Product Part Number: 03601/000Manual Part Number: 03601001ARevision: 0Language: UK English

Instruction Manual

Paracube® PremusDigital Paramagnetic Oxygen Sensor Module

WARNINGS, CAUTIONS AND NOTES:

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

CAUTION - (USE): As the final conditions of use are outside Servomex's control, it is the responsibility of the equipment designer or manufacturer to ensure that this sensor is safely installed and suitable for the intended application.

NOTE: For safety reasons any sensor returned to Servomex must be accompanied by the Decontamination Clearance Certificate contained in this manual. Unless the cell is accompanied by this certificate, Servomex 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 Servomex Group Ltd.

DECONTAMINATION

CLEARANCE CERTIFICATE

1. It is hereby certified that the product returned and described below has either never been exposed to biological hazards or has been decontaminated according to the methodology stated in the Servomex Operating Procedure 06-202 and should be free from hazardous biological agents.

2. It is hereby certified that the product returned and described below has not been exposed

to chemical substances hazardous to health or to radioactive hazards.

Product

Form No: 06-202/1 Issue 1

Note: Failure to complete this certificate and attach it to the outside of returned goods packaging will result in handling delays and may incur costs.

Signed: Print Name: Position:

Company: Date:

1

CONTENTS

SECTION 1: INTRODUCTION ......................................................................................................3

1.1 Mechanical Specification ........................................................................................................3

1.2 External Power Supply Specification.....................................................................................4

1.3 Environmental Specification...................................................................................................4

1.4 Performance Specification......................................................................................................5

1.5 Servomex Paramagnetic Measurement Principles...............................................................7

1.6 Functional components...........................................................................................................7

1.6 Functional components...........................................................................................................8

SECTION 2: GUIDELINES FOR EVALUATION AND INTEGRATION........................................9

2.1 Handling ....................................................................................................................................9 2.1.1 Special Packaging.........................................................................................................9 2.1.2 How to Handle the Sensor ............................................................................................9

2.2 How to Minimise Exposure of Pneumatic System to Contaminants ..................................9

2.3 Mechanical Arrangement ......................................................................................................10 2.3.1 Mounting Arrangement ...............................................................................................10 2.3.2 Location of Sensor ......................................................................................................10 2.3.3 Orientation of Sensor ..................................................................................................10

2.4 Pneumatic Arrangement........................................................................................................11 2.4.1 Sampling Configuration...............................................................................................11 2.4.2 Conditioning of the Sample.........................................................................................11 2.4.3 Typical Sample System. .............................................................................................12 2.4.4 Applying External Pressure Compensation ................................................................13 2.4.5 Applying Internal Pressure Compensation .................................................................13

2.5 Electrical Arrangement..........................................................................................................14 2.5.1 Power Supply (to be fitted by OEM)............................................................................14 2.5.2 Electrical Connections.................................................................................................14 2.5.3 Earthing Arrangement.................................................................................................14 2.5.4 Electrical Separation ...................................................................................................15 2.5.5 Communication Protocol.............................................................................................15 2.5.6 Sensor Output .............................................................................................................15 2.5.7 Status Messages.........................................................................................................16 2.5.8 Sensor Serial Number.................................................................................................16

2.6 Operation and Calibration .....................................................................................................16 2.6.1 Start-up Checks ..........................................................................................................16 2.6.2 Calibration Gases........................................................................................................16 2.6.3 Calibration Procedure at Sea Level ............................................................................17 2.6.5 Single Point Adjustment..............................................................................................19

2

SECTION 3: WARRANTY AND PRODUCT RETURN...............................................................20

3.1 Product Failure during Warranty ..........................................................................................20

3.2 Product failure out of warranty.............................................................................................20

3.3 Maintenance............................................................................................................................20

3.4 Spares .....................................................................................................................................20

SECTION 4: APPENDICES ........................................................................................................21

Appendix 4.1 Outline Dimensions (Dwg 03601/821/0) ..................................................................22

Appendix 4.2 Sample Gas Cross Sensitivity Guide......................................................................23

Appendix 4.3 Mechanical Vibration and Shock Resistance.........................................................24

Appendix 4.4 Intrinsic Safety Certification ....................................................................................25

Appendix 4.5 Sample Cell Replacement ........................................................................................26

Appendix 4.6 Output and Status Flags ..........................................................................................27

3

SECTION 1: Introduction This section includes a description of the Paracube® Premus, its specification and an explanation of the Servomex paramagnetic measurement principle. The Paracube® Premus is a high performance paramagnetic oxygen sensor, designed to be incorporated into OEM instrumentation and deliver a reliable, accurate and low cost of ownership oxygen measurement. The sensor provides a digital output signal corresponding to a full measurement range of 0 to 100% O2. The Paracube® Premus uses the same paramagnetic measurement technology (described in Section 1.5 of this manual) as the Pm1158, which has been designed into numerous OEM products where reliability, long life and performance are key considerations. Servomex paramagnetic technology is non-depleting, which means that there are no consumable parts thus ensuring consistent performance over time. The selectivity of the paramagnetic measurement for oxygen results in negligible interference from other common background gases. The Paracube® Premus offers a stable and inherently linear measurement of oxygen. The inherent linearity of the Paracube® Premus makes it possible to calibrate it by checking two points only. There is no requirement for a reference gas during operation.

1.1 Mechanical Specification

See Appendix 5.1 for drawing no. 03601/821, “Outline Dimensions of Pm3601”. Dimensions (W X D X H) 80 x 88 x 55.5mm (3.15 x 3.46 x 2.16 ins) Weight 795gms Gas Connectors Two connections, 3.175mm (1/8") nominal OD, suitable for flexible or semi rigid tubing. Recommended Orientation Servomex label facing upwards. Materials in Contact with Gas Sample 316 stainless steel, viton ‘O’ ring, borosilicate glass, Electroless Nickel, platinum, platinum/iridium alloy,

4

1.2 External Power Supply Specification +5V dc ±5%, ripple and noise < 0.1V Pk to Pk. Current consumption: 5V supply rail = 75 mA (100mA max) A change of ±0.5V in supply Voltage results in a change of less than ±0.1% in oxygen concentration.

1.3 Environmental Specification Sample Gas Condition Dry, non-corrosive, free of entrained oil, less than 3 micron particulates. Non-condensing, dew point >10oC below the cell temperature. Pressure With the sample vented to atmosphere, the output signal is directly proportional to the barometric pressure. Operating Temperature 0oC to +65oC (32oF to 149oF) Storage Temperature -30oC to +70oC (-40oF to 158oF) Ambient Humidity 0 to 95% RH Altitude Range (Operating) -250m to +5000m (-770ft to +15400ft)

5

1.4 Performance Specification

Range (Operating) 0 to 100% O2 Range (Reporting – prior pressure compensation) -5 to 110% O2 Intrinsic error <± 0.1% O2 Zero stability 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 0 oC to +65 oC (32oF to 149oF) Zero: <± 0.03% O2/oC Span: <± 0.05% of O2 reading /oC Recommended sample flow rate 50 - 200ml/min Response time Rise Time (T10 - T90): 100% N2 to 100% Oxygen <2.5 sec at 200 ml/min Sample pressure range ±33kPag ( ±5psig ) Pressure drop across the cell <20mm H2O at 200ml/min Flow error A change of sample flow rate from 50 to 200ml/min produces a change in reading <0.1% O2.

NOTE

This specification applies when the sensor has been calibrated using standard gas values of Nitrogen and 100% O2.

Refer to Section 2.6 ‘Operation and Calibration’.

6

Soft magnetic material A change in the reading of <0.1% O2 will occur when a soft magnetic material is brought within 15mm of the case. Pneumatic leakage When pressurised to 20 psig the sample leak rate will be: < 0.5x10-6 atm ml/sec. Interference Effects The paramagnetic effect of common background gases at 20oC, for 100% concentration is shown below:

Interfering Gas Interference Effect (100% Interferant) (% 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 is outlined in the Servomex Application Note TN/34 (available on request). Tilt In the recommended orientation, a tilt of 15 degrees from the horizontal and with N2 in the cell, will cause a change in reading of less than 0.5% O2. 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 5.3. Intrinsic Safety Certification The sensor is component certified to: EExia IIC Baseefa 03ATEX0610U The power supply requirements for intrinsic safety applications are detailed in Appendix 5.4. Sample gas compatibility. Listed in Appendix 5.2 are gases that the standard sensor may be exposed to without compromising its performance.

7

1.5 Servomex Paramagnetic Measurement Principles 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, rare metal taut-band suspension. This 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.

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

Nitrogen filled glass spheres

Taut

Permanent magnets

magnetic field

Rotation

Mirror

Light source

Photodiodes

Current measurement

Conductive wire

Amplifier

8

1.6 Functional components

The main components of the Paracube® Premus are:

- The sensor Body - 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 machined 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 machined 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.

9

SECTION 2: Guidelines for Evaluation and Integration This section contains information to help achieve the optimum performance from the sensor when integrating into the host unit. It describes:

- Handling the sensor - How to minimise exposure of the pneumatic system to contaminants - Mechanical arrangement - Pneumatic arrangement - Electrical arrangement

2.1 Handling

2.1.1 Special Packaging

The sensor is manufactured in Class 10,000 clean room conditions. Dust caps are fitted to the paramagnetic cell gas connectors before the product leaves the clean area to be packaged. The sensor 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.

2.1.2 How to Handle the Sensor

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

2.2 How to 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 “dirty” operations, such as drilling, packaging, filling, cutting, deburring and finishing. Assemble components in a clean environment and ensure all the components in the sample line tubing have been cleaned for oxygen service and are bagged immediately after cleaning.

10

2.3 Mechanical Arrangement

2.3.1 Mounting Arrangement

The sensor body offers three M4 tapped fixing holes on its base for mounting the sensor to the OEM chassis. For positional and dimensional information refer to Appendix 4.1. Ensure there is clear access to the electrical connector.

2.3.2 Location of Sensor The sensor body should be fixed rigidly to the OEM assembly, away from vibrating components. If the OEM equipment is subjected to extensive 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 mounted away from soft magnetic materials. If this can not be avoided and a soft magnetic material is permanently fitted within 15mm of the sensor, the small error introduced will be nulled out during calibration. To minimise errors the sensor should not be mounted in an environment with varying ambient light levels. Protect the sensor 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 overcome varying environmental conditions and optimise its performance.

2.3.3 Orientation of Sensor The recommended orientation is shown in Appendix 5.1. Note that the Servomex label is facing upwards.

CAUTION:

When installing the sensor using the M4 tapped holes note that the maximum insertion depth for the fixing screws is 6mm. Exceeding this

depth may damage the sample cell body.

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2.4 Pneumatic Arrangement

2.4.1 Sampling Configuration The sampling configuration for the sensor 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 4.1.

2.4.2 Conditioning of the Sample The purpose of a sampling system is to convey clean sample gas to the sensor, with minimal effect on response time. Particulates and fluids must not enter the sample gas tubing as this may cause blockages and hence affect system performance. Field experience has demonstrated that when there is effective filtering of contaminants before the pneumatic system, many years of reliable and maintenance free operation are achievable from Servomex paramagnetic sensors. Attention must be paid to the following areas when designing a pneumatic system: Particulates: Filtering must remove particles greater than 3 micron. Fluids and water: Use of a water separator or catch-pot will prevent inflow into the system. Humidity: The sample gas dew point must be at least 10°C less than the sensor ambient temperature. This may be achieved by either drying the sample gas using additional components, or the sensor may be placed into an elevated temperature controlled environment. Sample temperature: By maintaining the sensor at a temperature of around 10°C above the gas sample, (and below the specified maximum operating temperature of 65°C) condensation within the sample cell will be avoided. Pump fluctuations: Fluctuations in flow will affect the sensor response time and oxygen output signal. Good flow control is essential for a high performance system. It is recommended that the sample is drawn through the sensor, fitting the pump downstream of the sensor. Depending on the type of sample pump used, it may be of benefit to install a damping volume of between 5 to 50ml between the sensor and pump to reduce the variation in output due to the pump pulsations.

12

Back Pressure Effects: Restrictions in the exhaust tube will cause the back pressure to vary with changes in flow rate. As the sensor is a partial pressure device, this will result in a change in observed oxygen output. Where the sample is not vented to the atmosphere, such as in a closed loop system, the pressure must be controlled or compensated for.

2.4.3 Typical Sample System.

The sample system shown in Figure 1 may be used to validate the performance parameters of the sensor. It incorporates the elements that help optimise the performance of the sensor in a typical OEM sample 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 1 Typical Sample System

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2.4.4 Applying External Pressure Compensation During the sensor calibration procedure the span gas value and pressure reading should be recorded. These values may then be used to correct the oxygen signal for changes in sample or barometric pressure according to the following formula (applies if both calibration points are made at the same pressure):

⎥⎦⎤

⎢⎣⎡×=

ind

calindcomp P

POO 22 %%

Where: % O2 comp : Compensated O2 value

% O2 ind : Current O2 value Pcal : Calibration pressure Pind : Current pressure

2.4.5 Applying Internal Pressure Compensation The sensor is capable of performing pressure compensation internally if provided with a pressure reading. The pressure reading must be transmitted to the sensor via the communication connection. To send a pressure reading to the sensor, first convert it to mBar (if in a different format), ensure that leading zeroes are suppressed and that there is no more than one digit after the optional decimal point, and then transmit the following ASCII coded string:

P0:Pcurrent where Pcurrent is the pressure reading to be used.

For example, if the ambient pressure is 972.6 mBar, transmit the following string to the sensor:

P0:972.6 followed by a carriage return. Pressure values must be in the range 570 to 1100 mBar. Pressure data can be transmitted to the sensor at any time, but pressure updates must be no more frequent than one per second. When internal pressure compensation is not used, the sensor uses a default pressure reading. As long as no external pressure reading is provided, no compensation takes place. As soon as a pressure reading is supplied, internal pressure compensation is used. If internal pressure compensation is used a pressure value must be provided before calibration, furthermore a valid two point calibration must be carried out before measuring an unknown oxygen concentration.

14

The calibration data recorded in the sensor memory includes pressure data. If the internal pressure compensation is no longer required, cycle power to the sensor then perform a valid two point calibration without supplying any pressure data.

2.5 Electrical Arrangement

2.5.1 Power Supply (to be fitted by OEM) The sensor requires an external power supply; refer to Section 1.2 for the specification.

2.5.2 Electrical Connections All electrical connections to the sensor must be made using the correct style of “Molex” connector:

4 way connector, “Molex” part number 22-01-2047. Crimp terminals, “Molex” part number 08-50-0032.

A listing of authorised “Molex” component distributors is available by accessing: www.molex.com Refer to Figure 2 for the sensor electrical pin out.

2.5.3 Earthing Arrangement The conductive paths within the sensor provide a discharge path for static electricity. The earth connection to the OEM host unit must be made via the M3 tapped hole provided. This is located on the sensor magnet frame. Refer to Appendix 4.1.

CAUTION

Failure to ensure correct electrical connections can result in irreparable damage being caused to the sensor.

CAUTION

If using internal pressure compensation, a pressure value must be provided before first calibration and a valid two point calibration must be carried out before measuring an unknown oxygen concentration. Failure

to do so may result in incorrect readings.

15

2.5.4 Electrical Separation

The electrical and communications connections to the sensor should be kept to a minimum length. The cable should be of a shielded 4-core construction; connect the electrical screen to the equipment chassis earth star point.

Power supply 0V. Rx Communcation ‘receive’. Tx Communcation ‘transmit’. +5V Power supply +5V.

2.5.5 Communication Protocol Sensor serial communications summary.

- Non return to zero format (NRZ) - 0 & 5 Volt signalling voltages - Full duplex - 19200-baud transmission rate - 1 start bit - 1 stop bit - No parity - No handshaking - ASCII text format - Non addressable

2.5.6 Sensor Output The sensor oxygen output is expressed as an ASCII character string with leading zeros being suppressed and replaced by spaces. The sensor will transmit 5 oxygen readings per second (refer to Appendix 4.6). Once power is applied to the sensor, there will be a delay of not more than 12 seconds prior to the oxygen reading becoming available.

Figure 2 Electrical connections

Tx +5V Rx

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2.5.7 Status Messages The sensor will transmit a status flag messages within 6 seconds of a condition being detected. Appendix 5.6 describes the status flags that may occur, giving possible causes and recommended actions. 2.5.8 Sensor Serial Number The sensor is identified by a unique serial number. This is assigned during manufacture and displayed on the sensor case. This serial number is stored in the sensor memory and may be accessed by sending ASCII ! followed by ASCII ↵. The sensor will respond within 400 msec by sending a fifteen digit serial number in the following format:

Pm3601: XXYYYZZZZ

2.6 Operation and Calibration This section describes how to set up the sensor for the initial evaluation and for calibration under different operating conditions.

2.6.1 Start-up Checks Following installation it is recommended that the sensor is powered for half an hour at normal operating conditions before calibration.

2.6.2 Calibration Gases Ensure calibration gas is certified to 0.1% oxygen accuracy. Gas flow controller: 50 to 200 ml/min.

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

Product number

Year code

Sequential day code Sequential identifier

17

2.6.3 Calibration Procedure at Sea Level The sensor calculates oxygen concentrations using two calibration values (cal 1 & cal 2), which are stored within the sensor memory. These calibration values are set during manufacture as: Cal 1 = 0 & Cal 2 = 100 i.e. 0% O2 & 100% O2 During calibration these values are modified by sending to the sensor the appropriate ASCII code for the current calibration gas followed by a carriage return. As an example for a 40% O2 calibration gas, send ASCII 40↵ or ASCII 40.0↵. The sensor should be allowed to stabilise at each calibration gas for at least 30 seconds, prior to sending the ASCII calibration code. To calibrate the sensor the instructions detailed in Flow chart 1 should be followed.

The sensor calibration procedure is demonstrated by way of an example. Here the factory set contents of cal 1 and cal 2 are modified such that cal 1 becomes 33% O2 and cal 2 becomes 55% O2. The contents of cal 1 & cal 2 memory locations for each stage are detailed within the shaded boxes.

Start

Allow the sensor output signal to stabilize (~30 sec)

Send ASCII code: Cal 1gas = 33.0% O2: ASCII 33↵

Apply cal 1 gas to the sensor (33% O2 in this example)

Stop

Apply cal 2 gas to the sensor (55% O2 in this example)

Allow the sensor output signal to stabilize (~ 30 sec)

Send ASCII code: Cal 2 gas = 55.0% O2: ASCII 55↵

Flow chart 1.

Cal 1 = 0% O2 Cal 2 = 100% O2

Cal 1 = 33% O2 Cal 2 = 100% O2

Cal 1 = 0% O2 Cal 2 = 100% O2

Cal 1 = 33% O2 Cal 2 = 100% O2

Cal 1 = 33% O2 Cal 2 = 100% O2

Cal 1 = 33% O2 Cal 2 = 55% O2

18

NOTE

If the sensor is presented with a calibration concentration that does not match either of the current cal 1 or cal 2 values, the oldest stored value will be overwritten. A ‘C’ flag might be appended until the second gas

point is calibrated.

NOTE

It is important that the sensor be calibrated in the orientation of intended use. Changes in orientation after calibration may result in oxygen

reading errors.

NOTE

The cal points are independent of each other but the sensor will append a ‘C’ flag to the output if the difference between the cal 1 & cal 2 values is less than 0.5%. However, a minimum of 20% difference is recommended

in order to maintain performance within specification. Optimum accuracy will be achieved by using 0 and 100% as the cal points.

If the application violates this restriction contact Servomex Applications.

NOTE

It is important to note that no input values can be presented to the sensor during a calibration or serial number interrogation cycle.

If an input value is presented during either of these cycles a ‘B’ status flag will result.

NOTE

The sensor will only recognise a valid ASCII string if it is followed by an ASCII carriage return.

In the event of a non-valid character string being sent, a ‘B’ error flag will be appended to the oxygen reading.

To clear this error flag send a carriage return, and then either calibrate the Sensor or interrogate the electronic serial number.

NOTE

During the time period required for the sensor to process new calibration values the Sensor will output an ASCII ‘S’ character string. This process

lasts approximately 2 seconds for each calibration value.

19

2.6.5 Single Point Adjustment To optimise measurement accuracy between routine two point calibrations, a single point adjustment may be made. It is recommended that this type of adjustment be made within the host unit software. Apply a known concentration of oxygen e.g. Air (20.9% O2) to the sensor, and store in the host system memory the difference between the oxygen reading and the known oxygen concentration. Subsequent oxygen readings may then be corrected by removing this stored offset value.

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SECTION 3: Warranty and Product Return

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

3.2 Product failure out of warranty Servomex will examine sensor returns on request in order to determine the root cause for a reported product failure.

3.3 Maintenance There is no requirement for regular maintenance as the sensor uses Servomex’s non-depleting paramagnetic technology, which means that the sensor has an unlimited shelf life. The result (provided there is adequate control of flow, pressure and no cell contamination by fluids or particulates) is that there are no components that will require regular maintenance. Replacement of Sample Cell If the sample cell becomes contaminated it must be replaced by an experienced engineer (refer to Appendix 4.5 ‘Sample Cell Replacement’). Alternatively, Servomex may service the unit.

3.4 Spares The available spares are: Sensor Part No 03601000 Paramagnetic cell Part No S0325000 Instruction Manual Part No 03601001A

NOTE:

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

with returned product.

21

SECTION 4: Appendices

22

App

endi

x 4.

1 O

utlin

e D

imen

sion

s (D

wg

0360

1/82

1/0)

23

Appendix 4.2 Sample Gas Cross Sensitivity Guide

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

24

Appendix 4.3 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 m/s2) Duration: 6 msec Pulse shape: half sine

BS EN 60068-2-6:1996 (IEC 68-2-6) Sinusoidal Vibration Frequency range: 10Hz to 200 Hz Acceleration amplitude: 1g (9.8 m/s2) 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: 0.02 g2/Hz Duration: 9 min

25

Appendix 4.4 Intrinsic Safety Certification If compliance with intrinsically safe component certification is required, the following power limitation requirements must be applied to the sensor. P1 pin 4: Maximum voltage = 5.9V. Maximum current = 3.3A peak, 0.17A continuous (fused). Maximum power = 1.0W. All other connections to P1: Maximum voltage = 5.9V. The total power entering all other P1 connections must be limited by series resistance to 0.1W or less.

26

Appendix 4.5 Sample Cell Replacement Users must ensure they have the skills and knowledge necessary to undertake the procedures described below. Servomex 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 cell feedback connections,

(yellow & black wires).

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 it 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 2.6 of this operating manual.

NOTE

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

CAUTION

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

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.

27

Appendix 4.6 Output and Status Flags The resolution is 0.001% oxygen. The general format for the output is as follows: Hundreds digit Replaced by <space> instead of leading zero. Could also show <minus> for negative reading.

Tens digit Replaced by <space> instead of leading zero. Could also show <minus> for negative reading.

Units digit Always a number. Will show zero if leading zero Decimal point Tenths digit Hundredths digit Thousandths digit Space Can be replace by <B> if error occurs

Space Can be replaced by <C> if error occurs

Space Can be replaced by <E> or <M> if error occurs

Carriage Return

20.9% Oxygen will be shown as: <space><2><0><.><9><0><0><space><space><space><carriage return> Status Flags:

Status Flag Sensor Output Possible Cause Recommended Action

X ‘X’ character string Electrical or sensing

element malfunction Return sensor to Servomex

E O2 reading with error flag ‘E’ appended

Sensor is being operated outside of specification e.g. temperature

Check operating conditions. Perform calibration. If ‘E’ flag persists return sensor to Servomex

Incorrect character string sent to sensor or character string sent during calibration

Send carriage return and interrogate for serial number

B

O2 reading with error flag ‘B’ appended

Invalid calibration conditions Send carriage return and perform calibration

C O2 reading with error flag ‘C’ appended

Difference between cal 1 and cal 2 values <0.5% O2

Check calibration gases and repeat calibration procedure.

S ‘S’ character string Calibration in progress Wait for calibration to complete <10

sec

M

O2 reading with error flag ‘M’ appended

Photodiode current < check limit. O2 value outside specified limits.

Repeat calibration ensuring all conditions are valid including temperature and pressure. If error persists return to Servomex.

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