instruction manual - hummingbird · page 12 of 34 01154001a 3.2 mechanical specification see...

8 Hummingbird Group Ltd. 2012. All rights reserved

Paracube® Premus-A

Analogue Paramagnetic Oxygen Sensor

Instruction Manual Product Part Numbers: 01154/000. Manual Part Number: 01154001A Revision: 0 Language: UK English

8 Hummingbird Group Ltd. 2012. All rights reserved

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WARNINGS, CAUTIONS AND NOTES: This publication includes WARNINGS, CAUTIONS and NOTES which provide, where appropriate, information relating to the following: WARNINGS: Hazards that may result in personal injury or death (coloured red). CAUTIONS: Hazards that will result in equipment or property damage. NOTES: Alerts the user to pertinent facts and conditions.

WARNING - (USE): As the final conditions of use are outside Hummingbird's control, it is the responsibility of the equipment designer or manufacturer to ensure that the sensor is integrated in accordance with any regional standards or regulations governing the final application. The sensor should not be relied upon as a single source of safety monitoring unless expressly permitted within the regional standards or regulations governing the final application.

NOTE: For safety reasons any sensor returned to Hummingbird must be accompanied by the Decontamination Clearance Certificate contained in this manual. Unless the cell is accompanied by this certificate, Hummingbird reserves the right to refuse to undertake any examination of the product. Apply appropriate anti-static handling procedures. Sensor returns must be packed in the original packing material to prevent damage in transit.

NOTE: The information in this document is subject to change without notice. This document contains proprietary information which is protected by copyright. All rights are reserved. No part of this document may be copied, reproduced or translated to another language without the prior written consent of Hummingbird.

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UK Legislation Health and Safety at Work Act 1974 Control of Substances Hazardous to Health Regulations 2002 (as amended) Ionising Regulations 1999 Important Notice Hummingbird ensures that all products dispatched to customers have been suitably purged and cleaned prior to packaging, so that no hazards from the use of factory calibration gases or liquids will be present. No item returned to Hummingbird or its representatives, for any reason whatsoever, will be accepted unless accompanied by a copy of the following form fully completed and signed by a responsible person. This is a requirement to comply with the above listed legislation and to ensure the safety of the employees of Hummingbird and its representatives. ………………………………………………………………………………………… Please tick one of the following sections as applicable to your equipment. Decontamination Statement. It is hereby certified that a suitable and sufficient decontamination process has been carried out and we have taken reasonable action to ensure that the returned equipment described below will be free of potential toxic, corrosive, irritant, flammable, radioactive or biological hazards and is safe to be handled, unpacked, examined and worked upon by Hummingbird employees and its representatives. Please give detail of decontamination process used:-_________________________ ____ ________________________________________________________________________ Decontamination Clearance Certificate. It is hereby certified that the equipment described below has never been exposed to any potential toxic, corrosive, irritant, flammable, radioactive or biological hazards, therefore it is reasonably expected that it should be safe for Hummingbird employees and its representatives to handle, unpack, examine and work upon the equipment described below. Equipment _______________ ______ Reason for return ______ ______________ ________________________ _____ ___________________________ _______ ______________ _____________ _______ Serial no __________________ ____ ___________________________ _______ __________________ _________ _______ _____________________ _______ ______ Company ______________ _ ____ _______ ________________________ ___ _______ Signature _________________ _____ Print name _____________________ Company seal or stamp:- Position ___________________ ____ Date __________________________ Form: 5000/2 issue2

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Table of Contents 1: INTRODUCTION TO PARACUBE® PREMUS-A ........................................................................................... 7

2: HUMMINGBIRD PARAMAGNETIC MEASUREMENT PRINCIPLE ................................................................ 8

3: PRODUCT SPECIFICATION ..................................................................................................................... 10

3.1 PERFORMANCE SPECIFICATION (UNDER CONSTANT CONDITIONS) ....................................................................... 10 3.2 MECHANICAL SPECIFICATION .................................................................................................................... 12 3.3 EXTERNAL POWER SUPPLY SPECIFICATION ................................................................................................... 12 3.4 ENVIRONMENTAL SPECIFICATION .......................................................................................................... 12

4: INTEGRATION OF PARACUBE® PREMUS-A ............................................................................................ 14

4.1 FUNCTIONAL COMPONENTS OF THE PARACUBE® PREMUS-A ............................................................................ 14 4.2 HANDLING OF THE PARACUBE® PREMUS-A ............................................................................................. 14

4.2.1 Special Packaging ......................................................................................................................... 14 4.2.2 How to Handle the Paracube® Premus-A ....................................................................................... 14

4.3 MINIMISE EXPOSURE OF PNEUMATIC SYSTEM TO CONTAMINANTS ................................................................ 15 4.4 MECHANICAL ARRANGEMENT .............................................................................................................. 15

4.4.1 Mounting Arrangement ........................................................................................................... 15 4.4.2 Location of Sensor ................................................................................................................... 15 4.4.3 Orientation of Sensor ............................................................................................................... 15

4.5 PNEUMATIC ARRANGEMENT ................................................................................................................ 16 4.5.1 Sampling Configuration of Paracube® Premus-A....................................................................... 16 4.5.2 Conditioning of the Sample ...................................................................................................... 16 4.5.3 Typical Sample System ............................................................................................................. 16 4.5.4 How to apply Pressure Compensation to the Signal Output....................................................... 17

4.6 ELECTRICAL ARRANGEMENT ..................................................................................................................... 18 4.6.1 Power Supply (to be fitted by OEM) .......................................................................................... 18 4.6.2 Electrical Connections .............................................................................................................. 18 4.6.3 Earthing Arrangement ............................................................................................................. 18 4.6.4 Remote Zero and Span Adjustment .......................................................................................... 18 4.6.5 Electronic Thermometers ......................................................................................................... 19 4.6.6 Feedback loop failure indication. .............................................................................................. 19

5: OPERATION AND CALIBRATION ............................................................................................................ 21

5.1 SETTING THE DESIRED OUTPUT CONFIGURATION ............................................................................................ 21 5.2 START- UP CHECKS................................................................................................................................. 22 5.3 CALIBRATION EQUIPMENT ....................................................................................................................... 22 5.4 CALIBRATION PROCEDURE USING OPTIONAL REMOTE POTENTIOMETERS ............................................................ 22 5.6 CALIBRATION AT HIGH ALTITUDES.............................................................................................................. 23

6: TROUBLE SHOOTING GUIDE .................................................................................................................. 24

7: MAINTENANCE, WARRANTY AND PRODUCT RETURN .......................................................................... 28

7.1 TESTS ON SUSPECTED FAULTY SENSOR ........................................................................................................ 28 7.2 PRODUCT FAILURE DURING WARRANTY ...................................................................................................... 28 7.3 PRODUCT FAILURE OUT OF WARRANTY ........................................................................................................ 28 7.4 MAINTENANCE ..................................................................................................................................... 28 7.5 SPARES ............................................................................................................................................... 29 7.6 DECONTAMINATION OF THE PARACUBE® PREMUS-A ...................................................................................... 29

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8: APPENDICES ......................................................................................................................................... 30

APPENDIX 8.1 MECHANICAL VIBRATION AND SHOCK RESISTANCE ...................................................................... 30 APPENDIX 8.2 OUTLINE DIMENSIONS OF PM 01154 (DRAWING 01154/821) ......................................................... 31 APPENDIX 8.3 SAMPLE CELL REPLACEMENT ...................................................................................................... 32 APPENDIX 8.4 SAMPLE GAS COMPATIBILITY ....................................................................................................... 33

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1: Introduction to Paracube® Premus-A The Paracube® Premus-A is a high performance paramagnetic oxygen sensor, designed to be incorporated into OEM instrumentation where reliability and accuracy are considered to be at a premium. The sensor provides configurable analogue outputs with full scale deflections detailed in section 3.1, under “Range and Output”. Hummingbird’s non-depleting paramagnetic technology ensures consistent performance over time with added cost-of-ownership benefits. The selectivity of the measurement to oxygen means there is little or no interference from other common background gases. The Paracube® Premus-A offers a stable and inherently linear measurement of oxygen making it possible to calibrate the sensor by checking two points only. There is no requirement for a reference gas during operation. The sensor uses Hummingbird’s world renowned paramagnetic technology (described in section 2 of this manual) which has been designed into many OEM products where reliability, long life and performance are major considerations.

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2: Hummingbird Paramagnetic Measurement Principle The sensor utilises the paramagnetic susceptibility of oxygen, a physical property which distinguishes oxygen from most other common gases. The sensor incorporates two nitrogen-filled glass spheres mounted on a strong, noble metal taut-band suspension. This assembly, termed the “Suspension Assembly” is suspended in a symmetrical non-uniform magnetic field. When the surrounding gas contains paramagnetic oxygen, the glass spheres are pushed further away from the strongest part of the magnetic field. The strength of the torque acting on the suspension is proportional to the oxygen content of the surrounding gases. Fig.1 The measuring system is "null-balanced". The 'zero' position of the suspension assembly, as measured in nitrogen, is sensed by a split photo-sensor that receives light reflected from a mirror attached to the suspension assembly. The output from the photo-sensor is processed and then fed back to a coil wound around the suspension assembly. This feedback achieves two objectives: When oxygen is introduced to the cell, the torque acting upon the suspension assembly is balanced by a restoring torque due to the feedback current in the coil. The feedback current is directly proportional to the volume magnetic susceptibility of the sample gas and hence, after calibration, to the partial pressure of oxygen in the sample. A voltage output is derived which is proportional to the feedback current.

Taut Band

Permanent Magnet

N2 filled Spheres

Magnetic Field

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Fig.2 In addition, the electromagnetic feedback stabilises the suspension (heavily damping oscillations) thus making it resilient to shock and vibration.

Rotation

Mirror

Light source

Photodiodes

Current measurement

Conductive wire

Amplifier

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3: Product Specification 3.1 Performance Specification (under constant conditions) This specification applies when the sensor has been calibrated using standard gas values of N2 and 100% O2 using the calibration procedure described in section 5. Unless otherwise stated, the performance figures quoted are derived from two standard deviation analysis. Where marked (†) testing has been conducted in accordance with the requirements of IEC 61207-1 1994. Range and Output 0 to 100% O2 gives 0 – 1V dc 0 to 100% O2 gives 0 – 4V dc 0 to 25% O2 gives 0 – 1V dc 0 to 25% O2 gives 0 – 4V dc Linearity† < 0.1% O2 Repeatability† < 0.01% O2 Intrinsic Error† < 0.1% O2 Zero Stability (permanent drift from calibration value)† When operating between the temperatures of 0oC to +65oC (32oF to 149oF). Short term stability: < 0.1% O2 during first 24 hours of operation. Long term stability: < 0.2% O2 per month of operation. Temperature Coefficient† Within a range of 0oC to +65oC (32oF to 149oF) Zero: < 0.03% O2/oC Span: < 0.05% of O2 reading /oC

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Output Fluctuation ≤±0.01% (4 times Standard Deviation). Tilt <±0.05% O2 equivalent for a 15° change in orientation from the calibration point.

Thermometer output available (ref. fig. 4) P1/12: 1mV/K 3K (10oC to +60oC) 5K (0oC to +65oC) P1/14: 10mV/C 2.5oC (10oC to +60oC) 4oC (0oC to +65oC) Operational Flow Rate 200ml/min maximum. Response Time Rise Time (T10 – T90): 100% N2 to 100% Oxygen <2.5 seconds at 200 ml/min. Pressure range 33kPag (5psig).

Pressure drop across the cell <20mm H2O at 200ml/min.

Flow Error – Based on gases with molecular weights of 28-30g/mol. For more detail see Servomex application note HBAN-PM41 A change of sample flow rate from 20 to 250ml/min produces a change in reading <+/-0.1% O2.

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3.2 Mechanical Specification See Appendix 8.3 for drawing no. 01154/821, Aoutline Dimensions of Pm11154@. Dimensions (W X D X H) 80 x 88 x 55mm (3.15 x 3.46 x 2.16 inches). Weight 794gms (28 ozs) Gas Connectors Two connections, 3.125mm (1/8”) nominal OD, suitable for flexible or semi rigid tubing. Materials In Contact with Gas Sample 316 stainless steel, viton >O= ring, borosilicate glass, electroless nickel, platinum, platinum/iridium alloy. Pneumatic leakage <1x10-5 mbar.l.sec-1 (<1x10-5 SCCS).

3.3 External Power Supply Specification An external power supply is required to provide: +5V dc (7V maximum), current consumption using 5V rail = 100mA maximum. Ripple and noise: <0.1V Pk to Pk. A change of ±0.25V in supply Voltage results in a change of less than ±0.1% in oxygen concentration.

3.4 Environmental Specification Sample Gas Condition Dry, non-corrosive, non-flammable gas, free of entrained oil, less than 3 micron particulates, non-condensing, dew point 10°C below the sensor operating temperature. Pressure With the sample vented to atmosphere, the output voltage is directly proportional to the barometric pressure. Operating Temperature 0oC to +70oC (32oF to 158oF)

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Storage Temperature -30oC to +70oC (-22oF to 158oF) Storage Pressure 10kPa – 200kPa (1.5psi - 30psi), Ambient Humidity 0 to 95% RH Altitude Range (Operating) -500m to +5000m (-1540 ft to +15400ft) Soft magnetic material Brought within 15mm of the case will result in a change in the reading of <0.1% O2. Interference Effects The paramagnetic effect of common background gases at 20oC, for 100% concentration is shown below: Interfering Gas Interference Effect (100% Interferent) (% O2) N2O -0.20 CO2 -0.26 H2O -0.03 Methane -0.16 CO 0.06 Helium 0.29 NO 42.56 NO2 5.00 A comprehensive list detailing the effect of other background gases and a sample calculation is detailed in Hummingbird Application Note HBAN PM 25 (available on request). Shock & Vibration Meets the requirements of BS EN 60068-2-6:1996 (IEC 68-2-6), BS EN 600-2-27:1993 (IEC 68-2-27) and IEC 68-2-34. Details of these requirements are given in Appendix 5.1. Sample gas compatibility. Listed in Appendix 8.4 are gases that the standard Paracube® Premus-A variants may be exposed to without compromising the sensor performance.

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4: Integration of Paracube® Premus-A This section contains information to help achieve the optimum performance from the Paracube® Premus-A when integrating into the host unit.

4.1 Functional components of the Paracube® Premus-A The main components of the Paracube® Premus-A are the “Sensor Body” and the “Optical Assembly and Electronics Control PCB”. The Sensor Body The sensor body consists of the paramagnetic cell and the magnet frame. The interior of the paramagnetic cell is the only sample wetted surface. It is a precision component containing the suspension assembly, and is secured within the magnet frame. Optical Assembly and Electronics Control PCB The optical assembly consists of a precision optical mounting bracket onto which the integrated electronics board and the small photo-sensor board are fitted. The optical assembly is secured to the magnet frame. The electronics board contains the LED source, temperature compensation thermistors and all other associated signal processing components, including a 16-way IDC connector and the multi-turn zero and span potentiometers.

4.2 Handling of the Paracube® Premus-A

4.2.1 Special Packaging The Paracube® Premus-A is manufactured under clean conditions. Dust caps are fitted to the paramagnetic cell gas connectors before the product leaves the clean area to be boxed. The Paracube® Premus-A is fitted into an anti-static foam insert for transport, and it is recommended that the sensor is stored in the insert until required for production.

4.2.2 How to Handle the Paracube® Premus-A

Remove the Paracube® Premus-A body carefully from the anti-static foam packaging, using the recesses cut into the foam to access the side of the sensor. It is recommended that the normal anti-static handling procedures are applied. The Paracube® Premus-A should be fitted into the OEM equipment under clean conditions. In order to minimise the likelihood of contaminants entering the Paracube® Premus-A or the OEM system, do not remove the dust caps until the piping is ready to be fitted to the gas connectors.

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4.3 Minimise Exposure of Pneumatic System to Contaminants Keep the components of the pneumatic system, whether in the laboratory or in the production assembly area, away from the Adirty@ operations, such as drilling, packaging, filling, cutting, deburring and finishing. Assemble components in a separate positive pressure controlled room. Ensure all the components in the sample line tubing have been cleaned for oxygen service and are bagged immediately after cleaning.

4.4 Mechanical Arrangement

4.4.1 Mounting Arrangement The Paracube® Premus-A body provides two fixing locations using 3 off M4 threaded tapped holes. These fixing points must be used to mount the sensor to the OEM chassis. For positional and dimensional information refer to Appendix 8.2. Ensure there is clear access to the electrical connector and potentiometers.

4.4.2 Location of Sensor The sensor body should be fixed rigidly to the OEM assembly and away from vibrating components and in particular, care should be taken to avoid mounting the sensor onto a chassis or plate that may act as a lever or spring. If the OEM equipment is subjected to excessive mechanical shocks and vibration during use, it may be necessary to mount the sensor on shock absorbers to dampen the impact on the output of the sensor. The sensor should be protected from sudden temperature variations, such as from cooling fans, as this can affect both the zero and span calibrations. Fitting the sensor into a temperature controlled environment will eliminate varying environmental conditions and optimise its performance.

4.4.3 Orientation of Sensor To achieve optimum performance, the sensor should be operated in the orientation of calibration. Any small offsets resulting from a change in orientation may be removed by performing a single point offset correction or a full calibration.

CAUTION

When installing the Paracube® Premus-A using the M4 tapped holes note that the maximum insertion depth for the screws for both fixing locations is 6mm. Exceeding this depth may damage the sample cell body.

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4.5 Pneumatic Arrangement

4.5.1 Sampling Configuration of Paracube® Premus-A The sampling configuration for the Paracube® Premus-A should be such that the sample gas is fed into the top most gas connector and vented from the bottom most gas connector. Reference should be made to Appendix 8.2.

4.5.2 Conditioning of the Sample The purpose of the sampling system is to convey clean sample gas to the sensor and attention should be paid to the following areas when designing a pneumatic system: Particulates: Filtering must remove particles of greater than 3 micron size. Fluids and water: Use of a water separator or catch-pot will prevent inflow into the system. Humidity: Where appropriate the use of Nafion tube or similar is recommended. Sample temperature: To minimise condensation it is recommended that the sensor is operated at +10°C relative to the sample as dew point. Pump fluctuations: Depending on the type of sample pump used, it may be beneficial to install a damping volume of between 5mL and 50mL between the sensor and pump. Back Pressure Effects: The Paracube® Premus-A is a partial pressure device; hence where the sample gas is not exhausted directly to atmosphere care should be taken to avoid errors induced by variations in back pressure. Reverse Flow: The Paracube® Premus-A is designed such that the sample flow should enter port 1 and exit port 2, see appendix 8.2. Sudden reversal of the sample flow should be avoided as this may result in permanent damage to the sensor.

4.5.3 Typical Sample System The sample system shown in Figure 3 may be used to validate the performance parameters of the Paracube® Premus-A. It incorporates the elements that help optimise the performance of the Paracube® Premus-A in a typical OEM sample

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system. The final selection of the elements will depend on the application and the performance specification required of the system. Note: The flow through controller 1 should be set around 50ml/min greater than the flow through controller 2 (sample flow rate). Ensure that the flow through controller 2 does not exceed the rated specification of the sensor. The pneumatic components, including pipework, should be cleaned for oxygen service.

Figure 3 - Typical Sample System

4.5.4 How to apply Pressure Compensation to the Signal Output Complete the zero and span calibration procedures described in Section 5.

Store the pressure at calibration, Pcal.

To correct the oxygen output for changes in barometric pressure, apply the following formula:

PPcal reading Oxygen Current = Value Oxygen Corrected

R

where:

Pcal is the pressure reading taken at calibration. PR is the barometric pressure measured at the time of the oxygen reading.

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4.6 Electrical Arrangement

4.6.1 Power Supply (to be fitted by OEM) An external dc power supply is required to drive the electronics. See Section 3.3 for the specification.

4.6.2 Electrical Connections

All electrical connections to the Paracube® Premus-A are made through the 16-way IDC polarised low profile header P1. Refer to Figure 4. The mating female connector must be compatible with a MULTICOMP - MC9A22-1634 - HEADER, RIGHT ANGLE, 16WAY. If exposed to radiated fields greater than 3V/m cabling to the sensor must be shielded.

4.6.3 Earthing Arrangement The conductive paths within the sensor provide a discharge path for static electricity. The earth connection to the OEM host unit chassis star point must be made via the M3 tapped hole provided. This is located on the sensor magnet frame. Refer to Appendix 8.3.

4.6.4 Remote Zero and Span Adjustment Optional remote potentiometers for the Zero and Span adjustment may be fitted by the OEM. Remote zero: The remote potentiometer should be a high resolution multi-turn 10kOhm potentiometer. To use the remote zero adjustment: Connect the remote potentiometer terminals to P1/1 (CCW), P1/2 (CW) and P1/3 (WIPER). Adjust the sensor Zero potentiometer to its mid-position. Calibrate as described is Section 5. Remote span: The remote potentiometer should be a high resolution multi-turn 10kOhm potentiometer. To use the remote span adjustment: Adjust the sensor Span potentiometer RV2 to its fully clockwise position. Connect the remote potentiometer terminals to P1/7 (WIPER), P1/8 (CW) and P1/11 (CCW). Calibrate as described in Section 5.

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4.6.5 Electronic Thermometers Two reference outputs are available 1mV/Kelvin at P1/12, and 10mV/Celsius at P1/14. These may be used to control the Paracube® Premus-A ambient temperature.

4.6.6 Feedback loop failure indication. In the event of a servo loop failure the oxygen output P1/10 will take up one of two out of range oxygen values. The default (as supplied) failure indication is a negative value. There is an option for a positive failure indication. Default negative failure level: Oxygen output will be -1.0V for all scaled output ranges. Optional positive failure level: Oxygen output will scale by a factor of 2 times the normal FSD for the range chosen. The optional failure indication level may be activated by connecting P1/16 to +5V (pin 6). NB: For default failure indication, P1/16 must be left unconnected.

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Figure 4 - Electrical connections to plug P1

P1 Pin No.

Description

1

Remote Zero pot (CCW) (Optional)

2

Remote Zero pot (CW) (Optional)

3

Remote Zero pot (WIPER) (Optional)

4

0V Internally connected

5

Supply 0V

6

Supply +5V

7

Remote Span pot (WIPER) (Optional)

8

Remote Span pot(CW) (Optional)

9

O2 output 0V

10

O2 output signal

11

Remote Span pot (CCW) (Optional)

12

Sensor temperature (1mV/Kelvin)

13

Do not connect (Test only)

14

Sensor temperature (10mV/Celsius)

15

Do not connect (Test only)

16

Feed back loop failure indication

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5: Operation and Calibration This section describes how to set up the Paracube® Premus-A for calibration under different operating conditions.

5.1 Setting the desired output configuration Set the jumper (shorting link) arrangement to give the required output range. (See below). Jumper changes must be made prior to applying power to the sensor. Employ suitable ESD protection to the PCB during handling of static sensitive components.

01154 Main IDC header PL1 and jumper links header LK1 LK1 JUMPER CONFIGURATION: 0-100% 1V output – both jumpers located in LK1 pins 1-2 & 3-4 (jumper condition “A” below)

0-100% 4V output – remove jumper from LK1 pins 3-4 (see jumper condition “B” below) 0-25% 1V output – remove jumper from LK1 pins 1-2 (see jumper condition “C” below) 0-25% 4V output – remove jumper from LK1 pins 1-2 & 3-4 (see jumper condition “D” below)

Fig 5 – Jumper configuration for scaling voltage output.

PL1

LK1 /3-4 /1-2

(Magnet

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5.2 Start- up Checks

Following installation, it is recommended that the sensor is powered for half an hour under constant operating conditions before calibration. Following a change in ambient temperature the sensor should be allowed to stabilise for a minimum of 4 hours. The sensor should be calibrated at the zero and span points, as follows.

5.3 Calibration Equipment Test gas: Nitrogen Zero gas; Span gas >20% Oxygen concentration.

Gas flow controller: 50 to 200 ml/min.

A digital Voltmeter (0.1mV resolution).

A suitable adaptor to provide access to P1/9 and P1/10.

5.4 Calibration Procedure Using Optional Remote Potentiometers Ensure the remote potentiometers have been correctly installed and that the transducers on-board potentiometers have been adjusted in accordance with Section 4.6.4. Follow the procedures described in Section 5.5 and 5.6, as applicable, replacing references to AZero@ and ASpan@ potentiometers with ARemote Zero@ and ARemote Span@ potentiometers.

5.5 Calibration Procedure at Sea Level Set flow to zero using flow control valve on gas supply line.

Ensure outlet gas connector vents freely to atmosphere to eliminate back-pressure effects.

Apply power to the sensor. Select the nitrogen Zero gas.

CAUTION: Care must be taken not to exceed the maximum specified sample flow rate during the calibration procedure.

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Set Zero gas flow to the sample flow level as seen in the OEM host unit. Adjust the Zero potentiometer RV1 such that the output voltage on P1/10 wrt P1/9 reads 0V 0.2mV. Set Zero gas flow to zero using flow control valve on gas supply line. Select the Span gas. Set Span gas flow to the sample flow level as seen in the OEM host unit. Monitor the output voltage on P1/10 wrt P1/9, and set to the required level by adjusting the Span potentiometer RV2. For example, 25% oxygen span gas should be set to produce an output of 250mV if set to the 0-1 Volt for 0-100% oxygen range. If the sensor in scaled to a different voltage output, adjust values accordingly.

5.6 Calibration at High Altitudes The Paracube® Premus-A may be used at any altitude between 250m (770 ft) below sea-level and 5000m (15400 ft) above sea level.

Apply the calibration procedure described previously at the altitude of operation. However at extreme altitudes there may be insufficient span adjustment available. In this case replace the span calibration procedure above with the following. Adjust the span potentiometer RV2 fully clockwise

Select the Span gas. Set Span gas flow to the sample flow level as seen in the OEM host unit. Monitor the output voltage on P1/10 wrt P1/9, and adjust the coarse span potentiometer RV3 such that the output voltage is 20% greater than the calibration gas value. For example, 25% oxygen span gas should be set to produce an output of 300mV. Monitor the output voltage on P1/10 wrt P1/9, and set to the required level by adjusting the Span potentiometer RV2. For example, 25% oxygen span gas should be set to produce an output of 250mV if set to the 0-1 Volt for 0-100% oxygen range. If the sensor in scaled to a different voltage output, adjust values accordingly.

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6: TROUBLE SHOOTING GUIDE The generation of an Aoxygen error@ message by the OEM equipment may be due to the failure of one or more components of the system. The Trouble Shooting Guide may be used to help eliminate the Paracube® Premus-A as the root cause of the Aoxygen error@ message.

This guide describes the step-by-step tests that may be applied to a Paracube® Premus-A to determine whether it is functional, and if it is appropriate to return it to Hummingbird for further analysis. Follow the flow chart described in “Flow chart 1 – fault diagnostics” and perform the appropriate tests as described below.

Test 1 - Powered Gas Test To determine if the gas ports and sample cell are free of contamination and whether the suspension assembly in the sample cell has been damaged Equipment Required: Power supply for Paracube® Premus-A Adapter to access pins on Paracube® Premus-A connector P1 Digital voltmeter with 0.1mV resolution. Suitable flow control device (50 =>200/min). Clean dry nitrogen. Clean dry instrument grade air. Clean dry 100% oxygen. Procedure:

i. Connect the sensor under test to the P1 adapter and apply power.

ii. Connect the digital voltmeter to P1/10 wrt P1/9, switch on and select an

appropriate measurement scale dependent on the sensors range and output.

iii. Set the nitrogen test gas flow rate to zero and connect the sensor to the

nitrogen test gas.

iv. Set the nitrogen test gas at the host system sample gas flow rate, and allow

the sensor output to settle prior to noting the reading on the voltmeter.

v. Reduce the nitrogen test gas flow rate to zero.

vi. Select the air test gas, ensuring that the sample flow rate is set to zero.

vii. Adjust the air test gas to the host system sample gas flow rate, and allow the

sensor output to settle prior to noting the reading on the voltmeter.

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viii. Reduce the air test gas flow rate to zero.

ix. Select the oxygen test gas, ensuring that the sample flow rate is set to zero.

x. Adjust the oxygen test gas to the host system sample gas flow rate, and allow

the sensor output to settle prior to noting the reading on the voltmeter.

xi. Calculate and note the difference in mV between the nitrogen and air

readings. This should be correct for the selected range and output +/- 50% of

the expected mV value.

xii. Calculate and note the difference in mV between the air and oxygen test gas

readings. This should be correct for the selected range and output +/- 50% of

the expected mV value.

If the sensor fails to fall within either of the stated limits in the air and oxygen tests (Items xi and xii respectively) it has failed the Powered Gas Test 1. If the sensor meets the stated figures, it has passed Test 1.

Test 2 - Visual Examination To determine the presence of contaminants in the sample cell and the integrity of the optical components and the solder joints. Equipment Required: Calibrated torque driver fitted with M3 Allen key bit. (Set to 1.2Nm). Stereo-microscope with 15X to 30X magnification. Anti-static work surface and earthed wrist strap Procedure:

i. Fit the earthed wrist strap, and using the microscope examine the soldered

cell feedback connections, yellow & black wires. ii. Holding the sensor securely over the work bench de-solder the sample cell

feedback connections (yellow & black wires). Using the calibrated torque driver, release the sample cell locking mechanism and carefully remove the sample cell from the magnet frame.

iii. Using the microscope examine the components and junctions of the optics assembly paying attention to the soldered photo-cell connections (red & green wires), the photo-cell assembly checking for damage to and/or lifting of the photo-cell chips and the LED soldered connections.

iv. Using the microscope examine the sample cell for general contamination (loose particulates or evidence that liquids have been present). The pole piece area should be free from any magnetic particles.

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v. Using the microscope check the general form of the suspension paying attention to the suspension mirror which should be clean and not show signs of corrosion.

vi. A gentle movement of the sample cell should induce a rotation and then oscillation of the suspension assembly. This would imply that the suspension welds are sound.

If the examination described in Sections iii, iv and v above identifies evidence of contamination and/or damage, then the sensor has failed the Visual Examination, Test 2. Please refer to appendix 8.3 “Sample cell replacement”.

Following the visual examination, re-assemble the sensor in the following sequence.

Carefully refit the sample cell into the magnet frame, and tighten the sample cell locking mechanism using the calibrated torque driver. Re-solder the sample cell feedback connections: Yellow wire to yellow indicating dot, black wire to black indicating dot. Test 3 - Re-calibration Procedure

Equipment Required: As per the requirements for “Test 1- Powered Gas Test”, except for instrument grade air.

Procedure:

i. Adjust RV2 and RV3 fully clockwise. Connect the sensor to the P1 adapter

and apply power. ii. Connect and switch on the digital voltmeter, set the range dependent on the

scaled voltage output of the sensor. iii. Set the nitrogen test gas flow rate to zero, and connect to the sensor sample

cell gas inlet and outlet. iv. Set the nitrogen test gas to the host system sample gas flow rate, and allow

the sensor output to settle. v. Monitor the output voltage at P1/10 wrt P1/9 and adjust the zero

potentiometer RV1 to give 0V 0.4mV. vi. Select the oxygen test gas, ensuring that the sample flow rate is set to zero. vii. Adjust the oxygen test gas to the host system sample gas flow rate, and allow

the sensor output to settle. viii. Monitor the sensor output at P1/10 wrt P1/9 and adjust the coarse span

potentiometer RV3 to give 1.2V 40mV. ix. Monitor the sensor output at P1/10 wrt P1/9 and adjust the fine span

potentiometer RV2 to give 1.0V 2mV. If the sensor cannot be calibrated as above, it has failed Test 3.

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Trouble Shooting Flow Chart

START

REMOVE TxrHOST UNIT

HOST UNITCONTAMINATED ?

UNIT FUNCTIONAL

RETURN TO HUMMINGBIRD VIA OPERATING

UNIT

DISCARD

POWER GASTEST 1

VISUAL EXAM.TEST 2

RECALIBRATETEST 3

VISUAL EXAM.TEST 2

NO

PASS

PASS

FAIL

PASS

FAIL

FAIL

FAIL

PASS

YES

Flow chart 1 – fault diagnostics

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7: Maintenance, Warranty and Product Return

7.1 Tests on Suspected Faulty Sensor In the event of a suspected product failure, test the sensor by following the instructions given in the Trouble Shooting Guide, Section 6. The Trouble Shooting Guide will provide useful information on whether the sensor is at fault or whether it is system related. If the sensor is to be returned to Hummingbird for examination, use the original packing material to prevent damage in transit. All product returns must conform to the requirements of the Decontamination Protocol, described in section 7.6.

7.2 Product Failure during Warranty Hummingbird will replace a unit free of charge if it has failed whilst under warranty, providing that any failure is not due to misuse. For example, failures due to excessive flow, excessive pressure, contamination or condensate in the cell is regarded as misuse. Under these conditions Hummingbird reserves the right to charge for replacement.

7.3 Product failure out of warranty

Hummingbird will examine sensor returns on request in order to determine the reason for a reported product failure.

7.4 Maintenance

There is No Requirement for Regular Maintenance

Note: For Health and Safety reasons, Hummingbird reserves the right to refuses to examine product returned without a completed Decontamination Clearance Certificate. Apply appropriate anti-static handling procedures. Sensor returns must be packed in the original packing material to prevent damage in transit

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The Paracube® Premus-A offers the Hummingbird non-depleting paramagnetic technology, which means that the Paracube® Premus-A has an unlimited shelf life. The result is, that provided there is adequate control of flow and pressure, with no cell contamination by fluids or particulates, there are no components that will require regular maintenance. Replacement of Sample Cell If the sample cell becomes contaminated, it must be replaced. Please refer to Appendix 8.3 “Sample cell replacement”.

7.5 Spares

The available spares are: Sensor: Part No 01154000 Paramagnetic cell: Part No S0325000 Instruction Manual Part No 01154001A

7.6 Decontamination of the Paracube® Premus-A In order to meet the requirements of UK Health & Safety legislation, all sensor returns must be accompanied by a completed Decontamination Clearance Certificate a copy of which can be found on page 4 of this manual.

Note: Contaminated cells should be disposed of in accordance with local Environmental and Health & Safety regulations. They must not be shipped with returned product.

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8: APPENDICES

Appendix 8.1 Mechanical Vibration and Shock Resistance The sensor will meet the requirements of the following clauses of the International Standard IEC 68-2 Basic Environmental Testing Procedures. BS EN 60068-2-27:1993 (IEC 68-2-27) Shock Peak acceleration: 100g (980 ms-2) Duration: 6 ms Pulse shape: Half sine BS EN 60068-2-6:1996 (IEC 68-2-6) Sinusoidal Vibration Frequency range: 10Hz to 500 Hz Acceleration amplitude: 1g (9.8ms-2)

Type and duration of endurance: 10 sweep cycles in each axis IEC 68-2-34 Random Vibration, Wide Band Frequency range: 20Hz to 500Hz Acceleration spectral density: 0.02g2Hz-1 Duration: 9 min

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Appendix 8.2 Outline Dimensions of Pm 01154 (Drawing 01154/821)

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Appendix 8.3 Sample Cell Replacement Users must ensure they have the skills and knowledge necessary to undertake the procedures described below. Hummingbird does not accept any liability for any loss or damage incurred partially or wholly through any action based on the information provided on sample cell replacement below. Equipment Required: - Calibrated torque driver fitted with M3 Allen key bit. Set to1.2Nm. - Anti-static work surface and earthed wrist strap. Procedure: 1: Fit the earthed wrist strap, and de-solder the yellow & black wires from the cell feedback connections. 2: Hold the sensor securely over the work bench, and using the calibrated torque driver release the sample cell locking mechanism. Carefully remove the old sample cell from the magnet frame. 3: Re-assemble the sensor in the following sequence: Carefully fit the new sample cell into the magnet frame (yellow dot uppermost) ensuring that the cell is in contact with the lower magnet, and tighten the sample cell locking mechanism using the calibrated torque driver. Re-solder the sample cell feedback connections: Yellow wire => yellow indicating dot, black wire => black indicating dot. Recalibrate the sensor using the procedure detailed within section 6 of this operating manual.

CAUTION The magnets used in the sensor have a very strong magnetic field, and extreme care is advised during handling.

NOTE The old sample cell should be disposed of in accordance with the requirements of local regulations.

NOTE If the sensor is to be returned for failure analysis, the sample cell should be purged with clean dry nitrogen at a flow rate of 120ml/min for a minimum period of 24 hours.

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Appendix 8.4 Sample gas compatibility

Gas Formula

Gas

Formula

Acetylene

HCCH

Freon 114

C2Cl2F4

Allyl alcohol

CH2CHCH2OH

Halothane

C2HBrClF3

Argon

Ar

Helium

He

Benzene

C6H6

n-Heptane

C7H16

1,2 Butadiene

C4H6

n-Hexane

C6H14

1,3 Butadiene

C4H6

Hydrogen

H2

n-Butane

C4H10

Isoflurane (Forane)

C3H2F5ClO

iso-Butane

(CH3)2CHCH2

Krypton

Kr

iso-Butylene

(CH3)2CH=CH2

Methane

CH4

1 Butyne

CH3C3H2

Methyl cyclopentane

C6H12

Carbon dioxide

CO2

Monochlorobenzene

C6H5Cl

Carbon disulphide

CS2

Neon

Ne

Carbon monoxide

CO

Nitrogen

N2

Carbon tetrachloride

CCl4

Nitrous oxide

N2O

Carbon tetraflouride

CF4

n-Nonane

C9H20

Chloroform

CHCl3

n-Octane

C8H18

Cyclohexane

C6H12

Oxygen

O2

Cyclopentane

C5H10

Ozone

O3

Cyclopropane

C3H6

iso-Pentane

C5H12

Dichloroethylene

(CHCl)2

n-Pentane

C5H12

Freon 11

CCl3F

Phenol

C6H5OH

Freon 12

CCl2F2

Propane

C3H8

Freon 113

CHCl2CH2Cl

iso-Propanol

(CH3)2CHOH

Enflurane(Ethrane)

C3H2F5ClO

Propene

CH3CH=CH2

Ethane

C2H6

Propylene

C3H6

Ethanol

C2H5OH

Styrene

C6H5CH=CH2

Ethyl acetate

CH3COOC2H5

Tetrachoroethylene

Cl2C=CCl2

Ethyl chloride

C2H5Cl

Vinyl chloride

CH2=CHCl

Ethylene

C2H4

Xenon

Xe

Ethylene glycol

(CH2OH)2

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