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Operation Manual
O2-Controller
(Rev. D)
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Table of Contents
1
General............................................................................................................. 4
2.1
2.2
3
Version ............................................................................................................. 5
CE Mark ........................................................................................................... 5
Introduction....................................................................................................... 6
3.1
3.2
4
4.1
4.2
4.3
4.4
5
5.1
5.2
5.3
5.3.1
5.3.2
6
General .......................................................................................................... 11
Normal operation ............................................................................................ 11
Manual Entry of Parameters ........................................................................... 11
Checking parameters ............................................................................... 11
Changing parameters............................................................................... 11
Parameters ..................................................................................................... 12
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
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6.25
6.26
6.27
6.28
6.29
6.30
7
7.1
7.2
7.3
7.4
7.5
7.6
8
General .......................................................................................................... 19
Status Words 1 and 2 ..................................................................................... 19
Error List Status Word 1 - System Errors ...................................................... 20
Error List Status Word 2 Malfunctions ........................................................... 21
Checking the function of the oxygen probe .................................................... 22
Function Control of Evaluating Unit via Control Input E2 ................................ 22
Installation ...................................................................................................... 23
8.1
8.2
8.3
8.4
8.5
8.5.1
8.5.2
8.5.3
8.5.4
8.5.5
8.5.6
8.5.7
8.5.8
8.5.9
8.6
9
General .......................................................................................................... 23
Proper Use ..................................................................................................... 23
Installation Notes and Safety Precautions ...................................................... 23
General .......................................................................................................... 24
Terminal Allocation ......................................................................................... 25
Ground Connection .................................................................................. 25
Power Supply Connections ...................................................................... 25
Binary Control Inputs................................................................................ 26
mA Control Input ...................................................................................... 26
Probe Signal Input.................................................................................... 27
External Temperature Signal Input........................................................... 27
Current Output for Probe Heating ............................................................ 28
mA Control Output ................................................................................... 28
Switching Outputs .................................................................................... 29
O2- Bus Board Terminal Allocation ................................................................. 30
Technical Specifications ................................................................................. 31
9.1
9.2
9.3
9.4
10
O2-Controller .................................................................................................. 31
Power Supply Module .................................................................................... 32
Analyser Cell .................................................................................................. 33
Diagram of Oxygen Probe .............................................................................. 33
Declaration of Conformity ............................................................................... 34
11
11.1
11.2
11.3
11.4
11.5
11.6
Scope of Warranty.......................................................................................... 35
Warranty Period ............................................................................................. 35
Procedures ..................................................................................................... 35
Exclusions ...................................................................................................... 36
Operating Errors ............................................................................................. 36
General Provisions ......................................................................................... 36
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1 General
This Manual is protected by copyright. All rights to this Manual and any part thereof, especially
the rights of translation, printing, oral presentation, the use of illustrations and tables,
broadcasting or copying in any other manner and storage on data processing systems, are
reserved. Copying of this Manual or any part thereof is only permitted within the limits set by
the Copyright Act of the Federal Republic of Germany of 9 September 1965, as subsequently
amended. All copying shall be subject to the payment of fees. Any infringement of these
restrictions shall be subject to the punishments provided for in the Copyright Act.
The use of any trade name or trade mark in this Manual, even if a trade name or trade mark is
not designated as such in this Manual, shall not be construed as meaning that any such trade
name or trade mark is in the public domain within the terms of the applicable legislation and
may be used without restriction by anyone.
The issuer of this Manual shall not be deemed to have warranted that any reference to or
quotation from any standard or code of practice(e.g. DIN, VDI, VDE) which may be made in
this Manual is correct, complete or up-to-date. Users are recommended to obtain complete
copies of the latest issue of any such standard or code of practice which they may need for
their own work.
The issuer of this Manual does not assert that any information given in this Manual is free from
patents and proprietary rights. This Manual shall not be deemed to grant any implied or other
license under any patent or proprietary right.
The software of the O2 Controller must not be copied or made available to third parties
without our written permission.
All due care has been taken in compiling the information given in this Manual. However, the
information in this Manual shall not be construed as representing performance warranties. Our
warranty obligations shall be governed by our standard conditions.
Errors and the right to make amendments required by technical progress are reserved.
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2 Important Notes
2.1
Version
The O2-Controller, Rev.B, described in this document is not compatible with the preceding
model.
The three components, the O2-Bus, the O2-PSU and the processor module, must not be
installed in combination with components of the previous version.
If it is necessary to replace an O2-Controller, the complete unit, comprising bus board, power
supply unit and processor module, must be replaced.
Before commissioning the unit, always check the model (nameplate), the version and
the parameters set. Otherwise, the unit or the equipment connected may be damaged
or destroyed.
Please read this Manual carefully, even if you are already familiar with the O2-Controller, as
the meanings of some of the parameters and the installation instructions have changed.
2.2
CE Mark
CE marks are applied in accordance with a Directive of the Council of the European
Communities of 29 April 1991 on the approximation of the laws of the Member States relating
to the mutual recognition of conformity.
The O2-Controller described in this Manual is supplied complete with a CE mark, guaranteeing
compliance with the following requirements:
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3 Introduction
3.1
Description of Functions
The O2-Controller measures and monitors the mV output signal of a zirconium dioxide probe
within the range from -10 mV to 2500 mV. The oxygen concentration in % by volume is
calculated from this signal.
The O2-Controller is equipped with an LED display for the indication of cell voltage, the oxygen
concentration calculated from this voltage and the current of the probe heating system.
An analogue output (0/4 - 20 mA) is available for the connection of the O2-Controller to other
instruments.
In addition, two limit contacts (one for oxygen concentration and one for heating current
monitoring) can be activated.
The O2-Controller comprises a processor module and a power supply module, both connected
to a bus board.
All connections required are made using the screw-type terminals on the bus board.
The processor module receives the analogue heating current and probe voltage signals from
the oxygen probe and indicates them on the display.
The probe heating and probe monitoring systems can be activated by an external system
either via a control input (E1) or via parameter 30 (option parameter).
If the probe voltage exceeds the switchover point which has been set, the O2-controller
activates the switch output " O2-concentration OK"; if the probe voltage falls below the
setpoint, the output " O2-concentration OK" is deactivated.
The O2-Controller is equipped with a heating current monitoring system which continuously
checks whether the heating current is within the admissible range. If the heating current is
within the limits selected, the switch output "heating current OK" is activated.
The O2-Controller is equipped with an mA output (0/4mA - 20mA module which makes either
the probe voltage (mV) or the oxygen concentration (in % by volume) available for processing
by external systems.
The power supply module supplies power to the processor module and the probe heating
system.
Four relays, controlled by the processor module, are installed on the power supply module.
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3.2
Block diagram
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4 Controls
4.1
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4.2
Display
The 4-character display indicates the measured values or, in the case of parameter input, the
value of the parameter concerned. The 2-figure parameter display indicates the parameter
currently selected.
4.3
Status Display
<1%
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4.4
Keypad
setting of parameters
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5 Operation
5.1
General
All functions, such as parameter setting, selection of measured value to be displayed and
troubleshooting functions, are operated using the keypad. Parameter setting and
troubleshooting functions can only be accessed after entering a password and should only be
used by the person commissioning the controller.
5.2
Normal operation
5.3
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6 Parameters
6.1
Parameter 1:
O2-concentration
When this parameter is selected, the current oxygen concentration in % by volume derived
from the probe voltage at a defined temperature of 820C is displayed.
Oxygen concentration is indicated in a range from 0.0 % to 20.9 % with a resolution of 0.1 %
by volume.
6.2
Parameter 2:
probe voltage
When parameter 2 is selected, the voltage of the oxygen probe is displayed (in mV). The
measuring range is -999 mV to 2000 mV with a resolution of 1 mV.
6.3
Parameter 3:
heating current
When parameter 3 is selected, the probe heating current is indicated in Amps; the measuring
range is 0.00 A to 2.50 A with a resolution of 0.01 A.
6.4
Parameter 4:
When this parameter is selected, the unit displays the temperature measured by an external
type K thermocouple; the measuring range is 0C to 1250C and the resolution is 1C.
6.5
Parameter 5:
When this parameter is selected, the unit displays the terminal temperature of the external
type K thermocouple; the measuring range is 0C to 55C and the resolution is 1C.
6.6
Parameter 6:
The O2-Controller is equipped with an mA input designed for measuring current signals in the
range from 0 mA to 20 mA with an accuracy of 0.1 mA.
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6.7
Parameter 9:
status word 1
In the event of a system error in the O2-Controller, status word 1 indicates the cause. If there is
no error, the 4-character display indicates "----" when this parameter is selected (for further
details, see Section 6 "Troubleshooting").
6.8
In the event of a process malfunction, status word 2 indicates the cause. If there is no
malfunction, the 4-character display indicates "----" when this parameter is selected (for further
details, see Section 6 "Troubleshooting").
6.9
This parameter determines the probe voltage respectively calculated oxygen concentration at
which the relay O2-concentration OK is activated. The value can be set between 0 mV and
150 mV in steps of 1 mV corresponding to oxygen concentrations between 12.5 % and 0.0 %
by volume (see diagram in section 8.4).
If the option bit 2 is set in parameter 30, the calculated oxygen content will be used as trigger
criterion considering the probe-specific correcting values of the connected measuring cell
stored in parameters 27 and 28.
The set value of parameter 11 is changed from mV to Vol.% oxygen content.
In the range 0,5 Vol.% to 5,0 Vol.% the switch point can be modified in steps of 0,1 Vol.%
*)
These parameters are only accessible after entering a password ( see parameter 99 ).
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*)
These parameters are only accessible after entering a password ( see parameter 99 ).
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These parameters are only accessible after entering a password ( see parameter 99 ).
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activate O2-Controller
function control O2-Controller (only possible, unless option bit 1 is set)
not used
not used
*)
These parameters are only accessible after entering a password ( see parameter 99 )
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Warning!
*)
These parameters are only accessible after entering a password ( see parameter 99 )
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Designation
Range
1
2
3
4
5
6
9
10
11
11
12
12
13
14
15
20
21
22
23
24
25
26
27
oxygen concentration
probe voltage
heating current
NiCrNi temp.
terminal temp.
mA input current
status word 1
status word 2
O2-setpoint
O2-setpoint
hyst. O2-setpoint
hyst. O2-setpoint
heating current min
heating current max
hyst. heating current
mA output mode
mA output range
lower O2-value mA
upper O2-value mA
lower mV value mA
upper mV value mA
mA output current
Correction value 1
measuring cell
Correction value 2
measuring cell
option parameter
binary inputs
binary outputs
mA output manual
software version
display and I/O test
password entry
28
30
32
33
39
40
97
99
Basic setting
50mV
1 Vol.%
10 mV
0,7 Vol.%
1,0A
2,0 A
0,01 A
mV
4-20 mA
0.0 Vol%
20.0 Vol%
0.0 mV
2000 mV
Remarks
display
display
display
display
display
display
display
display
1 % by Vol.%
0.0 mV
1.)
1.)
2.)
2.)
display
3.)
-50 C to 50C
0 C
3.)
0000 / 0011
L/H
L/H
0.0 mA - 21.0 mA
0000
0000 inactive
display
display
Version 08.12
0000 - 9999
4567
1.) Parameters 22 and 23 can only be selected, if parameter 20 was set to O2". (O2-content to be output in Vol.% via
current output)
2.) Parameters 24 and 25 can only be selected, if parameter 20 was set to mV" (probe voltage of measuring cell to be
output in mV, factory setting).
3.) Parameters 27 and 28 can only be selected, if the option bit 2 was set in parameter 30.
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7 Troubleshooting
7.1
General
The software of the O2-Controllers conducts comprehensive cyclical tests of the status of the
unit hardware and software in order to ensure high reliability.
If any errors or malfunctions are detected while the unit is in operation, the program switches
the status display LED's, the relays and the error bits in status words 1 and 2 as appropriate in
view of the type of malfunction or error (see parameters 9 and 10).
7.2
Status word 1 indicates errors detected in the system which may have a detrimental impact on
reliable operation.
Status word 2 indicates the status of the sensors connected and the process data calculated.
The malfunctions recorded in this status word can assist service personnel in performing
effective troubleshooting work in the event of a malfunction.
Errors stored in status words 1 and 2 are indicated in hexadecimal notation in the upper
display. If no errors or malfunctions are active, four hyphens ("----") are displayed.
Each error switches one bit in the status word concerned.
If more than one error is recorded, the signals are added to form a hexadecimal number.
Example:
status word 2
"0021"H
According to the table on the following page, this indicates the following error or
malfunctions
"0001"H breakage of wire to oxygen probe
"0020"H breakage of wire in mA output circuit
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7.3
Error number
"0001" H
"0002" H
Bit
position
Bit 0
Bit 1
"0004" H
Bit 2
"0008" H
"0010" H
Bit 3
Bit 4
"0020" H
"0040" H
Bit 5
Bit 6
"0080" H
"0100" H
Bit 7
Bit 8
"0200" H
"0400" H
"0800" H
"1000" H
"2000" H
"4000" H
"8000" H
Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15
Cause
Remedy
Remarks
1,2
-
a,b,e
c,e
b,e
b,e
3
2
d,f,i
f,g,h
2
2
f,g,h
f,g,h
not used
not used
not used
not used
not used
not used
not used
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7.4
Error number
Cause
Remedy
Remarks
"0001" H
Bit
position
Bit 0
b,d,f,h,j,k
"0002" H
Bit 1
"0004" H
Bit 2
"0008" H
Bit 3
if error persists
for more than
10 minutes 1,2,3
if error persists
for more than
10 minutes 1,2,3
1,2,3
e,i
"0010" H
"0020" H
Bit 4
Bit 5
if error persists
for more than
5 minutes 4,1,2,3
no error
5,2
b,h
d,g
"0040" H
"0080" H
"0100" H
"0200" H
"0400" H
"0800" H
"1000" H
"2000" H
"4000" H
"8000" H
Bit 6
Bit 7
Bit 8
Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15
not used
not used
not used
not used
not used
not used
not used
not used
not used
not used
a,g,h,m
c,l,g
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7.5
The check of the oxygen probe can be only execute when the inner cover
is removed from the base.
The O2- Controller indicates an concentration between 20.9 % and 19.0 % by volume when
the outlet oft the base is ventilated with air.
In this state the value of the probe voltage amount of ca. 10 mV.
When parameter 2 has been selected, the actual voltage of the oxygen probe is displayed (in
mV).
In addition the PLC checks the function of the probe at the beginning of every annealing
process. The signal from the oxygen probe must be going below
1% by volume.
7.6
The function of the evaluating unit can be controlled in an automated way by a superior control
system (PLC) via the control input E2.
Conditions:
-
After a switch signal has been placed via the control input E2, the evaluation unit switches its
switch outputs:
A1
A2
A3
In addition a loop current of 12 mA is generated via the analogue signal output (mA-output).
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8 Installation
8.1
General
Some manufacturers do not explain the significance of the CE declaration of conformity for
their products and the legal consequences clearly to their customers. We would like to help
you to install the unit in accordance with the CE requirements.
When installing a unit with a CE declaration of conformity, it should be noted that the
declaration of conformity in connection with EMC legislation only applies to the installation
configuration which has been tested by the manufacturer. On the other hand, it would be
practically impossible for a manufacturer to test every conceivable installation configuration.
The following paragraphs describe the installation configuration which we have selected. In
normal conditions, it is not necessary to take all the action described to ensure reliable
operation. However, in an environment subject to electromagnetic interference, this action is
essential.
It is the responsibility of the user to determine whether the configuration described
should be implemented without conducting separate tests.
You should also note that it may be necessary to follow the requirements of other regulations
(such as the machinery directive) depending on the specific installation configuration.
8.2
Proper Use
8.3
The user is responsible for ensuring compliance with the EMC legislation in the specific
application.
The O2-Controller contains components which may be damaged by electrostatic charges.
Before handling an open unit or working on or near equipment connections, personnel must
LOI Thermprocess GmbH
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discharge any electrostatic charges (for example by touching a grounded bare metal screw or
surface).
If any equipment not in accordance with the requirements of European Standard EN50082-2
as regards interference immunity is operated in the vicinity of the O2-Controller, the possibility
of electromagnetic interference on such equipment cannot be excluded. Similarly, the O2Controller may be affected by interference from equipment not meeting the interference
emission limits of European Standard EN500081-2.
The conformity of a plant with CE requirements depends on the installation configuration and
the care taken in installation. Special attention must be paid to shielding and grounding.
8.4
General
The O2-Controller should be operated only in connection with the bus system designed for the
purpose. If the unit is operated in connection with bus systems of other manufacturers, we
cannot give any warranty as we are not in a position to test components produced by other
manufacturers
A decisive factor in protection against electromagnetic interference is the correct shielding and
grounding of cables. Both ends of the shield must be connected to a grounded surface over as
large an area as possible using cable clamps or PG-skin glands.
Where possible, the positive and negative terminals of unused control inputs should be
connected to each other at the terminals of the bus system (shorted).
The various functional units of the O2-Controller are isolated from each other and have no
common ground connection (see O2-bus board terminal allocation). In accordance with the
standards for low-voltage systems, you can therefore set the reference voltages as required
for 1mm creepage and air gaps between functional units and 3mm between each functional
unit and the mains connection.
Please take note of the following paragraphs before commissioning the unit.
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8.5
Terminal Allocation
: PE
(3)
Cross section
: 0.75mm2
Cable type
: non-shielded
:N
:L
Cross section
: 0.75mm2
Cable type
: non-shielded
(1)
(2)
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: control input 1 +
: control input 1 : control input 2 +
: control input 2 : control input 3 +
: control input 3 : control input 4 +
: control input 4 -
Cross section
: 0.25mm2
Cable type
: shielded
(23)
(22)
(21)
(20)
(19)
(18)
(17)
(16)
: mA input
: GND 3
Cross section
Cable type
: 0.50mm2
: shielded or twisted pair
(24)
(25)
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: O2-probe
: GND 2a
Cross section
: 1.50mm2
Cable type
: shielded
(12)
(13)
: 0 .. 1250C:
Terminals
: NiCrNi +
: GND 2b
Cross section
: 0.50mm2
Cable type
: shielded
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(27)
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: heating
: heating
Cross section
: 1.50mm2
Cable type
: shielded
(14)
(15)
: mA OUT
: GND 1
Cross section
: 0.50mm2
Cable type
(10)
(11)
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6
7
: heating OK
: heating OK
8
9
Cross section
: 0.50mm2
Cable type
: shielded
4
5
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8.6
Apart from GND 2a and GND 2b, there are no internal connections between the GND
terminals.
Terminal GND 2a is connected to the PE terminal via the screwed cap of the oxygen probe.
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9 Technical Specifications
9.1
O2-Controller
Operating voltage
Current drain
5 V DC
approx. 600 mA
Analogue inputs
Digital inputs
4 floating inputs 12 - 24 V DC
Analogue outputs
1 analogue mA output
configuration by parameters
galvanically isolated
signal range: 0 mA to 21 mA
accuracy, typical : 0.05 mA
accuracy, max.
: 0.5 mA
load: 600 Ohm
Digital outputs
Electrical connection
Size
Operating temperature
Storage temperature
- 25 .. 70 C
Climatic conditions
Front panel
IP 65
CE conformity
EN 50081 / Part 2
EN 50082 / Part 2
Weight
approx. 300g
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9.2
Operating voltage
Power absorbed
max. 50 VA
Outputs
3 relay contacts
24 V / 0.5 A
Voltage outputs
5 V DC / 2A
12 V AC / 2,5 A
Electrical connection
Size
Operating temperature
0 .. 55 C
Storage temperature
-25 .. 70 C
Climatic conditions
Front panel
IP 65
CE conformity
EN 50081 / Part 2
EN 50082 / Part 2
Weight
approx. 1000g
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9.3
Analyser Cell
Type
Accuracy
Reaction time
Power supply
9.4
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10 Declaration of Conformity
DECLARATION OF CONFORMITY
in accordance with the EC
electromagnetic compatibility directive (89/336/EEC)
as amended by 91/263/EEC; 92/31/EEC; 93/68/EEC
This Declaration applies to the following product:
Equipment type:
Type designation:
O2 controller
O2 Controller CE
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__________________
Dr.-Ing. Karl Nolte
Managing Director
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This warranty covers all parts of the unit. Any parts of the unit which may become
defective as a result of defects in materials and workmanship will be replaced free of
charge to the purchaser. This warranty shall only apply if the parts concerned have
demonstrably been used properly and the purchaser has complied with the
appropriate operating instructions. Any manuals and software supplied with the unit
shall be excluded from this warranty.
b)
LOI THERMPROCESS will bear the material and labor cost incurred in repairing
defective parts, but not carriage expenses.
c)
Any parts which are replaced shall become the property of LOI THERMPROCESS.
d)
b)
The warranty period shall commence on the date of delivery of the unit.
c)
Work carried out under this warranty shall not operate to extend the warranty period
or to start a new warranty period. The warranty period for any spare parts installed
shall end on the same date as the warranty period for the entire unit.
11.3 Procedures
a) Units to be repaired under warranty shall be shipped to and from the points where
repairs are to be carried out at the cost, risk and expense of the purchaser.
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11.4 Exclusions
LOI THERMPROCESS shall be under no warranty obligations whatsoever in any case in
which:
a)
b)
a unit has been stored or operated under conditions not in accordance with the
technical specifications;
c)
damage has been caused by improper handling, especially failure to comply with the
system description and the operating instructions;
d)
a unit has been repaired or modified by any person not authorized by LOI
THERMPROCESS;
e)
f)
b)
This warranty shall only be available to the first owner of the unit and shall not be
transferable to subsequent purchasers.
c)
The venue for any disputes between the purchaser and LOI THERMPROCESS shall be
Essen, if the purchaser is entered in a commercial register. In the event that the
purchaser does not have a general venue for disputes in the Federal Republic of
Germany or relocates its normal place of residence outside the Federal Republic of
Germany following the conclusion of the purchase contract for the unit or the place of
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normal residence of the purchaser is not known at the time when any proceedings are
initiated, the venue for any disputes between LOI THERMPROCESS and the Purchaser
shall be the place where LOI THERMPROCESS has its registered office.
d)
The purchase contract for the unit shall be governed by and construed and interpreted
in accordance with the law of the Federal Republic of Germany.
e)
The international conventions concerning the international sale of goods shall not apply.
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