SERVO TOUGH OxyExact (2210)

Part Number: 02210/005ARevision: 10Language: UK English

Installation Manual

SERVOTOUGHOxyExact (2210)

Control Unit

PROCESS ANALYSERS

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SERVOTOUGH OxyExact Installation Manual 02210005A_10

I

TABLE OF CONTENTS

1. INTRODUCTION ....................................................................................................................... 1

1.1 SAFETY INFORMATION .............................................................................................................. 1 1.2 SCOPE OF THIS MANUAL ........................................................................................................... 1 1.3 EC DIRECTIVE COMPLIANCE ..................................................................................................... 1 1.4 GENERAL DESCRIPTION ........................................................................................................... 2

1.4.1 Standard Attributes ............................................................................................................ 2 1.4.2 Optional Attributes ............................................................................................................. 2

1.5 HAZARDOUS AREA APPROVAL AND CERTIFICATION .................................................................... 3

2. INSTALLATION ......................................................................................................................... 4

2.1 OVERVIEW OF THE INSTALLATION .............................................................................................. 4 2.2 CONTROL UNIT OPTION CARDS ................................................................................................ 5 2.3 INSTALLATION LOCATION .......................................................................................................... 6 2.4 ELECTRICAL SUPPLY REQUIREMENTS ....................................................................................... 7 2.5 SIGNAL OUTPUTS/INPUTS ......................................................................................................... 7

2.5.1 MODBUS Communications ............................................................................................... 7 2.5.2 Analog Output Board ......................................................................................................... 7 2.5.3 Relay Board ....................................................................................................................... 9 2.5.4 Digital Inputs Board ......................................................................................................... 10

2.6 TAG NUMBERS ....................................................................................................................... 10

3. MECHANICAL INSTALLATION ............................................................................................. 11

3.1 UNPACKING AND INSPECTION.................................................................................................. 11 3.2 CONTROL UNIT DESCRIPTION ................................................................................................. 11 3.3 FIXING CENTRES .................................................................................................................... 12

4. ELECTRICAL INSTALLATION ............................................................................................... 14

4.1 CE MARKINGS ....................................................................................................................... 14 4.2 GLANDS AND CABLE ENTRIES ................................................................................................. 15 4.3 IDENTIFICATION AND LOCATION OF COMPONENTS .................................................................... 15 4.4 EARTH/GROUND REQUIREMENTS ............................................................................................ 17 4.5 ELECTRICAL POWER SUPPLY CONNECTION ............................................................................. 17 4.6 TRANSMITTER UNIT TO CONTROL UNIT CONNECTION............................................................... 18

4.6.1 Cable Termination Link ................................................................................................... 19 4.7 SIGNAL AND OUTPUT/INPUT CONNECTIONS ............................................................................. 19

4.7.1 MODBUS® Connection ................................................................................................... 19 4.7.2 Analog Output Board ....................................................................................................... 21 4.7.3 Relay Board ..................................................................................................................... 21 4.7.4 Digital Inputs Board ......................................................................................................... 22

5. AUTOCALIBRATION OPTIONS ............................................................................................. 23

6. INSTALLATION CHECK LIST ................................................................................................ 28

7. ROUTINE MAINTENANCE ..................................................................................................... 29

APPENDIX 1 TECHNICAL SPECIFICATION ............................................................................. 30

APPENDIX 2 MODBUS PROFILE .............................................................................................. 31

APPENDIX 3 CERTIFICATION ................................................................................................... 41


II

FIGURES

FIGURE 1-1: ATEX CERTIFICATION DETAILS ..................................................................................................... 3 FIGURE 1-2: IECEX CERTIFICATION DETAILS ..................................................................................................... 3 FIGURE 2-1: ANALYSER SYSTEM CONFIGURATIONS ............................................................................................ 5 FIGURE 3-1: FLUSH PANEL MOUNTING DETAILS ................................................................................................ 12 FIGURE 3-2: MECHANICAL ARRANGEMENT ....................................................................................................... 13 FIGURE 4-1: ELECTRICAL CONNECTIONS ........................................................................................................... 16 FIGURE 5-1: AUTOCALIBRATION CYCLE ........................................................................................................... 24 FIGURE 5-2: AUTOCALIBRATION CONFIGURATIONS .......................................................................................... 26

TABLES

TABLE 2-1: NAMUR NAS4 VS SYSTEM DISPLAY .............................................................................................. 9 TABLE 4-1: PATCH LEAD WIRE COLOURS .......................................................................................................... 20 TABLE 5-1: AUTOCALIBRATION LOGIC TABLE ................................................................................................... 25 TABLE 5-2: SOFTWARE CONFIGURATION OPTIONS ............................................................................................ 27 TABLE 6-1: INSTALLATION CHECKLIST ............................................................................................................. 28


INTRODUCTION 1

1. INTRODUCTION

1.1 Safety Information This manual includes WARNINGS, CAUTIONS and NOTES which provide information

relating to the following

WARNING

Warnings highlight specific hazards which, if not taken into account, may result in personal injury or death.

CAUTION

Cautions highlight hazards which, if not taken into account, can result in damage to the Laser monitor or to other equipment or property.

This manual also incorporates “be aware of” information, which is used as follows:

This highlights information which it is useful for you to be aware of (for example, specific operating conditions, and so on).

1.2 Scope of this Manual This manual covers installation and routine maintenance of the SERVOTOUGH OxyExact Control Unit. For details of operation refer to the Operator manual, part number 02210/001A. For technical specification refer to Appendix 1. Contacts for technical assistance and spares

are given at the back of this manual. A service manual is available for use by qualified personnel, part number 02200002A.

About this manual

Ref: 02210/005A/10

Order as part number: 02210005A

1.3 EC Directive Compliance The SERVOTOUGH OxyExact complies with the EMC Directive 89/336/EEC (as

amended by Directives 92/31/EEC and 93/68/EEC) and the ATEX Directive 94/9/EC.


2 INTRODUCTION

1.4 General Description The SERVOTOUGH OxyExact Control Unit is designed to work with any of the SERVOTOUGH OxyExact Transmitters. The simple graphical user interface allows for simple operation and has multi-language capability as standard. In addition it offers:

Certification for hazardous areas, flammable dust and flammable gas

atmospheres

Simple two-wire connection to up to six transmitters

Digital communications

Configurable options for relays and mA outputs

Configurable options for digital (status/action) inputs The control unit provides full access to set up such functions as autocalibration, alarms, relays and faults. A full set of diagnostics information is available that can be used to

assist with predictive maintenance. The unit is compliant with the requirements of NAMUR.

1.4.1 Standard Attributes

Graphics display and user interface

English, French and German languages

The ability to connect multiple transmitters to a single control unit

Digital communications ‘enabled’ with "Modbus"

Autocalibration software as standard (operation will need one of the relay option

cards)

1.4.2 Optional Attributes

Four option slots exist; any of the following may be fitted into each slot:

mA card - two 4 - 20 mA outputs and two relays

Relay card - four relays

Digital input card - eight channels


INTRODUCTION 3

1.5 Hazardous Area Approval and Certification Copies of the Hazardous Area Certificates are held in Appendix 2. In summary, the

SERVOTOUGH OxyExact Control Unit is certified for use in Zone 2/Division 2 areas

(both gases and dusts) and is available with the following hazardous area approvals: USA

FM Class I, Division 2, Groups A, B, C and D

FM Class II, Division 2, Groups F and G

FM Class III, Division 2

T4, ambient temperature 50°C maximum

Also American Class I, Zone 2 approval, IIC T4 (Ta = 50°C) with IS outputs Canada

CSA Class I, Division 2, Groups A, B, C and D

CSA Class II, Division 2, Groups E, F and G

CSA Class III

Type 4X, T4, ambient temperature 50°C maximum

Also Canadian Class I, Zone 2 approval, IIC T4 (Ta = 50°C) with IS outputs

Europe The control unit is ATEX approved as shown on the marking plate (see Figure 1-1). In

addition, the serial number and year of manufacture are marked on an external rating

label with duplicate details within the unit.

Figure 1-1: ATEX Certification Details

International The control unit is IEC Ex approved non-incendive and intrinsically safe. Code: Ex ic nA nC [ia Ga] IIC T4 Gc -20°C<Ta <+50°C Ex tc IIIC T70°C Dc

Figure 1-2: IECEx Certification Details


4 INSTALLATION

2. INSTALLATION

WARNING

You must ensure that, when the analyser is in its installation location:

To avoid propagating brush discharges, the unit is not to be installed in a high velocity dust laden atmosphere.

The unit must only be cleaned with a damp cloth.

This section gives an overview of the installation and includes details of the signal outputs and inputs available in the SERVOTOUGH OxyExact Control Unit. It also

outlines conditions of use that should be considered prior to installation. Installation will require only the use of standard hand tools. Section 3 carries details of mechanical installation. See Section 4 for electrical installation. Section 5 details autocalibration options and requirements. The installer is advised to read all parts of this manual before commencing installation.

2.1 Overview of the Installation The SERVOTOUGH OxyExact system consists of a SERVOTOUGH OxyExact Control Unit and one or more transmitter units. The two units can be located up to 1km apart (total cable length). A single control unit can be connected to one or more transmitter units using a two- wire

semi-duplex connection. The configurations possible are shown in Figure 2-1. The transmitter unit contains the measuring cell. The control unit is primarily the user interface, however, it also supports autocalibration when required. Depending on

options fitted it provides the following connections:

Two-wire communications to transmitters

Digital communications port (MODBUS)

0/4-20mA output signals for gas concentration

Relays for fault status, alarms or calibration

Digital input signals for the status of associated external devices or initiating

specific functions The control unit also requires connection to the electrical supply independent of a

transmitter unit.


INSTALLATION 5

Installation details in this manual do not include operation. See the Operator manual for this information.

Figure 2-1: Analyser system configurations

Key to Figure 2-1

1. Control unit connected to a single transmitter unit

2. Multiple transmitter units with the control unit terminating the

connecting cable

3. Multiple transmitter units with the transmitter units terminating

the connecting cable

2.2 Control Unit Option Cards As standard the control unit is fitted with either a MODBUS RS485 interface or a

MODBUS TCP Ethernet interface. Other signal outputs and inputs are available using

the following options:

Analog output board o Two 0/4-20mA outputs o Two low voltage relays with changeover contacts

Relay board o Four relays with changeover contacts

Digital input board o Eight digital inputs


6 INSTALLATION

Up to four boards in any combination can be fitted to the control unit. All outputs and

inputs are software configurable.

2.3 Installation Location The equipment complies with EN 601010-1: 1993 (IEC 601010-1).

If the control unit is to be installed in an area which may be hazardous due to the

presence of flammable vapours or gases then any "Special Conditions for Safe Use" and/or "Schedules of Limitation", as detailed in the Safety Certification, must be

followed. The degree of protection of the enclosure is IP66 and NEMA 4X. The SERVOTOUGH OxyExact Control Unit may be wall or flush panel mounted. The

site chosen should be protected from extreme weather conditions. Consideration should

be given to the effect of sun, rain, snow or wind on the ambient temperature rating. It may be necessary to install the unit in a protective enclosure. Ambient operating temperature range is -10°C to +50°C (14°F to 122°F). Ambient temperature fluctuations should be minimised. If low ambient temperatures are

expected then a heated enclosure may be required. There should be adequate room for installation and subsequently servicing the unit. The

location should be reasonably vibration-free. Relative humidity <95%, non-condensing. The SERVOTOUGH OxyExact Control Unit is rated in accordance with IEC 664 for "Pollution Degree 2".

Where the installation is such that the enclosure ingress protection is maintained

to IP66 (NEMA 4X) and covers remain securely fitted, the apparatus is suitable

for use in locations where there may be significant deposits of dusts or fibres, (Pollution Degree 4) and/or where there may be drips, splashes of water or subjected to hose down.

The covers may be removed during installation or servicing only if there is

negligible risk of pollution or contamination of the electronic circuits contained

within the enclosures and the covers are securely replaced immediately after the

operation is completed. Altitude <3,000m (10,000ft)


INSTALLATION 7

2.4 Electrical Supply Requirements The supply must be switched and fused external to the control unit. The electrical installation must comply with the requirements for the hazardous zone of the location and any local or national regulations. An electrical supply is required. The SERVOTOUGH OxyExact Control Unit is rated in accordance with IEC 664 for "Installation Category II". The SERVOTOUGH OxyExact Control Unit is designed for use with a "grounded neutral" supply and must also be connected to an external protective earthing system. Rated voltage range: The SERVOTOUGH OxyExact Control Unit is factory configured to operate over the range:

100V ac to 120V ac, or

220V ac to 240V ac The required range must be specified at time of order. The control unit includes an internal replaceable fuse, rated (to IEC-127) at:

T 1.0Amp HRC (for 100 to 120V operation), or

T 0.5Amp HRC (for 220 to 240V operation) Power consumption is 30VA max. The supply installation should be rated accordingly.

2.5 Signal Outputs/inputs With the exception of MODBUS, the following signal outputs/inputs are only available when the relevant option board is fitted in the control unit. A maximum of four option boards may be installed, however, any combination is permissible.

2.5.1 MODBUS Communications

This is available as standard from a connector on the processor board. Protocol is defined in Appendix 2.

2.5.2 Analog Output Board

Each optional analog output board has two mA output channels and two relays with changeover contacts.

The mA output is designed such that, whilst the hardware will limit maximum current to 21.5mA, under normal operation the output will not exceed 20.5mA.


8 INSTALLATION

Maximum load resistance - 1,000 ohms

500V minimum isolation voltage

Galvanically isolated

According to NAMUR specification NE43 Each of the analog outputs can be assigned to a transmitter measurement. For the type SERVOTOUGH OxyExact Transmitter these are:

Oxygen gas concentration

Sample gas pressure (only available when the internal pressure sensor is fitted in the transmitter)

Retransmission of the two analog input signals (if connections made at the transmitter)

A number of features associated with the mA output may be configured:

1. The nominal output range may be set up to be 0 - 20 or 4 - 20mA and optionally reversed, i.e. 20 - 0 or 20 - 4mA.

2. Each output may be configured as ‘dual range’.

3. When using the dual range facility, the second range may be selected by external contact closure (requires the digital input board) or automatically by setting a threshold value.

4. The corresponding measurement values at the nominal limits may be set to two decimal places. (For the type 2210 the oxygen values, for example, may be set within the range -25% to 150% oxygen - a minimum difference of 0.5% oxygen is recommended).

5. When a 4mA limit is selected, an absolute under range value may be set.

6. The output may be set to ‘Jam’ (either low; 0.00mA or high; 21.0mA) under transmitter fault conditions. The output will be 0.00mA when the transmitter is de-energised.

7. Under controlled calibration conditions (e.g. autocalibration), the output may be

set to ‘Freeze’ (i.e. the output will ‘not Follow’ the gas concentrations during calibration).

The function of each of the two relays can be configured in software for:

Gas concentration alarm (high and low)

Output range indicator

Status indicator

Driver for autocalibration solenoid valve

Autocalibration in progress Each relay contact on the analog output board is rated:

Changeover contacts

30V, 1A, AC/DC, resistive load only, SELV only

500V isolation voltage


INSTALLATION 9

2.5.3 Relay Board

Each optional relay board has four relays with changeover contacts. Relays can be configured in software for:

Gas concentration alarm (high and low)

Output range indicator

Status indicator

Driver for autocalibration solenoid valve

Autocalibration in progress When used as either Status or Alarm functions, relay operation is fully configurable for fail-safe operation (i.e. normally de-energised in Fault or Alarm condition). The relay contacts are rated:

Changeover contacts

250V, 3A, AC

30V, 1A DC

4KV minimum isolation voltage

WARNING

The maximum ratings of the ‘Type n’ PCBs must be adhered to in order to maintain the T-Rating of the equipment. These

are the ‘nA’ ratings in BAS01ATEX3370X certificate.

To give reliable operation, it is recommended that the switching current is >10mA at 12Vdc. When used as ‘Status' indicators, available functions are defined in accordance with NAMUR recommendation NA64, i.e.:

NAMUR NAS4

terminology Meaning OxyExact 2200

system display

"Breakdown" The measured signal is invalid due to

a fault on the transmitter unit or its

peripheral equipment

Fault

"Check request" The measured signal is still valid but the "attrition reserves" will soon be

used up.

Maintenance

required

"In service" Work is in progress on the transmitter unit

Service in

progress

Table 2-1: NAMUR NAS4 vs System Display

In addition, a ‘message’ status function may be assigned.


10 INSTALLATION

2.5.4 Digital Inputs Board

Each optional digital input board has eight input channels. These can be configured in software for:

Range select

Initiate autocalibration routine

Inhibit autocalibration routine

External fault

External maintenance required

External service in progress

External message

Clear all alarms Action functions (such as initiate autocalibration) are initiated by momentary (0.5 to 1.5 seconds) change of state of the required input. ‘Conditions’ (such as external fault) will be maintained for as long as the signal is applied. All inputs are configurable for:

volt-free contacts, or

24V (nominal) logic Volt-free contact operation The board has a 24Vdc supply available. This may be used for supplying volt-free contacts. 24v Logic operation

Input voltage ON - 13 to 33 Vdc

Input voltage OFF - 0 to 6 Vdc at 0 to 1mA

Nominal input current - 5 mA/channel at 24 Vdc

Isolation voltage - 500 V minimum

2.6 Tag Numbers The control unit enclosure must not be drilled or modified in any way. A tag number may be written on the unit identification label on the side of the unit. The system can also be configured to show transmitter tag numbers on the display.


MECHANICAL INSTALLATION 11

3. MECHANICAL INSTALLATION

3.1 Unpacking and Inspection

WARNING

The control unit weighs approximately 12Kg (26lbs). Care must be taken when handling it.

Remove the SERVOTOUGH OxyExact 2210 Control Unit and accessories from their packing and inspect for any damage due to transit. (The enclosure has handholds on both sides to facilitate lifting.) If damage has occurred, inform Servomex or its agent immediately. Retain all packing and shipping information. Check that the supplied parts agree with the purchase specification. See also any Instrument Modification Sheets which may form part of this manual. Supplied parts:

One SERVOTOUGH OxyExact Control Unit

One accessories kit comprising: o Spare fuses o 1 x Allen key o 1 x Installation manual o 1 x Operator manual

(Other order specific items may also be included.)

3.2 Control Unit Description The SERVOTOUGH OxyExact Control Unit is essentially an aluminium enclosure finished with protective epoxy powder paint. A glass window facilitates viewing the integral display and the user interface is via a polyester keypad. All weatherproof seals are silicone rubber.

The internal electronics are of modular form and fit into seven positions within a card frame, the minimum configuration being:

Interfaces board

Processor board

Power supply unit

Optional signal input/output boards, as defined in Section 2.5, may be fitted The display and keypad are mounted on the rearside of the front door. Access to the enclosure is made by removing the four screws securing the cover and opening the hinged door.


12 MECHANICAL INSTALLATION

3.3 Fixing Centres The control unit must be mounted vertically (either surface or flush panel). See Figure 3-1 and Figure 3-2 for fixing centres and dimensions. Note that there should be sufficient space at the base and sides of the enclosure for routing cables and opening covers, etc. Flush panel fixing screws are supplied to order and locate in the rear of the flange around the enclosure.

Figure 3-1: Flush panel mounting details


MECHANICAL INSTALLATION 13

Figure 3-2: Mechanical arrangement

Key to Figure 3-2

1. Surface mount fixing hole 2. Display window 3. Keypad 4. Door, in open position 5. Power and signal cable entries 6. Functional (EMC) earth/ground terminal 7. Transmitter connection cable entries


14 ELECTRICAL INSTALLATION

4. ELECTRICAL INSTALLATION

CAUTION

It is a condition of certification that the unit must be installed following the appropriate national or international legislation or codes of practice. In particular, the correct glands

must be fitted to cable entries and the weatherproofing of the enclosure must not be compromised.

To retain certification the unit must not be modified, mechanically or electrically.

Additional holes must not be drilled into any part of the unit's enclosure.

Insulation testing: to prevent damage to the control unit it is necessary to disconnect cables being tested from the unit.

WARNING

The installation must conform to relevant safety requirements, National Electrical Code and any local

regulations. The installation must be safe for any extremes of operating conditions which may occur in the operating

environment of the analyser system.

4.1 CE Markings The Servomex 2200 oxygen analyser system complies with the European Directives on CE Marking (93/68/EEC) and Electromagnetic Compatibility (EMC 89/336/EEC).

CAUTION

To comply with the European Community Directives the interconnecting cables used for all signal inputs and outputs must be screened/shielded or equivalent protection

provided.

To comply with EMC emissions and susceptibility standards the functional earth/ground must always be connected to a local EMC ground.


ELECTRICAL INSTALLATION 15

4.2 Glands and Cable Entries All cable entries must be fitted with appropriate glands or plugs to maintain the required weatherproofing of the enclosures. Whilst the SERVOTOUGH OxyExact has been tested to meet IP66 actual certification requirements are less onerous, however, as a minimum:

All entries to the enclosure must be sealed to meet IP54.

When used in a hazardous dust area, all entries must be sealed to meet IP6X. Reminder to maintain the full integrity of the control unit all entries to both

enclosures must be sealed to meet IP66. Power supply cable entry: 1 x 3/4" NPT Signal cable entries: 4 x 3/4" NPT Transmitter connection entries: 2 x 1/2" NPT Accessories are available to convert to M20 or PG 13.5 and are supplied if ordered.

4.3 Identification and Location of Components See Figure 4-1 for location of terminal blocks, etc.



Figure 4-1: Electrical connections

Key to Figure 4-1

1 - Interfaces board 6 - Network (MODBUS) connector

2 - Processor board 7 - Power supply terminals

3 - Option board - analog output 8 - Mains fuse

4 - Option board - digital input 9 - Transmitter connection block

5 - Option board - relay



4.4 Earth/ground Requirements For compliance with EMC standards the external functional (EMC) earth/ground terminal located on the external base of the unit (see Figure 3-2) must always be connected to a local earth/ground. The terminal is suitable for:

Flexible conductors - up to 10mm2

Solid conductors - up to 10mm2

WARNING

The control unit contains intrinsically safe circuits. When the control unit is installed in a hazardous area the safety earth/ground must

comply with relevant national or international standards to ensure a safe installation, whether by the electrical supply or by a separate

connection.

4.5 Electrical Power Supply Connection

CAUTION

The unit is factory configured to operate on either 100V ac to 120V ac or 220V ac to

240V ac. Refer to Section 2.4 for additional installation rating details.

Specific voltage rating information is given on the label located on the right-hand side of the unit. Ensure that the unit is configured to operate on the correct supply voltage.

The unit does not include an integral switch for disconnecting the electrical supply. The installer must include a means of isolating electrical power by a switch or circuit breaker located close to the control unit. It must be marked as the disconnecting device for the

equipment.

The branch circuit supplying power to the control unit should be installed with a suitable fuse rated not greater than 15A or a suitable over current protection device set not

greater than 15A.

The electrical supply terminals are suitable for:

Flexible conductors - 0.5 to 1.5mm2 (20 to 16 AWG)

Solid conductors - 0.5 to 2.5 mm2 (20 to 14 AWG)

Cables should be suitable for temperatures of at least 70°C.



Connection is made to the terminal block located on the power supply unit (identified ‘PSU'). Terminal order from the top is:

L - Live (AC)

N - Neutral (ACC)

- Protective earth/ground

4.6 Transmitter Unit to Control Unit Connection One or more transmitter units can be connected to a single control unit using a two-wire, semi-duplex, bi-polar connection. The possible system configurations are shown in Figure 2-1 earlier in this manual. The maximum total cable length depends on cable parameters and certification conditions (refer to Appendix). However, typically, a single transmitter/control unit configuration may be separated by up to 1km of cable. Cable is to be a screened/shielded, twisted pair with the screen/shield connected to the control unit ground. The screen/shield must not be connected directly to the transmitter unit ground. The terminals are suitable for:

Flexible conductors - 0.5 to 1.5mm2 (20 to 16 AWG)

Solid conductors - 0.5 to 1.0mm2 (20 to 18 AWG) Cables should be suitable for temperatures of at least 70°C. Connection is made to the terminal block on the interfaces board. For a control unit at the ‘end’ of the data connection cable, connections are made to terminal numbers:

1 - ‘A’ from the cable

2 - ‘B’ from the cable For a control unit located in the ‘middle’ of the data connection cable, connections are made to terminal numbers:

1 - ‘A’ from cable 1

2 - ‘B’ from cable 1

3 - ‘A’ from cable 2

4 - ‘B’ from cable 2 The cable screen/shield is connected to the terminal post adjacent to the gland hole.

In order to avoid ground loops, the screen/shield termination is not connected directly to ground for this cable within the transmitter.

The screen/shield is directly connected to ground at the control unit.

The control unit features 1M ohm resistors from the ‘A' and ‘B' lines to ground to discharge associated cable capacitance.



4.6.1 Cable Termination Link

A link exists within the control unit that configures the cable termination to either be a ‘mid-point’ or an ‘end’ (by definition an ‘end’ occurs when the second cable is not installed). The link is made across terminals 4 and 5 and must be fitted when the second cable is not installed. E.g., reference Figure 2-1; the link is required in configurations 1 and 2, but not 3.

4.7 Signal and Output/Input Connections To comply with EMC standards, connections to signal outputs/inputs must use screened/shielded or shielded cable. This may be either separately screened/ shielded pairs or twisted pairs with an overall screen/shield. The screens/shields or drain wire must be terminated at the terminal posts located on the internal base of the enclosure. All terminals are suitable for: Flexible conductors - 0.5 to 1.5mm2 (20 to 16 AWG) Solid conductors - 0.5 to 1.0mm2 (20 to 18 AWG) Cables should be suitable for temperatures of at least 70°C. Connections are made with plugs and sockets. After assembly the socket must be secured to the relevant board using the screws supplied, apart from the RJ45 Ethernet connector which incorporates its own retaining tab. Cables should be identified and labelled with their associated option board. Cables should be dressed so that they do not cause a strain on the sockets and boards.

4.7.1 MODBUS® Connection

Reference Section 2.5.1 and Figure 4-1. Connection is made to the 'NETWORK' connector on the front panel of the 'PROCESSOR' board. Details of these connections depends on the network option fitted as described below.



MODBUS Serial RS4S5 Interface Connections are made to the designated terminals on the removable connector. For a single-wire system (control unit as an 'end-node') connections are made to terminal numbers:

Pin 1 - ‘A’ from cable 1 Pin 2 - ‘B’ from cable 1

For multiple configurations (control unit as 'mid-point node') the second cable should be routed to:

Pin 3 - ‘A’ from cable 2 Pin 4 - ‘B’ from cable 2

The cable screen/shield is connected to the terminal post adjacent to the gland hole. Cable termination link: A link exists within the control unit that configures the cable termination to either be a 'mid-point' or an 'end' (by definition an 'end' occurs when the second cable is not installed). The link is made across terminals 4 and 5 and must be fitted when the second cable is not installed. MODBUS TCP Ethernet Interface Ethernet cabling should use shielded (STP) CAT 5 cable or better. The cable should first be passed through the control unit gland and then assembled on to a standard RJ45 connector. The cable screen/shield is connected to the terminal post adjacent to the gland hole. The table below lists the functions of each connector pin.

Pin 1 - Transmit +

Pin 2 - Transmit –

Pin 3 - Receive +

Pin 6 - Receive –

Pins 4, 5, 7, 8 - Not used For guidance, the tables below show the corresponding wire colours specified in TIA/EIA-568A and TIA/EIA-568B for patch leads as viewed from the back of the plug with the tab facing down. It is the responsibility of the installer to ensure the correct connections are made.

TIA/EIA-568A

1 2 3 4 5 6 7 8

white/green green white/orange orange

TIA/EIA-568B

1 2 3 4 5 6 7 8

white/orange orange white/green green

Table 4-1: Patch Lead wire colours



4.7.2 Analog Output Board

Reference Section 2.5.2 and Figure 4-1. Connection is made to the connector on the front panel of the 'mA O/P' board.

Pin 1 - Analog output 1 +ve

Pin 2 - Analog output 1 -ve

Pin 3 - Relay 1, N/C: closes on power fail

Pin 4 - Relay 1, C: Common

Pin 5 - Relay 1, N/O: opens on power fail


Pin 7 - Relay 2, C: Common


Pin 9 - Analog output 2 +ve

Pin 10 - Analog output 2 -ve

4.7.3 Relay Board

Reference Section 2.5.3 and Figure 4-1. Connection is made to the connector on the front panel of the 'RELAY' board.

Pin 1 - Relay 1, C: common



Pin 4 - no connection














4.7.4 Digital Inputs Board

Reference Section 2.5.4 and Figure 4-1. Connection to a DCS or similar system Terminations 1 and 2 are at approximately ground/earth potential for a common connection to the DCS. Connection is made to the connector on the front panel of the 'DIGITAL I/P' board.

Pin 1 - Input common

Pin 2 - Input common

Pin 3 - Channel 1

Pin 4 - Channel 2

Pin 5 - Channel 3

Pin 6 - Channel 4

Pin 7 - Channel 5

Pin 8 - Channel 6

Pin 9 - Channel 7

Pin 10 - Channel 8

Pin 11 - Switch supply





AUTOCALIBRATION OPTIONS 23

5. AUTOCALIBRATION OPTIONS

Autocalibration is the function of automatically adjusting or checking the calibration data held within a transmitter. However, the software routine that controls this calibration does not reside within the transmitter. Autocalibration (or ‘autocal') is achieved by subjecting the transmitter measuring system to real live' conditions (i.e. by passing a number of calibration gases through the gas sensor) and recording the effects of these conditions. The autocalibration routines held within the SERVOTOUGH OxyExact Control Unit offer the following as standard:

1. Initiation by:

direct access through the user interface

setting timer parameters within the control unit

digital input (requires installation of a digital input board or Modbus network link)

2. The option to conduct full calibration (low and high) or one at either end point.

(i.e. just a low or just a high).

3. The ability to use two-way or three-way solenoid valves to control up to three different gases to the transmitter:

Sample

Low calibration

High calibration

This enables the following optional configurations: A. full zero and span autocal with three two-way solenoid valves. B. full zero and span autocal with two three-way solenoid valves. C. auto-zero (or span) using two two-way solenoid valves. D. auto-zero (or span) using one three-way solenoid valve.

4. Optional sample inerting - to isolate the sample gas from one of the calibration

gases and/or to pass a safe' gas through the transmitter during warm up conditions.

The ‘isolation’ of sample from a calibration gas (should the sample be flammable) is achieved by adding an ‘inerting’ stage to the autocalibration cycle. It does not, therefore, impact on the number of solenoid valves but the contents of one of the calibration gases must be selected accordingly.

Complete gas shut off is not available with options B and D above and flammable samples ‘isolation’ is not applicable to options B, C or D.

5. The ability to calibrate single transmitters or ‘groups’ of units at the same time.

6. The ability to adopt the ‘NAMUR’ users solenoid configuration.


24 AUTOCALIBRATION OPTIONS

When autocalibration is installed, any designated solenoid valves will also be activated, as necessary, when manual calibration routines are invoked from the control unit.

Full autocalibration cycle

The full cycle is best described pictorially, see Figure 5-1 below. The full cycle includes the inerting stages and utilises a low calibration gas for this purpose.

Figure 5-1: Autocalibration cycle

Key to Figure 5-1

1. High calibration gas target concentration 2. Sample gas concentration 3. Low calibration gas target concentration 4. High calibration gas tolerance concentration 5. Low calibration gas tolerance concentration 6. Start of autocalibration, gas stream changes from sample to low calibration gas.

If configured accordingly, the mA output freeze is activated. 7. Customer configurable flush time 8. Gas stream changes from low to high calibration gas 9. Customer configurable flush time 10. Gas stream changes from high to low calibration gas 11. Low calibration gas left running for a customer configurable flush time 12. Gas stream changes from low calibration gas to sample 13. Customer defined flush time 14. End of autocalibration, if configured, the mA output freeze would be de-activated

and the new calibration figures utilised.



It is acceptable to ‘reverse’ this arrangement and utilise the high calibration gas at the inerting stages. In such cases the solenoids would switch as follows:

6 Sample to high calibration gas 8 High to low calibration gas 10 Low to high calibration gas 12 High calibration gas to sample

Autocalibration logic table It is possible, in software, to assign a relay to control each specific gas. This permits direct wiring to two-way solenoid valves. The following table gives the logic:

Relay (& nominal

designation)

No power to control unit

Sample 'Zero' gas 'Span' gas

1 (Sample) Off On Off Off

2 (Low Cal) Off Off On Off

3 (Hi Cal) Off Off Off On

Table 5-1: Autocalibration logic table

The above permits various three-way valve configurations and inlet hardware configured potentially as shown below in Figure 5-2.

Figure 5-2 is intended to demonstrate that there is no software change to the autocalibration routines - there may be additional preferred arrangements.


26 AUTOCALIBRATION OPTIONS

Figure 5-2: Autocalibration configurations

Key to Figure 5-2

1. Three-way valve configuration 2. Optional configuration 3. Example of NAMUR users configuration 4. Electrical connections to Relay 1 5. Electrical connections to Relay 2 6. Electrical connections to Relay 3 7. Gas connection to transmitter inlet 8. Gas connection - Low calibration gas 9. Gas connection - High calibration gas 10. Gas connection - Sample gas



Customer configuration (user interface): Customers are offered full flexibility and the following overview is provided of software configuration options. Refer to the Operator manual for further details. A pair of autocalibration digital logic inputs may be defined (requires a digital input option board):

1. Initiate an autocalibration - momentary contact

2. Disable timed autocalibration - whilst a contact is closed

Category Parameter Units (in 2200)

Gas Parameters

Target concentration for low calibration % Oxygen

Target concentration for high calibration % Oxygen

Tolerance associated with low calibration % Oxygen

Tolerance associated with high calibration % Oxygen

Time Parameters

(Stages associated with figure)

Time of first autocalibration Date and Time

Period between autocalibrations Hrs/Days

Flush time for low calibration gas at stage 7

Minutes (decimals allowed)

Flush time for high calibration gas at stage 9

Flush time for low calibration gas at stage 11

Flush time for final sample gas stage 13

Hardware Parameters

Address' of relay assigned to sample gas (N/A for three-way calibration valves)

Text

Address' of relay assigned to low cal gas

Address' of relay assigned to high cal gas

Status of above relays under normal operation, i.e. normally energised or de-energised

Transmitter mA output (if applicable) to Freeze

Control unit mA output (if applicable) to Freeze

‘Type' Full, High only, Low only

Check or Calibrate

Table 5-2: Software configuration options


28 INSTALLATION CHECKLIST

6. INSTALLATION CHECK LIST

Following completion of the installation procedure check:

Item Checked

Unit is firmly mounted

Supply voltage agrees with unit supplied

The unit is correctly earthed/grounded

Connection is made to transmitter unit

Connection is made to analog outputs (as required)

Connection is made to digital outputs (as required)

Connection is made to alarm relays (as required)

Connection is made to digital inputs (as required)

Sockets are secured to their relevant boards

All wiring terminations are tightened

Screws in unused terminals are tightened

I/O cable screen connections are secure

Cable glands are secured and made weather-tight

Cables are dressed neatly within the control unit

Inner door is secured

Hazardous area safety requirements are complied with

External electrical connections are labelled

Covers are secured and weatherproof

Table 6-1: Installation checklist

It is now possible to apply power to the unit. See the Operator manual for commissioning and operating the unit.


ROUTINE MAINTENANCE 29

7. ROUTINE MAINTENANCE

The SERVOTOUGH OxyExact Control Unit requires minimal routine maintenance.

WARNING

The unit must only be cleaned with a damp cloth.

In very dusty environments, it will be prudent to occasionally clean off the outer surfaces using a damp cloth. Spares The SERVOTOUGH OxyExact Control Unit contains no parts that require routine service. Refer to the Service manual for full service instructions.


30 APPENDIX 1 – TECHNICAL SPECIFICATION

APPENDIX 1 TECHNICAL SPECIFICATION

FUNCTIONAL

Power supply: Either 100-120V ac 50/60Hz, -10% and +10%. or 220-240V ac 50/60Hz, -15% and +10%. Power required: 30VA Physical: Width: 280mm

Height: 242mm (300mm including mounting) Depth: 250mm Weight: 12kg

ENVIRONMENTAL General: Suitable for indoor and sheltered outdoor locations Ingress protection: IP66 and Type 4X (NEMA 250) Operating temperature: -10 to 50°C (14°F to 122°F), in sheltered location Storage temperature: -20 to 70°C (-4°F to 158°F) Relative humidity: 95% RH maximum, non-condensing

Atmospheric pressure: 76 to 112 kPaa (11 to 16.2 psia)

Altitude: 3000m (10,000 feet) maximum

Installation category: II - in accordance with IEC 664 Pollution degree: 2 - in accordance with IEC 664 Warm up time: Not applicable PERFORMANCE No degradation of associated transmitter performance.


APPENDIX 2 – MODBUS PROFILE 31

APPENDIX 2 MODBUS PROFILE

The control unit supports the Modbus slave communication through the network connector on the processor board. The following facilities are provided:

Access to transmitter measurement data

Access to transmitter and control unit status information

Access to transmitter calibration information

Progress indication during autocalibration

Network inputs and outputs

Diagnostics

Error handling These are described below. Transmitter data The measurement data from each registered transmitter is available in a block of input registers that can be read using Modbus function code 04. The specific range of registers used is related to the transmitter address as shown in the following table:

Register Range

Transmitter address

Comments

1 – 100

101 – 200

201 – 300 … …

1401 – 1500

01

02

03 … …

15

Measurements and data for each registered transmitter. All data is read-only.

The format of the data within each block of registers is shown in the following table. The register offset values in that table should be added to the base value appropriate to the Transmitter address in the table above. For example, the Measurement for the Transmitter at address 02 can be read from registers 108-109.

Measurement data is in IEEE 754 floating point format. Each value requires 2 registers as follows:

Register N = High word Register N + 1 = Low word


32 APPENDIX 2 – MODBUS PROFILE

Register offset

Name Comments

0 - 6 Name A 13 character string denoting the user- entered transmitter name/tag.

7 - 8 Oxygen measurement Final oxygen measurement in IEEE 754 floating point format.

9 - 11 Gas formula Contains the text "O2 " (6 characters).

12 - 14 Oxygen units A 5 character string containing the oxygen units.

15 - 16 Analog input 1 measurement

The measurement value at analog input 1 in IEEE 754 floating point format.

17 - 19 Analog input 1 description A 6 character string containing the user- entered name of analog input 1.

20 - 22 Analog input 1 units A 5 character string containing the user entered units of analog input 1.

23 - 24 Analog input 2 measurement

The measurement value at analog input 2 in IEEE 754 floating point format.

25 - 27 Analog input 2 description A 6 character string containing the user- entered name of analog input 2.

28 - 30 Analog input 2 units A 5 character string containing the user entered units of analog input 2.

31 - 32 Internal pressure measurement

Internal pressure measurement in IEEE 754 floating point format.

33 - 35 Internal pressure description

A 6 character string containing the user- entered name of the internal pressure measurement.

36 - 38 Internal pressure units A 5 character string containing the user- entered internal pressure units.

39 – 40 Low target value Low calibration gas concentration (gas 1) in IEEE 754 floating point format.

41 – 42 Low tolerance value Low calibration tolerance in IEEE 754 floating point format.

43 – 44 Low target compared value

Oxygen measurement value immediately before low calibration in IEEE 754 floating point format.

45 – 46 High target value High calibration gas concentration (gas 2) in IEEE 754 floating point format.

47 – 48 High tolerance value High calibration tolerance in IEEE 754 floating point format.

49 – 50 High target compared value

Oxygen measurement value immediately before high calibration in IEEE 754 floating point format.

51 Last low calibration action Indicates whether the last maintenance action was a check or a calibrate. Integer value: 0=none 1=check 2=calibrate 52

Last high calibration action

53 - 60 Transmitter software ID A 16 character string containing the transmitter software identity.



Transmitter status information Transmitter status information from each registered transmitter is available in a block of discrete inputs that can be read with function code 02. The specific range of inputs used is related to the transmitter address as shown in the following table:

Input Status Range

Transmitter address

Comments

1 – 100

101 – 200

201 – 300 … …

401 – 500

01

02

03 … … 15

Status information for each registered transmitter. All data is read-only.

The format of the data within each block of inputs is shown in the following tables. A data value of "1" indicates that the status condition is raised. Addresses are in the form of an offset from the start of the block. For example, for a Transmitter at address 02, the Discrete Input for the summary Message status flag would have the address 104 (=101 + 3). Status Conditions - Summary

Input Offset Description

0 Transmitter Fault status raised

1 Transmitter Maintenance Required status raised

2 Transmitter Service In Progress status raised

3 Transmitter Message status raised

4 - 7 Unused (zero)

Status Conditions - Detail

Fault


8 Transmitter not responding. If set, the Fault status will be set and all other statuses will be zero.

9 Raw Oxygen Input Voltage Low Fault

10 Raw Oxygen Input Voltage High Fault

11 Cell Temperature Low Fault

12 Cell Temperature High Fault

13 Pressure Low Fault

14 Pressure High Fault

15 Not used (zero)

16 Cell Temperature Measurement Fault

17 Paramagnetic Cell Feedback Fault



18 Paramagnetic Cell Photocell Fault

19 Low Flow Fault – internal flow sensor

20 High Flow Fault – internal flow sensor

21 Flow Sensor Fault – external flow sensor

22 Flow Fault – external flow sensor

23 Analog Input 1 Invalid – Fault 1

24 Analog Input 2 Invalid – Fault 1

25 Digital Input 1 Active – Fault 2




29 Software Processing - Fail

30 Non-Volatile Memory Fail

31 Internal ADC Fail

32 External ADC Fail

33 System RAM Fail

34 Program Integrity Fail

35-39 Unused (zero)

Maintenance Required


40 Raw Oxygen Input Voltage Low Check

41 Raw Oxygen Input Voltage High Check

42 Pressure Low Check

43 Pressure High Check

44 Warmup Time Exceeded

45 Oven Temperature Measurement Check

46 Feedback Check

47 Photocell Check

48 Low Flow Check

49 High Flow Check

50 Analog Input 1 Invalid – Maintenance Required 1

51 Analog Input 2 Invalid – Maintenance Required 1

52 Low Calibration Fail

53 High Calibration Fail

54 Pressure Compensation Calibration Fail

55 Internal Pressure Transducer Calibration Fail

56 Internal Flow Alarm Calibration Fail

57 Digital Input 1 Active – Maintenance Required 2




61 Using system Default Data

62 – 63 Unused (zero)



Service In Progress


64 Analog Input 1 Invalid - Service Mode 1

65 Analog Input 2 Invalid - Service Mode 1

66 Digital Input 1 Active - Service Mode 2




70 Controller Requested Service Mode

71 Unused (zero)

Message


72 Analog Input 1 Invalid – Message 1

73 Analog Input 2 Invalid – Message 1

74 Digital Input 1 Active – Message 2




78 Warming Up

79 to 99 Unused (zero)

Notes:

1. The status type that can be raised by the external mA inputs is user configurable.

2. The status type that can be raised by the external digital inputs is user configurable.

Control unit identity Read only access to the Control Unit software identity is available in a block of holding registers that can be read with function code 03.

Register Name Comments

101 - 108 Control unit software ID A 16 character string containing the control unit software identity



Control unit status information Read-only access to control unit status information is available in the following block of discrete inputs that can also be read with function code 02. Status Conditions Summary

Discrete Input Description

6001 Control unit Fault status raised

6002 Control unit Maintenance Required status raised

6003 Control unit Service In Progress status raised

6004 Control unit Message status raised

6005 - 6008 Unused (zero)

Status Conditions - Detail

Fault


6009 System Data Defaults In Use

6010 Watchdog Fault

6011 Non-Volatile Memory Fail

6012 Communications Failure

6013 Software Processing Fail

6014 RAM Fail

6015 Program Integrity Fail

6016 Display Card Reset

6017 Option Card 1 Reset








6025 External Fault 1 1







Maintenance


6033 Option Card 1 Reset Override








6041 External Maintenance Required 1 1




6045 Invalid System Time/Date


Service In Progress


6049 External Service Mode 1 1




6053 Controller Requested Service Mode


Message


6057 Auto Calibration Group 1 In Progress






6063 External Message 1 1




6067 Alarm History 80% Full

6068 Alarm History Full

6069 Calibration History 80% Full

6070 Calibration History Full

6071 Status History 80% Full

6072 Status History Full



Notes: 1 Any of the Control Unit digital inputs may be user-assigned to raise any of the

“External” statuses. The status type that is raised is also user-configurable. Autocalibration progress An indication of progress during autocalibration is available by reading holding register 1 using function code 03. The value returned will be one of the following:

Value Meaning

0 No autocalibration in progress

1* Preparing for autocalibration

2 Flushing with calibration gas 1


4* Capturing calibration point for gas 2


6* Capturing calibration point for gas 1 and applying new calibration

7 Flushing with sample gas

8* Restoring normal operation

*These values are only present for very short times and are unlikely to be returned. Network digital inputs Network digital inputs are functionally identical to physical digital inputs such as those provided by the digital inputs board. Modbus adds 8 network digital inputs to any physical digital inputs and allow these to be selected and set up in the same way. Network digital inputs will be identified as N:1 to N:8. To a Modbus master these network digital inputs will appear as coils according to the table below. Their state can be written using function codes 05 or 15 and read back using function code 01.

Coil Description

00001 Network Digital Input 1 0 = open circuit, 1 = closed circuit










Network relays Network relays are functionally identical to physical relays such as those provided by the relay board. Modbus adds 8 network relays to any physical relays and allow these to be selected and set up in the same way. Network relays will be identified as N:1 to N:8. To a Modbus master these network relays will appear as discrete inputs according to the table below. Their state will be read using function code 02.


7001 Network Relay 1 0 = De-energised, 1 = Energised








Network analog outputs Network analog outputs are functionally identical to physical analog outputs such as those provided by the analog output board. Modbus adds 8 network analog outputs to any physical outputs and allow these to be selected and set up in the same way. Network analog outputs will be identified as N:1 to N:8. Read-only access will be provided to the mA values of these network analog outputs in the holding registers listed in the table below. These will be read using function code 03.

Measurement data is in IEEE 754 floating point format. Each value requires 2 registers as follows:

Register N = High word Register N + 1 = Low word

Registers Description

2 - 3 Network Analog Output 1










Diagnostics Modbus function code 08 provides a diagnostic capability for checking communication between the master and the control unit. Following the function code is a 2-byte sub function code that specifies the test to be performed, followed by 2 bytes of data. The only supported sub function code is 00. This causes the query message, including the 2 data bytes, to be copied back as the response. Error handling If a communications error (e.g. framing error, checksum error) is detected during the receipt of a Modbus message, that message will be ignored and no response will be generated. All correctly received Modbus messages will be checked for a valid function code and data address. If a problem is detected the following exception responses will be returned.

Condition Exception code

Requested function code is not supported 01

Register or coil address outside of supported range 02


APPENDIX 3 – CERTIFICATES 41

APPENDIX 3 CERTIFICATION

The following pages contain the ATEX certificate for this analyser. It details conditions of safe use and important parameters that shall be followed for safe installation.


42 APPENDIX 3 – CERTIFICATES











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SERVO TOUGH OxyExact (2210)