Oxymit™ Transmitter
Oxymit™ Transmitter
Operator’s Manual
Revision 013
Oxymit™ Transmitter
Manual #: 019
Rev No: 011
Rev No: 012
Rev No: 013
Page 2 of 97
Date: March 17, 2014
Date: February 24, 2015
Date: May 1, 2015 (Firmware revision 2.39 and higher)
All trademarks used in this publication are duly marked and the sole property of their
respective owners. No attempt at trademark or copyright infringement is intended or
implied.
COPYRIGHT
No part of this publication may be reproduced, transmitted, transcribed, stored in a
retrieval system, or translated into any language or computer language, in any form
or by any means, electronic, mechanical, magnetic, optical, chemical, manual, or
otherwise, without prior written permission of United Process Controls Inc.
DISCLAIMER:
The Oxymit™ Transmitter is to be used by the industrial operator under his/her
direction. United Process Controls Inc. is not responsible or liable for any product,
process, damage or injury incurred while using the Oxymit™ Transmitter. United
Process Controls Inc. makes no representations or warranties with respect to the
contents hereof and specifically disclaim any implied warranties or merchantability or
fitness for any particular purpose.
For assistance please contact:
United Process Controls Inc.
TEL: +1 513 772 1000 • FAX: +1 513 326 7090
Toll-Free North America +1-800-547-1055
[email protected]
www.group-upc.com
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Oxymit™ Transmitter
Page 3 of 97
TABLE OF CONTENTS
1.
General Description
6
2.
Safety Summary
11
3.
Analog Output Channels
12
4.
Digital Event Input
12
5.
Sensor Test Connections
12
6.
Connections
12
6.1.
Grounding and Shielding.........................................................................................................14
7.
Operational Specifications
15
8.
Process Control Options
17
9.
Control Modes
17
9.1.
Time Proportioning (TP) ..........................................................................................................18
9.2.
Time Proportioning Dual (TD)..................................................................................................18
9.3.
Direct Current Output ..............................................................................................................18
9.4.
Direct or Reverse Control Action .............................................................................................19
10.
Analog Output Channels
19
11.
Alarms
19
11.1. Process Alarms.......................................................................................................................22
OFF ................................................................................................................................................22
Full Scale HI....................................................................................................................................22
Full Scale LO ..................................................................................................................................22
Deviation Band................................................................................................................................22
Deviation High.................................................................................................................................22
Deviation Low .................................................................................................................................22
Output High.....................................................................................................................................22
Output Low .....................................................................................................................................22
Fault ...............................................................................................................................................22
Probe ..............................................................................................................................................23
Time ...............................................................................................................................................23
Start ................................................................................................................................................23
Soak ...............................................................................................................................................23
11.2.
Alarm Action ...........................................................................................................................24
11.3.
Alarm Delay Times..................................................................................................................24
11.4.
Diagnostic Alarms ...................................................................................................................24
12.
Front Panel Operation
26
12.1.
Enter Key................................................................................................................................27
12.2.
Remote Key ............................................................................................................................27
12.3.
Setpt Key ................................................................................................................................28
12.4.
Setup Key ...............................................................................................................................28
13.
Digital Input Event
40
OFF ................................................................................................................................................40
PROB .............................................................................................................................................40
AUTO (controller only).....................................................................................................................41
rEn (controller only) .........................................................................................................................41
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ACK ................................................................................................................................................41
PrOC (controller only)......................................................................................................................41
Strt (controller only) .........................................................................................................................41
HOLd (controller only) .....................................................................................................................41
End (controller only) ........................................................................................................................42
13.1. Dual Key Functions .................................................................................................................42
Starting Probe Tests........................................................................................................................42
Start Timer ......................................................................................................................................42
Edit Timer .......................................................................................................................................42
Monitor Mode ..................................................................................................................................42
14.
Timer Function
43
14.1.
Setting the Timer ....................................................................................................................43
14.2.
Time .......................................................................................................................................45
14.3.
Guaranteed Start Timer ..........................................................................................................45
14.4.
Guaranteed Soak Timer ..........................................................................................................46
14.5.
Timer Alarm Behavior .............................................................................................................46
14.6.
Timer State Diagram ...............................................................................................................47
15.
Timer SIO Operations
15.1.
16.
Controlling the Timer Remotely ...............................................................................................49
Probe Impedance Test
16.1.
48
50
Why Measure Sensor Impedance? .........................................................................................51
17.
Probe Verification (Oxygen only)
52
18.
Sensor Burnoff (Carbon or Dew Point only)
54
19.
Procedure to Test an Oxygen Sensor
56
19.1.
Correctly set up the parameters in the Oxymit for the Probe Testing........................................56
19.2.
To manually start a probe test procedure ................................................................................56
19.3.
If a Probe Fault occurs ............................................................................................................57
20.
Tuning
20.1.
21.
57
What is tuning? .......................................................................................................................57
Scaling Analog Inputs
60
Linear A example ................................................................................................................................60
21.1.
Keyboard Function during Input Slope.....................................................................................60
22.
Scaling Analog Outputs
61
23.
Calibration
62
23.1.
Calibration Displays and Keyboard Operation .........................................................................62
23.2. Preparing for Input Calibration.................................................................................................63
Calibration of Temperature and Cold Junction .................................................................................64
Calibration of the Thermocouple Input (linear mode)........................................................................66
Calibration of the Probe Millivolt Input..............................................................................................66
23.3.
24.
Calibration of the Analog Output Channels ..............................................................................66
Process Variable Calculations
68
24.1.
Percent Oxygen ......................................................................................................................68
24.2.
Percent Carbon.......................................................................................................................68
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Oxymit™ Transmitter
24.3.
25.
Page 5 of 97
Dew Point ...............................................................................................................................70
Communications
71
25.1. Modbus...................................................................................................................................71
RTU Framing ..................................................................................................................................71
Address Field ..................................................................................................................................72
Function Field .................................................................................................................................72
Data Field .......................................................................................................................................72
Error Check Field (CRC) .................................................................................................................72
25.2.
MMI Message Protocol ...........................................................................................................74
25.3. Instrument Type ‘U’ Command Set..........................................................................................77
‘X’ Command ..................................................................................................................................77
Block Commands ............................................................................................................................80
MMI Error Codes .............................................................................................................................83
26.
Memory Map
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84
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Oxymit™ Transmitter
Page 6 of 97
1. General Description
The Oxymit™ Transmitter has been updated with display interface connection and is
available in several different configurations. These configurations now include a
controller option based on the Versapro controller. The following table includes the
part numbers for each type in transmitter.
Transmitter Part
Number
F840033
F840034
F840035
F840043
F840044
F840045
F840053
F840054
F840055
Process
Oxygen
Carbon
Dew Point
Oxygen
Carbon
Dew Point
Oxygen
Carbon
Dew Point
Monitor
X
X
X
X
X
X
Controller
Output
Channels
(4-20mA)
X
X
X
X
X
X
X
X
X
The most cost-effective configuration is the monitor without output channels. These
units can be connected to a SCADA system using the RS485 serial interface using
either a Marathon protocol or the Modbus protocol.
The controllers use the two 4-20mA output channels to drive current actuators or
SCR controls. There are no contact or ON/OFF outputs available.
The standard configuration is the monitor with re-transmit capability using the output
channels.
All of these units can be fully configured in the field using the F840060 Transmitter
Display and the HDMI plug to plug connection cable F840061.
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Page 7 of 97
NOTE:
Please specify the following parameters when ordering a transmitter; process type,
process range, thermocouple type, temperature scale F/C, analog output 1 process
and scale, analog output 2 process and scale. The following tables show the
standard default settings.
Typical Oxygen Transmitter Calibration (°F)
Calibration Function
Cold Junction
Thermocouple min
Thermocouple max
Millivolt
Analog 1 Zero
Analog 1 Span
Analog 2 Zero
Analog 2 Span
Measured Value or
Input
Room Temp
800° (B type)
standard t/c type
3200° (B type)
standard t/c type
0.0 – 2000
0% O2 ± 0.1
20.9% O2 ± 0.1
800°F ± 13°
3200°F ± 13°
Output / Units
°F
°F
°F
mV
4.0 mA ± 0.1
20.0 mA ± 0.1
4.0 mA ± 0.1
20.0 mA ± 0.1
Typical Oxygen Transmitter Calibration (°C)
Calibration Function
Cold Junction
Thermocouple min
Thermocouple max
Millivolt
Analog 1 Zero
Analog 1 Span
Analog 2 Zero
Analog 2 Span
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Measured Value or
Input
Room Temp
420° (B type)
standard t/c type
1680° (B type)
standard t/c type
0.0 – 2000
0% O2 ± 0.1
20.9% O2 ± 0.1
420°C ± 8°
1680°C ± 8°
Output / Units
°C
°C
°C
mV
4.0 mA ± 0.1
20.0 mA ± 0.1
4.0 mA ± 0.1
20.0 mA ± 0.1
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Page 8 of 97
Typical Carbon Transmitter Calibration (°F)
Calibration Function
Cold Junction
Thermocouple
Min
Thermocouple
Max
Millivolt
Analog 1 Zero
Analog 1 Span
Analog 2 Zero
Analog 2 Span
Measured Value or
Input
Room Temp
0° (K type)
standard t/c type
2000° (K type)
standard t/c type
0.0 – 2000
0% Carbon ± .01
2.5% Carbon ± .01
0°F ± 12.5°
2000°F ± 12.5°
Output / Units
°F
°F
°F
mV
4.0 mA ± 0.1
20.0 mA ± 0.1
4.0 mA ± 0.1
20.0 mA ± 0.1
Typical Carbon Transmitter Calibration (°C)
Calibration Function
Cold Junction
Thermocouple
Min
Thermocouple
Max
Millivolt
Analog 1 Zero
Analog 1 Span
Analog 2 Zero
Analog 2 Span
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Measured Value or
Input
Room Temp
0° (K type)
standard t/c type
1200° (K type)
standard t/c type
0.0 – 2000
0% Carbon ± .01
2.5% Carbon ± .01
0°C ± 7.5°
1200°C ± 7.5°
Output / Units
°C
°C
°C
mV
4.0 mA ± 0.1
20.0 mA ± 0.1
4.0 mA ± 0.1
20.0 mA ± 0.1
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Page 9 of 97
Typical Dew Point Transmitter Calibration (°F)
Cold Junction
Thermocouple
Min
Thermocouple
Max
Millivolt
Analog 1 Zero
Analog 1 Span
Measured Value or
Input
Room Temp
0° (K type)
standard t/c type
2000° (K type)
standard t/c type
0.0 – 2000
-99.9°F Dewpt ± 2°
212°F Dewpt ± 2°
Analog 2 Zero
0°F ± 12.5°
4.0 mA ± 0.1
Analog 2 Span
2000°F ± 12.5°
20.0 mA ± 0.1
Calibration Function
Output / Units
°F
°F
°F
mV
4.0 mA ± 0.1
20.0 mA ± 0.1
Typical Dew Point Transmitter Calibration (°C)
Calibration Function
Cold Junction
Thermocouple
Min
Thermocouple
Max
Millivolt
Analog 1 Zero
Analog 1 Span
Analog 2 Zero
Analog 2 Span
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Measured Value or
Input
Room Temp
0° (K type)
standard t/c type
1200° (K type)
standard t/c type
0.0 – 2000
-50°C Dewpt ± 1°
100°C Dewpt ± 1°
0°C ± 7.5°
1200°C ± 7.5°
Output / Units
°C
°C
°C
mV
4.0 mA ± 0.1
20.0 mA ± 0.1
4.0 mA ± 0.1
20.0 mA ± 0.1
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Page 10 of 97
The Oxymit™ Transmitter has been designed to work as an analog or digital interface
for any zirconia based oxygen sensor used to track dew point, carbon potential, or
oxygen. The transmitter connects to the temperature and millivolts outputs of an
oxygen sensor and can produce analog outputs proportional to the selected process
value.
The features available are:
•
•
•
•
•
•
•
•
Isolated inputs for thermocouple and sensor millivolt
24 bit Sigma-Delta ADC for two inputs and cold junction temperature.
Serial EEPROM to store setup and calibration values.
Two optional isolated self-powered 4-20mA outputs.
Isolated RS485 serial port.
Sensor impedance test capability.
Sensor verification or burnoff capability.
Configurable digital input.
The transmitter makes a carbon or oxygen sensor an intelligent stand-alone analyzer.
The transmitter is located near the probe, preferably mounted in an enclosure. The
transmitter mounts onto a DIN rail and requires a 24VDC power supply. It measures
the sensor temperature and millivolts. If the transmitter display is not available, the
transmitter must be ordered with the correct configuration. The results of any of the
calculations are made available via two 4-20mA loop outputs or over a serial
interface. Typically the first output is set up for the process value the second output
transmits the sensor temperature. In the controller version one of the outputs can be
configured to control the process via the 4-20mA current loop.
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Oxymit™ Transmitter
Page 11 of 97
5V_B
3
A
4
EVT
COM
EVT
N.O.
B
5V_A
+24V
12
Power
Supplies
24V
COM
11
5V_A
5V_B
+15V
-15V
+15V
-15V
5V_B
A
RS485
B
10
RTX+
9
RTX-
ISOLATED
ISOLATED
5V_A
5V_A
44M
+15V
D/A
22M
C
C
C
1
T/C INPUT
6
EEPROM
5
mV INPUT
8
2
A/D
CONV.
ANALOG
OUT 1
4-20mA
-15V
7
Process
Controller
ISOLATED
5V_A
+15V
D/A
D
D
D
14
13
ANALOG
OUT 2
4-20mA
DISPLAY
CONN.
-15V
16
SENSOR
TEST
15
A
Figure 1 BLOCK DIAGRAM
2. Safety Summary
All cautions and instructions that appear in this manual must be complied with to
prevent personnel injury or damage to the Oxymit Transmitter or connected
equipment. The specified limits of this equipment must not be exceeded. If these
limits are exceeded or if this instrument is used in a manner not intended by United
Process Controls Inc., damage to this instrument or connected devices could occur.
Do not connect this device directly to AC motors, valves, or other actuators. The
Oxymit Transmitter is not certified to act as a safety device. It should not be used to
provide interlocking safety functions for any temperature or process functions. Alarm
capabilities are provided for probe test and input faults via the digital interface and
are not to be considered or used as safety information in any application.
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Oxymit™ Transmitter
Page 12 of 97
3. Analog Output Channels
The analog outputs are factory configured to provide 4 to 20mA signals proportional
to selectable process values.
NOTE
The Analog Output Channels are isolated self-powered current
sources and do not require an external supply.
If a chart recorder is to be used, it should have input specifications within 4 to 20 mA.
If the recorder only responds to VDC inputs it will be necessary to add a 250 ohm
dropping resistor across its input terminals.
The ideal location of the recorder is adjacent to the instrument but it may be located
remotely if the connecting wires are properly shielded. For best results, the chart
recorder input(s) should be isolated from ground.
4. Digital Event Input
The digital event input should only be connected to a contact closure. Never connect
AC or DC power to terminals 3 or 4. A 100ms contact closure is required to register
with the transmitter.
5. Sensor Test Connections
The sensor test connections allow for a maximum 24VDC, 0.5AMP, 12 W load. It is
recommended external fusing is used since the transmitter has no internal fuse. The
test function switches a normally open SPST relay contact suitable for a DC relay
coil. Always use an interposing relay for the probe test function.
6. Connections
The Oxymit Transmitter has four removable terminal blocks grouped with four
terminals each. Each terminal is a wire clamp type with a standard slot screw. Each
clamp can accommodate AWG 24 to 12 flexible stranded wire. Maximum torque on
the terminal screws should not exceed 0.8 Nm.
The figure below shows the arrangement of the terminals.
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Page 13 of 97
1
2
-
+
AO1
5
6
TC
+
4
Outside Terminal
Block
7
8
Inside Terminal
Block
-
MV
+
DISPLAY
CONNECTOR
-
3
EVT EVT
COM N.O.
9 10 11 12
+
RS485
+
24VDC
13 14 15 16
-
+
AO2
TEST TEST
COM N.O.
Inside
Terminal Block
Outside Terminal
Block
Figure 2 Terminal Layout
The next figure shows a schematic representation of the Oxymit Transmitter and
typical connections required in the field.
Figure 3 Schematic Connections
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Oxymit™ Transmitter
6.1.
Page 14 of 97
Grounding and Shielding
To minimize the pick-up of electrical noise, the low voltage DC connections and the
sensor input wiring should be routed away from high-current power cables. Use
shielded cables with the shield grounded at the Oxymit Transmitter enclosure ground
as show above.
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Oxymit™ Transmitter
Page 15 of 97
7. Operational Specifications
Power input
21.6 to 26.4 volts DC / 130mA
Thermocouple input
Thermocouple
type
B
C
E
J
K
N
NNM
R
S
T
Zero ºF
Span ºF
Zero ºC
800
3000
420
32
3000
0
32
1300
0
32
1300
0
32
2300
0
32
2300
0
32
2000
0
300
3000
150
300
3000
150
32
700
0
Bold shows default
Accuracy after linearization +/- 1°
Millivolt input
-200 to 2000 millivolts +/- 0.1 millivolt
Input Impedance
25 Megohm
Cold junction compensation
DC outputs (Isolated)
Isolation
No Isolation
Calculations
Span ºC
1680
1680
700
700
1200
1200
1100
1650
1650
360
+/- 1°
4 to 20mA (650Ω max)
0 to 20mA (650Ω max)
1000V DC/AC
Power input to signal inputs
Power input to communications
Thermocouple input to Millivolt input, inputs must be differential.
Percent carbon 0 – 2.55%, no CO compensation
Dew Point -99.9°F (-50.0°C) – 212 °F (100°C), no hydrogen
compensation
Percent oxygen. 0 – 20.9% (default)
Calibration Setups Thermocouple Null
Thermocouple Span
Cold Junction Trim
Millivolt Null
Millivolt Span
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Page 16 of 97
Communications port
RS-485 Half Duplex Only
Protocol
Modbus RTU or Marathon block / slave protocols
Baud rates 1200, 2400, 4800, 9600, 19.2K (19.2K default)
Parity
None, Even, Odd
Address
1 – 254 (Address 1 is default) Modbus protocol
1 – 15 Marathon protocol
Housing
Material
Polyamide PA non-reinforced
Inflammability
Evaluation Class V0 (UL94)
Temperature Range -40 to 100°C
Dielectric Strength
600 kV/cm (IEC243-1)
Mounting
Snaps on to EN 50022 top hat (T) style DIN rail.
Terminals
Wire clamp screw terminals on four position removable terminal blocks.
Wire Size
AWG 24 – 12 flexible stranded, removable terminal
blocks.
Max. Torque
0.8 Nm
Weight
10 oz
Environmental Conditions
Operating Temperature
-20 °C to 55 °C (-4 to 130 F)
Storage Temperature
-40 °C to 85 °C (-40 to 185 F)
Operating and Storage Humidity
85% max relative humidity, noncondensing, from –
20 to 65°C
Note: This instrument is designed for installation inside a grounded enclosure.
Always observe anti-static precautions when installing or servicing any electronic
device. Ground your body to discharge any static field before touching the body or
terminals of any electronic device.
CAUTION
DO NOT CONNECT ANY AC SOURCE OR LOAD TO INSTRUMENT CONTACTS
CAUTION
DO NOT CONNECT OR DISCONNECT HOUSING PLUGS WHILE MODULE IS
POWERED OR UNDER LOAD.
This specification can change without notification.
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Page 17 of 97
8. Process Control Options
The following parameters and functions are best accessed using the F840060
transmitter display assembly. The display assembly and the transmitter work exactly
like a UNITED PROCESS CONTROLS Versapro with the exception that the
transmitter does not have control or alarm contacts.
The Oxymit can be configured to perform a number of specific monitor or control
functions. The following table outlines the available process functions for the oxygen
controller / monitor. The functions and operation are similar for the carbon and dew
point instruments. The oxygen instrument has a sensor verification function whereas
the carbon and dew point instruments have a sensor burnoff function. Both use the
same hardware configurations allowing either a verification gas or air into the sheath
of the sensor.
Table 1 Instrument Control Options
Function
Oxygen
Linear Input A
Linear Input B
Description
Uses the millivolt and
temperature signals from a
zirconia sensor to calculate
oxygen concentrations and
control to an oxygen set point.
Uses the millivolt signal from a
linear sensor connected to
terminals +TC / -TC
Uses the millivolt signal from a
linear sensor connected to
terminals +MV / -MV
9. Control Modes
The Oxymit controller provides two 4-20mA outputs for monitor or control. The control
function can be set to direct acting or reverse acting.
Direct acting increases the output control signal to increase the process. Reverse
acting decreases the output control signal to increase the process.
The percent of the output drives the proportional output of the analog channels.
Since no contacts are available the percent output that is calculated from the time
proportioning function. The position proportioning and on/off control modes do not
produce a meaningful percent output for a constant current output and should not be
used.
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9.1.
Page 18 of 97
Time Proportioning (TP)
Time proportioning adjusts the duty cycle of the control device to maintain control.
This is usually done with solenoid valves controlling the flow of a trim gas or air to the
process. The on/off time has no meaning for the current output so the calculated
percent output value is used to drive the current outputs if they are configured for
PO1, PO2, POUT.
9.2.
Time Proportioning Dual (TD)
This mode is used when there are two processes to control that have complementary
effects; like gas and air. The time proportioning dual mode uses two control outputs;
one for gas and one for air. There is never a time when both outputs are on
simultaneously. The control loop computes a percent output from -100 to +100%.
When positive, the proportioning action applies to the forward output (gas). When
negative the proportioning action applies to the reverse (air) output.
9.3.
Direct Current Output
The Oxymit has two analog output channels that provide an isolated 4 to 20mA signal
proportional to selectable process values. The analog outputs can be configured to
control the process by driving actuators with a 4-20mA signal proportional to the
calculated percent output of the PID loop. One or both output channels can be used
depending on the control mode selected. POUT selection drives the output signal
based on the HIPO and LOPO settings. If a Dual Time Proportioning control mode is
selected with a HIPO = 100 and a LOPO = -100 then the output will be 4mA for –
100%, 12mA for 0%, and 20mA for +100% output. This setting is helpful if one
actuator is driving two valves in a split configuration where air is fully opened at –
100% and gas is fully opened at +100% or both are closed at 0%.
It is possible to drive two actuators independently by setting on output to PO1 or PO2
where PO1 is the 0 to +100% control output and PO2 is 0 to –100%. In this
configuration both outputs are at the maximum (±100%) with an output of 20mA.
It is also possible to drive one actuator with an output channel and a solenoid with a
control contact. For example, select PO1 for one analog output channel to drive a
gas actuator and connect an air solenoid to the reverse control contact. The percent
output for both functions is determined by the PID settings. The cycle time should be
set to the stroke time required to fully open the actuator from a fully closed condition.
Typical stroke times would be 30 to 45 seconds.
The control contacts will still act as described in the previous modes even if the
analog output channels are being used.
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Oxymit™ Transmitter
9.4.
Page 19 of 97
Direct or Reverse Control Action
Control action determines how the output of the controller will react to effect a change
on the process. The control action is considered ‘direct’ if an increase in the output
produces an increase in the process value. A ‘reverse’ control action would be when
an increase in the output produces a decrease in the process.
For example oxygen would require a reverse acting control if the process component
the instrument is controlling is a trim gas. Increasing the trim gas will result in a
decrease in the oxygen reading. It would be considered a direct acting control if the
process component under control is additional air. Either process would use the first
control contact, it would just be activated above or below the process set point
depending on what is being added to the process.
10. Analog Output Channels
The two analog output channels can be set to retransmit selectable process values.
The Analog Output Offset and Range can be set to correspond to the process range.
The default settings for these channels are 0 – 20.9% oxygen for channel 1 and
800°F to 3000°F temperature for channel 2.
These outputs are active meaning they provide the current for each loop. An external
power supply for loop power is not required. Each analog channel is completely
isolated from the other.
The Oxymit output channels can drive a chart recorder, PLC input, or actuators. The
remote input should be configured for of 0 - 5 VDC or 4 - 20 mA. If the input device
only responds to a DC voltage input, it will be necessary to add a 250 ohm dropping
resistor across its input terminals.
The ideal location of the input device such as a recorder is adjacent to the instrument
but it may be located remotely if the connecting wires are properly shielded. For best
results, the chart recorder input(s) should be isolated from ground with the cable
shield grounded on one end of the cable.
11. Alarms
The instrument has two types of alarms, process alarms and diagnostic alarms. If an
alarm has been selected and conditions are such that the alarm becomes active, the
instrument will display this condition on the center LCD display of the transmitter
display assembly and set the appropriate bits in the FAULT memory register. Alarms
can be configured as latched or non-latched and as direct or reverse. Latched
alarms can only be acknowledged through the digital input event or the display
assembly Enter key.
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A reverse configuration would be considered a failsafe setting since the alarm contact
is closed during normal conditions and opens if power is removed to the instrument or
the configured alarm condition occurs.
The alarm message will be displayed on the LCD screen with it occurs. If the LCD
screen is written with another message all active alarms can be seen be pressing the
up or down arrow keys.
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The display cannot be cycled to other parameters such as temperature or probe
millivolts if an alarm is active.
ALARM DISPLAY
HIGH ALARM
CONDITION
Alarm contact assigned to
FSHI, dUbd, bdHI, HIPO
LOW ALARM
Alarm contact assigned to
FSLO, dUbd, bdLO, LOPO
PROBE CARE
FAULT
Alarm contact assigned to
PrOb
TIMER END
Alarm contact assigned to
TinE, Strt, SOAK
LLLL
Display only
HHHH
Display only
FLASH CSUM
Alarm contact assigned FALt
EEPROM CSUM
Alarm contact assigned FALt
KEYBOARD
Alarm contact assigned FALt
FLASH ERASE
Alarm contact assigned FALt
FLASH / EE SIZE
Alarm contact assigned FALt
TEMP OPEN
Alarm contact assigned FALt
MV OPEN
Alarm contact assigned FALt
CPU FAULT
Alarm contact assigned FALt
CPU IDLE ZERO
Alarm contact assigned FALt
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ACTION
Full Scale High, above Deviation Band, or
above percent output setting. Contact
automatically resets unless latched.
Full Scale Low or below Deviation Band,
or below percent output setting. Contact
automatically resets unless latched.
Probe impedance high or probe recovery
time exceeds limit. Contact resets
monetarily unless latched.
Timer end alarm when the timer counts to
zero for Timer, Start, or Soak timer
modes. The contact latches until reset by
pressing the Enter key or through the
Input Event.
Displays process value is negative and
exceeds display range or exponent
setting
Displays process value is positive and
exceeds display range or exponent
setting
Reset instrument power. Return to
Marathon if error does not clear.
Reset instrument power. Return to
Marathon if error does not clear.
Reset instrument power. Do not push
any keys while instrument is powered on.
Return to Marathon if error does not clear.
Programming error,
Reset instrument power, attempt reload.
Programming error,
Reset instrument power, attempt reload.
Check thermocouple for open condition or
loose connection.
Check probe millivolt signal for open
condition or loose connection. This signal
can only be tested if the probe
temperature is above 1300°F and
exposed to process gas.
Reset instrument power. Return to
Marathon if error does not clear.
Idle timer of CPU has counted to zero.
This means that a CPU process has
exceeded an allocated time slot. Possible
during extended block transfer requests.
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11.1. Process Alarms
The process alarms can be setup to activate either or both of the two alarm contacts
provide on the Oxymit. Nine user selectable modes are available.
OFF
Disables the alarm function and the alarm contacts
Full Scale HI
An alarm is generated any time the process value goes above the Full Scale HI
alarm value. This alarm is reset if the process falls below the alarm value or
acknowledgement from the front panel or through the event input (if configured).
Full Scale LO
An alarm is generated any time the process value drops below the Full Scale LO
alarm value. The alarm will arm once the process is measured above the alarm
value. This alarm is reset with an acknowledgement from the front panel or
through the event input (if configured).
Deviation Band
An alarm is generated any time the process value goes above or below the band
alarm setting. The alarm setting is ± value of the band. For example, if a value
of 10 is entered as the alarm value, an alarm is generated if the process goes 10
units above or 10 units below the set point. Units are the process units such
percent or degrees. This alarm will not arm until the process is in-band of the set
point.
Deviation High
An alarm is generated any time the process value goes above the band alarm
setting. The alarm setting is number of units allowed above set point. Units are
the process units such percent or degrees. This alarm will not arm until the
process is in-band of the set point.
Deviation Low
An alarm is generated any time the process value goes below the band alarm
setting. The alarm setting is number of units allowed below the set point. Units
are the process units such percent carbon or degrees. This alarm will not arm
until the process is in-band of the set point.
Output High
An alarm is generated any time the control percent output exceeds the alarm
value. The alarm setting is maximum percent output allowed.
Output Low
An alarm is generated any time the control percent output drops below the alarm
value. The alarm setting is minimum percent output allowed.
Fault
An alarm is generated any time an open input occurs on either the T/C or MV
inputs. Both inputs are pull up to a maximum value if no input is connected or if
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the input fails in an open circuit mode. An open T/C input fault is ignored for the
Linear configuration. The center display will indicate which of these conditions
has caused the alarm. The alarm process will also become active if any of the
listed hardware faults occur. The center display will indicate which of these
conditions has caused the alarm.
Probe
An alarm is generated any time the probe exceeds the maximum probe
impedance setting, or the verification test tolerance. All of the probe values and
limits are configured in the Probe Menu. The center display will indicate which of
these conditions has caused the alarm.
Time
This alarm setting is necessary for the timer function to work. The timer will only
run if it is enabled in the Ctrl Setup menu and a timer setpoint value other than
zero has been assigned. This alarm setting allows the timer to start running
when it is activated at the Start Timer parameter in the Setpt key menu, when the
dual key combination Left Arrow and Enter keys are pressed, or if the Input Event
has been configured for Start and a contact closure occurs. The timer will start
running as soon as it starts, independent of any process values. See the Timer
section for more details.
Start
This alarm setting is necessary for the timer function to work. The timer will only
run if it is enabled in the Ctrl Setup menu and a timer setpoint value other than
zero has been assigned. This alarm setting allows the timer to be activated from
the Start Timer parameter in the Setpt key menu, when the dual key combination
Left Arrow and Enter keys are pressed, or if the Input Event has been configured
for Start and a contact closure occurs. The timer will start running as soon as the
process level is above the alarm value and will continue to run once it has
started. See the Timer section for more details.
Soak
This alarm setting is necessary for the timer function to work. The timer will only
run if it is enabled in the Ctrl Setup menu and a timer setpoint value other than
zero has been assigned. This alarm setting allows the timer to be activated from
the Start Timer parameter in the Setpt key menu, when the dual key combination
Left Arrow and Enter keys are pressed, or if the Input Event has been configured
for Start and a contact closure occurs. The timer will start running as soon as the
process level is within the band around set point determined by the alarm value.
The timer will stop any time the process falls outside the band limit. See the
Timer section for more details.
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11.2. Alarm Action
Each alarm can be configured to operate in several different modes. Each alarm can
be configured as a reverse (normally closed) contact. This mode is usually used for
failsafe alarms that will open during an alarm condition, fault, or power failure. Each
alarm can also be configured as a direct (normally open) contact that closes when an
alarm condition occurs. In both cases the alarm will automatically clear if the alarm
condition is resolved.
Each alarm can also be configured for either reverse or direct latched conditions. In
this mode the alarm contact will remain active until an acknowledgement is received
through the configured Event Input terminals or by pressing the ENTER key.
11.3. Alarm Delay Times
Each alarm can have delay ON, delay OFF, or both delays applied. Delays can be
applied in increments of a second, up to a maximum of 250 seconds. ON delays are
helpful if a known upset in the process can be ignored. This avoids nuisance alarms
but still maintains an active alarm if the alarm condition persists following the delay.
OFF delays will hold the alarm contact active for a determined period of time once the
alarm condition has cleared. This can be helpful as an interlock to other process
functions that may have to recover following an alarm condition.
11.4. Diagnostic Alarms
A diagnostic alarm is shown on the instrument’s center display when a fault is
detected in the internal hardware during power up. These alarms included:
FLASH CSUM FAULT
A fault has been detected in the Flash memory.
EEPROM CSUM FAULT
A fault has been detected in the EEPROM.
KEYBOARD FAULT
A key is stuck or was held down during power up.
FLSH ERASE FAULT
This error may occur during instrument programming.
The Flash memory may be faulty. Retry programming,
make sure the communications link to the instrument is
working properly.
FLSH SIZE FAULT
This error may occur during instrument programming.
The Flash memory may be faulty. Retry programming,
make sure the communications link to the instrument is
working properly.
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CPU IDLE ZERO
A CPU process has exceeded the allotted process time.
Maybe due to extended serial communications block
transfers. Limit the number of parameters requested in a
block in this condition occurs.
CPU FAULT
Occurs if the CPU has not initialized correctly. Try
resetting power.
The front panel display will show LLLL if the process value is below the display
resolution, or HHHH if the process value is above the display resolution. It may be
necessary to adjust the exponent and/or the decimal point settings if these symbols
occur.
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12. Front Panel Operation
The transmitter display assembly is optional equipment that plugs into the transmitter
and used as a temporary configuration tool. The operator has full access to all of the
setup and calibration functions of the instrument. The display is self-contained and is
powered by the 24VDC power of the transmitter. It can be plugged into and
unplugged from a powered transmitter. Upon initial power up the center LCD display
may not show any text. The LCD display can be refreshed by press the Enter key.
This assembly has a 2 x 4 keyboard group, two groups of four LED seven segment
displays (upper and lower), and a single line sixteen character LCD display.
2 .0 2
1753
Figure 4 Oxymit Display Assembly
The LEDS to either side of the LED segment arrays light when the corresponding
function is active.
• COMM flashes when the instrument is properly interrogated over the RS485 port.
• PWR is hard wired to the instrument 5VDC supply
• AUTO is lit when the instrument is controlling to a set point (controller option)
• REM is lit when the instrument is controlling to a remote set point (controller
option)
• REM and AUTO flash together if the instrument is in manual mode.
• REM will flash if timer is running.
The upper display indicates the process value or the Setup Menu Heading when the
SETUP key has been pressed.
The center display indicates what the measured process calculation is and what the
lower display indicates. In figure 2 the instrument is indicating % oxygen is being
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measured. This default measurement range is 0 to 20.90%. The lower display
shows the set point.
The center display also shows the parameter name in Setup mode or fault and alarm
messages if any are active.
The lower display shows the instrument set point if the controller is in automatic or
remote mode. The display will switch to control output level when the instrument is
changed to manual. The lower display can also be configured to show the probe
temperature
12.1. Enter Key
If the normal process display is showing on the LED and LCD displays, then pressing
the Enter key will cycle the LCD and lower LED down a standard parameters.
Pressing the Rem key will cycle up the parameter list. The display for the controller
will cycle through the following list. The monitor will show only a partial list.
PROCESS / SETPT
PROCESS / TEMP
PROCESS / %OUT
PROBE MILLIVOLT
VERIFY READING (BOFF MILLIVOLT)
PROBE IMPEDANCE
PROBE IMP RECOVERY
NEXT PROBE TEST
REMAINING TIME
The process value will always be displayed in the top LED display. The display
cannot be cycled if there is an active alarm. If the alarm is not displayed on the LCD
screen then the UP or DOWN arrow keys can be pressed to display all of the active
alarms.
12.2. Remote Key
Pressing the REM key causes the Oxymit to cycle between Remote, Automatic, or
Manual control. This key has no function in the monitor version. When switching
from Automatic to Manual or Manual to Automatic, the control output remains at the
last output value in either mode. This allows for a bumpless control transition
between either manual or automatic mode.
When the controller is set to Automatic mode the “Auto” LED lights and the lower
display indicates the process setpoint (default).
When the controller is set to Remote mode the “Rem” LED lights and the Oxymit will
accept a remote setpoint from a master on the host serial interface. The lower
display indicates the process setpoint (default). The Setpt key does not work if the
instrument is in remote mode.
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When the controller is set to Manual mode both the “Rem” and “Auto” LED’s will flash
together and the lower display indicates the power output of the controller. This value
can be manually increased or decreased in 1% steps by pressing the UP or DOWN
arrow keys. Pressing the RIGHT or LEFT arrow keys changes the output in 10%
steps. The output will remain in the last control level if the instrument is switched into
manual mode from remote or automatic or back to either setpoint control mode.
12.3. Setpt Key
The Setpt key provides access to the instrument process set point. The Setpt key
does not work on the monitor version of the instrument. When the key is pressed the
center display will show “SET POINT”. The set point value in the lower display can
then be manually changed by moving the flashing digit cursor with the RIGHT or
LEFT arrow keys and increasing or decreasing the selected digit with the UP or
DOWN arrow keys. You can exit the set point function by pressing the Setpt key
again. Any changes that are made to the set point are then displayed in the lower
window if the instrument is set up of Automatic control.
The following table outlines the options available under the Set Point key.
Table 2 Setpoint Ranges
Parameter
Name
SET POINT
TIMER
SETPOINT
START TIMER
Range
Description
0 – 20.90%
oxygen
0 – 2.55% carbon
-99.9°F – 212°F
dewpt
-999 – 9999
0 – 9999
Units for process or
linear input.
YES / NO
Starts timer when
YES is selected.
This is the same as
pressing the dual
keys LEFT arrow and
Enter to start the
timer.
Units in minutes
12.4. Setup Key
The instrument can be placed in setup mode by pressing and holding the SETUP key
for 5 seconds. The upper display initially shows the first setup menu while the center
and lower displays are blank. At this level you can select different menus by pressing
the RIGHT or LEFT arrow keys. The upper display will change accordingly.
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You can enter a menu by pressing the ENTER key when the desired menu heading
is being displayed. Pressing the arrow keys will change menu parameters. Value
changes can be saved or the next parameter can be selected by pressing the ENTER
key. The menu parameters will continue to cycle through the display as long as the
ENTER key is pressed. A new menu can be select only when the menu heading is
displayed. You can exit from the Setup mode by pressing the SETUP key at any
time.
The following tables outline the Setup menus available in the Oxymit Controller and
Monitor when the operator presses the SETUP key.
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Table 3 Setup Menus
Setup Menu
Heading
CtrL
Inpt
CaLc
Prob
Aout
ALr
Host
Info
CaL
Description
Control functions and PID
Thermocouple type and Millivolt setup
Oxygen exponent setting
Probe tests and verification
parameters
Analog output selection and
parameters
Alarm contact configurations
Communication protocols and
parameters
General information displays
Input / Output calibration
You have to press the SETUP key for five seconds to activate the setup mode.
Initially when the setup mode is activated, the LCD display will show the first menu
heading, the upper and lower LED displays are blank. Page to the next Menu
heading by pressing the RIGHT or LEFT arrow keys. The menu headings will
continue to wrap around as the RIGHT or LEFT arrow keys are pressed. Pressing
the SETUP key at any point while in the Setup Menus will return the display to the
normal process display. See figure 3.
The displayed menu is selected by pressing the
ENTER key. The first parameter name in the
Ct r L
selected menu list will appear in the center
display. The upper LED group continues to
display the menu name, the center display
shows the parameter name, and the lower LED
O2
group shows the parameter value. A flashing
cursor in the lower LED display indicates which
digit can change if the parameter value is
numeric. The UP or DOWN arrows increase or
decrease the digit value. The digit value will
change from 0 to 9 or 9 to 0 depending on the arrow key that is pressed. The RIGHT
or LEFT arrow keys move the cursor to the right or left digit. No wrap-around is
provided for this cursor function.
If the parameter has a number of choices such as thermocouple types, the various
selections can be displayed by pressing the UP or DOWN arrows. No digit flashes in
parameter displays that have a choice selection. In either case, the selection is set
when the ENTER key is pressed and the display advances to the next parameter.
In the example shown above, the selected menu is Control (CtrL), the selected
parameter is Process Source, and the displayed parameter value is oxygen. This is
one of several source types that are available. Different selections can be made by
pressing the UP or DOWN arrow keys.
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Pressing the SETUP key at any time escapes from the menu display and returns to
the normal process display. You can only select another menu heading when the
display is at a menu heading. A blank center and lower display indicate a menu
heading.
The following figures and tables outline the menu options and parameters under the
Setup key. This figure and the subsequent tables list all available functions for the
controller. The monitor version of the instrument will only display some of these
functions.
Figure 5 Setup Menu Tree
Table 4 Control Menu (CtrL)
Parameter Name
PROCESS
SOURCE
Units or Options
O2, INPUT A,
INPUT B
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Range
Display range:
0.000 to 9999 for
oxygen, scaled
input A or B
Description
Control type only available on
instrument’s specific
configuration. This selection
determines what source of the
control or monitor function.
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Parameter Name
CONTROL MODE
Units or Options
TP, TC, TD, or
NON
CONTROL
ACTION
PROPORTIONAL
BAND
DIR/REV
Process Value
0 – 9999
RESET
repeats/min
00.00 – 99.99
RATE
Minutes
00.00 – 9.99
CYCLE TIME
SECONDS
0 – 250
HI PERCENT OUT
0 – 100
LOW PERCENT
OUT
TC OR MV BREAK
MAXIMUM
OUTPUT
MINIMUM
OUTPUT
ZERO / HOLD
Proportional Band value in
displayed process units for PID
control or Deadband in ON/OFF
control
Integral control value, no effect in
ON/OFF settings
Derivative control value, no effect
in ON/OFF settings
Proportional time period (TP, TC,
TD)
Motor cycle time (PP) Minimum
ON time (OF,OC,OD)
Sets max. forward control. Output
-100 to 100
Sets min. reverse control output
TIMER ENABLE
YES / NO
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Range
Description
See Control Modes if configured
as a controller, shows NON
(MONITOR) only if the instrument
is configured as a monitor.
Direct or Reverse control action
Sets output control to zero or
holds current output if a TC or
millivolt input open condition
occurs. Input A only checks TC
input, Input B only checks mV
input.
Enables timer function
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Table 5 Input Menu (InPt)
Parameter Name
TC TYPE
Units or Options
B, E, J, K, N, R, S,
T
Range
COLD JUNC APPLY YES or NO
IN A OFFSET
Only in Linear
mode
-999 – 9999
IN A SLOPE
Only in Linear
mode
-999 – 999
-99.9 – 99.9
-9.99 – 9.99
-.999 - .999
TEMP SCALE
TC FILTER
F OR C
IN B OFFSET
Works only in mV
Mode
-999 – 9999
IN B SLOPE
Works only in mV
Mode
-999 – 999
-99.9 – 99.9
-9.99 – 9.99
-.999 - .999
MV FILTER
DIG EVENT
0 – 450
0 – 450
OFF, PrOb, AUtO,
rEn, ACK, PrOC,
Strt, HOLd, End
Description
See Input calibration for
thermocouple ranges.
Has no effect in Linear mode, see
IN A OFFSET and IN A SLOPE.
Applies the cold junction
correction or not when a
thermocouple type is selected. In
LINEAR mode the cold junction is
never applied. Default is NO.
Linear offset to scale Input A to
Engineering Units when INPUT A
is selected as the process source.
Linear slope to scale Input A to
Engineering Units when INPUT A
is selected as the process source.
This is the slope number in the
linear calculation where: EU =
SLOPE(mV) + OFFSET
See key
Sets temperature scale.
Temperature filter setting in
seconds. Filters the temperature
value with a moving average time
window.
Linear offset to scale Input B to
Engineering Units when INPUT B
is selected at the process source.
This is the offset in used in the
SLOPE(mV) + OFFSET equation.
Linear slope to scale Input B to
Engineering Units when INPUT B
is selected as the process source.
This is the slope number in the
linear calculation where: EU =
SLOPE(mV) + OFFSET
Millivolt filter setting in seconds.
Filters the millivolt reading with a
moving average time window.
See Digital Event section for an
explanation of selections. See the
Timer section for the Strt, HOLd,
and End selections.
Table 6 Calculation Menu (CALC)
Parameter
Name
OXYGEN
EXPONENT
(oxygen only)
Units or Options
Range
Description
POWER OF
TEN
0 – 31
2 = %, 6 = ppm, 9 = ppb
Available in O2 only. The
negative value of the exponent
is assumed. (This parameter
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Parameter
Name
Units or Options
Range
Description
DEWPT DEG
(carbon or
dewpt only)
PROCESS
FACTOR
(carbon or
dewpt only)
DISPLAY
DECML PT
LOWER
DISPLAY
None
F/C
is also shown in control menu)
Selects scale for dew point
calculation
None
0-9999
Adjusts the process value to
accommodate for changes in
the sensor or the furnace.
Decimal point
0-4
Sets decimal pt., available for
O2, Input A and Input B.
Allows the operator to change
the displayed value in lower
LED display during REM and
AUTO modes. Setpoint
(SETP) is the default. MAN
always displays percent output
(PO). Oxygen Monitor always
shows probe temperature
(TENP).
SETP, TENP,
PO
The probe menu parameters will be different depending on whether the instrument is
configured for oxygen, carbon, or dew point. The oxygen process has the verification
function available as shown the in the following table. For carbon and dew point the
verification settings are replaced with burnoff parameters.
Table 7 Probe Setup Menu (PrOb)
Parameter Name
PROBE TEST
Units or Options
TEST INTERVAL
HRS.TENTHS
Range
NONE
RES
VER
BOTH
0 – 99.9
PROBE IMP LIMIT
KOHMS
10 – 100
IMP RECVRY
TIME
SECONDS
0 – 250
VERIFY DELAY
(oxygen only)
SECONDS
0 – 999
VERIFY AVG TIME
(oxygen only)
VERIFY
RECOVERY
(oxygen only
SECONDS
0 – 999
SECONDS
0 – 999
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Description
No test (NONE),
Impedance (RES), Verification
(VER), or BOTH impedance and
verification can be selected.
Sets time interval between
automatic probe tests, 0 disables
automatic testing.
Sets maximum impedance for
Probe alarm
Sets maximum Probe recovery
time, timer cut short if probe
recovers faster. The Probe alarm
is set if the probe signal does not
recover while this timer is active.
Initial verification delay. O2
function only. This delay allows
time for the verification gas to flow
to the tip of the probe.
Verification sampling time.
Recovery time for probe following
verification test. The PROBE
alarm is set if the probe signal
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Parameter Name
Units or Options
Range
VERIFY
STANDARD
(oxygen only)
VERIFY
TOLERANCE
(oxygen only)
% OXYGEN
0 – 25.0
% OXYGEN
0 – 25.0
BURNOFF TIME
(carbon or dewpt
only)
SECONDS
0 – 999
BOFF RECVRY
TIME
(carbon or dewpt
only)
MIN PROBE TEMP
SECONDS
0 – 999
F OR C
0° – 2000° F
0° – 1090° C
Description
does not recover before this timer
expires.
Percent of O2 used as verification
gas.
Tolerance (O2%) for acceptable
measurement. Specified in the
same units as the displayed O2.
O2 function only. The PROBE
alarm is set if the oxygen level
measured during verification
exceeds this tolerance.
Length of time the burnoff event is
on. Verify that temperature limits
of the sensor are not exceeded for
burnoff times > 60 seconds.
Time following the burnoff that
allows the process gas to return to
the sensor.
Minimum temperature for probe
impedance and verification tests.
Table 8 Analog Output Menu (AOUt)
Parameter Name
ANALOG 1 UNIT
Units or Options
Proc, LInA, TENP,
POUT, PO1, PO2,
PROG, LInB
Range
4 to 20mA output.
ANALOG 1
OFFSET
Offset for selected
process value or
percent output.
-30.0 to 300.0 for
O2 and LIN
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-300 to 3000 for
temperature
Description
Proc – retransmits oxygen,
carbon, or dewpt if selected as
process source.
LInA – scaled millivolt value of
input A depends on which input
selected as process source.
TENP – probe temperature when
oxygen is selected as process
source and a thermocouple type is
selected.
POUT – Power output is available
for the controller, allows for –
100% to 100% for split actuators.
PO1 or PO2 allow for just 0 –
100% output for either control
contact.
PROG - allows the output to be
controlled from the DACV1
memory location.
LInB – scaled millivolt value of
input A depends on which input
selected as process source.
This is the minimum value of the
process associated with the 4mA
output. The magnitude of this
number is based on the display
resolution.
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Parameter Name
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Units or Options
Range
LOPO for POUT
ANALOG 1
RANGE
ANALOG 2 UNIT
ANALOG 2
OFFSET
ANALOG 2
RANGE
Span scaling for
selected process
value or percent
output.
Proc, LInA, TENP,
POUT, PO1, PO2,
PROG, LInB
Offset for selected
process value or
percent output.
Span scaling for
selected process
value or percent
output.
0 or
DAC_OFFSET for
PROG
0 to 9999 for O2,
LIN, and Temp
HIPO for POUT
4096 or
DAC_SPAN for
PROG
Description
In POUT mode the offset is fixed
to the LOPO value.
When PROG is selected the offset
is fixed at 0
This is the maximum value of the
process associated with the 20mA
output. The magnitude of this
number is based on the display
resolution. When POUT is
selected this value is fixed to the
HIPO value.
When PROG is selected the
range is fixed at 4096
Same as Analog 1
Same as Analog 1
Same as Analog 1
Table 9 Alarm Menu (ALr)
Parameter Name
ALARM 1 TYPE
Units or Options
OFF
FSHI,
FSLO
dUbd
dbHI
dbLO
HIPO
LOPO
FALt
PROB
tinE
Strt
SOAk
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Range
Description
OFF disables alarm contact.
FSHI - Full Scale HI, active when
process is above ALARM 1
VALUE.
FSLO - Full Scale LO, active
when process is below ALARM 1
VALUE.
dUbd – Deviation Band available
for the controller only, active when
process is outside of symmetrical
band around setpoint.
dbHI – Deviation High, defines a
process band above the process
setpoint. The alarm is active if the
process moves outside this band.
dbLO – Deviation Low, defines a
process band below the process
setpoint. The alarm is active if the
process moves outside this band.
HIPO – Output High, this alarm
sets the threshold for the
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Parameter Name
ALARM 1 VALUE
ALARM 1 ACTION
ALRM 1 TM ON
DLY
ALRM 1 TMOFF
DLY
ALARM 2 TYPE
ALARM 2 VALUE
ALARM 2 ACTION
ALRM 2 TM ON
DLY
ALRM 2 TMOFF
DLY
Page 37 of 97
Units or Options
Range
REV, LREV, DIR,
LDIR
0 – 250
SECONDS
0 – 250
SECONDS
Same as ALARM 1
TYPE
Description
maximum control output allowed
which is set by ALARM 1 VALUE.
LOPO – Output Low, this alarm
sets the threshold for the
minimum control output allowed
which is set by ALARM 1 VALUE.
FALt – Fault, open inputs for mV,
thermocouple or hardware fault.
Prob – Probe, fault active if
impedance or verification are out
of range.
tinE – Time, establishes alarm
contact as the contact used for the
End alarm.
Strt – Start, same as Time.
SOAk – Soak, same as Time.
Trigger set point value
REV = Reverse (N.C.) can be
acknowledged even if the
condition still exists.
LREV = Latched Reverse (N.C.)
cannot be acknowledged if the
condition still exists.
DIR = Direct (N.O.) can be
acknowledged even if the
condition still exists.
LDIR = Latched Direct (N.C.)
cannot be acknowledged if the
condition still exists.
Delay ON time for ALARM1
Delay OFF time for ALARM1
OFF
Same as ALARM 1 TYPE
Trigger set point value
Same as ALARM 1 ACTION
Delay ON time for ALARM2
0 – 250
SECONDS
0 – 250
SECONDS
Delay OFF time for ALARM2
Table 10 Communication Menu (HOST)
Parameter
Name
PROTOCOL
Units or Options
ADDRESS
1 TO 15 (MMI)
1 TO 254
(MOD)
1200,2400,4800
BAUD RATE
PROP OR
BUSS
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Range
Description
PROP is UNITED PROCESS
CONTROLS protocol,
BUSS is Modbus
Default is 19.2K
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Parameter
Name
PARITY
DELAY
Page 38 of 97
Units or Options
, 9600,19.2K
None/Even/Odd
milliseconds
Range
NONE, 10, 20,
30
Description
Modbus is always None
NONE = 0 ms Delay
Table 11 Info Menu (InFO)
Parameter
Name
MILLIVOLT
TEMP IN
MILLIVOLT
PROB IN
COLD
JUNCTION
PERCENT
OUTPUT
(controller only)
PROB
IMPEDANCE
IMP RECVRY
TIME
VERIFY
READING
(oxygen only)
PROBE BOFF
MV
(carbon or
dewpt only)
PROBE BOFF
TEMP
(carbon or
dewpt only)
NEXT TEST
Units or Options
Range
Description
MILLIVOLTS
-10 to100
MILLIVOLTS
0 to 2000
DEG (F OR C)
0 to 255°F
% Output
LOPO to HIPO
Displays direct mV of
Temperature input
Displays direct mV reading of
probe input
Displays actual cold junction
temperature
Displays actual % output
Kohms
0 to 100
SECONDS
0 to 250
% OXYGEN
0 to 025.0
MILLIVOLTS
0 to 2000
DEG (F OR C)
0 to 3000
ADC COUNT
Counts
FIRMWARE
REV
Version number
Hours.tenths
0-255
Displays last probe impedance
value.
Displays last impedance
recovery time.
Displays last verification
reading. O2 configuration
only.
Displays mV reading of probe
during burnoff.
Displays temperature reading
of probe during burnoff.
Time to next probe test, shows
00.0 if test automatic test is
disabled.
Tracks any faults in the analog
to digital converter.
Table 12 Calibration Menu
Parameter
Name
CAL INPUT
Units or Options
NO / YES
TC mV ZERO
(CAL IN)
TC mV SPAN
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Range
Description
Default to NO, must be
changed to YES to enter input
calibration routine.
Changes calibration value for
thermocouple zero
Changes calibration value for
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Parameter
Name
(CAL IN)
PROBE mV
ZERO
(CAL IN)
PROBE mV
SPAN
(CAL IN)
CJ OFFSET
(CAL IN)
Units or Options
CAL OUTPUT
NO / YES
Range
Description
thermocouple span
Changes calibration value for
millivolt zero
Changes calibration value for
millivolt span
0 – 60° C
0 – 140° F
OUTPUT 1 MIN
(CAL OUTPUT)
OUTPUT 1
SPAN
(CAL OUTPUT)
OUTPUT 2 MIN
(CAL OUTPUT)
OUTPUT 2
SPAN
(CAL OUTPUT
Sets the cold junction offset
depending on the temperature
range selected
Default to NO, must be
changed to YES to enter
output calibration routine.
Sets signal level for the
minimum mA output.
Sets signal level for the
maximum mA output.
Sets signal level for the
minimum mA output.
Sets signal level for the
maximum mA output.
Pressing the Setup key once at any point in the Setup menu will return the instrument
to the normal process display.
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13. Digital Input Event
The Oxymit has a single digital input. This input is activated by making an isolated
contact closure between terminals TB-B 11 and 12. This input is debounced for a
momentary closure of at least 0.6 seconds.
NOTE
Do not connect either terminals TB-B 11 or 12 to any AC or DC
potentials. These terminals are internally connected to an isolated
5VDC source. Use only an isolated contact closure across these
terminals.
The input event can be set to any one of the following functions: OFF, PrOb (start
probe test), AUTO (set to auto), rEn (set to remote), ACK (alarm acknowledge), PrOC
(process hold), Strt (timer start), HOLd (timer hold), End (timer end acknowledge).
These settings can be selected in the Input Setup menu at the DIG EVENT
parameter. The selections can be made by pressing the up or down arrow keys and
then pressing the Enter key.
OFF
This selection disables the input event function. This is the default condition of this
feature unless another function is selected.
PROB
This selection will start the impedance (10Kohm) test and/or probe burnoff. The
various probe tests will run only if they are selected in the Probe Menu. The PrOB
input event will have no effect if no probe tests are selected.
If a probe test interval time is set to any value other than zero, activating this
function will reset the interval countdown timer. If the probe test interval time is set
to zero this function will operate only when the contact closure is made across the
event input terminals. The contact closure must open and close each time to
initiate another probe test.
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AUTO (controller only)
This selection will force the instrument from manual mode or remote mode into
local automatic mode. No change will occur if the instrument is already in
automatic mode.
rEn (controller only)
This selection will force the instrument from local setpoint mode or manual mode
into remote setpoint mode. No change will occur if the instrument is already in
remote setpoint mode.
ACK
This selection will acknowledge any latched active alarm except the timer end
alarm. This function will have no effect if the alarm condition persists when the
acknowledge signal is issued. This function resets a latched alarm similar to
pressing the Enter key.
PrOC (controller only)
This selection will place the process calculation in hold. The control output is also
held at the output level when the process hold event was set. This includes all
analog output signals as well as control contacts. This is similar to the state the
instrument is set to when the probe tests are running.
Strt (controller only)
This selection will start the timer function if the timer is enabled, the set point is
greater than 0, and one alarm contact is assigned to a timer function.
HOLd (controller only)
This selection will place the timer in a hold state for as long as the event input is
active.
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End (controller only)
This selection will acknowledge the end condition of the timer, clear the end state,
and reset the timer for another start.
13.1. Dual Key Functions
The Oxymit was four dual key functions as defined below:
RIGHT arrow / Enter
LEFT arrow / Enter
DOWN arrow / Enter
Rem / Enter
Start probe test sequence
Start Timer
Edit Remaining Timer
Monitor Mode
Starting Probe Tests
Pressing the RIGHT arrow / Enter keys simultaneously will start the probe tests if a
probe test function has been selected in the Probe Setup Menu, parameter Probe
Test, and the probe temperature is above the minimum probe temperature parameter
in the same menu.
If there is a value other than 0 entered in the Probe Test Interval parameter the probe
test will be performed after the selected interval time has elapsed from the time the
test was manually started. If the interval time is set to 0 then no additional tests will
be performed until the next manual start. Starting the test through this dual key
function is the same as if the Start Test parameter in the Probe menu had been
changed from NO to YES.
Start Timer
Pressing the LEFT arrow / Enter keys simultaneously will start the timer if the timer
has been enabled in the Control Setup menu, the timer set point is greater than zero,
and an alarm contact has been assigned a timer function. Press both keys while the
timer is running will stop the timer.
Edit Timer
Pressing the DOWN arrow / Enter keys simultaneously while the timer is running will
allow the remaining time to be changed. The remaining time can be increased or
decreased. The change in time takes effect when the Enter key is pressed and the
display returns to the normal remaining time display.
Monitor Mode
Monitor Mode is used by factory personnel only. Return to operate mode by cycling
power or sending the appropriate command word to the instrument.
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14. Timer Function
The Oxymit timer function is available on all process controller options. The timer can
operate independently or it can be dependent on the process based on how either
alarm contact is configured. The instrument has three possible functions; timer,
guaranteed start timer, and guaranteed soak timer. These functions are set through the
mode selection of alarm 1 or alarm 2 in the Setup menu. Only one alarm should be set
to a timer function at any time.
The timer will only work if three conditions are met; the timer function must be enabled
in the Setup Control Menu, an alarm contact must be configured for a timer function,
and the timer set point must be greater than zero.
The timer set point is set in the Setpt Key menu. The remaining time is displayed in the
display cycle list and can be edited when the timer is running. The timer set point is
entered in whole minutes. The remaining time will show the tenths of a minute if the
timer is less than 1000 and shown as whole minutes. The timer start setting follows the
remaining time display in the Setpt Menu.
14.1. Setting the Timer
The first step for using the timer is to enable the timer function in Setup Control
Menu. This allows the timer to be started in various ways and also allocates a serial
port channel for the timer.
The next step is to move to the Alarm menu and select a timer function for one of the
alarms. The alarm that is selected will close its alarm contact with the timer counts to
zero. Only one alarm should be selected for a timer function and any time.
NOTE
Do not set both alarms to timer functions at the same time.
The final step is to press the Setpt key and the Enter key until the TIMER SETPT
parameter appears. Enter the desired value of the timer. This value is the only set
point for the timer. This value will be used as the timer set point if the instrument is in
the local automatic or remote control mode. There is no separate remote timer set
point value. The local timer set point value will be over written by the value received
from a remote device like a computer or master instrument.
The final step is to start the timer. This can be done in the Setpt menu by pressing
the Enter key until the TIMER START parameter appears and selecting ‘YES’. The
timer can also be started by pressing a dual key sequence LEFT arrow and Enter,
through the serial interface, or through the digital event input.
Timer Dual Key Functions
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⇐ + Enter
In Auto or Remote mode this two key combination will activate or
deactivate the timer function.
⇓ + Enter
This two key combination allows the timer function remaining
time to be edited.
The behavior of the timer is controlled through the selection of the alarm modes. If
no timer alarm is selected for either alarm 1 or alarm 2 then the timer will not start.
The Time, Start, or Soak alarm modes must be selected for one alarm contact before
the timer will start.
The Rem LED on the front panel will flash while the timer is active in the RUN, HOLD,
or END modes. The timer will go inactive when END is acknowledged or if the timer
is disabled.
The timer can be stopped by pressing the Enter and Right arrow keys during an
active RUN state, sending a remote timer set point of 0 when the instrument is in
remote mode, or by changing the remaining time to zero.
The Event Input can be configured to start the timer, hold the timer, or acknowledge
the End state.
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14.2. Time
The Time alarm mode it will run continuously once it has started and the alarm
contract will close when the remaining time reaches zero. The alarm value has no
effect in the simple timer mode and the timer will not stop or hold if the process value
changes. The alarm message is ‘End’ will display on the LCD screen and the
appropriate alarm contact will activate.
14.3. Guaranteed Start Timer
The guaranteed start timer function works in conjunction with the alarm value. The
timer will hold until the process value is greater than the lower band value of the
process. The alarm value is the band value. In the figure below the alarm value is
10, which represents a band around set point of ∀10°. The timer will not HOLD once
it has met the initial starting conditions. The process can fluctuate outside of the
alarm band after the timer has started without placing the timer in a HOLD state. The
following figure shows the behavior of the guaranteed start timer.
Figure 6 Guaranteed Start
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14.4. Guaranteed Soak Timer
The guaranteed soak timer works in conjunction with the alarm process value. The
alarm value is the valid band around the process set point. The process must be
within the band around the process set point to start the timer once it has been
activated. If the process passes above or below the alarm band setting, the timer will
go to a HOLD state. The timer will be allowed to continue only when the process is
within the band setting. In the following figure the alarm value is set to 10 degrees for
a temperature process.
Figure 7 Guaranteed Soak
14.5. Timer Alarm Behavior
The alarm contacts do not work like normal process alarms when the timer, soak, or
start timer functions are selected. If the alarm is configured for the timer, the contact
will only activate when the remaining time counts down to zero and the timer reaches
the END state. Once this occurs the END Alarm message will appear on the LCD
display. The alarm will stay latched until it is acknowledged by pressing the Enter key
or closing a contact across the Digital Event terminals if the End setting is selected as
the Digital Event function. The Rem light flashes during the END state and stops
flashing when the timer is acknowledged and returns to the IDLE state.
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14.6. Timer State Diagram
The following diagram shows the conditions that control the state of the timer
function.
IDLE
Timer Enable = YES
Timer Start = NO
Remaining Time = 0
Timer Enable = NO OR
Timer Start = NO OR
Enter key OR
Remote Time Setpt = -1 OR
Event(END) = ON
END
Time Enable = YES
Timer Start = YES
Display = END Alarm
End Alarm = ON
Alarm contact = ON
Rem Light = Flash
Timer Enable = NO OR
Timer Start = NO OR
Remote Time Setpt = -1 OR
Enter/Left arrow
Event(STRT) = ON OR
Remote Timer SP = -2 OR
Enter / Left arrow OR
Timer Start = YES AND
Timer SP > 0
RUN
Timer Start = YES
Remain Timer = countdown
Time Alarm = OFF
Alarm Contact = OFF
Rem Light = Flash
Remain Time counts to 0
Event(HOLD) = OFF OR
Time Alarm = OFF
Timer Enable = NO OR
Timer Start = NO OR
Remote Time Setpt = -1 OR
Enter / Left arrow
Event(HOLD) = ON OR
Time Alarm = ON
HOLD
Timer Start = YES
Remain Time = hold
Time Alarm = ON
LCD Display = Hi/Lo Alarm
Alarm Contact = OFF
Rem Light = Flash
Figure 8 Oxymit Timer State Diagram
The timer has four states. The IDLE state is the inactive condition. The RUN state is
the active state when the timer is counting down. The HOLD state is when counting
is paused due to either Digital Event = HOLD or a configured alarm is active. The
END state is when the timer has timed-out but has not been acknowledged. The
configured alarm contact will activate when the END state is entered.
The following is a summary of ways to change the state of the Timer. These assume
the standard setups are in effect. It is assumed that the Timer is enabled for it to start
or run.
Timer will start if:
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1.
2.
3.
4.
5.
6.
7.
Page 48 of 97
Timer Enable = YES and
Alarm is set to timer function and
Timer Setpoint > 0 and
Digital STRT event = ON or
Enter/Left keys = CLOSE or
Timer Start = YES or
Remote Setpoint = -002
Timer will hold if:
1. Digital HOLD event = ON or
2. Alarm Soak or Run deviation is active
Timer will run if:
1. Timer Enable = YES and
2. Timer Start = YES and
3. Timer Setpoint > 0 and
4. Digital HOLD event = OFF and
5. Remaining Time > 0
Timer will reset to IDLE without activating END if:
1. Enable = NO or
2. Timer Start = NO or
3. Remote Timer setpoint = -001 or
4. Enter/Left keys pressed
Timer goes to END state if:
1. Timer countdown reaches 0
Timer returns to IDLE state from END when:
1. Enable = NO or
2. Timer Start = NO or
3. Operator presses Enter key or
4. Remote Timer setpoint = -001 or
5. Digital END input = ON
15. Timer SIO Operations
The Oxymit allocates a second host address if the timer function is enabled and the
host port protocol is set to PRoP (Marathon) using the Marathon slave protocol. If the
host port protocol is set to buss (Modbus) or the Marathon block protocol is used,
then the timer information is accessed directly. For the Marathon slave protocol, the
first address is the primary address set by the Address parameter setting in the Setup
HOST menu. The second address is assigned as Address +1 and will respond to
10Pro type commands. The setpoint commands affect the timer set point. The initial
state conditions must be met for the timer to run.
The remaining timer value will be transmitted as the process value when responding
in 10Pro slave mode. The timer values and process values are available at the host
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address if the instrument is responding to the Marathon block command or Modbus.
The Address + 1 address is always active while the timer is enabled and the serial
port protocol selection is MMI and inactive when Modbus is selected. It is important
to consider this extra address allocation if multiple slaves with timers are going to be
connected to a master. Only eight addresses are possible when the 10Pro command
mode is used. See the section on serial communication for details on these
differences. If only the Marathon block command is going to be used then the
instrument will not respond on the second address.
In the MMI 10Pro protocol, the value returned for the percent output command is the
timer control byte. The bits in the control byte are defined in the following table.
Timer Control Byte
0
1
2
Bit
3
4&6
7
Description
Timer Enabled
Timer Running
End
Hold
N/A
Control
Purpose
Indicates that the timer is enabled in the setup menu.
Indicates that the timer has started.
Indicates that the timer has timed out and not
acknowledged.
Indicates that the timer is in hold mode.
Not used.
Set when the timer is started. Reset when timer has
stopped. Is toggled by the Enter + Left Arrow or set by
the SIO sending a time setpoint.
15.1. Controlling the Timer Remotely
All timer setpoint values must be written to the host address + 1 and the timer
function must be enabled in the instrument control menu for the instrument to
recognize any host address + 1 command.
Control of the timer via the serial port using the 10Pro commands has limited
capabilities since the only value that can be written is the time set point. There are
special cases if the Oxymit is connected to Dualpro/Multipro as a slave. The master
instrument must first send a valid setpoint value from 1 to 9999. The master can then
send a setpoint of –002 to start the timer assuming all other configuration
requirements are met. If the master sends a setpoint of –001 the timer is reset and
stopped with no End alarm.
The master can set the timer functions, alarm values, and delay times using the
Marathon Block or Modbus protocols. The sequence of events is similar for either
Marathon Block or Modbus protocol.
The timer control word is located at parameter 70, Timer Control and Event (TCE).
The timer control byte is the upper byte of this word. The input event configuration is
in the lower byte of this word. Any configuration of the input event must be added to
the timer function values when this word is written to the Oxymit. In this example the
event configuration is set to none (0). It is suggested that this word be read by
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masking the upper byte of the word to record the input event configuration. This
value can then be added to the following timer control values to retain the input event
configuration.
The timer will only work when it is enabled, the timer setpoint is greater than 0, and at
least one alarm mode is set to a timer function. The alarm mode has to be manually
configured. Programming the timer involves the following sequence:
Enable the timer by writing a value 32768 (0x8000) to TCE.
Set the timer setpoint by writing setpoint value to parameter 3 (TSETPT)
Start the timer by writing a value 33024 (0x8100) to TCE.
The timer will indicate that it has timed out when TCE changes to value 34560
(0x8300).
Acknowledge the end alarm by writing a value 0 (0x0000) to TCE.
A description the TCE word and the timer flags in the TCE word can be found in the
Oxymit Memory Map table.
16. Probe Impedance Test
The sensor impedance test is performed by measuring the open circuit voltage of the
sensor, applying a known shunt resistor across it and measuring the shunted voltage
output. The value of the shunt resistor is 10kohm for carbon sensors.
To run a sensor impedance test it is necessary setup the sensor testing parameter in the
SETUP Sensor Menu. Please refer to Probe parameters table for an explanation of
these setup parameters. It is necessary to have the impedance (RES) test or both
(BOTH) selected at the PROBE TEST parameter in order to run the impedance test.
You may choose to accept the defaults for the other parameters in this menu or change
them to suit your applications.
NOTE
It is necessary that the sensor be above the MIN PROBE TEMP parameter setting
for this test to run. It is also necessary that the sensor is measuring a stable
process gas during this test.
There are two ways to start this test. The first way to start the test is by pressing the
ENTER and RIGHT ARROW keys at the same time. The test can be stopped by
returning to the START TEST parameter and changing YES to NO and then pressing
ENTER or by pressing the ENTER and RIGHT ARROW keys again. The sensor test
must be specified in the probe setup menu and the sensor temperature must be above
the minimum temperature for any test to run.
The second way to start the sensor test is to write a 1 to the PSTART (Probe Start) word
in the instrument memory Block 3 Parameter 72 via the serial communications interface.
Refer to the instrument memory map for details on the format of this word. The
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instrument will reset this value when the test starts and will ignore any changes while the
test is running.
The following table explains the various operations of the impedance test.
If the TEST INTEVAL parameter has a number other than 00.0 then the test will continue
to run each time the test interval timer counts down to 0. This test interval can be
stopped by setting the interval timer to 00.0.
Table 13 Probe Impedance Sequence
Sequence #
1
2
3
4
Description
Inhibit process variable calculations. Freeze all
process controls and outputs.
Freeze alarms at last state except clear any previous
probe test failure alarm.
Store present probe millivolt reading
Apply shunt resistor across probe
Wait for impedance test timer, fixed time of 30
seconds
Compute impedance of probe and remove shunt
resistor. Save measured impedance as PROBE
IMPEDANCE in INFO menu.
If impedance is greater than PROBE IMP LIMIT then
set probe test failure alarm.
Wait for probe to recover to >=99% of original
millivolts.
Evaluate actual recovery time to IMP RECVRY TIME
If recovery time is greater than IMP RECVRY TIME
then set probe test failure alarm.
Store recovery time (or max value ) as IMP RECVRY
TIME in INFO menu
If verification (burnoff) is to be performed then go to
step 1 of verification (burnoff) sequence
Otherwise wait 30 seconds and resume normal
operation of all instrument functions.
16.1. Why Measure Sensor Impedance?
It is important to track sensor impedance over a period of time to help determine the
replacement schedule for the sensor. A high impedance (>50 KΩ) indicates that the
electrode contact on the probe zirconia has deteriorate to a level that probably
warrants replacement. High sensor impedance results in a lower signal output from
the sensor and an eventual failure of the electrode connection on the process side of
the zirconia ceramic. This deterioration is more of a factor in highly reducing
atmospheres. In such applications, it may be necessary to check the impedance at
least once a month. Under light reducing, annealing, or brazing operations, the
impedance may not have to be check unless there is a question about the probe’s
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performance.
Typical impedance for a new probe is less than 1 KΩ. As the probe starts to age the
impedance will increase. Past 20 KOHM the sensor should be monitored more
closely. Above 50 KΩ, the sensor should be replaced. If it is necessary to replace
the sensor, remove it carefully, following the instructions supplied with the sensor.
Do not discard a sensor with high impedance. It may be possible to rebuild the
sensor if the ceramic parts are intact. Contact UNITED PROCESS CONTROLS for
information on rebuilding your sensor.
An impedance test can only be performed if the probe temperature is at or above
1100°F with stable atmosphere present. The instrument freezes all control functions
and process signals during the test.
A 10Ω resistor is shunted across the sensor output. The sensor impedance is
calculated as:
Rx = [(Eo/Es)-1]*Rs
Where Rx = sensor impedance, Eo = sensor’s open circuit voltage, Es = shunted
sensor’s voltage, and Rs = shunt resistor. The units of Rx are the same as Rs.
17. Probe Verification (Oxygen only)
Probe verification is performed by measuring the probe signal when a known
calibration gas has been allowed to flood the sheath of the oxygen probe. A ¼” CPI
compression fitting at the mounting hub of United Process Controls oxygen sensors
is provided for the connection the verification gas. When a gas of known oxygen
level is allowed to flow through this port, it floods the probe sheath and flows out and
around the oxygen sensor. This method does not use the process as the basis for
measurement nor does it have to assume that the process is stable, but the sensor
does have to be above the MIN PROBE TEMP parameter found in the PROBE setup
menu. This value is typically 1400°F or higher.
To run a probe verification test it is necessary setup the probe verification test
parameters in the SETUP Probe Menu. Please refer to Probe parameters table for
an explanation of these setup parameters. It is necessary to have the verification
(VER) test or both (BOTH) selected at the PROBE TEST parameter in order to run
the verification test. You may choose to accept the defaults for the other parameters
in this menu or change them to suit your application. It is necessary that the sensor
be above the MIN PROBE TEMP parameter setting for this test to run. It is not
necessary for the probe to be measuring a stable process gas during this test.
There are two ways to start this test. The first way to start the test from the process
display is by pressing the ENTER and RIGHT ARROW keys at the same time. The
test can be stopped by returning to the START TEST parameter and changing YES
to NO and then pressing ENTER.
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The second way to start the sensor test is to write a 1 to the PSTART (Probe Start)
word in the instrument memory Block 3 Parameter 72 via the serial communications
interface. Refer to the instrument memory map for details on the format of this word.
The instrument will reset this value when the test starts and will ignore any changes
while the test is running.
If the TEST INTEVAL parameter has a number other than 00.0 then the test will
continue to run each time the test interval timer counts down to 0. This test interval
can be stopped by setting the interval timer to 00.0.
Readings are averaged to eliminate variations in measurement due to initial flow
conditions. There are three operator inputs for verification time periods;
•
•
•
•
TEST INTERVAL is an interval timer that sets the time between automatic
verifications in hours and tenths. The verification can be manually initiating by
pressing and holding the Enter key and then the Right Arrow key. Setting the test
interval time to zero disables automatic testing.
VERIFY DELAY TIME is the initial stabilization period in seconds.
VERIFY AVG TIME is the measurement averaging time period in seconds.
VERIFY RECOVERY is the time period in seconds that allows the probe to
recover and return to the process level.
Two values allow the operator to set the actual value of the verification gas and the
allowed tolerance for the measured comparison.
•
•
•
VERIFY STANDARD is the oxygen level of the gas standard in percent oxygen.
VERIFY TOLERANCE is the measurement tolerance specified in percent oxygen.
MIN PROBE TEMP is the minimum probe temperature that must be met to allow
the test to proceed.
The following table outlines the actions the instrument takes at each sequence step.
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Table 14 Probe Verification Sequence
Sequence
#
1
2
3
4
Description
Inhibit process variable
calculations. Freeze all process
controls and outputs.
Freeze alarms at last state except
clear any previous probe test failure
alarm.
Close verification contact and wait
the VERIFY DELAY time period.
Average oxygen readings from
probe during the VERIFY AVE
TIME period.
Release the verification contact and
wait the VERIFY RECOVERY time
period.
Evaluate the averaged oxygen
reading to the VERIFY STANDARD
± VERIFY TOLERANCE. Set
alarm fault if comparison fails.
Save averaged verification reading
as VERIFY READING in INFO
menu.
Resume normal operation of all
instrument functions.
18. Sensor Burnoff (Carbon or Dew Point only)
Sensor burnoff is performed by flowing air into and around the oxygen sensor internal
ceramic substrate. This air creates a flame at the tip of the sensor that burns off any
accumulated carbon or soot. A ¼” CPI compression fitting at the mounting hub of
United Process Controls sensor is provided for the air connection. This air floods the
sensor sheath and flows out and around the sensor. The sensor does have to be
above the MIN PROBE TEMP parameter found in the PROBE setup menu. This
value is typically 1300°F or higher.
To run a sensor burnoff it is necessary setup the sensor test parameters in the
SETUP Probe Menu. Please refer to Sensor parameters table for an explanation of
these setup parameters. It is necessary to have the burnoff (BOFF) test or both
(BOTH) selected at the PROBE TEST parameter in order to run the burnoff. You
may choose to accept the defaults for the other parameters in this menu or change
them to suit your application. It is necessary that the sensor be above the MIN
PROBE TEMP parameter setting for this test to run. It is not necessary for the
sensor to be measuring a stable process gas during this test.
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There are two ways to start this test. The first way to start the test from the process
display is by pressing the ENTER and RIGHT ARROW keys at the same time. The
test can be stopped by returning to the START TEST parameter and changing YES
to NO and then pressing ENTER or by pressing ENTER and RIGHT ARROW.
The second way to start the sensor test is to write a 1 to the PSTART (Probe Start)
word in the instrument memory Block 3 Parameter 72 via the serial communications
interface. Refer to the instrument memory map for details on the format of this word.
The instrument will reset this value when the test starts and will ignore any changes
while the test is running.
Readings are averaged to eliminate variations in measurement due to initial flow
conditions. There are three operator inputs for verification time periods;
If the TEST INTEVAL parameter has a number other than 00.0 then the test will
continue to run each time the test interval timer counts down to 0. This test interval
can be stopped by setting the interval timer to 00.0.
•
•
•
TEST INTERVAL is an interval timer that sets the time between automatic
verifications in hours and tenths. The verification can be manually initiating by
pressing and holding the Enter key and then the Right Arrow key. Setting the test
interval time to zero disables automatic testing.
BURNOFF TIME is the period in seconds burnoff air is flowing to the sensor.
BURNOFF RECOVERY is the time period in seconds that allows the sensor to
recover and return to the process level.
The following table outlines the actions the instrument takes at each sequence step.
Table 15 Sensor Burnoff Sequence
Sequence
#
1
2
3
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Description
Inhibit process variable
calculations. Freeze all process
controls and outputs.
Freeze alarms at last state except
clear any previous probe test failure
alarm.
Close burnoff contact and wait the
BURNOFF time period.
Release the burnoff contact and
wait the BURNOFF RECOVERY
time period.
Save the mV reading as in INFO
menu.
Resume normal operation of all
instrument functions.
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19. Procedure to Test an Oxygen Sensor
The following section describes the steps required to do an automatic or manual test
of an oxygen sensor using the Oxymit Oxygen controller or monitor. For carbon/dew
point applications the same basic steps are followed but air is used for a burnoff
instead of a verification reference gas.
19.1. Correctly set up the parameters in the
Oxymit for the Probe Testing.
1. Press the SETUP key for five seconds to activate the setup mode
2. Page to the Prob Menu heading by pressing the RIGHT or LEFT arrow keys.
When Prob appears in the LCD display, press the Enter key.
3. The first parameter is probe test. Press the UP or Down Arrow keys until the lower
display reads Both. Press the Enter key to advance to the next parameter.
4. Test Interval (hours) should be set to 0 for a manual start test. A flashing cursor in
the lower LED display indicates which digit can change if the parameter value is
numeric. The UP or DOWN arrows increase or decrease the digit value. The
RIGHT or LEFT arrow keys move the cursor to the right or left digit. If a number is
entered here it is the interval in hours between automatic repeats of the probe
test. The probe test must be started manually the first time to initiate the repeat
function.
5. Probe Impedance Limit should be set to 20 (Kohms). This setting is where the
sensor electrodes are starting to wear and should be watched. If the impedance
reaches 50 Kohms, the sensor should be replaced.
6. Impedance Recovery Time (seconds) default value is 30. This value should
always be greater than the millivolts filter value in the Input menu.
7. Verify Delay (seconds) default value is 30, set to 60.
8. Verify Average Time (seconds) should be set to 10.
9. Verify Recovery should be set to 30.
10. Verify Standard should be set to % O2 reference gas used.
11. Verification Tolerance should be set to 1.0.
12. Minimum Probe Temperature should be set to 590 if C is used or 1100 if F is
used.
13. After pressing the ENTER key for the last parameter, press the SETUP key to exit
the Menu and return to regular process operation.
19.2. To manually start a probe test procedure
1. Simultaneously press the RIGHT Arrow + Enter keys with the display in normal
process mode.
2. The instrument will cycle through the test steps and return to normal operation
after completing the test if results are satisfactory.
3. You may access the results by cycling the display with presses of the Enter key.
If a probe fault alarm is displayed it will be necessary to go to the Info section of
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the SETUP Menu. The measured probe impedance, probe impedance test
recovery time, and the measured verification reading are viewable in either mode.
19.3. If a Probe Fault occurs
1. To clear a Probe Fault alarm, you must run a successful probe test procedure;
also see the Troubleshooting section of this document.
2. Access the Probe Test Results data from the Info section of the SETUP Menu.
Check the probe impedance, recovery time, and verification reading against the
parameter settings in the Probe setup section. If necessary, adjust the test
parameters to allow a successful test. Take the necessary actions to correct the
problem.
20. Tuning
Before attempting to tune the instrument make sure you understand the Operation
and Setup part of the instrument.
20.1. What is tuning?
Tuning the controller means that the control characteristics of the controller are
matched to those of the process in order to obtain hold the process to setpoint. Good
control means:
•
•
Stable, ‘straight-line’ control of the process variable at setpoint without fluctuation
No (minimum) overshoot, or undershoot, of the process variable relative to
setpoint
• Quick response to deviations from the setpoint caused by external
disturbances, thereby rapidly restoring the process variable to the setpoint
value.
Tuning involves calculating and setting the value of the parameters listed the
following table. These parameters appear in the Control Setup menu.
Table 16 PID Parameters
Parameter
Proportional band
Meaning or Function
The bandwidth, in display units, over which the output
power is proportioned between minimum and maximum.
Integral time
(Reset)
Determines the time taken by the controller to remove
steady-state error signals.
Derivative time
Determines how strongly the controller will react to the
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(Rate)
Cycle Time
Page 58 of 97
rate-of-change of the measured value.
The total amount of time used to calculate the
combination of percent on and percent off periods of the
control function.
The Oxymit uses the Proportional Band as a representation of the Proportion section
of PID, the Reset as a representation of the Integral section of PID, and the Rate as a
representation of the Derivative section of PID. Thus by following a simple
procedure, PID tuning can easily be implemented in any control situation. A
suggested procedure is diagramed in the next figure.
All of the PID parameters may be altered by changing these parameters in the Setup
/ Ctrl menu. The following procedure assumes the initial PID values for a typical
batch furnace. You may be able to start with a proportional band setting of 10 or less
for a smaller box or temper furnace.
You must determine want the initial cycle time should be. If you are using control
motors or continuous motors, set the cycle time to the time it takes the control motor
or actuator to fully open and fully close. If you are using quick acting solenoids to
control the process the cycle time setting is a compromise between longer times to
limiting contact cycles and extend the life of the actuator or shorter times to maintain
good control. A good rule is to watch to process value and turn on the solenoid.
Measure the time it takes for the process to react with a 5% change. Double this time
and enter it as the cycle time. Decrease the cycle time to get a smoother control.
If, after following the procedure, the process continues to oscillate, it may be
necessary to change the HIPO or LOPO parameters. Make sure that the control
output is linear through the full range from LOPO to HIPO. In situations where the
system is difficult to tune, it is most likely the output is not linear or there is too much
lag time between the control command and measurable changes in the process.
Test the system in manual mode to verify the output is linear.
A much higher proportional band may be necessary for extreme lag in the process
response. In most cases, the derivative part of the control equation is not necessary.
Generally, furnace control can be maintained using only the proportional band and
the reset parameters.
Make sure you record all operating parameters and keep them in a secure place for
later reference.
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START RESET
PROCEDURE HERE.
INCREASE PB BY
30%
OSCILLATING
START PROPORTIONAL
BAND PROCEDURE
HERE. THESE SETTINGS
ASSUME THE SYSTEM IS
STABLE WITH A PB OF
30. KEEP INCREASING
PB BY 50% IF
OSCILLATING.
A
CHANGE SETPOINT
BY 5%
RESET X 2
CHANGE SETPOINT
BY 5%
DECREASE PB BY
10%
STABLE
IS CONTROL
STABLE?
ALLOW PROCESS TO
STABILIZE
SET PB = 30
RESET = .01
RATE = .01
SETPT = TYPICAL
TUNING FINISHED
RECORD PID
VALUES
OSCILLATING
YES
RESET / 2
B
STABLE
B
RATE X 2
OVERSHOOT TOO HIGH
OVERSHOOT
ACCEPTABLE AND
STABLE?
CHANGE SETPOINT
BY 5% AND ALLOW
STABILIZATION
RESET X 2
BELOW SETPOINT
HOW IS SYSTEM
REACTING?
ALLOW SYSTEM TO
STABILIZE
A
OSCILLATING
RATE / 2
START RATE
PROCEDURE HERE.
Oxymit™ Transmitter
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Figure 9 PID Manual Tuning Procedure
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21. Scaling Analog Inputs
If either input is set to Linear mode the displayed value for that input can be scaled to
any desired engineering unit. This is helpful if the measured linear value has to be
scaled and re-transmitted on one of two analog output channels.
Using the equation y = mx + b, where
Y is the desired engineering unit to be displayed
X is the linear millivolt value
M is the Slope of the y/x relationship
B is the y intercept
Linear A example
Let us use Input A as an input for a linear oxygen transducer that outputs a 0mV to
53.2mV signal for a 0% to 100% oxygen range. Since both the signal output and the
process minimum are both 0, the Input A offset will be 0.
The slope can be calculated by dividing the maximum process value (100) by the
maximum input level (53.2mV). This gives a slope value of 1.879. This number can
be entered as the Input A slope. The decimal point can be shifted by placing the
flashing cursor on the most significant digit and pressing the Left arrow key until
decimal point shifts to the required position.
These scaling values produce a calculated process value of 100.0160% oxygen for a
maximum sensor input of 53.2mV. The process display can be configured to display
either 100 or 100.0 depending on the display decimal point setting. This process
value can then be retransmitted to other control devices are a recorder. The control
model of the Oxymit will be able to control to a set point for the new process value.
21.1. Keyboard Function during Input Slope
The four digits in the slope display can be change from 0 to 9 or the left digit and
change to the negative sign. This most significant digit position also allows you to
shift the decimal point by pressing the LEFT arrow key. The decimal point will shift
from first digit to the third digit as the LEFT arrow key is pressed. Pressing the
RIGHT arrow key when the cursor is on the least significant digit will shift the decimal
point to the right.
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22. Scaling Analog Outputs
The analog outputs are scaled as simple offset and span values. For example if
analog output 1 were to be scaled for a 0 to 25.00% oxygen value, the offset value
would be 0 and the span value would be 25.00. This assumes that the process
oxygen value is also scaled for percent oxygen where the oxygen exponent is set to
2.
For ppm values the analog output would be scaled to the display resolution of the
process. For example, if the process display is 6.5 ppm, with a oxygen exponent of
6, the full scale display resolution would be any number between 000.0 and 999.9.
The analog output can be scaled to a reasonable range of 0 to 10, which would drive
the 4 – 20mA output over a 0 to 10ppm range and the 6.5 ppm process value would
result in an output of 14.4mA.
The same rules apply to analog output 2. The range of the offset and span numbers
depends on the range of the process value that has been selected for either analog
output.
Additional selections for Power Output and Program mode have fixed offset and span
values. The power output offset and span values are fixed to the LOPO and HIPO
values selected for the control outputs under the Setup Control menu.
The Program mode selection has a fixed offset of 0 and a fixed span of 4096. When
this output mode is selected the analog output can only be changed by writing a
value to either the DACV1 or DACV2 registers.
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23. Calibration
There are two analog inputs, a cold junction compensation sensor, and two analog
outputs on the Oxymit. The input level is determined by which terminals are used for
the input signal. There are two pairs of input terminals: Terminals 5(-) and 6(+) for
the thermocouple (T/C) input and terminals 7(-) and 8(+) for the probe millivolt input.
The 4 – 20mA analog outputs are at terminals 1(-) and 2(+) for the analog output 1
channel and terminals 13(-) and 14(+) for analog output 2 channel.
The following is a brief description of input/output and its specifications.
a)
T/C Input
b)
Probe mV Input
Input range
Input impedance
Open input
c)
Output 1
d)
Output 2
Input range
TC burnout
-10 to +70 millivolts ± 2 µV
>full scale
-50 to +2000 millivolts ± .1 mV, linear
40 megohm
>full scale
Output range
Max. Load
0 to 20 milliamps
650 ohms
Output range
Max. Load
0 to 20 milliamps
650 ohms
23.1. Calibration Displays and Keyboard
Operation
When entering the Calibration Menu, the operator has to answer one of two
questions depending on which I/O functions have to be calibrated. If the
CALIBRATION IN prompt is answered with a YES, then the parameters related to the
thermocouple input, millivolt input, and cold junction can be changed. If this prompt is
skipped by pressing the Enter key, then a second prompt, CALIBRATION OUT is
displayed. If this prompt is answered with a YES, then the zero and span values for
both analog outputs can be changed.
In the Calibration Menu the displays and front panel keys take on special
assignments. The LCD display shows the input and calibration point being
calibrated. The upper LED display indicates that the instrument is in CAL mode. The
lower LED display indicates the actual input level for the input channels or the
calibration factor for the output channels.
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It is very important that the display is indicating the proper I/O parameter before
making an adjustment or the wrong value will be changed.
Once the particular calibration mode is selected the following keys perform the
described functions:
Key
Function
UP ARROW
Increases the displayed value.
DOWN ARROW
Decreases the displayed value.
RIGHT ARROW
Shifts to the upper digits to adjust the calibration factor for the
analog output calibration.
LEFT ARROW
Shifts to the lower digits to adjust the calibration factor for the
analog output calibration.
ENTER
Cycles to next input value and saves the calibration changes.
SETUP
Exits the calibration mode.
23.2. Preparing for Input Calibration
The thermocouple calibration can be done in several ways depending on the type of
calibrator available, the selected process source, and the cold junction setting. If the
process source has been set to LInA (input A) then the displayed values for offset
and span will be the direct millivolt inputs. If the process source is selected as
carbon, dew point, oxygen, or temperature then the display values will be in
temperature. When in temperature mode, this reading can also be affected by the
cold junction. If cold junction is not applied then the cold junction adjustment has no
affect and the temperature reading is not compensated. If cold junction is applied
then the cold junction correction is applied to the zero, span, and cold junction
adjustment values and the cold junction adjustment will have an effect on the
temperature reading.
These methods of calibrating the temperature input can be used in situations where
only one type of calibrator is available or in the field where a compensated
thermocouple source is the most likely source. If an uncompensated thermocouple
source is used then the connection to the instrument should be with copper wire and
the cold junction compensation should be turned off.
The following items are required to calibrate thermocouple and millivolt inputs
depending on the type of thermocouple input configuration.
•
Calibrated millivolt source, 0 – 2000mV with a 0.1 mV resolution (input B)
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•
•
•
•
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Calibrated millivolt source, -10mV to 50mV with a 0.1 uV resolution (input A
linear mode).
Copper wire to connect the millivolt source to the instrument (input A linear
mode or CJ non compensated).
Calibrated thermocouple simulator with internal cold junction compensation
(process mode with CJ compensation).
Thermocouple extension wire for the type of thermocouple to be used (process
mode with CJ compensation).
Calibration of Temperature and Cold Junction
There are several ways to calibrate the temperature input depending on the
circumstances. If the temperature various by a few degrees from a thermocouple
source then it may be possible to only adjust the CJ ADJUSTMENT found in SETUP,
CAL IN menu. To do this, go into calibration mode, select YES for Cal Input and
press Enter at TC Zero and TC Span. At CJ ADJUSTMENT correct the temperature
reading by pressing the Up or Down arrow keys. Press SETUP to escape calibration
mode.
For a complete calibration it is necessary to have a millivolt source with copper wire
and a cold junction compensated source using the correct thermocouple extension
wire. Use the following procedure for a full thermocouple calibration.
Calibration procedure:
1. Go into SETUP mode and select CtrL menu, press Enter and select the required
process such as carbon or dew point.
2. Press Rem to return to the top of the menu. Press the Right arrow to go to the
INPUT menu. Press Enter to verify the thermocouple type and set APPLY CJ to
NO.
3. Use a millivolt source with copper wire. Connect the wire to TB-1(+) and TB-2(-).
4. Set the source output for the equivalent zero millivolt level for the thermocouple
setting.
5. Press Rem to return to the top of the menu. Press the Left arrow to get to the
CAL menu. Press Enter to go to CAL IN and select Yes. Press Enter to get to
thermocouple zero.
6. Adjust the Zero display to match the corresponding zero temperature value and
press Enter to go to thermocouple span.
7. Set the source output for the equivalent span millivolt level for the thermocouple
setting.
8. Adjust the Span display to match the corresponding span temperature value.
9. Press Rem to return to the top of the CAL menu. Press the Left arrow to go to
INPUT menu. Press Enter to change APPLY CJ to Yes. Return to the CAL IN
menu, CJ ADJUSTMENT.
10. Correct the thermocouple extension wire for the type of thermocouple selected
and set the calibrator to the thermocouple span value.
11. Adjust the CJ Adjustment display to match the source temperature value.
Refer to the following tables for the equivalent millivolt level and temperature range.
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Table 17 Thermocouple Calibration Values
Zero
Temperat
ure
°F (°C)
800
(426.7)
T/C type
B
Zero
Millivolt
Equivalent
0.898
E
32(0.0)
0.000
J
32 (0.0)
0.000
K
32 (0.0)
0.000
N
32 (0.0)
0.000
300
(148.9)
300
(148.9)
R
S
T
32 (0.0)
1.032
1.021
0.000
Span
Temperat
ure
°F(°C)
3000
(1648.9)
1830
(998.9)
1400
(760.0)
2500
(1371.1)
2300
(1260.0)
3000
(1648.9)
3000
(1648.9)
700
(371.1)
Span
Millivolt
Equivalent
11.835
76.289
42.919
54.856
46.060
19.525
17.353
19.097
The usable ranges for the thermocouple types are shown in the following table. If it is
desirable to have a higher accuracy over a specific operating range then the input
should be calibrated over that range.
Table 18 Usable Thermocouple Range (°F)
T/C type
B
E
J
K
N
R
S
T
Minimum
Value (°F)
800
-440
-335
-340
-325
300 *
300 *
-380
Maximum
Value (°F)
3270
1830
1400
2505
2395
3210
3210
755
* Due to the extreme non-linearity of low level signals, using type R and S below 300°
F is not recommended.
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Calibration of the Thermocouple Input (linear mode)
Calibration procedure:
1. Connect terminals TB-B 1, 2 to an isolated, stable millivolt source calibrator using
standard copper wire, 20 AWG is sufficient.
2. Set the calibrator output to 0.00 mV.
3. Set the process source to LinA and activate the calibration mode by entering the
calibration SETUP menu and changing Calibration IN - NO to YES.
4. Use the Enter key to select the TC ZERO mode.
5. Using the arrow keys, adjust the displayed value to equal the calibrator input.
6. Press the Enter key to select the TC SPAN mode.
7. Set the calibrator output to 50.0mV (70mV maximum).
8. Using the arrow keys, adjust the displayed value to equal the calibrator output.
Calibration of the Probe Millivolt Input
Calibration procedure:
1. Connect terminals TB-B 3, 4 to an isolated, stable millivolt source calibrator using
standard copper wire, 20 AWG is sufficient. The input can respond to a maximum
2000 mV .
2. Set the calibrator output to 0.00 mV.
3. Activate the calibration mode by entering the SETUP menus, selecting the
Calibration menu and changing Calibration IN - NO to YES.
4. Use the Enter key to select the MV ZERO mode. Set the calibrator output to
0.00mV.
5. Using the arrow keys, adjust the process value to equal the calibrator input.
6. Press the Enter key to select the MV SPAN mode.
7. Set the calibrator output to the required millivolt span (2000 mV maximum).
8. NOTE: The displayed number will change in resolution. The millivolt value will
show the tenths digit if the measured value is less than 1000 mV. Above 999.9
mV the display will shift to whole numbers. Use the arrow keys to adjust the
process value to equal the calibrator output.
23.3. Calibration of the Analog Output Channels
The same calibration procedure can be used for either output channel.
Calibration procedure:
1. Connect terminals 1and 2 (or 13, 14) to a multimeter such as a Fluke 77. Select
the milliamp measurement range and verify that the test leads are plugged into
the milliamp jack and common on the multimeter.
2. Activate the calibration mode by entering the SETUP menu, selecting the
Calibration menu, press the ENTER key until CAL OUTPUT - NO is displayed.
3. Change the NO prompt to YES using the UP arrow key.
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4. Press the ENTER key to select the OUTPUT 1 MIN mode. If OUTPUT 2 is
required, continue pressing the ENTER key until OUT 2 MIN is displayed.
5. Using the UP or DOWN arrow keys, adjust the displayed number from 0 to 9.
Press the RIGHT or LEFT arrow keys to select the adjustment sensitivity. Adjust
the displayed value until the multimeter indicates the desired minimum output.
This is typically set for 4 mA (cal factor ~ 800), but this level can be adjusted to
0mA (cal factor ~ 0).
6. Press the ENTER key to select the OUTPUT 1 SPAN mode. If OUTPUT 2 is
required, continue pressing the ENTER key until OUTPUT 2 SPAN is displayed.
7. Using the arrow keys as explained in step 5; adjust the output to read 20mA on
the multimeter. A typical cal factor for 20mA is 3150. The maximum cal factor is
4095.
8. Press the SETUP key to save the calibration values and exit the calibration
routine.
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Oxymit™ Transmitter
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24. Process Variable Calculations
The transmitter has a selectable process calculation for percent carbon, percent
oxygen, or dew point. The following equations are used to derive these values;
24.1. Percent Oxygen
20.95
%O2 = -----------------------
e(E/0.0215*Tk)
Where: E = probe millivolts, Tk = probe temperature in degrees Kelvin.
The 20.95 is the %O2 in air.
24.2. Percent Carbon
The carburizing activity in a furnace are such that when equilibrium between carbon
monoxide and oxygen exists, then the carbon potential of the atmosphere is fixed at a
value determined by the relative amounts of these two gases. Assuming that the
carbon monoxide content of the atmosphere does not vary significantly, then the
carbon potential will depend mostly upon the oxygen content of the atmosphere.
The oxygen in the atmosphere is measured by a technique that exposes an in-situ
zirconia-platinum sensor to the gas. A millivolt signal generated by this sensor is
transmitted to a controller for processing. Also transmitted is the atmosphere
temperature by virtue of a thermocouple located in or near the oxygen sensor.
Assuming that the oxygen and carbon monoxide are in equilibrium and that the
carbon monoxide level does not vary significantly, we now have all the information
required to produce an approximate calculation of %C in the atmosphere.
The equation used as the basis for the controller’s calculation of %C is:
Where:
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E = oxygen probe output millivoltage
T = temperature of atmosphere (Kelvin)
PcoA = assumed partial pressure of carbon monoxide in atmosphere (= %CO/100 at
1 atm. pressure)
PcoM = measured partial pressure of carbon monoxide in atmosphere (= %CO/100
at 1 atm. pressure)
af = alloy factor for a given steel (Close to 1 for most carburizing steels); can be
calculated from the equation:
af (for low-alloy steels only) =
1 + %Si(.15 +.033%Si) + .0365(%Mn)
- %Cr(.13 -.0055%Cr) + %Ni(.03 +.00365%Ni)
- %Mo(.025 +.01%Mo) - %Al(.03 +.002%Al)
- %Cu(.016 +.0014%Cu) - %V(.22 -.01%V)
It should be noted that if the Carbon Monoxide content of the furnace is not known,
the term in the equation involving af and Pco can be thought of as a single, overall
constant for a given set of furnace and load conditions. It is for this reason that this
term was chosen as the location for the “Process Factor” adjustment in the Carbon
Controller. Mathematically, the “Process Factor” adjustment as entered on the front
panel for a given case relates to the term in the above equation as follows:
Where:
945.7 af
29(PF) + 400 = --------------Pco
PF = Process Factor (0-999) and
Pco = partial pressure of carbon monoxide in atmosphere (= %CO/100 at 1 atm.
pressure)
Adjustment of the Process Factor by the user will allow compensation to be made for
a wide range of conditions. A nominal 20% carbon monoxide methane-based
endothermic gas atmosphere, with an assumed alloy factor of 1 would require a
Process Factor of 149. If a propane-based endothermic (23% carbon monoxide),
would require a Process Factor of 128. For nitrogen-methanol systems, the Process
Factor used will be the same as for methane-based endo atmosphere. However, this
will depend entirely on the ratio of methanol to nitrogen and some experimentation
would be required to arrive at a working value. Note that for pure methanol, the
theoretical process factor would be 85. Note also that if high-nickel steels such as
3115 are to be accurately carburized, an alloy factor (af) will be important in
determining the correct Process Factor. Process factors for high alloy steels such as
tool steels are not directly calculable because of carbide interaction. These must be
arrived at experimentally.
As a practical matter, the correct Process Factor for a given set of circumstances is
best determined from experimentation with shim stock and/or carbon test bars; the
above equations may then be used as a basis for correcting the factor from a
mathematical standpoint. It is usually easier, however, to correct the Process Factor
in real-time by simply changing its value and observing the results in the %C display
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in relation to a known %C in the furnace. When using this method care must be taken
to gather enough solid data before making adjustments. Not allowing for statistical
variations between loads can be a potential cause of serious error in setting up a
Process Factor.
If a significantly different Process Factor than seems logical must be used to get a
correct %C display, a number of things must be investigated. The necessity of using
a relatively high Process Factor can possibly be taken to mean that soot is present in
the furnace, or that the oxygen probe is incorrectly located, or that the probe is
sooted. A low value for Process Factor might indicate a problem with reference air
supply to the probe or impending failure of the probe altogether.
24.3. Dew Point
The dew point calculation is based on an endothermic atmosphere in equilibrium with
the assumptions of 40% hydrogen and an initial process factor of 150.
4238.7
Dew Point = ---------------------------------9.55731 - log10(E / (Tk x 0.0215)
Where:
E = probe millivolts + mv offset, Tk = probe temperature in degrees Kelvin.
NOTE:
This calculation is only valid for Endothremic Rx gas in a state of equilibrium. The
equation will not work for a dew point calculation on Exothermic gases. Other types
of processes will require empirical analysis.
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Oxymit™ Transmitter
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25. Communications
The Transmitter is capable of digital communications using the Modbus protocol or
the UNITED PROCESS CONTROLS block or slave protocols. This is possible by
connecting to the half duplex RS-485 terminals using a shielded twisted pair.
25.1. Modbus
The MODBUS protocol describes an industrial communications and distributed
control system (DCS) that integrates PLCs computers, terminals, and other
monitoring, sensing, and control devices. MODBUS is a Master/Slave
communications protocol, whereby one device, (the Master), controls all serial activity
by selectively polling one or more slave devices. The protocol provides for one
master device and up to 247 slave devices on a RS-485 half duplex twisted pair line.
Each device is assigned an address to distinguish it from all other connected devices.
All instruments are connected in a daisy-chain configuration.
The instrument communicates with baud rate settings 1200, 2400, 4800, 9600, or
19.2K. The default baud rate is 19.2Kbuad. The default address is 1. Changes to
these values can be made by writing to the appropriate memory register.
The Transmitter communicates in Modbus RTU (Remote Terminal Unit) protocol
using 8-bit binary data characters. Message characters are transmitted in a
continuous stream. The message stream is setup based on the following structure:
Number of bits per character:
Start bits
Data bits (least significant first)
Parity
Stop bits
Error Checking
1
8
None only (no bits for no parity)
1
CRC (Cyclical Redundancy Check)
The Transmitter recognizes three RTU commands. These are: read single I registers
(command 4), read a single H register (command 3), and preset a single H register
(command 6)
In Modbus mode, the Transmitter can be only be configured for the ‘none’ parity
option.
The instrument never initiates communications and is always in receive mode unless
responding to a query.
RTU Framing
Frame synchronization can be maintained in RTU transmission mode only by
simulating a synchronous message. The instrument monitors the elapsed time
between receipt of characters. If three and one-half character times elapse without a
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Oxymit™ Transmitter
Page 72 of 97
new character or completion of the frame, then the instrument flushes the frame and
assumes that the next byte received will be an address. The follow command
message structure is used, where T is the required character delay. Response from
the instrument is based on the command.
T1,T2,T3 ADDRESS FUNCTION DATA
CHECKSUM
8-BITS
8-BITS
N X 8-BITS 16-BITS
T1,T2,T3
Address Field
The address field immediately follows the beginning of the frame and consists of 8bits. These bits indicate the user assigned address of the slave device that is to
receive the message sent by the attached master.
Each slave must be assigned a unique address and only the addressed slave will
respond to a query that contains its address. When the slave sends a response, the
slave address informs the master which slave is communicating.
Function Field
The Function Code field tells the addressed slave what function to perform.
MODBUS function codes are specifically designed for interacting with a PLC on the
MODBUS industrial communications system. Command codes were established to
manipulate PLC registers and coils. As far as the Transmitter is concerned, they are
all just memory locations, but the response to each command is consistent with
Modbus specifications.
The high order bit in this field is set by the slave device to indicate an exception
condition in the response message. If no exceptions exist, the high-order bit is
maintained as zero in the response message.
Data Field
The data field contains information needed by the slave to perform the specific
function or it contains data collected by the slave in response to a query. This
information may be values, address references, or limits. For example, the function
code tells the slave to read a holding register, and the data field is needed to indicate
which register to start at and how many to read.
Error Check Field (CRC)
This field allows the master and slave devices to check a message for errors in
transmission. Sometimes, because of electrical noise or other interference, a
message may be changed slightly while it is on its way from one device to another.
The error checking assures that the slave or master does not react to messages that
have changed during transmission. This increases the safety and the efficiency of
the MODBUS system.
The error check field uses a CRC-16 check in the RTU mode.
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The following is an example of a function 03 call for data at memory location 03. The
value returned by the instrument is the hex value 1E.
Address
Cmd
01
03
Address
Cmd
01
03
Transmit from Host or Master
Reg
Reg
Count
Count
HI
LO
HI
LO
00
03
00
01
Response from Transmitter
Byte
Byte
Data
Count
Count
HI
HI
LO
00
02
00
CRC
HI
74
CRC
LO
0A
Data
LO
CRC
HI
CRC
Lo
1E
38
4C
Note that all the values are interpreted as hexadecimal values. The CRC calculation
is based on the A001 polynomial for RTU Modbus. The function 04 command
structure is similar to the 03 structure.
The following is an example of a function 06 call to change data in register 01 to 200.
The response from the instrument confirms the new value as being set.
Address
Cmd
01
06
Address
Cmd
01
06
Transmit from Host or Master
Reg
Reg
Data
Data
HI
LO
HI
LO
00
01
00
C8
CRC
HI
D9
CRC
LO
9C
Response from Transmitter
Reg
Reg
Data
Data
HI
LO
HI
LO
00
01
00
C8
CRC
HI
D9
CRC
LO
9C
The Transmitter will respond to several error conditions. The three exception codes
that will generate a response from the instrument are:
01 – Illegal Function
02 - Illegal Data Address
03 – Illegal Data Value
04 – Slave Device Failure
The response from the Transmitter with an exception code will have the most
significant bit of the requested function set followed by the exception code and the
high and low CRC bytes.
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Oxymit™ Transmitter
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25.2. MMI Message Protocol
The instrument communicates in RS-485 half duplex mode using baud rate settings
1200, 2400, 4800, 9600, 19.2K. The data format uses one stop bit (logic 0), 7 data
bits (first bit 0), one stop bit (logic 1). The parity setting can be odd, even, or none,
where even parity is the default setting.
The basic United Process Controls message protocol format is shown below.
As indicated, the MMI or proprietary mode allows communication using the 10PRO
‘A’ command protocol or the ‘U’ block protocol.
The following command set applies to the ‘A’ command and is used for the Oxymit
and other 10PRO type instruments such as temperature controller slaves. The
command set is sent by a master to a 10PRO slave instrument. These commands
can also be used by any device such as a computer communicating with instruments
via an instrument network. The commands that are supported are shown in the
following table.
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Oxymit™ Transmitter
Command
Letter
Page 75 of 97
Table 19 10Pro / 10Pro-T Command Set
Process
Timer
p (low case)
Read Auto / Manual
mode
Same
o (low case)
Read Remote / Local
Same
Read Remote
Process Setpoint
Read Auto Process
Setpoint
Read Remote
Time Setpoint
Read Auto Time
Setpoint
Update Time
Setpoint
Temporarily
Update Time
setpoint
Permanently
Read Remaining
Time
Read Time
control byte
i (low case)
h (low case)
I (upper case
as in
Instrument)
Update Process
Setpoint Temporarily
J (upper case)
Update Process
Setpoint Permanently
l (lower case as
in limits)
Read Actual Process
m (low case)
Read % Output
P (upper case)
Update Auto/Manual
mode
Same
Returned Value
A = auto, B =
manual
A = local, B =
remote
integer decimal
number
integer decimal
number
integer decimal
number
integer decimal
number
integer decimal
number
integer decimal
number
A = auto, B =
manual
The following are examples of commands and responses using the 10Pro type
command set. The first row in each table shows the ASCII characters of the
command as they would appear if monitored on the serial port. The second row in
each table is the hexadecimal translation of the characters transmitted on the serial
port. These values must be known to calculate the checksum.
This is the command and response for reading the actual process value of a 10Pro
type slave instrument. In this example the 10Pro instrument address is 2 and the
return value is 0071. This could be 71 degrees. 0.71% carbon, 7.1 degrees dew
point, or 0.71% oxygen depending on the process and the instrument settings. Other
parameters and scaling are available if the linear inputs are selected. In general the
number that is returned is the number displayed on the instrument. Decimal point
information is assumed.
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Add
2
Prefix
A
0x32
0x41
Transmit from Host or Master
Cmd
Delim
l
<NULL
>
0x6C
0x00
LRC
<HEX
1F >
0x1F
<EOT>
0x04
Response from 10Pro
Add
Prefix
Cmd
D1
D2
D3
D4
Delim
LRC
<ACK>
2
A
l
0
0
7
1
<NULL>
<HEX
1F >
<EOT>
0x06
0x32
0x41
0x6C
0x30
0x30
0x37
0x31
0x00
0x1F
0x04
Here is an example of a request and response for the local setpoint of the instrument
in Automatic mode. The response indicates that the instrument’s address is 2 and
the local setpoint is 1500.
Add
2
Prefix
A
0x32
0x41
Transmit from Host or Master
Cmd
Delim
LRC
h
<NULL>
<HEX
1B >
0x68
0x00
0x1B
Response from 10Pro
<ACK>
Add
2
Prefix
A
Cmd
h
D1
1
0x06
0x32
0x41
0x68
0x31
D2
5
D3
0
D4
0
Delim
<NULL>
0x35
0x30
0x30
0x00
<EOT>
0x04
LRC
<HEX
19 >
0x19
<EOT>
0x04
Here is an example that shows how the HOST changes the instrument’s remote set
point. The instrument’s address is 15. The HOST has sent a command to update
the remote setpoint with 1450. The instrument responds by echoing the command.
Add
F
0x46
Prefix
A
0x41
Cmd
I
0x49
Transmit from Host or Master
D1
1
0x31
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D2
4
0x34
D3
5
0x35
D4
0
0x30
Delim
<NULL>
0x00
LRC
N
0x4E
<EOT>
0x04
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Oxymit™ Transmitter
<ACK>
0x06
Add
F
0x46
Prefix
A
0x41
Page 77 of 97
Response from 10Pro
Cmd
I
0x49
D1
1
0x31
D2
4
0x34
D3
5
0x35
D4
0
0x30
Delim
<NULL>
0x00
LRC
H
0x48
<EOT>
0x04
25.3. Instrument Type ‘U’ Command Set
The MMI (United Process Controls Inc.) command set supports the extensive
capabilities of the Dualpro the 10Pro-E and the Oxymit. The command set consists of
the characters shown in the following table.
Table 20 MMI Command Set
Update
Read
Description
X
x
Read / Writer
Table Parameters
Not
Allowed
*
Read Block
Transfer
‘X’ Command
The ‘X’ command allows almost unlimited access to all the instrument parameters.
The ‘X” command accesses the various parameter tables in the instrument. A typical
parameter table for most Marathon instruments has 240 parameters numbered
consecutively from 0 to 239 (0 – 0xEF). Instruments such as the Dualpro have many
tables (0 – 31), where each table has 11 blocks or more.
The Oxymit, 10Pro-E, and Version 3.5 Carbpro have only table 0. The table value is
assumed to be 0 and the parameter is addressed directly with the possible range of 0
to 71. These number correspond with the decimal numbers in the Oxymit Memory
Map table.
To READ a data value from a table / parameter number in the instrument, use the
following format:
AUx (Table # Parameter #) <delimiter> <checksum> <EOT>
Here is an example of a request and response for the instrument’s proportional band
setting in table 0, parameter 10 (0x0A). The instrument address is 1. The data value
that is returned by the instrument is hexadecimal 0014 or 20.
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Transmit from Host or Master
Add
Prefix
Cmd
1
U
x
0x31
0x55
0x78
Table
#
00
Par
#
0A
Delim
LRC
NULL
0x30
0x30
0x30
0x41
0x00
<HEX
6D >
0x6D
EOT
0x04
Instrument Response
<ACK>
0x06
D1
0
0x30
Add
Prefix
Cmd
2
0x32
U
0x55
x
0x78
D2
0
0x30
D3
1
0x31
D4
4
0x34
Table
#
00
0x30
0x30
Par
#
0A
0x30
0x41
Delim
<NULL>
0x00
LRC
J
0x4A
Data
Delim
$
0x24
<EOT>
0x04
The response from the instrument includes the ‘$’ character. This characters acts as
the data delimiter, which separates the parameter data from the parameter address.
Here is an example of a request and response for the instrument’s Alarm 1 value in
table 00 (0x00) parameter 06 (0x06). The instrument address is 1. The data value
that is returned by the instrument is 50 (0x32). The actual value is 0.50 where the
decimal point is implied by the process.
Transmit from Host or Master
Add
Prefix
Cmd
1
0x31
U
0x55
x
0x78
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Table
#
00
0x31
0x30
Par
#
06
0x31
0x33
Delim
LRC
NULL
0x00
1A
0x1A
EOT
0x04
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Response from Instrument
<ACK>
0x06
D1
0
0x30
D2
0
0x30
Add
Prefix
Cmd
1
0x31
U
0x55
x
0x78
D3
3
0x33
D4
2
0x32
Table
#
00
0x30
0x30
Par
#
06
0x30
0x36
Delim
<NULL>
0x00
Data
Delim
$
0x24
LRC
9
0x39
<EOT>
0x04
The parameter write command uses the following format:
AUX (Table # Parameter #) $ data <delimiter> <LRC> <EOT>
To write a value to the instrument for a specific parameter use the uppercase X. To
read a specific parameter from the instrument, use the lowercase x.
Here is an example of a parameter write command and response for data in table 00
(0x00) parameter 06 (0x06). The instrument address is 1. The data value that is
written to the instrument is 0000 (0x0000).
Transmit from Host or Master
D1
0
0x30
Add
Prefix
Cmd
1
0x31
U
0x55
X
0x58
D2
0
0x30
D3
0
0x30
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D4
0
0x30
Table
#
00
0x30
0x30
Par
#
06
0x30
0x36
Delim
NULL
0x00
Data
Delim
$
0x24
LRC
1E
0x1E
EOT
0x04
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Response from Instrument
ACK
0x06
D1
0
0x30
Add
Prefix
Cmd
1
0x31
U
0x55
X
0x58
D3
0
0x30
D4
0
0x30
D2
0
0x30
Table
#
00
0x30
0x30
Par
#
06
0x30
0x36
Delim
NULL
0x00
LRC
18
0x18
Data
Delim
$
0x24
EOT
0x04
The parameters for the Oxymit are listed in the manual appendix. This listing
includes the parameter name, number, and a short description that includes bit and
byte mapping information.
Block Commands
Block transfer commands are used to read and write data in a group of 24 words. The
Oxymit has only three blocks in table zero. The block transfer command has to
identify the table as well as the block.
A block read command format is shown below.
A U * tt bb D L E
(E)End of Transmission (EOT) HEX(04)
(L) LRC is the result of an XOR function performed
on all previous character in the messeage.
(D) Delimter marks the end of DATA and signals the
up coming EOT character.
NUL HEX(00) or Backspace HEX(08)*
*If LRC was going to be an EOT HEX(04) then D =
HEX(08).
(bb) Block number 0 - 2
(tt) Table number (HEX)
(*) Block Read command character
(I) Instruement Prefix: U = Dualpro/10Pro-E/V3.5/
Versapro.
(A) Address of instrument.
Figure 10 Block Read Command Format
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The reply to a Block read request follows.
A U * tt bb $ ddd-------ddd CC D L E
(E)End of Transmission (EOT) HEX(04)
(L) LRC is the result of an XOR function performed
on all previous character in the messeage.
(D) Delimter marks the end of DATA and signals the
up coming EOT character.
NUL HEX(00) or Backspace HEX(08)*
*If LRC was going to be an EOT HEX(04) then D =
HEX(08).
(CC) MOD 256 checksum of data characters ASCII
values in two (2) HEX digits.
Ninety-six (96) HEX digits of data, four (4) digits, (2)
bytes, (24) parameters
($) Data separator
(bb) Block number (HEX)
(tt) Table number (HEX)
(*) Block Read command character
(I) Instruement Prefix: U = Versapro instrument prefix.
(A) Address of instrument.
Figure 11 Block Read Response Format
The following is an example is for a block request from the Host and a reply from the
instrument. The Host sends the command:
1U*0000<00>N<04><06>
Where the instrument address is ‘1’, the instrument type is ‘U’, the table and block are
both zero (TTBB), and the delimiter, LRC and EOT follow.
The instrument responds with the string shown in the following table.
Table 21 Sample Block Response
Address
Type
Command
Register
Hex
1
U
*
0000
Delimiter
Parameter 1
$
C11C
Parameter 2
00E5
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ASCII
31
55
2A
30 30
30 30
24
43 31
31 43
30 30
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Parameter 3
8112
Parameter 4
0096
Parameter 5
0096
Parameter 6
00C8
Parameter 7
03B6
Parameter 8
07D0
Parameter 9
0000
Parameter 10
0C00
Parameter 11
03E8
Parameter 12
03E8
Parameter 13
0000
Parameter 14
0000
Parameter 15
0000
Parameter 16
0000
Parameter 17
0060
Parameter 18
1C25
Parameter 19
00F3
Parameter 20
3C69
Parameter 21
0001
Parameter 22
03E8
Parameter 23
0000
Parameter 24
3D62
MOD 256
Delimiter
LRC
EOT
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BF
00
1B
04
45 35
38 31
31 32
30 30
39 36
30 30
39 36
30 30
43 38
30 33
42 36
30 37
44 30
30 30
30 30
30 43
30 30
30 33
45 38
30 33
45 38
30 30
30 30
30 30
30 30
30 30
30 30
30 30
30 30
30 30
36 30
31 43
32 35
30 30
46 33
33 43
46 39
30 30
30 31
30 33
45 38
30 30
30 30
33 44
36 32
42 46
00
1B
04
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Page 83 of 97
Note that the MOD 256 is the 256 modulus of the sum of the ASCII values of the
parameters. The delimiter and LRC are calculated as described in a previous
section.
MMI Error Codes
The Marathon protocol for the Oxymit has three error codes that can be generated by
the instrument: E1 = Incorrect LRC detected on received message, E2 = Invalid
command detected, and E3 = Invalid table or parameter address.
The format for the error message is
<NAK> Error Code DEL LRC <EOT>
Where <NAK> is the hexadecimal value 15 followed by the ASCII characters for the
appropriate error code. The delimiter and LRC are calculated the same as for a
normal message. The EOT (hexadecimal 04) end every message in the MMI
protocol.
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Page 84 of 97
26. Memory Map
NOTE: Modbus refers to the hexadecimal register location. These parameters are
formatted as unsigned 16 bit integers. Any real number such as temperature can be
evaluated as a signed number; other parameters are bit mapped words that must be
evaluated as single bits are bit groups.
HEX
00
DE
C
0
PARAMETER
01
1
RSETPT
02
2
LSETPT
03
3
TSETPT
04
4
PROC
05
5
TIME
06
6
ALARM1
BLOCK 0
DESCRIPTION
R/W
Not used
Remote setpoint sent to the instrument from the
Host port. This number has to be scaled to the
range of the displayed process value based on the
decimal point and exponent settings of the
instrument.
Range = -999 to 9999
Default = 0.000
For example: If the process = oxygen, display
decimal point = 2, and exponent = 6, as remote
setpoint of 1234 would be interpreted and displayed
as 12.34 ppm.
Process setpoint set by the operator through the
Setpoint menu. This number is scaled to the range
of the displayed process value based on the
decimal point and exponent settings of the
instrument.
Range = -999 to 9999
Default = 0.000
Timer setpoint set via the Host port or locally.
Range = 0 to 999 minutes
Default = 0
This value is the calculated process value shown as
an integer. The decimal point and exponent values
are required to determine the actual scaled value.
Range = -999 to 9999.
For example: If the process = oxygen, display
decimal point = 2, and exponent = 6, and PROC =
1234, then the actual value and displayed as 12.34
ppm.
This is the remaining time on the timer as it counts
down from Time Setpoint. Zero indicates timer has
stopped.
Range = 0 to 999 minutes
Default = 0
Alarm value is based on process value display
decimal point and exponent. Both are required to
determine the real alarm value.
Range = -999 to 9999.
Default = 0000
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HEX
07
DE
C
7
08
8
PARAMETER
ALARM2
ALRMMD1
Page 85 of 97
BLOCK 0
DESCRIPTION
R/W
Alarm value is based on process value display
decimal point and exponent. Both are required to
determine the real alarm value.
Range = -999 to 9999.
Default = 0000
Alarm 1 configuration
BITS 0 – 3
0000 = OFF (DEFAULT)
0001 = DEVIATION BAND
0010 = BAND LOW
0011 = BAND HIGH
0100 = PERCENT OUT LOW
0101 = PERCENT OUT HIGH
0110 = FULL SCALE LOW
0111 = FULL SCALE HIGH
1000 = PROBE IMPEDANCE / VERIFY
1001 = SPARE
1010 = SPARE
1011 = SPARE
1100 = START
1101 = SOAK
1110 = TIMER
1111 = FAULT
R/W
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BIT 4 ACTION CONTROL
0 = DIRECT
1 = REVERSE
BIT 5 NO LATCH = 0, LATCHED = 1
BIT 6 – 15 SPARE
09
9
ALRMMD2
Alarm 2 configuration
BITS 0 – 3
0000 = OFF (DEFAULT)
0001 = DEVIATION BAND
0010 = BAND LOW
0011 = BAND HIGH
0100 = PERCENT OUT LOW
0101 = PERCENT OUT HIGH
0110 = FULL SCALE LOW
0111 = FULL SCALE HIGH
1000 = PROBE IMPEDANCE / VERIFY
1001 = SPARE
1010 = SPARE
1011 = SPARE
1100 = START
1101 = SOAK
1110 = TIMER
1111 = FAULT
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HEX
DE
C
PARAMETER
Page 86 of 97
BLOCK 0
DESCRIPTION
R/W
BIT 4 ACTION CONTROL
0 = DIRECT
1 = REVERSE
BIT 5 NO LATCH = 0 LATCHED = 1
0A
10
PB
0B
11
RESET
0C
12
RATE
0D
13
CYCTIM
0E
14
LDLN
0F
15
HIPO
10
16
LOPO
11
17
CONMD
BIT 6 – 15 SPARE
Proportional Band – Based on display units
Range = 1 to 9999
Default = 20
Reset – Based on seconds
Range = OFF to 9999
Where 0020 is assumed to be 00.20 seconds
Default = OFF (reset value = 0)
Rate – Based on seconds
Range = OFF to 9999
Where 0020 is assumed to be 00.20 seconds
Default = OFF (rate value = 0)
Cycle Time – Based on seconds
Range = 0.2 to 9999
Where 0002 is assumed to be 0002 seconds
Default = 30
Load Line – Range = -100 to 100
Default = 0
Control Output High Limit
Range = -100 to 100 where HIPO is always greater
than LOPO.
Default = 100
Control Output Low Limit
Range = -100 to 100 where LOPO is always less
than HIPO.
Default = 0
Control Type setting
BITS 0 – 2 = CONTROL PARAMETER
000 = SPARE
001 = Temperature
010 = Millivolt INPUT B
011 = Carbon
100 = Dew Point
101 = Oxygen
110 = Redox
111 = Millivolt INPUT A
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BIT 3 = NORMAL (0) FREEZE CONTROL
OUTPUT (1)
BITS 4 – 6 = MODE
000 = TIME PROPORTIONING
001 = TIME PROP W/ COMPLEMENT
010 = TIME PROP, DUAL
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HEX
DE
C
PARAMETER
Page 87 of 97
BLOCK 0
DESCRIPTION
R/W
011 = SPARE
100 = ON/OFF
101 = ON/OFF W/ COMPLEMENT
110 = ON/OFF, DUAL
111 = VALVE POSITIONING W/ FEEDBACK
BIT 7 = DIRECT (0) OR REVERSE (1)
ACTING
BIT 8 = MANUAL (0) OR AUTO (1)
BIT 9 = SETPT LOCAL (0) OR SETPT REMOTE
(1)
BIT 10 = MONITOR (0), CONTROLLER (1)
BITS 11 = SENSOR BREAK OUTPUT 0 (0),
OUTPUT HOLD (1)
12
18
CONFIG0
13
19
CTRLOUT
14
20
ALRMT1
BITS 12 – 15 NOT USED
Input Configuration
BITS 0-3 TC Input TYPE
0000 = B (DEFAULT)
0001 = E
0010 = J
0011 = K
0100 = N
0101 = R
0110 = S
0111 = T
1000 = SPARE
1001 = SPARE
1010 = SPARE
1011 = SPARE
1100 = SPARE
1101 = SPARE
1110 = SPARE
1111 = SPARE
BIT 4 = SPARE
BIT 5 0 = NO CJ APPLIED, 1 = CJ APPLIED
BIT 6 0 = °F, 1 = °C
BIT 7 0 = 60HZ FILTER
BIT 8 – 11 Millivolt Input TYPE
0000 = LINEAR (DEFAULT)
All other bit combinations are spare
BITS 12 – 15 are spare
Control Output, unsigned integer
Actual control output where:
1000 = 100.0% and 64536 = -100.0%
ALARM 1 ON/OFF TIMES
RANGE = 0 – 255 SECONDS
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HEX
DE
C
PARAMETER
15
21
ALRMT2
16
22
FAULT
17
23
CJTRM AND
COMP
Page 88 of 97
BLOCK 0
DESCRIPTION
R/W
DEFAULTS = 0
BIT 0-7 = ON TIME
BIT 8-15 = OFF TIME
ALARM 2 ON/OFF TIMES
RANGE = 0 – 255 SECONDS
DEFAULTS = 0
BIT 0-7 = ON TIME
BIT 8-15 = OFF TIME
FAULT BIT MAP
BIT 0 = Temperature Input Open
BIT 1 = MV Input Open
BIT 2 = Range of input is low
BIT 3 = Range of input is high
BIT 4 = Timer End
BIT 5 = Probe Care Fault
BITS 6 – 7 = SPARE
BIT 8 = CPU Fault
BIT 9 = Min Idle counter = 0
BIT 10 = Keyboard failure, stuck key or a key was
pressed during power up.
BIT 11 = Flash Erase Failed
BIT 12 = Flash Checksum Failed
BIT 13 = EEPROM Checksum Failed
BIT 14 = Flash/EEPROM Size Fault
BIT 15 = ADC Fault
LOW BYTE – CO / H COMPENSATION
RANGE 0 – 255
DEFAULT = 20 (% CO FOR CARBON)
DEFAULT = 40 (% H2 FOR DEW POINT)
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HIGH BYTE – COLD JUNCTION TRIM
COLD JUNCTION TRIM (unsigned integer)
RANGE = –128 TO +127 WHERE
1 COUNT = 1 DEG (C or F) and –128 = 65408
HEX
18
DEC PARAMETER
24
ASRC
BLOCK 1
DESCRIPTION
ANALOG OUT SOURCES
LOW BYTE, ANALOG OUTPUT 1
BITS 0 – 3
0000 = N/A
0001 = Temperature
0010 = Linear Input A
0011 = Carbon value
0100 = Dewpoint value
0101 = Oxygen value
0110 = Redox value
0111 = Output Power
1000 = Control Output 1
1001 = Control Output 2
1010 = Linear Input B
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HEX
DEC PARAMETER
Page 89 of 97
BLOCK 1
DESCRIPTION
1011 = Programmable*
R/W
*For Programmable, write required output value into
DACV1, where DACV1 = 0 is minimum output and
DACV1 = 4096 is maximum output.
BITS 4 – 7 SPARE
HIGH BYTE, ANALOG OUTPUT 2
BITS 8 – 12
0000 = N/A
0001 = Temperature
0010 = Linear Input A
0011 = Carbon value
0100 = Dewpoint value
0101 = Oxygen value
0110 = Redox value
0111 = Output Power
1000 = Control Output 1
1001 = Control Output 2
1010 = Linear Input B
1011 = Programmable*
*For Reference Number and Programmable , write
required output value into DACV2, where DACV2 =
0 is minimum output and
DACV2 = 4096 is maximum output.
BITS 13 – 15 SPARE
19
25
AOUTOF1
1A
26
AOUTRN1
1B
27
AOUTOF2
1C
28
AOUTRN2
Special case: If Analog Output 1 = CONTROL
OUTPUT 1 and Analog Output 2 = CONTROL
OUTPUT 2 and the Control Mode is dual, then
Analog Output 1 is 4-20ma for 0 to +100% PO and
Analog Output 2 is 4-20ma for 0 to -100% PO.
ANALOG OUTPUT 1 OFFSET
Minimum source value that correlates to minimum
Analog Output of 4 mA. The source value is based
on the selection in ASRC lower byte
ANALOG OUTPUT 1 RANGE
Maximum source value that correlates to maximum
Analog Output of 20 mA. The source value is
based on the selection in ASRC lower byte where
ANALOG OUTPUT 2 OFFSET
Minimum source value that correlates to minimum
Analog Output of 4 mA. The source value is based
on the selection in ASRC upper byte
ANALOG OUTPUT 2 RANGE
Maximum source value that correlates to maximum
Analog Output of 20 mA. The source value is
based on the selection in ASRC upper byte where
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HEX
DEC PARAMETER
1D
29
TEMPFIL
1E
30
MVFIL
1F
31
CONFIG2
20
32
COLDJCT
21
33
TEMP
22
34
MV
23
35
HADR AND
SIOSET
Page 90 of 97
BLOCK 1
DESCRIPTION
R/W
Temperature Input Filter in seconds
Range = 0 to 450. The higher the number the
slower the reading update.
DEFAULT = 10
Millivolt Input Filter in seconds
Range = 0 to 450. The higher the number the
slower the reading update.
DEFAULT = 10
SETUP VALUES
BITS 0 - 4 OXYGEN EXPONENT
RANGE = 0 to 31, where 2 = % and 6 = ppm
DEFAULT = 2
BITS 5 - 6 DISPLAY DECIMAL PLACE where:
0 = no decimal point in display
1 = Display XXX.X
2 = Display XX.XX
3 = Display X.XXX
DEFAULT = 0
BITS 8 – 12 REDOX METAL NUMBER
RANGE = 0 – 14
DEFAULT = 0
BITS 13 – 15 SPARE
COLD JUNCTION
Where 1 COUNT = 1°F (°C), RANGE = -99 TO
255°F (°C). Note this parameter is an unsigned
integer.
MEASURED TEMPERATURE
Where temperature is presented in degrees C or F,
based on the C/F setting. Note this parameter is an
unsigned integer of temperature -2721 = 62815
Range = max / min range of selected thermocouple.
MEASURED MILLIVOLT
Where this value is scaled in 0.1 mV increments,
i.e. 10001 = 1000.1.
Range = 0 to 2000 mV.
LOW BYTE – HOST ADDRESS
BITS 0-7
RANGE = 0 – 255
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HIGH BYTE – SIO SETUP
BITS 8 – 9 PARITY SETTING
00 = Even Parity, 7 bits, 1 Stop bit
01 = No Parity, 8 bits, 1 Stop bit
10 = Odd Parity, 7 bits, 1 Stop bit
BITS 10 – 11 RESPONSE DELAY
0 = No delay applied to response
1 = 10ms delay applied to response
2 = 20ms delay applied to response
3 = 30ms delay applied to response
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Oxymit™ Transmitter
HEX
DEC PARAMETER
24
36
PF
25
37
DACV1
26
38
DACV2
27
39
LOCK AND
PLIM
28
40
PIMP
29
41
PRTM
2A
42
PBOMV
Page 91 of 97
BLOCK 1
DESCRIPTION
BITS 12 – 14 BAUD SELECT
000 = 76.8K
001 = 38.4K
010 = 19.2K (DEFAULT)
011 = 9600
100 = 4800
101 = 2400
110 = 1200
111 = 600
R/W
BIT 15 HOST FORMAT
0 = MMI (PROP)
1 = MODBUS (DEFAULT)
PROCESS FACTOR FOR CARBON OR
DEWPOINT
RANGE = 0 to 4095
Carbon DEFAULT = 150
TruCarb DEFAULT = 1.000 ohm
This is is the RS00 cal value for the TruCarb
sensor assuming a 1.000 ohm resistance for 0%
carbon at 800°C.
ANALOG OUTPUT 1
0 to 4095 is 4 to 20 mA In dual mode 4mA = -100,
12mA = 0, 20mA = +100
ANALOG OUTPUT 2
0 to 4095 is 4 to 20 ma In dual mode 4mA = -100,
12mA = 0, 20mA = +100
LOW BYTE – LOCK LEVEL
BITS 0 – 2
LOCK LEVEL; 0-3 0 is full lock, 3 is wide open
BITS 3 – 7 SPARE
HIGH BYTE – PROBE IMPEDANCE LIMIT
0 – 255 KOHMS, DEFAULT VALUE = 20K
For TruCarb this limit has a default of 1.14 ohms
with a limit of 2.55 ohms.
LAST PROBE IMPEDANCE VALUE
For oxygen, carbon, and dew point this is the
impedance of an oxygen sensor (KOHMS X 10) i.e.
25 = 2.5 KOHMS
For TruCarb this is the RSTC cal. The final (lowest)
resistance value of the sensor resistance during a
decarb cycle. i.e. 2109 = 2.109 ohms.
LAST PROBE RECOVERY TIME FROM
IMPEDANCE TEST (SECONDS)
RANGE = 0 to 255
Available for Redox, Carbon, and Dewpoint. Not
available for TruCarb.
LAST MILLIVOLTS DURING PROBE BURN OFF
RANGE = -99 TO 2048
i.e. 1018 = 1018 mV
Available for Redox, Carbon, Dewpoint, and
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HEX
DEC PARAMETER
2B
43
PBOTC
2C
44
PBORT
2D
45
PREMT
2E
46
VGAS
2F
47
PMC
Page 92 of 97
BLOCK 1
DESCRIPTION
TruCarb.
LAST TEMPERATURE DURING PROBE
BURNOFF RANGE = 0 to 3000
i.e. 1715 = 1715° (F or C based on CONFIG0 BIT
6)
Available for Redox, Carbon, Dewpoint, and
TruCarb.
LAST PROBE BURNOFF RECOVERY TIME
RANGE = 0 – 255 SECONDS
Available for Redox, Carbon, and Dewpoint.
REMAINING TIME TO NEXT PROBE TEST
RANGE = 0 – 999
Where 999 = 99.9 hours
For Oxygen Controller: Measured Verification gas.
Value = Actual measured oxygen (0.1%)
PROBE MAINTENANCE CONTROL WORD
BITS 0 – 1
00 = START FULL MAINTENANCE
01 = START BURNOFF (VERIFY) ONLY
10 = START PROBE IMP ONLY
11 = NONE
BITS 2 – 6 UNDEFINED
BIT 7 = NORMAL (0), CANCEL (1)
BITS 8 – 15 = PROBE MAINTENANCE
SEQUENCE NUMBER
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HEX
30
DE
C
48
PARAMETER
PTINT
31
49
PTRECT
32
50
BOTM
33
51
BOREC
34
52
VSTD
35
53
VTOL
36
54
TAVE
37
55
TDEL1
38
56
TDEL2
Page 93 of 97
BLOCK 2
DESCRIPTION
R/W
PROBE TEST INTERVAL SETTING (HRS)
Operator input for interval setting
RANGE = 0 – 999
Where 999 = 99.9 hours
DEFAULT = 0 (Disable Probe test)
PROBE TEST RECOVERY TIME SETTING
(SECONDS)
RANGE = 0 to 999
DEFAULT = 30
BURN OFF TIME SETTING (SECONDS)
RANGE = 0 to 999
DEFAULT = 30
Burnoff function available for Redox, Carbon, and
Dew Point.
BURN OFF RECOVERY TIME SETTING
(SECONDS)
RANGE = 0 to 999
DEFAULT = 30
Burnoff function available for Redox, Carbon, and
Dew Point.
VERIFY TEST GAS STANDARD
This is the test standard value used to verify the
probe.
RANGE = 0 to 999
Where the value 999 = 99.9% oxygen
DEFAULT = 30 (3.0%)
Verify function available for Oxygen.
VERIFY TEST TOLERANCE SETTING
This setting establishes the limit as VSTD ± VTOL
when comparing to the measured value VGAS
Range = 0 to 999
Where 0005 = 00.5%
DEFAULT = 0005
Verify function available for Oxygen.
VERIFICATION SAMPLE AVERAGING SETTING
(SECONDS)
RANGE = 0 to 999
DEFAULT = 2
Verify function available for Oxygen.
VERIFY DELAY 1 SETTING (SECONDS)
RANGE = 0 to 999
DEFAULT = 30
Verify function available for Oxygen.
VERIFY DELAY 2 SETTING (SECONDS)
RANGE = 0 to 999
DEFAULT = 30
Verify function available for Oxygen.
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Page 94 of 97
BLOCK 2
DESCRIPTION
PARAMETER
39
DE
C
57
3A
58
TC_ZERO
MINIMUM TEMPERATURE FOR PROBE CARE
TEST
This setting establishes the lowest process
temperature allowed for a probe test to proceed.
RANGE = 500°F to 2000°F (260°C to 1090°C)
DEFAULT = 1400°F (760°C)
TC ZERO CALIBRATION NUMBER
3B
59
TC_SPAN
TC SPAN CALIBRATION NUMBER
3C
60
MV_ZERO
MV ZERO CALIBRATION NUMBER
3D
61
MV_SPAN
MV SPAN CALIBRATION NUMBER
3E
62
DAC 1 OFFSET CALIBRATION
3F
63
40
64
41
65
42
66
DAC_OFFSE
T_1
DAC_SPAN_
1
DAC_OFFSE
T_2
DAC_SPAN_
2
AZERO
43
67
ANUM
44
68
BZERO
45
69
BNUM
46
70
TIME
CONTROL
AND EVNT
TMIN
R/W
DAC 1 SPAN CALIBRATION
DAC2 OFFSET CALIBRATION
DAC2 SPAN CALIBRATION
LINEAR OFFSET, Y INTERCEPT LINEAR
SCALING FOR INPUT A
LINEAR SPAN VALUE FOR INPUT A
LINEAR OFFSET, Y INTERCEPT LINEAR
SCALING FOR INPUT B
LINEAR SPAN VALUE FOR INPUT B
LOW BYTE – INPUT EVENT CONFIGURATION
Bits 0 – 3
0000 = None
0001 = Auto Mode Selected
0010 = Remote Setpoint Selected
0011 = Acknowledge alarms
0100 = Timer Hold
0101 = Timer End
0110 = Timer Start
0111 = Start probe test
1000 = Process hold
Bits 4 – 7 not used.
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HIGH BYTE - TIMER CONTROL
BIT 0 – SPARE
BIT 1 – Timer stop(0), Timer start(1)
BIT 2 – Timer running(1)
BIT 3 – Timer End Active(1)
BIT 4 – Timer Hold Active(1)
BIT 5 – 6 SPARE
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HEX
47
DE
C
PARAMETER
71
SPARE
Page 95 of 97
BLOCK 2
DESCRIPTION
R/W
BIT 7 = Timer Disabled (0), Timer Enabled (1)
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Oxymit™ Transmitter
HEX
PARAMETER
48
DE
C
72
49
5A
5B
5C
5D
5E
5F
60
61
62
63
64
65
66
67
68
69
6A
6B
6C
6D
6F
70
71
72
73
74
75
76
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
8A
8B
8C
8D
8E
8F
90
91
92
93
94
95
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
PSTART
Page 96 of 97
BLOCK 3
DESCRIPTION
R/W
START PROBE TEST
Write 1 to start any probe test that has been
configured.
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Reach us at www.group-upc.com
United Process Controls brings together leading
brands to the heat treating industry including
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Monitors and Process-Electronic.
We provide prime control solutions through our
worldwide sales and services network with easyto-access local support.
UNITED PROCESS CONTROLS INC.
8904 Beckett Road, West Chester, OH 45069, USA
Phone: +1-513-772-1000 Fax: +1-513-326-7090
Toll-Free North America +1-800-547-1055
E-mail: [email protected]
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