTING
ALM 2
MODE
4.1.1.1
User Setup A: Display Range Select
This parameter allows the user to map the display and electrical output range scale of the model 1100 to
suit the application (Appendix E – Range / Output Chart).
Valid Settings: 1 (fixed range 0-1 %) • 2 (fixed range 0-10 %) • 3 (fixed range 0-25 %) • 4 (fixed range 050 %) • 5 (fixed range 0-100 %) • 8 (low auto-range) • 9 (high auto-range) • 10 (full auto-range)
Manual Part Number:
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Revision Level: A
Revision Date: January 19, 2004
Page 4-1
Maintenance and Troubleshooting
4.1.1.2
User Setup 1: Alarm-1 Relays Ascending/Descending Action
This parameter allows the user to set the Alarm-1 relay action to ascending (the relay is set to its active
state when the oxygen level is above the Alarm-1 level set point) or to descending (the relay is set to its
active state when the oxygen level is below the Alarm-1 level set point).
Valid Settings: 0 (Descending) • 1 (Ascending)
4.1.1.3
User Setup 2: Alarm-2 Relays Ascending/Descending Action
This parameter allows the user to set the Alarm-2 relay action to ascending (the relay is set to its active
state when the oxygen level is above the Alarm-2 level set point) or to descending (the relay is set to its
active state when the oxygen level is below the Alarm-2 level set point).
Valid Settings: 0 (Descending) • 1 (Ascending)
4.1.1.4
User Setup 3: Analog Voltage Output Setting
This parameter allows the user to set the Analog Output Voltage full scale to 1, 5, or 10 volts. Note that
the software settings must match the RA and RB jumper settings on the Main CPU PCB (section 4.1.3).
Valid Settings: 0 (0-5 VDC) • 1 (0-10 VDC), 2 (0-1 VDC)
4.1.1.5
User Setup 4: Serial Output Format
This parameter allows the user to set the RS-232 communications timed output format.
Valid Settings: 0 (Output on Request) • 1 (Human Readable) • 2 (Machine Code) • 3 (Machine Code with
Checksum) • 4 (Tab Delimited)
4.1.1.6
User Setup 7: Set Assume Low-End Calibration Range Code
DO NOT CHANGE THIS SETTING
4.1.1.7
User Setup F: Alarm-1 and Alarm-2 Relays Failsafe/Non Failsafe Action
This parameter allows the user to set the Alarm-1 and Alarm-2 relays to either failsafe action (relay coils
not powered in active alarm state) or non-failsafe (relay coils powered in active alarm state).
Valid Settings: 0 (Non-Failsafe) • 1 (Failsafe)
4.1.1.8
User Setup B: RS-232 Baud Rate
This parameter allows the user to set the RS-232 communications baud rate.
Valid Settings: 1 (300BPS) • 2 (1200BPS) • 3 (2400BPS) • 4(4800BPS) • 5 (9600BPS)
6 (19200BPS) • 7 (38400BPS)
4.1.1.9
User Setup 8: Factory Setup Restore.
This parameter allows the user to return the model 1100 to its initial factory-commissioned settings.
Always perform a gas calibration after restoring factory settings.
Valid Settings: 88. A setting of 88 will activate the Factory Setup restore.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 4-2
System Setup
4.1.2
System Setup via Service Port
The model 1100 analyzer features a Service Port, which is accessible for programming the system,
monitoring the analyzer output, and determining active fault codes for troubleshooting. The Service Port
has been designed for communication with a PC based computer or other device capable of receiving and
transmitting ASCII data packets over a standard RS-232 serial interface.
Access to the Serial Service Port may made through a terminal emulator program such as
HyperTerminal, available in Microsoft Windows 95 or later:
4.1.2.1
RS-232 Service Port Interfacing with HyperTerminal in Microsoft Windows 95 or later
Turn off your PC computer, and remove power from the Model 1100. Complete the instructions for
wiring and connecting the Model 1100 to a PC computer (section 2.1.3.10). Apply power to the Model
1100, and start up the PC computer.
On your PC computer, open HyperTerminal: Navigate from the Windows desktop – Select Start Æ
Programs Æ Accessories Æ Communications Æ HyperTerminal
In HyperTerminal, create and configure a new connection – follow the prompts:
PROMPT
YOU ENTER
CONNECTION NAME
CONNECT TO
1100
COM1, or other available COM port
In HyperTerminal, select the correct COM port properties, to interface properly with the Model 1100:
PROPERTIES
YOU ENTER
BITS PER SECOND
DATA BITS
PARITY
STOP BITS
FLOW CONTROL
TERMINAL EMULATION
9600
8
None
1
None
VT 100 *
* Not all versions of MS Windows prompt for this parameter.
Select “Apply” and “OK” as prompted. The Hyper Terminal program will immediately begin
communicating with the model 1100, and the model 1100 will commence sending data via ASCII code
dump to the PC. The information from the analyzer will be sent in ASCII strings, at 1-second intervals.
Data will be sent in the factory default “Human Readable” format.
4.1.2.2
Troubleshooting Your HyperTerminal Interface
If serial communications with the model 1100 fails, isolate the problem by performing the following tests:
Disconnect the RS-232 cable from the model 1100 by removing the terminal block connector from TB3.
Insert a jumper between pins 9 & 10 on the terminal block connector. Enter a few letters from the PC
keyboard. The PC monitor should display the corresponding alpha-characters as they are typed. If the
letters do not display on the monitor screen, there is a problem with the RS-232 cable, the PC serial COM
port, or the HyperTerminal setup.
Manual Part Number:
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Revision Level: A
Revision Date: January 19, 2004
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Maintenance and Troubleshooting
If the typed letters DO show on the monitor screen and serial communications with the model 1100 still
has not been established, then PC COM port pins 2 & 3 (1100 pins 9 & 10) may be reversed. Verify the
cable wiring (section 2.1.3.10). If no transmitted data from the model 1100 is seen on the monitor
screen, call the Neutronics Inc. Service Department for further assistance.
4.1.2.3
Organization of RS-232 Serial Data
There are three levels of access through the service port that can be used for interfacing with the model
1100:
Standard Access: ASCII dump to a PC, printer, or DAQ, and provides basic operator access.
Advanced Level-1 Access: Allows user setup and configuration, such as alarms, and data format.
Advanced Level-2 Access: Allows access to vital control areas via password.
4.1.2.4
Standard Level Access
Standard Level Access is the default level of access to the model 1100 available to the user via a host
computer or printer over a standard RS-232 serial interface. In Standard Level access, the user can make
inquiries about oxygen concentration, sensor signal level, and other parameters for system servicing, and
troubleshooting.
When communications are established between the model 1100 and a host computer, 2-way
communication begins automatically in Standard Level access. Data is sent out the analyzer RS-232
Service Port to the host terminal once-per-second, in the factory-default Human Readable format (section
4.1.2.4.2). There are no commands necessary to begin viewing information transmitted by the model
1100 in Standard Level access.
To request and view specific information via the RS-232 interface, type the desired command key
selected from he Standard Access level command chart below (It is not necessary to press return).
Helpful Hint: For viewing convenience, before requesting specific information from the model 1100,
disable automatic 1-second updates from the model 1100 and allow access of information by-requestonly (section 4.1.2.4.1), by typing “SSERFMT=0”, followed by the Return key. To return to automatic 1second updates of data from the analyzer in Human Readable format (section 4.1.2.4.2), type
“SSERFMT=1”, followed by the Return key.
The STANDARD ACCESS level commands
TYPED COMMAND
DESCRIPTION OF QUERIED FUNCTION
A
C
E
G
H
I
V
@
Short software version
Analyzer Model number
Sensor output in Percent Oxygen
Sensor output in Volts
Active Fault codes
Active Fault code descriptions
Long software version
Unit Serial Number
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 4-4
System Setup
There are several data formats of the ASCII data dump available. They may be changed from Standard
Level Access to suit the user’s needs as follows:
TYPED COMMAND
DESCRIPTION OF QUERIED FUNCTION
SSERFMT=0
SSERFMT=1
SSERFMT=2
SSERFMT=3
SSERFMT=4
SCALIBRATE=.XXXXXX
Disables RS-232 continuous periodic data-dump
Enables RS-232 output in HUMAN READABLE format
Enables RS-232 output in MACHINE format w/o Checksum
Enables RS-232 output in MACHINE format w/Checksum
Enables RS-232 output in TAB DELIMITED (Excel) format
The user can send a calibration value in decimal format where 100
% Oxygen = 1. The number format entered must be 6-decimal
places.
4.1.2.4.1 Disable RS 232 continuous output – SSERFMT=0
The factory default 1-second data-dump in Standard Level access can be disabled through the RS-232
interface in Standard Access level. While this setting is active, the user must request information by
pressing the desired key according to the STANDARD ACCESS level commands chart.
4.1.2.4.2 Human Readable Data Format – SSERFMT=1
The factory default format is Human Readable and can be changed via the analyzer control panel, or
through the RS-232 interface in Standard Level Access. Human Readable data is presented in dynamic
columns (columns appear only when data is present). It is intended for most users, to aid in setup and
maintenance of the unit. Column headings from left to right: Mode • O2 Concentration • Alarm-1 status •
Alarm-1 status • list of Fault codes active.
4.1.2.4.3 . Machine Data Format with NO Checksum
Machine format with NO checksum can be selected via the analyzer control panel, or through the RS232 interface in Standard Access level. Machine format with NO checksum data is streamed in packets
defined by start/stop transmit bits. The order of data in each packet is as follows: Start Transmit • O2
Concentration • Fault codes active • List of Fault Codes • Alarm-1 status • Alarm-1 status • End
Transmit. For detailed information on data formats, please contact the Neutronics Service Department.
4.1.2.4.4 Machine Data Format WITH Checksum
Machine format with checksum can be selected via the analyzer control panel, or through the RS-232
interface in Standard Access level. Machine format with checksum data is streamed in packets defined by
start/stop transmit bits. The order of data in each packet is as follows: Start Transmit • O2 Concentration
• Fault codes active • List of Fault Codes • Alarm-1 status • Alarm-2 status • Checksum • End Transmit.
For detailed information on data formats, please contact the Neutronics Service Department.
4.1.2.4.5 Tab delimited Data Format
Tab delimited format can be selected via the analyzer control panel, or through the RS-232 interface in
Standard Access level. Tab delimited data is presented in static columns (the same number of columns is
always transmitted in a complete data message). Column headings from left to right: Time since last reboot tab • Mode tab • O2 Concentration tab • Alarm-1 status tab • Alarm-2 status tab • list of Fault codes active tab.
For detailed information on data formats, please contact the Neutronics Service Department.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 4-5
Maintenance and Troubleshooting
4.1.2.5
Advanced Level 1 Access
Advanced Level-1 access is the computer-interfaced user Setup mode. Access to Advanced Level-1 can
be accomplished on a PC by typing “setup” when viewing the Human Readable ASCII output. The User
Setup menu will be displayed on the PC screen allowing access for changing the system setup.
Figure 12 – Level-1 Access (SETUP) Mode Menu
4.1.2.6
Advanced Level-2 Access
Advanced Level-2 access is available to the user via a PC by use of a password. This level of access allows
the manipulation of all code settings. Contact the Neutronics Inc. Service Department for support before
attempting to use Advanced Level-2 access.
4.1.2.7
SETTING UP THE MODEL 1100 – The RS-232 User Setup Menu
The RS-232 User Setup menu U00 is the “Home” screen in Advanced Level-1 access (section 4.1.2.5),
and provides access to all the parameters that may need to be adjusted by the user. The interactive menu
is initiated by typing “setup” and pressing the "Enter" key on the RS-232 terminal; as in entering
Advanced Level-1 access. To navigate backwards, use the <Esc> or “Q” key on the RS-232 terminal.
4.1.2.8
Return all Settings to Factory Delivered Settings
In case of severe corruption of calibration and setting information, this setting will allow the user to
restore the Model 1100 analyzer to its “out-of-box” setting. The user may type “Y” at the prompt to
initiate a restore, or “N” and the prompt to bypass a restore. This setting is accessed from the Setup Main
Menu by typing “F” on the RS-232 Terminal. To navigate backwards, use the <Esc> or “Q” key on the
RS-232 terminal.
4.1.2.9
System Information Display
The System Information Display U10 is a list of all the current settings for the 1100 analyzer. It is
accessed from the Setup Main Menu by typing “1” or “I” on the RS-232 Terminal.
Manual Part Number:
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Revision Level: A
Revision Date: January 19, 2004
Page 4-6
System Setup
4.1.2.10
(U20) Alarm Relay Setup Menu
The RS-232 Alarm/Relay Setup menu U20 provides access to all of the settings related to the Alarms,
controls, and relays on the Model 1100 analyzer. It is accessed from the Setup Main Menu by typing “2”
or “R” on the RS-232 Terminal. To navigate backwards, use the <Esc> or “Q” key on the RS-232
terminal.
Figure 13 – Relay Configuration Menu
4.1.2.10.1 Alarm-1 and Alarm-2 Relays Failsafe
This parameter allows the user to set the Alarm-1 and Alarm-2 relays to either failsafe or non-failsafe
action. Failsafe action is defined as; relay coils are not powered (contacts are in normal position) in active
alarm state. Non-Failsafe action is defined as; relay coils are powered (contacts are in non-normal position)
in active alarm state. The Alarm-1 and Alarm-2 Relays Failsafe setting may be set to “YES” or “NO”. This
setting is accessed from the Alarm and Relay Setup Menu by typing “1” or “F” on the RS-232 terminal.
4.1.2.10.2 Alarm-1 Level Setting (setpoint)
This setting sets the threshold level for Alarm-1. Depending on whether or not it is set to ascending or
descending, Alarm-1 becomes active when the oxygen concentration is above or below this threshold
level. The Alarm-1 setpoint may be set anywhere from 0.0 % to 100.0 %. This setting is accessed from
the Alarm Relay Setup Menu by typing “2” on the RS-232 terminal.
4.1.2.10.3 Alarm-1 Descending
This setting configures Alarm-1 to either ascending or descending action. Ascending is defined as Alarm1 active when the oxygen concentration is above the Alarm-1 setpoint level. Descending is defined as;
Alarm-1 active when the oxygen concentration is below the alarm-1 setpoint level. The descending
setting may be set to “YES” or “NO”. This setting is accessed from the Alarm and Relay Setup Menu by
typing “3” on the RS-232 terminal.
4.1.2.10.4 Alarm-2 Level Setting (setpoint)
This setting sets the threshold level for Alarm-2. Depending on whether or not it is set to ascending or
descending, Alarm-2 becomes active when the oxygen concentration is above or below this threshold
level. The Alarm-2 setpoint may be set anywhere from 0.0 % to 100.0 %. This setting is accessed from
the Alarm Relay Setup Menu by typing “4” on the RS-232 terminal.
Manual Part Number:
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Revision Level: A
Revision Date: January 19, 2004
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Maintenance and Troubleshooting
4.1.2.10.5 Alarm-2 Descending
This setting configures Alarm-2 to either ascending or descending action. Ascending is defined as Alarm2 active when the oxygen concentration is above the Alarm-2 setpoint level. Descending is defined as;
Alarm-2 active when the oxygen concentration is below the alarm-2 setpoint level. The descending
setting may be set to “YES” or “NO”. This setting is accessed from the Alarm and Relay Setup Menu by
typing “5” on the RS-232 terminal.
4.1.2.10.6 Relay Hold Time
This setting determines the minimum time that Alarm-1 and Alarm-2 relays will hold their active state
once the Alarm-1 and Alarm-2 setpoint levels have been exceeded, regardless of the actual Oxygen
concentration after Alarm-1 and Alarm-2 have been activated. The Hold Time level may be set
anywhere from 0 to 300 seconds. This setting is accessed from the Alarm Relay Setup Menu by typing
“6” or “H” on the RS-232 terminal.
4.1.2.10.7 Fault Relay Active during Warm-up
This setting determines the active status of the Fault relay during the Model 1100 warm-up routine
(section 4.3.1.2). The activate setting may be set to “YES” or “NO”. This setting is accessed from the
Alarm Relay Setup Menu by typing “7” or “W” on the RS-232 terminal.
4.1.2.10.8 Relays Disabled after CAL/Setup
This setting determines the time that relays will be held in their last state before returning to Run mode
from the control panel or service port user menus. The relays disabled time may be set anywhere from 0
to 14,400 seconds. This setting is accessed from the Alarm Relay Setup Menu by typing “8” or “S” on
the RS-232 terminal.
4.1.2.11
(U30) Analog Output Setup Menu
The RS-232 Analog Output Setup menu U30 provides access to all of the settings related to the Analog
Voltage Output (TB3-Pin 5, TB3-Pin 6) and Analog Current Output (TB3-Pin 7, TB3-Pin 8). It is
accessed from the Setup Main Menu by typing “3” or “A” on the RS-232 terminal. To navigate
backwards, use the <Esc> or “Q” key on the RS-232 terminal.
Figure 14 – Analog Output Configuration Menu
Manual Part Number:
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Revision Level: A
Revision Date: January 19, 2004
Page 4-8
System Setup
4.1.2.11.1 Analog Voltage Output Range
This menu sets the Analog Voltage Output full-scale value. It may be set to 0 (0-5 VDC minimum to full
scale), 1 (0-10 VDC minimum to full scale) or 2 (0-1 VDC minimum to full scale). This setting must
match the RA and RB hardware jumper settings on the bottom of the main CPU PCB (section 4.1.3).
This menu is accessed from the Analog Output Setup menu by typing “1” or “J” on the RS-232 terminal.
4.1.2.11.2 Analog Current Output Range
This menu sets the Analog Current Output range. It may be set to 0 (0-20mA minimum to full scale), or
1 (4-20mA minimum to full scale). This menu is accessed from the Analog Output Setup menu by typing
“2” or “I” on the RS-232 terminal.
4.1.2.11.3 Use Manual Analog Output Ranges
This menu is used to enable manual override of Analog output mapping to display range, and to force
minimum and maximum Analog outputs to absolute Oxygen measurement values. This menu is
accessed from the Analog Output Setup menu by typing “3” or “M” on the RS-232 terminal.
4.1.2.11.4 Force minimum Voltage Output to O2 Concentration
This menu sets the Oxygen concentration at which the Analog Voltage output is at zero. This setting is
entered in percent oxygen increments, and can be anywhere from 0.0% to 100.0%. This menu is
accessed from the Analog Output Setup menu by typing “4” on the RS-232 terminal.
4.1.2.11.5 Force Maximum Voltage to O2 Concentration
This menu sets the Oxygen concentration at which the Analog Voltage output is at maximum range
(section 4.1.2.11.1). This setting is entered in percent oxygen increments, and can be anywhere from
0.0 % to 100.0 %. This menu is accessed from the Analog Output Setup menu by typing “5” on the RS232 terminal.
4.1.2.11.6 Force minimum Current Output to O2 Concentration
This menu sets the Oxygen concentration at which the Analog Current output is at minimum range
(section 4.1.2.11.2). This setting is entered in percent oxygen increments, and can be anywhere from
0.0 % to 100.0 %. This menu is accessed from the Analog Output Setup menu by typing “6” on the RS232 terminal.
4.1.2.11.7 Force Maximum Current Output to O2 Concentration
This menu sets the Oxygen concentration at which the Analog Current output is at maximum range
(section 4.1.2.11.2). This setting is entered in percent oxygen increments, and can be anywhere from
0.0 % to 100.0 %. This menu is accessed from the Analog Output Setup menu by typing “7” on the RS232 terminal.
4.1.2.12
(U14) Display/Auto-Range Setup
The RS-232 Display/Auto-Range Setup menu U14 provides access for the user to map the display and
Analog output range scale(s) of the Model 1100 to suit the application (Appendix E – Range / Analog
output Chart). The Analog Output Range may be set to 1 (fixed range 0-1 %) • 2 (fixed range 0-10 %) • 3
(fixed range 0-25 %) • 4 (fixed range 0-50 %) • 5 (fixed range 0-100 %) • 8 (low auto-range) • 9 (high
auto-range) • 10 (full auto-range). This menu is accessed from the Setup Main Menu by typing “4” or
“G” on the RS-232 terminal. To navigate backwards, use the <Esc> or “Q” key on the RS-232 terminal.
Manual Part Number:
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Revision Level: A
Revision Date: January 19, 2004
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Maintenance and Troubleshooting
4.1.2.13
(U50) RS-232 Serial Setup Menu
This menu provides access to set the RS-232 serial communications options. It is accessed from the
Setup Main Menu by typing “5” or “S” on the RS-232 terminal. To navigate backwards, use the <Esc>
or “Q” key on the RS-232 terminal.
Figure 15 – Serial Output Configuration Menu
4.1.2.13.1 Baud Rate
This menu sets the RS-232 baud rate. The baud rate can be set to 1 (300BPS), 2 (1200BPS), 3
(2400BPS), 4 (4800BPS), 5 (9600BPS), 6 (19200BPS) or 7 (38400BPS). This menu is accessed from
the RS-232 Serial Setup menu by typing “1” or “B” on the RS-232 terminal.
4.1.2.13.2 Automatic Serial Output Format
This menu sets the format of the automatic timed RS-232 serial output (section 4.1.2.4). The timed
serial output format may be set to 0 (Output on Request), 1 (Human Readable), 2 (Machine Code), 3
(Machine Code with Checksum), 4 (Tab delimited) 5 (OA1 style; not used). This menu is accessed from
the RS-232 Serial Setup menu by typing “2” or “F” on the RS-232 terminal.
4.1.2.13.3 Serial Output Spacing
This menu sets the rate at which the RS-232 sends complete ASCII data packets to the Service Port. The
send rate can be set anywhere from 1 to 86,400 seconds (24-hours). This menu is accessed from the RS232 Serial Setup menu by typing “3” or “S” on the RS-232 terminal.
4.1.2.13.4 OA1 Style Output – NOT USED
4.1.2.14
Alarm Setpoint Lockout
If the Alarm Setpoint Lockout is enabled, the user may not change, but only view the Alarm-1 and
Alarm-2 level settings. The Alarm Lockout setting is accessed from the Setup Main Menu by typing “6”
on the RS-232 terminal. To navigate backwards, use the <Esc> or “Q” key on the RS-232 terminal.
4.1.2.15
Gas Calibration Lockout
If the Gas Calibration Lockout is enabled, the user may not change, but only view the Gas Calibration
value. The Gas Calibration Lockout setting is accessed from the Setup Main Menu by typing “7” on the
RS-232 terminal. To navigate backwards, use the <Esc> or “Q” key on the RS-232 terminal.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 4-10
System Setup
4.1.2.15.1 User Menu Lockout
If the Front Menu Lockout is enabled the user may not manually initiate any User mode from the control
panel. The User Menu Lockout setting is accessed from the Control panel Locks menu by typing “8” on
the RS-232 terminal. To navigate backwards, use the <Esc> or “Q” key on the RS-232 terminal.
4.1.2.16
Assume Low-End Calibration Range
WARNING: The Assume Low-End Calibration Range (Zero Calibration Range in the setup menu) is set to
0 % to 5 % Oxygen at the factory, and it should not be adjusted by the user. If the user changes the
Assume Low-End Calibration Range setting, the model 1100 will not operate properly.
4.1.2.16.1 Calibration Mode Auto Return to RUN
This setting determines the minimum time that the Model 1100 allows after exiting from control panel or
service port user menus, before returning the unit to on-line status. The calibration mode auto return
setting is accessed from the Control panel Locks menu by typing ”T” on the RS-232 terminal. To
navigate backwards, use the <Esc> or “Q” key on the RS-232 terminal.
4.1.2.17
4.1.3
4.1.3.1
220 Volt Line Voltage – NOT USED
Change factory settings via Hardware Jumpers
Analog Voltage Output
The Analog voltage output must be configured using the hardware settings. In addition, the software
settings must match the jumper settings. Software changes are made via the Control panel User Setup
menu (section 4.1.1), or the Service Port RS-232 User Setup menu (section 4.1.2.7).
4.1.3.1.1 Remove the unit from service
Make certain that all interfacing to the model 1100 is disabled at the user device. Make sure that
interrupting outputs, from the unit will not interfere with normal process monitoring or control.
Disconnect power from the model 1100 unit. Disconnect the removable terminal blocks from the rear of
the model 1100 chassis. Follow all lock-out/tag-out procedures.
4.1.3.1.2 Change jumper settings
Turn the model 1100 upside down to access the jumpers through the port provided. Identify the
appropriate jumper position. Use an insulated jumper-puller to remove and replace jumpers (Figure 12).
4.1.3.1.3 Return to service
Replace cables, and terminal blocks. Reapply power. Change Analog Voltage Output setting from
control panel or service port to match new hardware settings. Perform a calibration check. Check
function of changes to ensure the new settings are recognized by the model 1100.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 4-11
Maintenance and Troubleshooting
Model 1100 Bottom View
Jumper
access port
in analyzer
Case
RA
(JP4)
RB
(JP5)
Figure 16 – Range select jumpers
JP4 / JP5 JUMPERS
(1=SHORTED; 0=OPEN)
RA
0
0
1
SELECT VOLTAGE
OUTPUT RANGE
RB
1
0
0
Vout= 0-1 VDC
Vout= 0-5 VDC
Vout= 0-10 VDC
Figure 17 – Range select jumper settings
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 4-12
Periodic Maintenance
4.2
Routine Periodic Maintenance
Maintenance for the Model 1100 Oxygen analyzer is very simple. Apart from the normal maintenance
for any instrument, such as cleaning the chassis, wiping the display, and replacing the sensor, the Model
1100 does not require any major periodic servicing. Calibration of the sensor on a known gas source
should be performed on a regular basis. The chart below should serve as a general guide for maintenance
personnel.
TASK
RECOMMENDED FREQUENCY
AT
COMMISSIONING
EVERY
30-DAYS
√
√
Calibrate Sensor
Clean the analyzer chassis
and display panel with soft
cloth. Make sure the
ventilation ports are clear.
EVERY YEAR
√
√
Configure alarms
√
Check the Analog outputs
and RS-232 output against
display
√
AS REQUIRED
√
√
√
√
Replace the oxygen sensor
Sensor life
expectancy
2 years
Figure 18 –Maintenance schedule
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 4-13
Maintenance and Troubleshooting
4.3
Troubleshooting
4.3.1
Fault Codes
When trouble occurs during normal operation of the model 1100, the user has several tools available to
aid in isolating the cause(s) of given symptoms. As a starting point, the user may use the control panel to
enter into “View Active Faults” mode (section 3.2.4). The user may also view active faults and other
useful information via the Service Port (section 4.1.2). In addition, there are four system Hot-Keys
available to perform special functions, and to gather important information quickly and easily
(Appendix-D). Descriptions of faults are given below, with indication of common causes. Refer to the
appropriate sections of this manual for more details as needed.
4.3.1.1
Fault Code 2 – Relays are in Standby mode
The “Relays are in Standby mode” fault indicates that the user has aborted the control panel user mode
menu properly (section 3.2.5), and the unit is in a stabilization period to allow time to sweep the sample
lines with sample gas before returning the unit to on-line service. During the stabilization period, Alarm1, Alarm-2, and Fault relays remain inactive, and held to their last state before the control panel user
mode menu was accessed. The factory default setting for this period is 120-seconds. This setting is userconfigurable (section 4.1.2.10.8).
4.3.1.2
Fault Code 3 – Device is in Setup mode – Service Port
The “Device is in Setup mode” fault indicates that the user has entered the user setup mode from the
service port (section 4.1.2), and the model 1100 is not monitoring oxygen in the process. The 7-segment
alphanumeric display will show “SU”. The Device is in Setup Mode fault will clear when the user returns
the unit to Run mode.
4.3.1.3
Fault Code 5 – Analog Output range overflow
The “Analog Output range overflow” fault indicates an oxygen reading that is above the range
configuration entered in the model 1100 setup (section 4.1.2.12). Possible causes of fault code-5 may
be: Incorrect or contaminated calibration gases, faulty process or calibration sampling lines/components.
4.3.1.4
Fault Code 6 – Analog Output range underflow
The “Analog Output range overflow” fault indicates an oxygen reading that is below the range
configuration entered in the model 1100 setup (section 4.1.2.12). Possible causes of fault code-6 may
be: Analog Range lower limit set to a value greater than zero (section 4.1.2.11.1).
4.3.1.5
Fault Code 8 – A concentration reading is not yet available
The “concentration reading is not yet available” fault is active when the model 1100 is not ready for
online service. It is active during start-up, calibration and during fault code-2 – relays are in standby
mode.
4.3.1.6
Fault Code 10 –Sensor appears to be disconnected
The “Sensor appears to be disconnected” fault indicates that there is not a continuous electrical circuit
connecting the Model 1100 and the oxygen sensor. Possible causes may be: An open in the sensor
interface wiring, faulty connecting hardware on/in the model 1100 or the sensor, the sensor interface
cable has been un-plugged.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 4-14
Troubleshooting
4.3.1.7
Fault Code 11 – Non-native display range
The “non-native display range” fault indicates an oxygen reading that is above the range configuration
entered in the model 1100 setup (section 4.1.2.12). Fault code-11 is active when fault code 5 is active.
Possible causes of fault code-11 may be: Incorrect or contaminated calibration gases, faulty process or
calibration sampling lines/components.
4.3.1.8
Fault Code 12 – User calibration too large
The “user calibration too large” fault indicates that the reading during calibration was out of tolerance
high with respect to the known calibration gas concentration. The calibration tolerance window is
factory-set and cannot be changed by the user. Possible causes of fault code-12 may be: Incorrect or
contaminated calibration gases, faulty process or calibration sampling lines/components.
4.3.1.9
Fault Code 13 – User calibration too small
The “user calibration too small” fault indicates that the reading during calibration was out of tolerance
low with respect to the known calibration gas concentration. The calibration tolerance window is
factory-set and cannot be changed by the user. Possible causes of fault code-13 may be: Incorrect or
contaminated calibration gases, faulty process or calibration sampling lines/components, faulty or failing
sensor.
4.3.1.10
Fault Code 15 – Bad user calibration
The “bad user calibration” fault indicates that the user has attempted to calibrate the model 1100 with
what appears to be a faulty sensor. Possible causes of fault code 15 are: Incorrect or contaminated
calibration gases, improper calibration procedure, faulty sensor.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 4-15
5
5.1
CHAPTER 5 – APPENDICES
Appendix A – Spare Parts List
PART NUMBER
DESCRIPTION
5-06-4900-01-0
Operations Manual
C1-16-1000-01-0
Replacement Oxygen Sensor – model CAG-250E
C6-02-1000-10-0
Sensor Interface Cable – 3 meter with connectors
C1-11-1220-03-0
VAC Fuses for Power Supply Board (for VAC units only). – 1A, 250
VAC, Slo-Blo
C1-17-0052-00-0
Replacement terminal block – TB1
C1-17-0142-00-0
Replacement terminal block – TB2
C1-17-0112-00-0
Replacement terminal block – TB3
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 5-1
Appendices
5.2
Appendix B – Specifications
OXYGEN SENSOR
External weak-acid galvanic oxygen fuel-cell
DISPLAY
0.75” 7-segment LED digital display, 4 characters
Displays oxygen from 0 to 100 percent.
Resolution:
0.00–0.99 %
1.00–9.99 %
10.0–99.9 %
100.0 %
X.XX
X.XX
XX.X
XXX.X
Color -Coded LED’s for system status:
SIGNAL INTERFACE
RELAY OUTPUTS
RUN:
Green
FAULT:
Yellow
ALARM-1:
Red
ALARM-2:
Red
Serial Service Port:
Bi-directional RS-232
Analog Voltage Output:
0–1, 0–5, or 0–10 VDC
Analog Current Output:
Non-isolated 4 – 20 mA, 12 VDC, negative
ground, powered by analyzer, maximum
electrical load 250 Ohms
Range ID Voltage:
0 %–1 %
0 %–10 %
0 %–25 %
0 %–50 %
0 %–100 %
5.63 VDC + 0.1VDC
6.25 VDC + 0.1VDC
6.88 VDC + 0.1VDC
7.50 VDC + 0.1VDC
8.13 VDC + 0.1VDC
Alarm-1:
Field Adjustable Form C (SPDT) Voltage-free, 5A @
250 VAC, 5A @ 30 VDC. Configurable to fail-safe/non
fail-safe and ascending/descending action
Alarm-2:
Field Adjustable Form C (SPDT) Voltage-free, 5A @
250 VAC, 5A @ 30 VDC. Configurable to fail-safe/non
fail-safe and ascending/descending action
Fault:
Non-adjustable Form B (SPST) Voltage-free, 5A @ 250
VAC, 5A @ 30 VDC, non Fail Safe action, nonconfigurable.
Specifications are subject to change without notice.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 5-2
Appendix B - Specifications
RANGE
0–1 % • 0–10 %• 0–25 % • 0–50 % • 0–100 %
ACCURACY
+ 2.0 % of range @ calibrated temperature and pressure
RESPONSE TIME
T90 < 20 seconds
WARM UP TIME
None
HUMIDITY
Analyzer:
0-95 % non-condensing
Sensor:
5-95 % non-condensing
Analyzer:
32-149° F (0–65° C)
Sensor:
41-104° F (5–40° C)
OPERATING
TEMPERATURE
STORAGE
TEMPERATURE
Analyzer:
23-149° F (5–65° C)
Sensor:
41-79° F (5–25° C)
SAMPLE PRESSURE
15” Hg vacuum–7 PSIG (0.5–1.5 Bar)
SAMPLE FLOW
100–300 CCM (100 CCM nominal)
POWER
VAC Unit:
90–264 VAC, 47–63 Hz, Single Phase, 3 Watts
VDC Unit:
11–30 VDC, 3 Watts
Faceplate:
Height 3.75”x Width 7.00” • NEMA 4 • IP66
Panel Cut-out:
Height 2.91” x Width 6.20”
Electronic
Compartment:
Height 2.81“ x Width 5.98” x 3.60” Depth • NEMA 1
• IP20
MECHANICAL
WEIGHT
2 Lbs (0.9Kg)
WARRANTY
12-months from date of shipment
Specifications are subject to change without notice.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 5-3
Appendices
5.3
APPENDIX C – ANALYZER FACTORY CONFIGURATION SETTINGS
Alarm and Relay Setup Information
Alarm-1/Alarm-2 Relays Failsafe/Non-Failsafe
NON-FAILSAFE
Alarm-1/Alarm-2 Relay Ascending/Descending
ASCENDING
Alarm-1 Trigger Level
5%
Alarm-2 Trigger Level
10 %
Display Range
Analog Voltage Output
0–1 % Fixed
0–1 VDC
0–10 % Fixed
0–5 VDC
0–25 % Fixed
0–10DC
X
0–50 % Fixed
0–100 % Fixed
Relay Disable after Cal/Setup
Low Auto Ranging
120-seconds
X
High Auto Ranging
Full Auto Ranging
X
Rs-232 Baud Rate
Assume Low End Calibration Range
300 BPS
Single Point
1200 BPS
1–5 %
2400 BPS
1–50 %
4800 BPS
18–24 %
9600 BPS
X
X
19200 BPS
38400 BPS
Rs-232 Output Format
Output on Request Only
X
Human Readable Format
Machine Code
Machine Code With Checksum
Tab Delimited (Spreadsheet)
Supply Voltage
90 – 264 VAC, 47 – 63 Hz
RS-232 Dump Rate
X
1-second
X
11 – 30 VDC
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 5-4
Appendix D – Control Panel Hot-Key Functions
5.4
APPENDIX D – Control panel Hot-Key Functions
For convenience in operating and troubleshooting, the Model 1100 has four Control panel Hot-Key
functions that can be performed quickly via the control panel without entering the normal Control panel,
or Service Port user menus.
KEYS PRESSED
DESCRIPTION OF FUNCTION
UP + DOWN
UP + DOWN
(hold both keys for 10 seconds *)
DOWN then MODE
(hold both keys for 10 seconds *)
UP then MODE
(hold both keys for 10 seconds *)
Return to “RUN” mode from any User mode
Run Lamp Test
Show Sensor Voltage
Re-start Model 1100
* Hold all keys indicated until the 7-segment alphanumeric display shows “---“ then release the pressed
keys. To return to normal operation, press and release the same keys again.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 5-5
Appendices
APPENDIX E – Range / Output Chart
RANGE NAME
MEASURED
RANGE
DISPLAY
ANALOG RANGE
RANGE ID
VOLTAGE
OUTPUT
FULL AUTO
RANGE
0.00 % – .9 %
1.00 % – 9.99 %
10.0 % – 24.9 %
25.0 % – 49.0 %
50.0 % – 99.9 %
100.0 %
X.XX
X.XX
XX.X
XX.X
XX.X
XXX.X
0–1 %
0–10 %
0–25 %
0–50 %
0–100 %
5.63 VDC
6.25 VDC
6.88 VDC
7.50 VDC
8.13 VDC
LOW AUTO
RANGE
0.00 % – .99 %
1.00 % – 9.99 %
10.0 % – 24.9 %
X.XX
X.XX
XX.X
0–1 %
0–10 %
0–25 %
5.63 VDC
6.25 VDC
6.88 VDC
HIGH AUTO
RANGE
10.0 % – 24.9 %
25.0 % – 49.0 %
50.0 % – 100.0 %
XX.X
XX.X
XXX.X
0–25 %
0–50 %
0–100 %
6.88 VDC
7.50 VDC
8.13 VDC
FIXED RANGE
0–1 %
0.00 % – .99 %
X.XX
0–1 %
5.63 VDC
FIXED RANGE
0–10 %
FIXED RANGE
0–25 %
FIXED RANGE
0–50 %
0.00 % – 9.99 %
X.XX
0–10 %
6.25 VDC
0.0 % – 9.99 %
10.0 % – 24.9 %
0.0 % – 9.99 %
10.0 % – 49.9 %
X.XX
XX.X
X.XX
XX.X
0–25 %
6.88 VDC
0–50 %
7.50 VDC
FIXED RANGE
0–100 %
0.0 % – 99.9 %
100.0 %
XX.X
XXX.X
0–100 %
8.13 VDC
5.5
APPENDIX F – Zero Calibration Range Settings
ENTERED
VALUE
0
1
2
3
4
5
6
7
8
9
10
RANGE
Single Point Calibration
1 PPB – 50 PPB
1 PPB – 500 PPB
1 PPM – 5 PPM
10 PPM – 50 PPM
10 PPM – 500 PPM
0.0 % – 0.5 %
1%–5%
1 % – 50 %
18 % - 24 %
10 PPM – 20 PPM
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
AVAILABLE
SETTINGS
X
Revision Date: January 19, 2004
Page 5-6
Appendix G – MSDS Material Safety Data Sheet
5.6
APPENDIX G – MSDS Material Safety Data Sheet
1. Product Identification
Oxygen sensor, galvanic type, model CAG-250E furnished by Neutronics Inc. • 456 Creamery Way
• Exton, PA USA, 19341 • Telephone: 610-524-8800.
2. Hazardous Ingredients of Solution
Electrolyte composed of weak acid solution (Acetic Acid) Lead Acetate, Trihydrate. Anode is pure
lead. Components are encapsulated in a plastic housing. CAS Numbers: Glacial Acetic Acid 64-197, Lead Acetate 6080-56-4 Pb 7439-92-1
3. Health Hazard
Pb: 0.05 mg/cu.m. OSHA PEL, KOH: 2 mg/cu.m. ACGIH TLV, Acetic Acid, Glacial: 10 PPM OSHA
PEL, ACGIH/TLV 10 PPM (Stated for 100 %)
Lead Acetate, Trihydrate: 0.05mg/m3 OSHA
PEL 0.15 mg/m3 ACGIH/TLV
4. Physical and Chemical Data
KOH
PB (PURE)
ACETIC ACID
Melting Point
-10 to 0°C
328°C
Not Available
Boiling Point
100 to 115°C
1744°C
Not Available
Specific Gravity
1.09 @ 20°C
11.34
Not Available
pH
>14
N/A
3.5 to 4.5
Solubility in Water
Completely
Insoluble
Completely
% Volatiles by
Volume
None
N/A
Not Available
Appearance and
Odor
Colorless, odorless
solution
Grey Metal,
odorless
Colorless, Vinegar like
odor
5. Unusual Fire and Explosion Hazards
Lead acetate decomposes at boiling point and toxic gases are produced. Acetic acid vapors may flow
along surfaces to distant ignition sources and flash back. Closed containers exposed to high heat
may explode. Sensors are stable under normal operating conditions. Avoid contact of electrolyte
on skin and with strong acids or caustics.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 5-7
Appendices
6. Health Hazard Data
Lead (use for Lead Acetate & Lead): TLV/TWA 0.15 mg/m3, PEL 0.05 mg/m3
Toxicity: Intraperitoneal Rate LD 50 for lead acetate trihydrate is 200 mg/Kg
Carcinogenicity: This substance is listed as a NTP anticipated human carcinogen and an IARC
animal carcinogen.
Reproductive Effects: None identified
Effects of overexposure:
Inhalation – Tightness and pain in chest, coughing, difficult breathing
Skin Contact – Irritation
Eye Contact – Irritation
Skin Absorption – May be harmful
Ingestion – Is harmful and may be fatal, headache, nausea, vomiting dizziness, gastrointestinal
irritation
Chronic Effects – Anemia, kidney damage, blurred vision, lead build-up, in central nervous
system.
KOH electrolyte: (ACGIH TLV) 2mg/cu.m.
Toxicity: May be harmful or fatal if swallowed Oral LD50 (RAT)=3650 mg/kg
Reproductive Effects: None identified
Effects of overexposure:
Inhalation – unlikely
Skin Contact – Irritation
Eye Contact – Irritation, could result in permanent loss of vision
Skin Absorption – May be harmful
Ingestion – Is harmful and may be fatal.
Chronic Effects – Contact with skin or eyes will cause a burning sensation &feel soapy or
slippery to touch.
Acetic Acid (concentrated): TLV/TWA 25mg/cu.m.
Toxicity: May be harmful or fatal if swallowed Oral LD50 (RAT)=3310 mg/kg
Carcinogenicity: None Identified
Reproductive Effects: None identified
Effects of overexposure:
Inhalation – Irritation
Skin Contact – Irritation
Eye Contact – Irritation, could result in permanent loss of vision
Skin Absorption – May be harmful
Ingestion – Is harmful and may be fatal
Chronic Effects – Lung damage, teeth damage
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 5-8
Appendix G – MSDS Material Safety Data Sheet
7. Emergency and First-Aid Procedures
Eye Contact: Immediately flush with water for at least 15 minutes.
Inhalation: Expose to fresh air, inhalation unlikely.
Ingestion: Call a physician; take large amounts of water.
Skin Contact: Immediately flush skin with plenty of water for 15 minutes.
8. Handling
Wear respiratory, rubber gloves, and eye protection
Protective measures during cell replacement:
•
Do not remove sensor from shipping container until ready to install
•
Inspect the sensor for leakage before removal from shipping package. If it is leaking, do not remove
from package.
•
Put on gloves and eye protection when replacing sensor
Note: The above data is based on MSDS provided by the manufacturers of components and by tests conducted by
Neutronics. Neutronics believes that this information to be accurate and reliable. This information is supplied as
reference only. Neutronics disclaims any liability for damage or injury which results from the use of the data and
nothing contained therein shall constitute a guarantee, warranty, or merchantability or representation by
Neutronics with respect to the data, the product described, or their use for any specific purpose, even if that purpose
is known to Neutronics.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 5-9
Appendices
5.7
APPENDIX H – Warranty
Neutronics warrants to the original purchaser, that the Model 1100 Oxygen analyzer is free from defects
in material and workmanship for a period of one (1) year from the date of shipment from Neutronics or
from one of Neutronics’ authorized dealers. Our liability will be limited to the repair or replacement, at
our factory, of parts found to be defective within the warranty period, as determined by Neutronics. The
parts will be repaired or replaced free of charge if shipped prepaid to the factory in the original shipping
carton. This warranty is void if the product has been subject to misuse or abuse, including but not limited
to: exposure to water, humidity, temperature, shock or pressure outside of the listed specifications, or has
not been operated or installed in accordance with operating and maintenance instructions, for repairs
which were not performed by Neutronics or by one of its authorized dealers, or if the identifying markings
on the product label have been altered or removed.
The seller assumes no liability for consequential damages of any kind, and the buyer, by acceptance
through purchase of this product, will assume all liability for the consequences of its use or misuse by the
buyer, his employees, or others.
Neutronics reserves the right to use any materials in the manufacture, repair or service of the products
and to modify the design as deemed suitable, in so far as these materials or modifications maintain the
stated warranty.
It is the sole responsibility of the buyer / user to determine if this product is suitable for the intended
application.
THESE WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, OR
IMPLIED INCLUDING WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE.
Intended Use for the Model 1100
The model 1100 Oxygen analyzer was designed to provide the trained operator with useful information
relating to the concentration of Oxygen. This information may be used in process control or to minimize
possible hazardous conditions, which may be present in various processes. Before implementation, the
user must fully understand the operation and limitations of this instrument as well as the application for
its use. The responsibility for the proper application, operation, installation, and maintenance of the
model 1100 Oxygen analyzer is the sole obligation of the trained operator. The purchaser is required to
ensure operators are properly trained in the use of this unit as well as in the possible hazards associated
with its use or with the intended application. The purchaser must ensure that all of the proper warnings,
labels, instruction manuals, lock outs, redundant components, hazard analysis, and system validation
have been completed and provided to the trained operator before implementation of the model 1100
instrument.
Manual Part Number:
C5-06-4900-01-0
Revision Level: A
Revision Date: January 19, 2004
Page 5-10
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