SST OXY-Flex Manual de usuario

DS0073 Rev 10

FEATURES

 High accuracy linear output

 Configurable outputs:

4-20mA and 0-10VDC or RS232 comms

interface

 Selectable output measurement ranges:

Standard ranges of 0-25% O2 and

0-100% O2or fully adjustable via RS232 when

configured in 0-100% O2mode

 Externally triggered automatic or manual

calibration

 Can be calibrated in normal air (20.7% O2) or in

any other known O2 concentration

 Cycling 3.3VDC logic output allows direct

monitoring of the O2 sensor pump cycle for

diagnostic purposes

 Selectable output filtering allows adaptive, fast

and dynamic or slow and stable output

SPECIFICATIONS

Maximum ratings

Supply voltage 24VDC ± 10%

Current consumption 500mA max

@ 24VDC

4-20mA Load 100 to 600Ω

Temperature limits (electronics enclosure)

Storage -10 to 85C

Operating -10 to 85C

Temperature limits

(permissible gas temperature at sensor tip)

Operating (Standard Temp) -100 to 250C

(High Temp) -100 to 400C

Gas flow rate 0 to 10 m/s

Weight <450g

Incidental permissible acceleration 30g

Repetitive permissible acceleration 5g

Sealing Rating IP65

OXY-Flex-0-H

APPLICATIONS

 Combustion control including oil, gas and

biomass boiler applications

 Composting

 Laboratory & building air quality monitoring

including confined space personnel safety

 Industrial process control i.e. gas mixing for

welding and steel making

 Oxygen generation systems

 Medical

 Scientific including respiratory studies of a

community or an organism, plants and

animals

 Food and beverage packaging

 Applications where low oxygen is key

including fermentation, rust and corrosion

prevention, inerting and purging

OXY-Flex Oxygen Analyser

DS0073 Rev 10

DESCRIPTION

The OXY-FLEX-X Series Standard Temperature

Oxygen Analyser is designed to determine the oxygen

concentration in air or inert gas mixtures with temperatures

of -100 to +250°C max.

The OXY-FLEX-X-H Series High Temperature Oxygen

Analyser is designed to determine the oxygen

concentration in air or inert gas mixtures with temperatures

of -100 to +400°C max.

These products are particularly suitable for measuring

oxygen in areas that are not easily accessible, or in

closed systems, such as ventilation pipes, flues and

containers.

The OXY-FLEX Series can be user configured to output

measuring ranges of 0-25% O2 and 0-100% O2 . The entire

measurement range is linear in both cases. Factory default

is 0-25% O2. When configured for 0-100% O2 the user can

also customise the analogue output ranges to suit their

application.

The outputs can be configured to either

4-20mA and 0-10VDC or RS232 interface. Prior to

shipping all OXY-FLEX’s are preconfigured with a

measuring range of 0.1% to 25% Vol. O2with linear

4-20mA and 0-10VDC outputs.

All settings can be changed by the customer should their

measurement or interface requirements change by simply

altering the position of jumper links on the PCB.

The actual oxygen sensor is mounted in the tip of the

stainless steel probe and is protected by a stainless-steel

sintered cap which acts as both a large particulate filter

and also as a flame trap. The IP65 waterproof die-cast

aluminium housing accommodates the electronics and is

mechanically connected to the sensor probe.

The OXY-FLEX outputs the measured values

simultaneously via 2 output channels (4-20mA and

0-10VDC or RS232 Rx and Tx) both channels are

referenced to the system GND.

A digital 3.3VDC logic output cycles at the same

frequency as the electrochemical pumping action of the

oxygen sensing cell during normal operation, thus

providing a real time sensor health check, if the output

ceases to cycle the sensor has entered a start-up or error

state. This provides fault proof operation. The digital

output is also used during the calibration process to

indicate the interface status.

A green on-board LED mirrors the CYCLE output and can

be used to visually determine the sensor status or during

the calibration process. A red LED indicates the unit has

power applied.

SST’s range of oxygen sensors do not directly measure

the oxygen concentration but instead measure the partial

pressure of oxygen within the measurement gas. In order

to output an oxygen concentration (%) the OXY-FLEX

must be calibrated, or more specifically, re-referenced in a

known gas concentration, typically normal air.

Calibration, or re-referencing, is achieved by connecting

the calibration input to GND and monitoring the status of

the digital cycle output or by visually monitoring the

on-board green LED. During the calibration process the

output will either automatically calibrate to a fixed

reference or can be manually calibrated to any output by

way of a PCB mounted potentiometer. The fixed

reference is factory set to 20.7% O2for calibration in

normal air though this value may be altered via the RS232

interface for calibration with a reference gas of any known

oxygen concentration. Calibration is stored on power loss.

Again the auto or manual calibrate function is user

configurable. Regular calibration removes the effects of

application and atmospheric pressure changes and also

eliminates any sensor drift that may occur during the first

few hundred hours of operation.

For more detailed information on the operation of

SST Sensing Oxygen Sensors please refer to the

following application note via our website:

AN0043 Operation Principle and Construction of

Zirconium Dioxide Oxygen Sensor.

OXY-Flex Oxygen Analyser

DS0073 Rev 10

PERFORMANCE CHARACTERISTICS

Characteristics Min. Typ. Max. Unit

Output inactive start up delay (heater warm up) 60 s

Initial warm up time (till stable output) 5 10 min

Measuring ranges

25% Configuration

100% Configuration

0.1 (1)

100

% O2

Accuracy After Calibration (2) (3) 1 % O2

Repeatability After Calibration (2) 0.5 % O2

0-10 VDC Output Resolution 0.01 V

4-20mA Output Resolution 0.01 mA

RS232 Output Resolution 0.01 % O2

Reaction time (adaptive output filtering in normal air) 1 s

Notes:

(1) Prolonged operation below 0.1% O2can damage the sensing element.

(2) Assuming barometric pressure remains constant.

(3) As the O2 sensor measures the partial pressure of oxygen (PPO2) within the measurement gas deviations in the

Barometric Pressure (BP) from that present during calibration will cause readout errors proportional to the

change. For example if the sensor was reading 21% O2at 1013.25mbar and the BP increased by 1% the sensor

readout would also increase by 1% to 21.21% O2.

OXY-Flex Oxygen Analyser

DS0073 Rev 10

OUTLINE DRAWING AND MOUNTING INFORMATION

Mounting holes accessible on

removal of housing lid

PCB LAYOUT (REMOVE HOUSING LID TO VIEW)

OXY-Flex Oxygen Analyser

DS0073 Rev 10

ELECTRICAL CONNECTIONS

Housing Connector: Amphenol Ecomate C016 30C006 100 12

Mating Connector: Binder 99-4218-00-07

(Mating Connector supplied with each product)

Output pins 5 and 6 are both referenced to the supply GND (pin 2). Due to high current flow in the supply GND, when

monitoring the 0-10VDC output (pin 6) it is recommended that a separate GND wire for the measurement system is taken

from PIN 2. This removes errors due to voltage drops in the power supply connections.

SYSYEM BLOCK DIAGRAM

PIN Description

1 24VDC ± 10%

2 GND

3Calibrate

4 Cycle

5 4-20mA/RS232 Tx

6 0-10VDC/RS232 Rx

CENTRE Housing/Probe Earth

OXY-Flex Oxygen Analyser

DS0073 Rev 10

OXY-Flex Oxygen Analyser

RS232 COMMUNICATION SETTINGS

When connecting the OXY-FLEX via the RS232 connections ensure Tx goes to Rx of the PC and Rx goes to Tx of the

PC.

The OXY-Flex communicates via standard COM port settings that are default on most PCs and many other RS232

compatible devices. If however communication problems are occurring use the settings below to configure the PC or

device COM Port.

DS0073 Rev 10

CONFIGURATION

The OXY-FLEX may be reconfigured at any time by

adjusting the position of the header pin jumper links on the

interface PCB.

WARNING: Prior to re-configuration the OXY-FLEX MUST

be powered down. The jumper links MUST also be

repositioned correctly and in the correct orientation.

Failure to adhere to the above could result in product

damage. Products damaged due to incorrect

configurations will not be covered under warranty.

 Power down the OXY-FLEX

 Remove the lid using a Philips screwdriver

 Adjust the position of the jumper links to the desired

configuration. The diagrams below and on Page 4

show the correct positioning for each user

configurable option. Thin nosed pliers should be

used to remove and replace the Jumper Links.

Ensure the Jumper Links are correctly seated before

reapplying the power

NOTE: Each Jumper Link must be placed in one of the two

positions. When selecting the output, you must choose

either 4-20mA and 0-10VDC or RS232 Tx and Rx. Ensure

the Jumper Links are always inserted horizontally between

2 adjacent pins.

RS232 OPERATION

With the OXY-FLEX RS232 outputs connected to a PC or

any other RS232 compatible device the user has the

ability to access two modes of operation, continuous data

streaming and the menu screens. Recommended

programs for communicating via PC serial RS232 are

Hyperterminal (windows default), Teraterminal and PuTTY.

A freeware PuTTY link can be found below;

http://the.earth.li/~sgtatham/putty/latest/x86/putty.exe

Continuous Data Streaming

On power up, after the initial 60s heater delay, the OXY-

FLEX will automatically begin outputting the measured O2

concentration and sensor Td as both an averaged and raw

value. The averaged values give a stable output with the

amount of averaging user variable whilst the raw un-

averaged values allow the user to detect sudden oxygen

changes. The averaged value is the measurement output

on both the 4-20mA and 0-10VDC outputs. The sensor Td

value is the measure of the partial pressure of oxygen in

the measurement gas. The O2concentration (%) is the Td

value scaled by the stored calibration value.

To stop or restart the data streaming ‘s’ (lower or upper

case) should be sent to the unit. Data streaming

automatically ceases during calibration.

Menu Screens

If the OXY-FLEX receives an enter character from the

connected PC or device it automatically enters the menu

password screen and stops outputting O2% and Td

values. After the correct password is entered followed by

the enter character, the menu screens are accessed. The

menu screens are primarily for diagnostics and information

although there are user configurable options that may be

changed. These are the automatic O2calibration %, the

amount of output filtering (averaging) and the analogue

output ranges. All three processes are further described

on Page 8. The menu access password may also be

changed by the user.

Changing the Menu Access Password

The password is factory set to ‘default’. This however may

be changed to a user specific password.

 Connect the OXY-FLEX via the RS232 interface to

the PC.

 Press Enter then enter your current security

password. Press Enter to access the menu screen.

 In the Configuration menu (menu 2) enter ‘3’ to

access the password menu screen.

 Enter the new password then press Enter to save.

 The new password is now stored in memory and is

retained on power loss.

Pressing ESC returns the screen to the previous menu.

OXY-Flex Oxygen Analyser

DS0073 Rev 10

RS232 USER CONFIGURABLE OPTIONS

Changing the Automatic Calibration Value

The system is factory set to automatically calibrate to

20.7% O2to allow simple calibration in normal air. The

auto calibration value is factory set to 20.7% to take into

account average humidity in the atmosphere. If a

calibration with a gas of a different known O2

concentration is required the factory set value may be

changed via the RS232 interface.

 Connect the OXY-FLEX via the RS232 interface to

the PC. See CONFIGURATION on Page 7.

 Press Enter then enter your security password.

Press Enter to access the menu screen.

 In the Configuration menu (menu 2) enter the auto

calibration value screen (option 1 - Enter

Auto Calib).

 The number entered should be the oxygen

concentration (%) of the calibration gas to 2 decimal

places. Press Enter to save.

 The new Automatic Calibration value is now stored

in memory. This value is retained on power loss.

If calibration is required with a different gas of known O2

concentration and access to the RS232 menus with a PC

is not available in order to change the calibration

percentage, a manual calibration must be performed.

Variable Output Filtering (Td Averaging)

The OXY-FLEX is factory default to use adaptive output

filtering to give an optimum balance between output

stability and response to oxygen changes. However this

balance may be altered by the customer to suit the needs

of the application.

 Connect the OXY-FLEX via the RS232 interface to

the PC. See CONFIGURATION on Page 7.

 Press Enter then enter your security password.

Press Enter to access the menu screen.

 In the Configuration menu (menu 2) enter the Td

average screen (option 2 - Enter Td Averaging).

 The number entered should be between 0 and 200.

0 for adaptive filtering (recommended), 1 for very

fast and dynamic output response but relatively

unstable to 200 for an extremely stable output but

very slow response to oxygen changes.

 Press Enter to save.

 The new averaging value is now stored in memory.

This value is retained on power loss.

Adjusting the Minimum and Maximum Ranges of the

Analogue Outputs (4-20mA and 0-10VDC)

The OXY-FLEX is factory default to output a range of

0-25% O2via its two analogue outputs. This range can be

expanded to 0-100% O2as described on Page 7. When

the unit is reconfigured to output 0-100% O2the user also

has the option to fully customise the output ranges via

RS232. This is extremely useful in applications where the

O2variation is within a narrow band as it allows the

analogue outputs to be tailored to this limited range.

 Ensure the OXY-Flex is configured for 0-100% and

RS232 operation, See CONFIGURATION on Page

 Connect the OXY-FLEX via the RS232 interface to

the PC.

 Press Enter then enter your security password.

Press Enter to access the menu screen.

 In the Configuration menu (menu 2) enter the

maximum range screen (option 3 - Enter O2 Max

Range).

 The number entered should be between 1.00 and

100.00 to represent the maximum output range. The

number must also be greater than the saved

minimum range.

 Press Enter to save the ESC to return to the

configuration menu.

 Enter the minimum range screen (option 4 - Enter

O2 Min Range).

 The number entered should be between 0.00 and

99.00 to represent the minimum output range. The

number must also be less than the saved maximum

range.

 Press enter to save.

 The new ranges are now stored in memory and are

retained on power loss.

An example of changing the min and max output ranges

would be in an normal air atmosphere where the O2range

is between 20-21%. The user could set the minimum

output range to 19% and the maximum output range to

22% and the outputs would vary linearly in between. The

min and max ranges lock out the outputs at the set limits

so 19% O2or lower would set the analogue outputs to

0VDC/4mA and 22% O2or higher would set the analogue

outputs to 10VDC/20mA.

The min and max range adjustment does not apply to the

RS232 output and is overruled if the unit is reconfigured

for 0-25% operation.

OXY-Flex Oxygen Analyser

DS0073 Rev 10

CALIBRATION PROCEDURES

Automatic Calibration

 Ensure the OXY-FLEX is configured for automatic

calibration. See CONFIGURATION on Page 7.

 Place the sensor probe in the calibration gas,

typically normal air.

 Allow the output to stabilise for at least 5 mins. 10

mins if powering from cold.

 Apply GND to the CALIBRATE input (PIN 3) for a

minimum 12s. During the 12s the CYCLE output

(PIN 4) and the green LED will go high/on, blink

rapidly, go high/on, go low/off then return to cycling

normally to indicate normal operation has resumed.

At this point remove GND from PIN 3.

 The output will now track to the correct value for the

calibration gas.

 Calibration is complete. Calibration values are

retained on power loss.

Manual Calibration

 Ensure the OXY-FLEX is configured for manual

calibration. See CONFIGURATION on Page 7.

 Place the sensor probe in the calibration gas,

typically normal air.

 Allow the output to stabilise for at least 5 mins. 10

mins if powering from cold.

 Apply GND to the CALIBRATE input (PIN 3) for a

minimum 5s or until the CYCLE output and green

LED blink at a steady 1Hz. Remove GND from PIN

3. Manual Calibration is now initialised.

 Adjust the MANUAL CAL POT until the output

equals the correct value of the calibration gas

concentration.

 Re-apply GND to PIN 3 for a minimum 5s. During

the 5s the CYCLE output/LED will blink rapidly, go

high/on, go low/off then return to cycling normally to

indicate normal operation has resumed. At this point

remove GND from PIN 3.

 The output will now track to the correct value for the

calibration gas.

 Calibration is complete. Calibration values are

retained on power loss.

SEE PAGE 4 FOR THE LOCATION OF THE SENSOR/

POWER LEDs AND THE MANUAL CAL POT.

ERROR CONDITIONS

If the oxygen sensor is damaged the OXY-Flex will

highlight this by blinking the CYCLE output (pin 4) and

green LED in a 3 short blinks 1 long blink pattern or

continuously OFF. An error code is also displayed on the

RS232 output and the analogue outputs will go to 4mA

and 0V.

OXY-Flex Oxygen Analyser

DS0073 Rev 10

OXY-Flex Oxygen Analyser

SENSOR OPERATING TIPS

To get the best performance from the OXY-Flex analyser it is important that the oxygen probe is installed and

maintained in the correct manner. The following two pages outline some useful sensor operating tips and a list of gases

and materials that must be avoided to ensure a long sensor life.

Operating the Sensor in Aggressive Humid Environments:

When operating the sensor in warm, humid environments it is important the sensor remains at a higher temperature

than it’s surroundings, especially if there are corrosive components in the measurement gas. During operation this is not

a problem due the 700°C generated by the heater, but this means when the sensor or application is being powered

down the sensor heater must be the last thing to be turned off after the temperature of the surroundings have suitably

cooled. Ideally the sensor should be left powered at all times in very humid environments.

Failure to adhere to the above will result in condensation forming on the heater and sensing cell as these will be the first

components to cool due to their connections to the outside world. When the sensor is re-powered the condensation will

evaporate, leaving behind corrosive salts which very quickly destroy the heater and cell as illustrated below. Note how

the sensor’s external metalwork looks completely normal.

Protecting from Water Droplets:

In environments where falling water droplets are likely the sensor should be protected from water falling directly onto the

very hot sensor cap as this can cause massive temperature shocks to the cell and heater. Popular methods include a

hood over the sensor cap or for the sensor to be mounted in a larger diameter cylinder.

At a very minimum the sensor cap should be angled downwards in the application as this will deflect any falling moisture

and prevent the sensor cap from filling with water.

Using the Sensor With Silicones:

SST Sensing’s oxygen sensors, like all other Zirconium Dioxide sensors, are damaged by the presence of silicone in the

measurement gas. Vapours (organic silicone compounds) of RTV rubbers and sealants are the main culprits and are

widely used in many applications. These materials which are often applied as a liquid or gel still outgas silicone vapours

into the surrounding atmosphere even after they have cured. When these vapours reach the sensor the organic part of

the compound will be burned at hot sensor parts, leaving behind a very fine divided Silicon Dioxide (SiO2). This SiO2

completely blocks the pores and active parts of the electrodes.

If silicone cannot be avoided in the application we advise using high quality, high temperature cured materials which do

not outgas when subsequently heated. SST can provide guidance if there is concern about use of silicone within the

application.

When installing the sensor do not use any lubricants or grease which may contain silicone.

In addition to silicones other gases which may interfere will the sensor are listed overleaf.

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