Oxygen Detector O 025 User Manual
Contents
1. This warranty does not apply to units that have been altered had attempted repair or been subject to abuse accidental or otherwise The warranty also does not apply to units in which the sensor element has been overex posed or gas poisoned The above warranty is in lieu of all other express warranties obligations or liabilities This warranty applies only to the service transmitter Automatikprodukter shall not be liable for any incidental or consequential damages arising out of or related to the use of the O transmitters 15 A Au tomatikprodukter MA2. Test measuring signal 40 mV 4 0 mA Switch on the operating voltage e Each pressing on the Zero push button increases the signal by 0 5 mV 0 05 mA Press the button repeat edly until the measuring signal reaches 40 0 2 mV After 44mV the signal starts again at 36 mV The correction is only possible within the 10 seconds after having switched on the power supply An impulse pause of more than 10 sec cancels the release of the correction function 5 A Au tomatik prod ukter EMEN GED Oxyxen Detector O 025 Feb 13 5 2 Calibration Depending on the version and the control mode there are three different possibilities to calibrate the transmitter Manual calibration Manual calibration is only possible if the transmitter is equipped with the push button Zero and the potentiom eter Gain version for manual calibration Manual calibration is possible both in analog mode and in GCD 05_ Bus mode In the GCD 05 Bus mode the jumper V A has to be set before manual calibration Only by doing so the control volt age is available at the test pins X6 Remove the jumper after calibration Calibration with the DGC 05 Service Tool In the standard version equipped with the communication connector X12 the transmitter is delivered for tool and or software calibration In the analog mode the service tool calibration is only possible with the 3 wire technique of the transmitter In the DGC 05_ Bus mode calibr
3. V and or Power voltage not applied Two wire Pin 1 and 4 control voltage lt 30 mV Three wire Pin 1 and 2 only for starting signal 2V 4 mA PCB ATO3 not plugged in correctly at X4 and X5 Replug PCB correctly calculated value Sensor sensitivity lt 30 Replace sensor element No reaction of the output signal in BISOUS Cone mane Trouble Case Solution 4 Measure tension at X4 Pin 1 and Power voltage not applied 2 Yellow LED not shining ie not plugged in correctly at X4 ReBl g PCB correctly Check wiring Transmitter not addressed check bus wiring incl topology and termi nation Voltage 16 V No control voltage at calibration Set the jumper Remove it after Jumper V A not set i calibration No communication at the transmit Yellow LED not flashing n 8 Cross sensitivity Data The cross sensitivity can be read from the table Technical Data see section 9 The table doesn t claim to be com plete Other gases can have an influence on the sensitivity too The indicated sensitivity data are only standard values referring to new sensor elements 10 A Au tomatikprodukter EMEN GID Oxyxen Detector O 025 Feb 13 9 Technical Data General sensor performances SSCS Humidity 0 95 RH non condensing A Powersupply gt reverse polarity protected 2 wire modeonly Power consumption without options Analog mode Bus mode Output signal Analog output signal Sele
4. N NO fF A DN Selection analog output signal Fig 4 Set Set Set Calibration adapter Fig 5 Type Calibr set 14 Automatikprodukter MIN G Oxyxen Detector O 025 Feb 13 11 Part Disposal Since August 2005 there are EC wide directives defined in the EC Directive 2002 96 EC and in national codes con cerning the waste electrical and electronic equipment and also regarding this device For private households there are special collecting and recycling possibilities For this device isn t registered for the use in private households it mustn t be disposed this way You can send it back to your national sales organisation for disposal If there are any questions concerning disposal please contact your national sales organisation Outside the EC you have to consider the corresponding directives 12 Notes and General Information It is important to read this user manual thoroughly and clearly in order to understand the information and instruc tions The O transmitters must be used within product specification capabilities The appropriate operating and maintenance instructions and recommendations must be followed Due to on going product development Automatikprodukter reserves the right to change specifications without notice The information contained herein is based upon data considered to be accurate However no guarantee is expressed or implied regarding the accuracy of this data 12 1 Intended Prod
5. Oxygen Detector O 025 User Manual Feb 2013 A Au tomatikprodukter MA GED Oxyxen Detector O 025 Feb 13 Table of contents 1 General overview 74 9 93 a a a ee ee a RR m nd 3 2FunctionalDescription 4255 29 ok or RR RRR DEER DD RRR DED ROKR DRT ROOT OS 3 2 1 Control Mode nrk rakk s a os sas 3 2 2 5SensOK ead es SERRE EEE GS SEER EERE Ree seder ee RE ag 3 3 Installation EE ee a we ee RO 4 3 1 Mounting Instructions uu lt s st RUE EAR ae Bk a SE 4 GM eS SEE ea oq a e 4 3 2Installation srs eo ee a nd ee ste dl Ge eide AUR Adee ek hee i 4 4 Electrical Connection ue eR oo eR aa a a RR EG EEE 4 4 1 Wiring Connection es ee se Tar sk saa ee Pee a Be E oS Re ii 5 5 COMMISSIONING asasan tee a HS ES A eos v Se A See Lee A TE od 5 5 1 Calibration of the Zero point at the Analog Output Signal 2 les 5 5 2 Calibration 2 aie eR RR ER o DD eR Oe EEE o 6 5 3 Manual calibrati Ois s siot sooo Ses mo AE DE E E E Ko E E POR ee we BOY s 6 5 4 Calibration with GCD 05 Service Tool lans 7 5 5 Calibration with GCD EasyConf aaao ho a s sas 7 5 6 ModBus Mode sss hh hs 8 5 7 Option Relay Output hh o ens 8 6 Inspection and Service eee eee ee eee ra 9 6 LINSPECHNON RR ERE CT NE RA Be ee ae E 9 6 2 Service and Calibration rv rv ho a sas 9 6 3 Exchange of Sensor Element rv rav rakk knarr kr A asas 9 7 Trubleshooting 2 sk x ke
6. a 2 Functional Description 2 1 Control Mode In addition to the analog output the transmitter is equipped with a serial interface RS 485 and ModBus protocol Analog mode The analog output can be selected as current signal with 0 4 20 mA or as voltage signal 0 2 10 V In the 4 20 mA mode and without any supplementary options the O detector also works in the 2 wire technique M DGC 05 Bus Mode The transmitter can be connected to the GCD 05 system via the RS 485 interface In this mode there is an analog input for the connection of an additional 4 20 mA transmitter The two measuring values are transmitted via the RS 485 interface ModBus protocol The cable topology for the RS 485 bus can be taken from the Guidelines for wiring and commissioning of the GCD 05 hardware The two control modes are available in parallel 2 2 Sensor The chemical process of the measurement is based on the principle of a galvanic micro fuel cell The gas or the am bient air to be monitored diffuses through a membrane filter into the measuring cell towards the cathode Cathode and anode are electrically contacted therefore due to the oxidation there is an electric current proportional to the oxygen partial pressure This current signal is linear to the oxygen concentration The current is evaluated by the connected amplifier and transformed into a linear output signal The diffusion through the membrane and the thin electrolytic coat are complex tem
7. ation is always possible Software calibration via PC with Software GCD05 EasyConf In the standard version equipped with the communication connector X12 calibration can also be done by means of the DGCO5 Configuration and Calibration Software DGC 05 EasyConf Software calibration is possible for both control modes 5 3 Manual calibration 5 3 1 Zero point The zero point is factory set therefore zero calibration is not necessary 5 3 2 Gain e Connect digital voltmeter to pin Test Connect calibration adapter carefully to the sensor element Apply calibration test gas O2 150 ml min 1 Bar 14 5 psi 1096 e Wait two minutes until the signal is stable adjust control voltage with potentiometer Gain until the signal cor responds to the calculated value see 5 3 3 Calculation of Control Voltage Remove calibration adapter with a careful light turn Check the sensor for correct mounting By limiting the gain factor calibration will not be possible any more when the sensitivity of the sensor reaches a residual sensitivity of 30 Then the sensor has to be replaced 5 3 3 Calculation of Control Voltage Signal start 2 V 4 mA 160 mV x test gas concentration O vol 6 Control voltage mV 40 mV measuring range O vol Signal start O V 0 mA 200 mV x test gas concentration O vol Control voltage mV measuring range O vol 6 A Au tomatikprod ukter MA GIDD Oxyxen De
8. ctable Current voltage Starting point O 20 96 ete O Wire connection Screw type terminal min 0 25 to 2 5 mm 24 to 14 AWG Wire distance analog mode Current signal ca 500 m 1500 ft Voltage signal ca 200 m 600 ft 1 The table doesn t claim to be complete Other gases too can have an influence on the sensitivity The mentioned cross sensitivity data are only reference values valid for new sensors Indications only for option stainless steel for further types see datasheet enclosure 22 mA max 0 6 VA 12 mA max 0 3 VA 0 4 20 mA load lt 500 O 0 2 10 V load 2 50k Q proportional overload and short circuit proof 11 A Au tomatikprod ukter MA GT Oxyxen Detector O 025 Feb 13 Gudenes ec trece 2008208 JW tas O COTTON S Waring gr esting SSCS TCC Power supply 18 28 VDC AC 0 3 A 7 5 VA Analog input AAA Only for RS 485 mode 4 20 mA overload and short circuit proof input resistance 200 O Power supply for external transmitter 24 VDC max 50 mA Temperature controlled 3 C 2 C 37 5 F 35 5 F 12 tomatikprodukter MA GT Oxyxen Detector O 025 Feb 13 10 Figures Application Analog mode Fig 1 Controller 4 20 mAT 24V OV X wo Roo Bus B Option Bus A Relay 4 20 mA Inp R1 4 1 Analog Out 2 24 VDC O
9. e and then perform automatic gain calibration Remove calibration adapter carefully by turning lightly Check the sensor for correct mounting By limiting the gain factor calibration will not be possible any more when the sensitivity of the sensor reaches a residual sensitivity of 30 96 In this case the sensor has to be replaced Further information can be taken from the user manual of the DGC 05 Configuration and Calibration Software 7 A Auto matik prod ukter MEE GED Oxyxen Detector O 025 Feb 13 5 6 ModBus Mode In the GCD 05 Bus mode each transmitter gets its communication address In the standard version with the communication connector X12 addressing is done by means of the DGC 05 Service Tool or by the DGC 05 Configuration and Calibration Software See user manual of the Service Tool or of the Con figuration and Calibration Software In the manual addressing version which can be identified by the address switch being equipped there is a maxi mum of 60 addresses to be selected See fig 3 The jumper is responsible to define the address group and the switch to define the address according to the follow ing table Switch position Jumper pos 01 Jumper pos 02 Jumper pos 03 Jumper pos 04 aa EN BEES inactive inactive X inactive inactive 5 7 Option Relay Output The two relays are activated in dependence of the gas concentration If the gas concentration exceeds the adjus
10. es for the signal line but do not connect the shield e Recommended cable for analog mode J Y St Y 2x2yx0 8 LG 20 AWG max resistance 73 O km 20 8 0 1000 ft e tisimportant to ensure that the wire shields or any bare wires do not short the mounted PCB e Serial Interface Mode Required cable for RS 485 mode J Y St Y 2x2x0 8 LG 20 AWG max res 73 O km 20 8 Q 1000 ft When se lecting and installing the cables you have to comply with the regulations concerning the RS 485 bus installation The installations have to be executed in line topology Cable length and type have to be considered as well e It is important to ensure that the wire shields or any bare wires do not short the mounted PCB 4 A Au tomatikprod ukter EBENEN GED Oxyxen Detector O 025 Feb 13 4 1 Wiring Connection Open the cover Unplug basic PCB carefully from terminal blocks X4 and X5 Insert the cable and connect cable leads to terminal blocks See fig 1 and 2 Replug the PCB in the terminal blocks X4 X5 Replace the cover Note The connection of the power supply at the output signal X4 pin 4 can destroy the transmitter 5 Commissioning Consider commissioning instructions at any exchange of the sensor elements Only trained technicians should perform the following Check mounting location Select output signal form Current or voltage and starting point 0 or 20 See fig 4 Check power voltage e Check PCB ATO3 for correct mou
11. nspections and services must be documented The date for the next maintenance has to be affixed to the transmitter 6 1 Inspection The PolyGard Transmitter should be controlled regularly by a competent person according to EN 45544 4 The following has to be checked in particular e Maintenance calibration interval not exceeded e Visual inspection of the transmitter including cable for damage etc e Remove dust deposits especially at the gas inlet The filter at the gas inlet has to be replaced if extremely dirty 6 2 Service and Calibration When performing the maintenance you have to do the calibration and the functional test in addition to the inspec tion Calibration See section 5 e Functional test Check the output signal at the test pins during calibration 6 3 Exchange of Sensor Element e Consider static electricity See point 3 e Sensor should always be installed without power applied Unplug basic PCB ATO3 carefully from the bottom part Unplug old sensor element from the PCB Take the new sensor out of the original packing Plug the sensor element in the PCB at X7 Replug the PCB ATO3 in the terminal blocks X4 X5 carefully Calibrate according to section 5 9 A Au tomatik prod ukter EMEN GED Oxyxen Detector O 025 Feb 13 7 Trubleshooting 7 1 Analog Mode Trouble Case Solution oo Jumper 0 20 not set Check jumper position Measure voltage at X4 Output signal lt 3 mA 1 5
12. nting at X4 and X5 Check the sensor for proper mounting at the connectors X3 of the PCB ATO3 Addressing of the transmitter in the Bus mode e Calibrate the transmitter if not already factory calibrated Required instruments for commissioning calibration of the transmitter e Test gas bottle with test gas O in the range of 20 9 vol or ambient air 20 9 vol O Gas pressure regulator with flow meter to control the gas flow to 150 ml min Calibration adapter with tube Calibration set see fig 5 Digital voltmeter with range 0 300 mV accuracy 196 Small screwdriver Calibration tool GCD 05 STL only for calibration with service tool GCD 05 e DGCO5 Configuration and Calibration Software incl USB RS 485 communication set only for software calibration mode Note Prior to calibration the sensor must be connected to the power supply and fully stabilised for at least 1 hour without interruption Please observe proper handling procedures for test gas bottles regulations TRGS 220 Please observe proper handling procedures for test gas bottles regulations TRGS 220 5 1 Calibration of the Zero point at the Analog Output Signal The analog output signal is factory set to the zero point If necessary a manual adaptation of the analog signal is possible within 10 sec after having applied the supply voltage e Jumper 0 20 for signal start has to be set 4 mA or 2 V Connect digital voltmeter 300 mV at test pint
13. perature dependant electro chemical processes influencing the ion current of the sensor Therefore the sensor is temperature compensated within the specified temperature range The electrolyte the catholyte and the composition of the anode are in a way that the oxygen diffusing towards the cathode is electrochemically reduced The electrolyte is used up by the electrochemical process So the sensor life time is limited to two years Calibration during sensor life time is not necessary Caution There is a small quantity of corrosive liquid in the sensor element If in case of damage persons or objects touch the liquid you have to clean the affected areas as fast and carefully as possible with tap water Out of use sensors must be disposed in the same way as batteries 3 A Au tomatikprodukter MA GID Oxyxen Detector O 025 Feb 13 3 Installation Note Avoid any force e g by thumb on the sensor element during operation or installation Electronics can be destroyed by static electricity Therefore do not touch the equipment without a wrist strap connected to ground or without standing on a conductive floor acc to DIN EN100015 3 1 Mounting Instructions When choosing the mounting site please pay attention to the following e The specific weight of oxygen O is higher than that of air factor 1 10 Recommended mounting height is 1 5 m 5 feet to 1 8 m 6 feet above floor for combustial process Consult AP website for other mo
14. s ra a a EGG 10 7 1 Analog Mode lll ss s s knr ho a a os sas 10 8 Cross sensitivity Data cs RR RO e RC PR UE RUE UR E SUE GE GE Ge RU De KE G 10 9 Technical Data svada sed ekke Te SE Se aa ue e Ge CR Ue an ere n 11 10 Figures rr 13 11 Part DISPOSAl EEE eee ER eee RUE A X X RO ee eS 15 12 Notes and General Information es 15 12 1 Intended Product Application ee 15 12 2 Installers Responsibilities ee 15 12 3 Maintenance zuo dE eke e E aod web Bh ie SEE ee SEE ee G ibus dh 15 12 4 Limited Warranty conosca eee Fre EHR OSA a AEE a a 15 2 A Au tomatikprodukter MAA GED Oxyxen Detector O 025 Feb 13 1 General overview The O analog digital transmitter ADT 93 1195 with digital processing of the measuring values and temperature compensation is used for the continuous monitoring of the ambient air to detect the presence of oxygen concentra tions Main application ranges are laboratories food production etc where changes of the oxygen concentrations might be possible The intended sites are all areas being directly connected to the public low voltage supply e g residential commer cial and industrial ranges as well as small enterprises according to EN50 082 The O analog digital transmitter must not be used in potentially explosive atmospheres The transmitter must only be employed in areas within the environmental conditions as specified in the Technical Dat
15. tector O 025 Feb 13 Example Measuring range 25 vol Test gas concentration 20 9 vol 40 Control voltage Signal start 2 V 4 mA 173 7 mV Control voltage Signal start O V 0 mA 67 2 mV Signal start 2 V 4 mA Signal start 0 V 0 mA 40 mV 167 2 mV 160 mV x 20 9 vol 9 40 mv 173 7 mV 200 mV x 20 9 vol 96 25 vol 96 25 vol 96 5 4 Calibration with GCD 05 Service Tool Connect the DGC 05 Service Tool to the transmitter open menu Calibration e Enter measuring range and test gas concentration e Connect calibration adapter carefully to the sensor element Apply test gas O2 150 ml min 1 Bar 10 Wait until the measuring value is stable and then perform automatic gain calibration Remove calibration adapter carefully by turning lightly Check the sensor for correct mounting By limiting the gain factor calibration will not be possible any more when the sensitivity of the sensor reaches a residual sensitivity of 30 96 In this case the sensor has to be replaced Further information can be taken from the user manual of the DGC 05 Service Tool 5 5 Calibration with GCD EasyConf e Connect the PC via USB RS 485 communication set to the transmitter open menu Calibration e Enter measuring range and test gas concentration e Connect calibration adapter carefully to the sensor element Apply test gas O2 150 ml min 1 Bar 10 e Wait until the measuring value is stabl
16. ted alarm threshold the corresponding relay switches on If the gas concentration falls below the threshold minus hys teresis the relay switches off again The contact function for relay 2 NC normally closed or NO normally open can be selected via the jumper NO NC See fig 1 and 3 Relay 1 is equipped with a change over contact Via the ModBus interface the two alarm thresholds and the hysteresis are freely adjustable at the PC within the measuring range The procedure can be read from the user manual ModBus Software The following parameters are factory set Alarm threshold 1 Relay 1 19 vol 96 Alarm threshold 2 Relay 2 17 vol 96 Switching hysteresis 1 vol 96 8 A Au tomatikprodukter EMEN GT Oxyxen Detector O 025 Feb 13 6 Inspection and Service Inspection service and calibration of the transmitters should be done by trained technicians and executed at regular intervals We therefore recommend concluding a service contract with Automatikprodukter or one of their authorized partners According to EN 45544 4 inspection and service has to be executed at regular intervals The maximum intervals have to be determined by the person responsible for the gas warning system according to the legal requirements Automatikprodukter recommends checking the PolyGard Transmitter every three months and maintaining it every 12 months If different intervals are indicated always consider the shortest interval I
17. uct Application The O transmitters are designed and manufactured for control applications and air quality compliance in commer cial buildings and manufacturing plants 12 2 Installers Responsibilities It is the installer s responsibility to ensure that all O transmitters are installed in compliance with all national and local codes and OSHA requirements Installation should be implemented only by technicians familiar with proper installation techniques and with codes standards and proper safety procedures for control installations and the latest edition of the National Electrical Code ANSI NFPA70 It is also essential to follow strictly all instructions as provided in the user manual 12 3 Maintenance It is recommended to check the O transmitter regularly Due to regular maintenance any performance deviations may easily be corrected Re calibration and part replacement in the field may be implemented by a qualified technician and with the appropriate tools Alternatively the easily removable plug in transmitter card with the sensor may be returned for service to Automatikprodukter 12 4 Limited Warranty Automatikprodukter warrants the service transmitters for a period of one 1 year from the date of shipment against defects in material or workmanship Should any evidence of defects in material or workmanship occur during the warranty period Automatikprodukter will repair or replace the product at their own discretion without charge
18. unting heights Choose mounting location of the sensor according to the local regulations e Consider the ventilation conditions Do not mount the transmitter in the centre of the airflow air passages suction holes e Mount the transmitter at a location with minimum vibration and minimum variation in temperature avoid direct sunlight Avoid locations where water oil etc may influence proper operation and where mechanical damage might be possible Provide adequate space around the sensor for maintenance and calibration work Duct mounting e Mount only in a straight section of duct with minimum air vortex Keep a minimum distance of 1 m 3 5 feet from any curve or obstacle Mount only in a duct system with a maximum air velocity of 10 m s 2000 ft min or less Mounting must be performed so that the probe openings are in line with the airflow 3 2 Installation Open the cover Unplug basic PCB carefully from the bottom part e Fix bottom part by screws vertically to the wall terminal blocks to the ground Replug the basic PCB at X4 and X5 with care Replace the cover 4 Electrical Connection Consider static electricity See 3 Mounting e Installation of the electrical wiring should only be executed by a trained specialist and according to the connec tion diagram without any power applied to conductors and according to the corresponding regulations e Avoid any influence of external interference by using shielded cabl
19. ut 3 OV 4 24 VACIDC Nr 8r5 R2 00 X5 Transmitter Two wire connection 4 20 mA output signal without options Application GCD 05 Bus or ModBUS mode Fig 2 7 Bus B Option 6 Bus A Relay 5 4 20 mA Inp R1 z 1 4 Analog Out 2 3 24 VDC Out 3 2 0 VDC 4 1 24 VDC fars X4 R2 o X5 Transmitter a8 2255 YO mm N Connection field bus and voltage Do not connect power supply at this pin OVDC 24 VAC or O VAC will destroy the detector Option Controller 4 20 mA 24V Transmitter Three wire connection VCD output signal 0 20mA output signal Relay output Heating Do not connect 24 VAC at pin 2 and pin 4 or 24 VDC at pin 2 and 0 VDC at pin 4 Short Circuit R10 Ohm will burn Analog Out 0 VAC DC 24 VAC DC Transmitter ADTX3 Option Analog 7 Bus B Relay Transmitter 6 Bus A 4 20 mA 5 4 20 mA_Inp p4 711 0 VDC F 4 Analog Out 2 24 VDC ro 3 24 VDC Out 3 2 10 VDC 4 1 24 VDC lt rer 5 X4 R2 lo X5 Transmitter Connection analog transmitter Two or three wire connection depending on detector type 13 A Au tomatikprodukter EMEN GID Oxyxen Detector O 025 Feb 13 PCB ATO3 Fig 3 Position 4 T 2 1 359x245 C RR O
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