Transcript
PROCESS ANALYSERS
SERVOTOUGH OxyExact (2213) Control Unit
Installation Manual
Part Number: Revision: Language:
02213/005A 10 UK English
This page intentionally blank
SERVOTOUGH OxyExact Installation Manual 02213005A_10 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 ......................................................................................................................... 5
2.1 OVERVIEW OF THE INSTALLATION .............................................................................................. 5 2.2 CONTROL UNIT OPTION CARDS ................................................................................................ 6 2.3 INSTALLATION LOCATION .......................................................................................................... 7 2.4 ELECTRICAL SUPPLY REQUIREMENTS ....................................................................................... 8 2.5 SIGNAL OUTPUTS/INPUTS ......................................................................................................... 8 2.5.1 MODBUS Communications ............................................................................................... 8 2.5.2 Analog Output Board ......................................................................................................... 8 2.5.3 Relay Board ..................................................................................................................... 10 2.5.4 Digital Inputs Board ......................................................................................................... 11 2.6 TAG NUMBERS ....................................................................................................................... 11 3. 3.1 3.2 3.3 4.
MECHANICAL INSTALLATION ............................................................................................. 12 UNPACKING AND INSPECTION.................................................................................................. 12 CONTROL UNIT DESCRIPTION ................................................................................................. 12 FIXING CENTRES.................................................................................................................... 13 ELECTRICAL INSTALLATION ............................................................................................... 15
4.1 CE MARKINGS ....................................................................................................................... 15 4.2 GLANDS AND CABLE ENTRIES ................................................................................................. 16 4.3 IDENTIFICATION AND LOCATION OF COMPONENTS .................................................................... 16 4.4 EARTH/GROUND REQUIREMENTS ............................................................................................ 18 4.5 ELECTRICAL POWER SUPPLY CONNECTION ............................................................................. 18 4.6 TRANSMITTER UNIT TO CONTROL UNIT CONNECTION............................................................... 19 4.6.1 Cable Termination Link ................................................................................................... 20 4.7 SIGNAL AND OUTPUT/INPUT CONNECTIONS ............................................................................. 20 4.7.1 MODBUS® Connection ................................................................................................... 21 4.7.2 Analog Output Board ....................................................................................................... 22 4.7.3 Relay Board ..................................................................................................................... 22 4.7.4 Digital Inputs Board ......................................................................................................... 23 5.
AUTOCALIBRATION OPTIONS ............................................................................................. 24
6.
INSTALLATION CHECK LIST ................................................................................................ 29
7.
ROUTINE MAINTENANCE ..................................................................................................... 30
APPENDIX 1
TECHNICAL SPECIFICATION .............................................................................. 31
APPENDIX 2
MODBUS PROFILE .............................................................................................. 32
APPENDIX 3
CERTIFICATION ................................................................................................... 42
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 FIGURES FIGURE 1-1: ATEX CERTIFICATION DETAILS ..................................................................................................... 4 FIGURE 1-2: IECEX CERTIFICATION DETAILS ..................................................................................................... 4 FIGURE 2-1: ANALYSER SYSTEM CONFIGURATIONS ............................................................................................ 6 FIGURE 3-1: MECHANICAL ARRANGEMENT ....................................................................................................... 14 FIGURE 4-1: ELECTRICAL CONNECTIONS ........................................................................................................... 17 FIGURE 5-1: AUTOCALIBRATION CYCLE ........................................................................................................... 25 FIGURE 5-2: AUTOCALIBRATION CONFIGURATIONS .......................................................................................... 27
TABLES TABLE 2-1: NAMUR NAS4 VS SYSTEM DISPLAY ............................................................................................ 10 TABLE 4-1: PATCH LEAD WIRE COLOURS .......................................................................................................... 22 TABLE 5-1: AUTOCALIBRATION LOGIC TABLE ................................................................................................... 26 TABLE 5-2: SOFTWARE CONFIGURATION OPTIONS ............................................................................................ 28 TABLE 6-1: INSTALLATION CHECKLIST ............................................................................................................. 29
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SERVOTOUGH OxyExact Installation Manual 02213005A_10
1. 1.1
INTRODUCTION 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: 02213/005A/10 Order as part number: 02213005A 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.
INTRODUCTION
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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 Explosion proof design, which means no instrument purge required 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
1.4.2
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) Optional Attributes
Four option slots exist; any of the following may be fitted into each slot:
2
mA card - two 4 - 20 mA outputs and two relays Relay card - four relays Digital input card - eight channels
INTRODUCTION
SERVOTOUGH OxyExact Installation Manual 02213005A_10 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 1/Division 1 areas (both gases and dusts) and is available with the following hazardous area approvals: USA
FM Class I, Division 1, Groups B, C and D FM Class II, Division 1, Groups E, F and G FM Class III, Division 1 T4, ambient temperature 50°C maximum
Also American Class I, Zone 1 approval, AEx d ia [ia IIC] IIB +H2, T4 (Ta = 50°C). Canada
CSA Class I, Groups B, C and D CSA Class II, Groups E, F and G CSA Class III Type 4X, T4, ambient temperature 50°C maximum
Also Canadian Class I, Zone 1 approval, Ex d ia [ia] IIB + H2, T4 (Ta = 50°C). Europe The control unit is ATEX approved (both gases and dusts) 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. Japan The control unit is approved by TIIS (Technical Institution of Industrial Safety) as intrinsically safe and flameproof. Code: Ex ia d IIC T4 International The control unit is IEC Ex approved non-incendive and intrinsically safe. Code: Ex d ia [ia Ga] IIC T4 Gb -20°C10mA at 12Vdc. When used as ‘Status' indicators, available functions are defined in accordance with NAMUR recommendation NA64, i.e.: NAMUR NAS4 Meaning terminology "Breakdown"
OxyExact 2200 system display
The measured signal is invalid due to Fault a fault on the transmitter unit or its peripheral equipment
"Check request" The measured signal is still valid but Maintenance required the "attrition reserves" will soon be used up. "In service"
Work is in progress on the transmitter Service in progress unit
Table 2-1: NAMUR NAS4 vs System Display In addition, a ‘message’ status function may be assigned.
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INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02213005A_10
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 2.6
Input voltage ON Input voltage OFF Nominal input current Isolation voltage
-
13 to 33 Vdc 0 to 6 Vdc at 0 to 1mA 5 mA/channel at 24 Vdc 500 V minimum
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.
INSTALLATION
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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 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 a 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 unit comprises two separate compartments (see Figure 3-1); Right: An explosion proof enclosure for the power supply and a card frame assembly. The electronics are of modular form and fit into seven positions within the card frame, the minimum configuration being: o Interfaces board o Processor board o Power supply unit
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MECHANICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02213005A_10
Optional signal input/output boards, as defined in Section 2.5, may be fitted. Connections to all status input/output boards and the electrical power supply are made inside this enclosure. Access to this enclosure is by releasing the locking screw in the explosion proof cover and unscrewing it anti(counter)-clockwise.
Left:
3.3
An enclosure for the display and keypad. The electronics within this enclosure are intrinsically safe. Connections to associated Servomex transmitters are made inside this enclosure. Access to this enclosure is by removing the four screws securing the cover, and opening the hinged door.
Fixing Centres
The control unit must be mounted vertically. See Figure 3-1for 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.
MECHANICAL INSTALLATION
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SERVOTOUGH OxyExact Installation Manual 02213005A_10
Figure 3-1: Mechanical arrangement Key to Figure 3-1 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
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MECHANICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02213005A_10
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 SERVOTOUGH OxyExact 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
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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 IP20. 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: Signal cable entries: Transmitter connection entries:
1 x 3/4" NPT 4 x 3/4" NPT 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.
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ELECTRICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02213005A_10
Figure 4-1: Electrical connections Key to Figure 4-1 12345-
Interfaces board Processor board Option board - analog output Option board - digital input Option board - relay
ELECTRICAL INSTALLATION
6789-
Network (MODBUS) connector Power supply terminals Mains fuse Transmitter connection block
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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 3-1) must always be connected to a local earth/ground. The terminal is suitable for:
Flexible conductors Solid conductors -
up to 10mm2 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 WARNING ATEX REQUIREMENTS Cable entry holes are provided as specified on the certified drawings for the accommodation of suitable BASEEFA certified flameproof cable entry devices, with or without the interposition of a suitable BASEEFA certified flameproof thread adaptor. Unused entries are to be fitted with suitable BASEEFA certified flameproof stopping plugs. Suitable flameproof cable entry devices, thread adaptors and stopping plugs certified as Equipment (not a Component) under an EC Type examination Certificate to Directive 94/9/EC may also be used in the manner specified above.
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. 18
ELECTRICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02213005A_10 The electrical supply terminals are suitable for:
Flexible conductors Solid conductors -
0.5 to 1.5mm2 (20 to 16 AWG) 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: 4.6
L N
-
Live (AC) Neutral (ACC) Protective earth/ground
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 Solid conductors -
0.5 to 1.5mm2 (20 to 16 AWG) 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. ELECTRICAL INSTALLATION
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 NOTE 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 WARNING ATEX REQUIREMENTS Cable entry holes are provided as specified on the certified drawings for the accommodation of suitable BASEEFA certified flameproof cable entry devices, with or without the interposition of a suitable BASEEFA certified flameproof thread adaptor. Unused entries are to be fitted with suitable BASEEFA certified flameproof stopping plugs. Suitable flameproof cable entry devices, thread adaptors and stopping plugs certified as Equipment (not a Component) under an EC Type examination Certificate to Directive 94/9/EC may also be used in the manner specified above.
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 Solid conductors -
0.5 to 1.5mm2 (20 to 16 AWG) 0.5 to 1.0mm2 (20 to 18 AWG)
Cables should be suitable for temperatures of at least 70°C.
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ELECTRICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02213005A_10 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 ELECTRICAL INSTALLATION
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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
white/green
green
white/orange
2
3
4
5
6
7
8
7
8
orange
TIA/EIA-568B 1
white/orange orange
4
white/green
5
6 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 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10
4.7.3
-
Analog output 1 +ve Analog output 1 -ve Relay 1, N/C: closes on power fail Relay 1, C: Common Relay 1, N/O: opens on power fail Relay 2, N/C: closes on power fail Relay 2, C: Common Relay 2, N/O: opens on power fail Analog output 2 +ve Analog output 2 -ve
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. 22
Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8
-
Relay 1, C: common Relay 1, N/O: opens on power fail Relay 1, N/C: closes on power fail no connection Relay 2, C: common Relay 2, N/O: opens on power fail Relay 2, N/C: closes on power fail no connection ELECTRICAL INSTALLATION
SERVOTOUGH OxyExact Installation Manual 02213005A_10 4.7.4
Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14 Pin 15
-
Relay 3, C: common Relay 3, N/O: opens on power fail Relay 3, N/C: closes on power fail no connection Relay 4, C: common Relay 4, N/O: opens on power fail Relay 4, N/C: closes on power fail
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 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14
-
Input common Input common Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 7 Channel 8 Switch supply Switch supply Switch supply Switch supply
ELECTRICAL INSTALLATION
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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. NOTES 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
SERVOTOUGH OxyExact Installation Manual 02213005A_10
NOTE 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. 2. 3. 4. 5. 6.
High calibration gas target concentration Sample gas concentration Low calibration gas target concentration High calibration gas tolerance concentration Low calibration gas tolerance concentration 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.
AUTOCALIBRATION OPTIONS
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 NOTE 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. NOTE Figure 5-2 is intended to demonstrate that there is no software change to the autocalibration routines - there may be additional preferred arrangements.
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AUTOCALIBRATION OPTIONS
SERVOTOUGH OxyExact Installation Manual 02213005A_10
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
AUTOCALIBRATION OPTIONS
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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
Gas Parameters
Time Parameters
Parameter
Units (in 2200)
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 of first autocalibration
Date and Time
Period between autocalibrations
Hrs/Days
Flush time for low calibration gas at stage 7 Flush time for high calibration gas at stage 9 (Stages associated Flush time for low calibration gas at stage 11 with figure) Flush time for final sample gas stage 13 Address' of relay assigned to sample gas (N/A for three-way calibration valves)
Minutes (decimals allowed)
Text
Address' of relay assigned to low cal gas Hardware Parameters
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
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AUTOCALIBRATION OPTIONS
SERVOTOUGH OxyExact Installation Manual 02213005A_10
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.
INSTALLATION CHECKLIST
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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.
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ROUTINE MAINTENANCE
SERVOTOUGH OxyExact Installation Manual 02213005A_10
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:
50VA
Physical:
Width: Height: Depth: Weight:
280mm 242mm (300mm including mounting) 250mm 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 1 – TECHNICAL SPECIFICATION
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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
01
Measurements and data for each registered transmitter.
101 – 200
02
All data is read-only.
201 – 300 … …
03 … …
1401 – 1500
15
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
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APPENDIX 2 – MODBUS PROFILE
SERVOTOUGH OxyExact Installation Manual 02213005A_10
Register offset 0-6 7-8 9 - 11 12 - 14 15 - 16 17 - 19 20 - 22 23 - 24 25 - 27 28 - 30 31 - 32 33 - 35 36 - 38 39 – 40 41 – 42 43 – 44 45 – 46 47 – 48 49 – 50 51 52 53 - 60
Name
Comments
A 13 character string denoting the user- entered transmitter name/tag. Final oxygen measurement in IEEE 754 floating Oxygen measurement point format. Gas formula Contains the text "O2 " (6 characters). Oxygen units A 5 character string containing the oxygen units. Analog input 1 The measurement value at analog input 1 in measurement IEEE 754 floating point format. A 6 character string containing the user- entered Analog input 1 description name of analog input 1. A 5 character string containing the user entered Analog input 1 units units of analog input 1. Analog input 2 The measurement value at analog input 2 in measurement IEEE 754 floating point format. A 6 character string containing the user- entered Analog input 2 description name of analog input 2. A 5 character string containing the user entered Analog input 2 units units of analog input 2. Internal pressure Internal pressure measurement in IEEE 754 measurement floating point format. Internal pressure A 6 character string containing the user- entered description name of the internal pressure measurement. A 5 character string containing the user- entered Internal pressure units internal pressure units. Low calibration gas concentration (gas 1) in IEEE Low target value 754 floating point format. Low calibration tolerance in IEEE 754 floating Low tolerance value point format. Low target compared Oxygen measurement value immediately before value low calibration in IEEE 754 floating point format. High calibration gas concentration (gas 2) in High target value IEEE 754 floating point format. High calibration tolerance in IEEE 754 floating High tolerance value point format. High target compared Oxygen measurement value immediately before value high calibration in IEEE 754 floating point format. Last low calibration action Indicates whether the last maintenance action was a check or a calibrate. Last high calibration Integer value: 0=none 1=check 2=calibrate action Name
Transmitter software ID
APPENDIX 2 – MODBUS PROFILE
A 16 character string containing the transmitter software identity.
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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
1 – 100
01
101 – 200
02
201 – 300 … … 401 – 500
03 … … 15
Comments 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 0 1 2 3 4-7
Description Transmitter Fault status raised Transmitter Maintenance Required status raised Transmitter Service In Progress status raised Transmitter Message status raised Unused (zero)
Status Conditions - Detail Fault Input Offset 8 9 10 11 12 13 14 15 16 17 34
Description Transmitter not responding. If set, the Fault status will be set and all other statuses will be zero. Raw Oxygen Input Voltage Low Fault Raw Oxygen Input Voltage High Fault Cell Temperature Low Fault Cell Temperature High Fault Pressure Low Fault Pressure High Fault Not used (zero) Cell Temperature Measurement Fault Paramagnetic Cell Feedback Fault APPENDIX 2 – MODBUS PROFILE
SERVOTOUGH OxyExact Installation Manual 02213005A_10 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35-39
Paramagnetic Cell Photocell Fault Low Flow Fault – internal flow sensor High Flow Fault – internal flow sensor Flow Sensor Fault – external flow sensor Flow Fault – external flow sensor Analog Input 1 Invalid – Fault 1 Analog Input 2 Invalid – Fault 1 Digital Input 1 Active – Fault 2 Digital Input 2 Active – Fault 2 Digital Input 3 Active – Fault 2 Digital Input 4 Active – Fault 2 Software Processing - Fail Non-Volatile Memory Fail Internal ADC Fail External ADC Fail System RAM Fail Program Integrity Fail Unused (zero) Maintenance Required
Input Offset 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 – 63
Description Raw Oxygen Input Voltage Low Check Raw Oxygen Input Voltage High Check Pressure Low Check Pressure High Check Warmup Time Exceeded Oven Temperature Measurement Check Feedback Check Photocell Check Low Flow Check High Flow Check Analog Input 1 Invalid – Maintenance Required 1 Analog Input 2 Invalid – Maintenance Required 1 Low Calibration Fail High Calibration Fail Pressure Compensation Calibration Fail Internal Pressure Transducer Calibration Fail Internal Flow Alarm Calibration Fail Digital Input 1 Active – Maintenance Required 2 Digital Input 2 Active – Maintenance Required 2 Digital Input 3 Active – Maintenance Required 2 Digital Input 4 Active – Maintenance Required 2 Using system Default Data Unused (zero)
APPENDIX 2 – MODBUS PROFILE
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 Service In Progress Input Offset
Description Analog Input 1 Invalid - Service Mode 1 Analog Input 2 Invalid - Service Mode 1 Digital Input 1 Active - Service Mode 2 Digital Input 2 Active - Service Mode 2 Digital Input 3 Active - Service Mode 2 Digital Input 4 Active - Service Mode 2 Controller Requested Service Mode Unused (zero)
64 65 66 67 68 69 70 71
Message Input Offset
Description Analog Input 1 Invalid – Message 1 Analog Input 2 Invalid – Message 1 Digital Input 1 Active – Message 2 Digital Input 2 Active – Message 2 Digital Input 3 Active – Message 2 Digital Input 4 Active – Message 2 Warming Up Unused (zero)
72 73 74 75 76 77 78 79 to 99
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.
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Register
Name
101 - 108
Control unit software ID
Comments A 16 character string containing the control unit software identity
APPENDIX 2 – MODBUS PROFILE
SERVOTOUGH OxyExact Installation Manual 02213005A_10 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 Discrete Input 6009 6010 6011 6012 6013 6014 6015 6016 6017 6018 6019 6020 6021 6022 6023 6024 6025 6026 6027 6028 6029 to 6032
Description System Data Defaults In Use Watchdog Fault Non-Volatile Memory Fail Communications Failure Software Processing Fail RAM Fail Program Integrity Fail Display Card Reset Option Card 1 Reset Option Card 2 Reset Option Card 3 Reset Option Card 4 Reset Option Card 5 Reset Option Card 6 Reset Option Card 7 Reset Option Card 8 Reset External Fault 1 1 External Fault 2 1 External Fault 3 1 External Fault 4 1 Unused (zero)
APPENDIX 2 – MODBUS PROFILE
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 Maintenance Discrete Input 6033 6034 6035 6036 6037 6038 6039 6040 6041 6042 6043 6044 6045 6046 to 6048
Description Option Card 1 Reset Override Option Card 2 Reset Override Option Card 3 Reset Override Option Card 4 Reset Override Option Card 5 Reset Override Option Card 6 Reset Override Option Card 7 Reset Override Option Card 8 Reset Override External Maintenance Required 1 1 External Maintenance Required 2 1 External Maintenance Required 3 1 External Maintenance Required 4 1 Invalid System Time/Date Unused (zero) Service In Progress
Discrete Input 6049 6050 6051 6052 6053 6054 to 6056
Description External Service Mode 1 1 External Service Mode 2 1 External Service Mode 3 1 External Service Mode 4 1 Controller Requested Service Mode Unused (zero) Message
Discrete Input 6057 6058 6059 6060 6061 6062 6063 6064 6065 6066 6067 6068 6069 6070 6071 6072
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Description Auto Calibration Group 1 In Progress Auto Calibration Group 2 In Progress Auto Calibration Group 3 In Progress Auto Calibration Group 4 In Progress Auto Calibration Group 5 In Progress Auto Calibration Group 6 In Progress External Message 1 1 External Message 2 1 External Message 3 1 External Message 4 1 Alarm History 80% Full Alarm History Full Calibration History 80% Full Calibration History Full Status History 80% Full Status History Full
APPENDIX 2 – MODBUS PROFILE
SERVOTOUGH OxyExact Installation Manual 02213005A_10 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 0 1* 2 3 4* 5 6* 7 8*
Meaning No autocalibration in progress Preparing for autocalibration Flushing with calibration gas 1 Flushing with calibration gas 2 Capturing calibration point for gas 2 Flushing with calibration gas 1 Capturing calibration point for gas 1 and applying new calibration Flushing with sample gas 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 00001 00002 00003 00004 00005 00006 00007 00008
Description Network Digital Input 1 Network Digital Input 2 Network Digital Input 3 Network Digital Input 4 Network Digital Input 5 Network Digital Input 6 Network Digital Input 7 Network Digital Input 8
APPENDIX 2 – MODBUS PROFILE
0 = open circuit, 0 = open circuit, 0 = open circuit, 0 = open circuit, 0 = open circuit, 0 = open circuit, 0 = open circuit, 0 = open circuit,
1 = closed circuit 1 = closed circuit 1 = closed circuit 1 = closed circuit 1 = closed circuit 1 = closed circuit 1 = closed circuit 1 = closed circuit
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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. Discrete Input Description 7001 7002 7003 7004 7005 7006 7007 7008
Network Relay 1 Network Relay 2 Network Relay 3 Network Relay 4 Network Relay 5 Network Relay 6 Network Relay 7 Network Relay 8
0 = De-energised, 0 = De-energised, 0 = De-energised, 0 = De-energised, 0 = De-energised, 0 = De-energised, 0 = De-energised, 0 = De-energised,
1 = Energised 1 = Energised 1 = Energised 1 = Energised 1 = Energised 1 = Energised 1 = 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 2-3 4-5 6-7 8-9 10 - 11 12 - 13 14 - 15 16 - 17
40
Description Network Analog Output 1 Network Analog Output 2 Network Analog Output 3 Network Analog Output 4 Network Analog Output 5 Network Analog Output 6 Network Analog Output 7 Network Analog Output 8
APPENDIX 2 – MODBUS PROFILE
SERVOTOUGH OxyExact Installation Manual 02213005A_10 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 2 – MODBUS PROFILE
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SERVOTOUGH OxyExact Installation Manual 02213005A_10 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.
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APPENDIX 3 – CERTIFICATES
SERVOTOUGH OxyExact Installation Manual 02213005A_10
APPENDIX 3 – CERTIFICATES
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SERVOTOUGH OxyExact Installation Manual 02213005A_10
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APPENDIX 3 – CERTIFICATES
SERVOTOUGH OxyExact Installation Manual 02213005A_10
APPENDIX 3 – CERTIFICATES
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SERVOTOUGH OxyExact Installation Manual 02213005A_10
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APPENDIX 3 – CERTIFICATES
