OXITEC® 5000 Ex (ATEX)

O2 Analyser System
ATEX Certified Explosion-Proof Design
with SME 5 Electronic Unit

Installation & Operating

Manual

Version No. 09
Valid for Software Version 1.50
Revision Date 31 May 2007

ENOTEC GmbH Höher Birken 6

Process and Environmental D-51709 Marienheide/Germany TÜV approved for
Measuring Technology Phone: +49 (0) 2264 - 4578 - 0
13. BImschV and 17. BImschV
Fax: +49 (0) 2264 - 4578 - 31
DIN EN ISO 9001
Email: [email protected]
Internet: www.enotec.de
www.enotec.com
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O2 Analysesystem OXITEC® 5000 EX Version 09.150 Seite 2

 Introduction
Dear customer,

Thank you for selecting our OXITEC® 5000 Ex as your InSitu Flue Gas Oxygen measuring system.

For many years now, our OXITEC® Ex oxygen analyser systems have been operating in numerous
applications with many thousand units being produced and shipped around the world. ENOTEC
are committed to total quality and performance and we have continuously enhanced our products
to integrate various additional features and functions. In this package, the electronic unit uses the
very latest Microprocessor Technology, making the SME5 electronic unit one of the most advanced
and up-to-date monitoring units, permitting you to reduce your maintenance & fuel costs, and to
achieve increased measuring accuracy with more operational reliability using these new monitoring
functions.

In our oxygen measuring probes you will find that the Zirconium Oxide measuring cell is soldered
in place using a special process and technique developed by our company. This results in a con-
siderably increased service life compared to "glued or cemented" measuring cells, which have a
tendency to leak or crack during operation. The OXITEC® cell is a proven gas-tight design, provid-
ing greater measuring accuracy, durability and longer working life.

All ENOTEC instruments are thoroughly tested in the factory and are subject to a strict ISO 9001
Quality Assurance procedure. Therefore, with the correct installation, the operation of the
OXITEC®5000 Ex oxygen analyser system is very easy and user friendly and will provide you with
many years of operation with perfect measuring results. Please read this manual carefully and fol-
low the instructions as directed.

In some applications only the measuring probe is located in the area designated Exd with the elec-
tronic unit installed in a safe area. For these applications ENOTEC offers an electronic unit in a
general purpose field housing with fail-safe heater switch-off. Any differences in design, installa-
tion, start-up or maintenance are specified in this manual in the respective chapter.

If you have any questions, or you are unclear about any aspect of the installation or operation, our
Service Department, regional sales offices or approved distributors will be pleased to assist. The
factory contact points are Tel: +49 2264-45780 or Fax: +49 2264 457831. You may also visit us at
our website www.enotec.de or www.enotec.com or contact us by e-mail: [email protected], or
[email protected] within UK, or [email protected] for North America, or
[email protected] within Asia.

Marienheide, 31 May 2007

Dipl.-Ing. Fred Gumprecht
Managing Director
ENOTEC GmbH

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 3

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O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 4

Table of contents

1 Instructions for the Operator 11

1.1 Warranty 11
1.2 Declaration of EC-Conformity 12
1.3 Information on the CE-Certification 13
1.4 Notes on this Document 13
1.5 Symbols used in this Document 14
2 Intended Use 15
3 Explosion Protection 16
4 Safety Instructions for the Operation of
OXITEC® 5000 Ex Analyser System 17
4.1 General Safety Instructions 17
4.2 Maximum Ambient Temperature 17
4.3 Corrosion 17
4.4 Waiting Times 18
4.5 Installation Notes 18
4.6 Safety Hazards 18
5 General System Description 19
5.1 Measuring Principle 19
5.2 Design of the complete Analyser System 20
5.3 Design of the OXITEC® 5000 Ex Analyser System
(completely explosion-proof) 20
5.4 Design of the OXITEC® 5000 Ex Analyser System
with explosion-proof Probe and Electronic Unit in
General Purpose (GP) Field Housing 21
6 Description of the OXITEC® 5000 Ex
System Components 23
6.1 Design and Function of the Measuring Probe
KEX500x 23
6.2 Special Probe Cable 24
6.3 Special Pneumatic Cable 26

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 5

 6.4 Design of the Electronic Unit in Ex-Housing 26
6.5 Design of the Electronic Unit in General Purpose
(GP) Field Housing with fail-safe Heater Switch-off 27
6.6 Design of the Electronic Unit in 19 inch Rack with
fail-safe Heater Switch-off 29
6.7 Description of Function of the Microprocessor
Electronic Unit 30
7 Installation of the OXITEC® 5000 Ex
Analyser System 31
7.1 Installation of the Measuring Probe 31
7.1.1 Checking the Location for the Probe Installation 31
7.1.2 Installing the Probe 31
7.1.3 Adjusting the Filter Head 34
7.1.4 Electrical and Pneumatic Terminations at the Probe
Connection Box 35
7.2 Installation of the SME5 Electronic Unit 37
7.2.1 Requirements for the Location of the Electronic Unit 37
7.2.2 Requirements for Connecting Power Supply and other
Electrical & Pneumatic Cables 37
7.2.3 Connection of the pneumatic connections 39
7.2.4 Connection Diagram of the OXITEC® 5000 Ex Analyser
System 40
®
7.2.5 Connection Diagram of the OXITEC 5000 in General
Purpose (GP) Field Housing with Heater Switch-off 41
7.2.6 Terminal Connections of the SME5 Electronic Unit (both
Versions) 42
7.2.7 Terminal Connections of the SME5 Electronics in 19” 3HE
Rack 43
7.2.8 Terminal Allocation according to the installed options 43
7.2.9 Terminal Diagram of the Fail-Safe Heater Switch-Off 45
7.2.10 Instructions for Connection of Probe Special Cable 46
7.2.11 Fitting the ferrite sleeves (EMC) 46

8 Start-up of the OXITEC® 5000 Ex System 47

8.1 Probe Heating Phase 47
9 Operating Instructions for the OXITEC®
5000 Ex Electronic Unit 49
9.1 General Operating Instructions 50

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 6

 9.2 Main Window 50
9.3 Actual Value Menu 51
9.3.1 Lambda 52
9.4 Parameter menu 53
9.4.1 Changing a Parameter Value using the Alteration of O2 Limit
as an Example 54
9.4.2 Changing a Parameter Value using the Alteration of
“Measuring Range 1” as an Example 55
9.4.3 H2O Correction 56
9.4.4 Limits, Limit Curves (Option) 56
9.5 System Menu of the OXITEC 5000 Ex* with explosion
proof Electronic Unit 58
9.5.1 First Steps for Calibration 59
9.5.2 O2 Single Point Calibration (Electronic Unit in Ex housing) 62
9.5.3 O2 Two Point Calibration (Electronic Unit in Ex Housing) 65
9.5.4 Automatic Calibration (ACAL) with Air (20.95% O2) 69
9.5.5 Measured Value Memory 70
9.5.6 System Test with Test Gas (Electronic Unit in Ex-Housing) 70
9.5.7 System Test with Test Air (Electronic Unit in Ex-Housing) 72
9.5.8 Setting O2 Current Output 73
9.5.9 Measuring Range Switching 73
9.5.10 Change Code 74
9.5.11 Damping of O2 mA Output 74
9.5.12 Call up max. / min. Values 74
9.5.13 Change Language 74
9.5.14 Service 74
9.5.15 Software 75
9.6 System Menu of the OXITEC 5000 Ex* with Electronic
Unit in General Purpose (GP) Field Housing and 19”
Rack 75
9.6.1 First Steps for Calibration 76
9.6.2 Single Point Calibration (Electronic Unit in GP Field Housing) 77
9.6.3 Two Point Calibration (Electronic Unit in GP Field Housing and
19” Rack) 80
9.6.4 Automatic Calibration (ACAL) with Air (20.95% O2) 84
9.6.5 Measured Value Memory 85
9.6.6 System Test with Test Gas (Electronic Unit in GP Field
Housing and 19” Rack) 85

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 7

 9.6.7 System Test with Test Air (Electronic Unit in GP Field Housing
or 19” Rack) 86
9.6.8 Setting Current Output 87
9.6.9 Measuring Range Switching 87
9.6.10 Change Code 87
9.6.11 Damping of O2 mA Output 88
9.6.12 Call up Max. / Min. Values 88
9.6.13 Change Language 88
9.6.14 Service 88
9.6.15 Software 88
9.7 Status Messages (Error Messages) 89
9.8 Heater Switch-off in Case of Failure 91
10 System Description / Adjustments 93
10.1 In Case of Loss of the System Code 93
10.2 Bridge on the Rear Side of Display Unit 93
10.3 Adjustment of Display Contrast 94
10.4 Relay Outputs / Functions and Correlation of the
Relays 94
10.5 Digital Inputs 95
10.5.1 Digital Inputs at Limit Curves Option 96
10.6 Pressure and Flow rates for Test Air and/or
Reference Air 96
10.7 Stability Criteria for Calibration 96
10.8 Reaction Time of the mA Output 97
10.9 Extension Modules 97
10.9.1 RS 232 Interface (option) 97

11 Technical Data 104

11.1 Technical Specification Electronic Unit in Ex-
Housing 104
11.2 Technical Specification Electronic Unit in GP Field
Housing 105
11.3 Technical Specification Probe 106
12 Service and Maintenance 107
12.1 Switching between 230 V and 115 V operation 107
12.2 Replacing the Fuses 108
O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 8
 12.3 Adjusting the Flow Rate of Reference and Test Air
(Electronic Unit in Ex-Housing) 109
12.4 Adjusting the Flow Rate of Reference and Test Air
(Electronic Unit in GP Field Housing with integrated
Pneumatics) 110
12.5 Adjusting the Flow Rate of Reference and Test Air
(Electronic Unit in 19” Rack 3HE) 112
12.6 Replacing the Filter Head 112
12.7 Exchange of ZrO2 Measuring Cell 113
12.8 Exchange of Probe Inner Parts 116
12.8.1 Exchange of Thermocouple Element 116
12.8.2 Exchange of Heating Element 116
12.8.3 Exchange of Signal Measuring Wire 117
12.8.4 Exchange of 4-Hole Ceramic Rod 117

13 Trouble Shooting 118

13.1 Display remains at the Measuring Range End or is
higher than expected 118
13.2 O2 Display Indicates 0 %, although the Process
Operation Mode expects a higher O2 Value 119
13.3 Local Displays correct, Output not correct 120
13.4 Unsteady, widely varying Measuring Value 120
14 Dimensional Drawings of the Electronic
Unit 121
15 Dimensional Drawings of Probes 123
15.1 Probe Components 125
15.2 Parts List of Probes 127
16 Pneumatic Connection and
Requirements for the Gas Supply 128
16.1 Pneumatic Connections of the Ex Electronic Unit 128
16.2 Pneumatic Connections of the Electronic Unit in GP
Field Housing 128
16.3 Requirements for the Gas Supply (Systems with
Instrument Air Supply) 129

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 9

 16.4 Requirements for the Gas Supply (Systems with
Pumps) 130
17 Mounting Overview of the Electronic Unit131
17.1 Mounting Overview of the Electronic Unit in Ex
Housing 131
17.2 Mounting overview of the Electronic Unit in GP Field
Housing 133
18 Table of Figures 136

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 10

 1 Instructions for the Operator*

1.1 Warranty
ENOTEC

2 YEAR WARRANTY

ENOTEC warrants that the equipment manufactured and sold by it will, upon
shipment, be free of defects in workmanship or material. Should any failure to
conform to this warranty become apparent during a period of two years after
the date of shipment, ENOTEC shall upon prompt written notice from the pur-
chaser, correct such nonconformity by repair or replacement of the defective
part or parts. The purchaser is not entitled to claim any other legal remedies
on the basis of this warranty. Please refer to the complete ENOTEC warranty
policy for details.

ENOTEC does not warrant equipment supplied by it against normal deteriora-

tion. Corrosive gases and solid particles may cause damage and make a re-
pair or a replacement necessary as a consequence of normal wear and tear
during the warranty period.

Note: When installing the equipment, the customer must ensure that all nec-
essary supply lines are connected and the operating temperature of the probe
is reached. Experience has shown that products installed but not taken into
operation may be damaged by the process or by external influence. ENOTEC
will not accept any responsibility for such damages.

In the case of combination of ENOTEC products with non-ENOTEC products,

which are not approved by ENOTEC, any warranty claim is invalid.

MANUFACTURER:

ENOTEC GmbH
Höher Birken6
51709 Marienheide
GERMANY
TEL: 02264/4578 0
FAX: 02264/4578 31
Email: [email protected] and
[email protected]

*
Technical subject to change without notice! Please contact ENOTEC for further information.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 11

 1.2 Declaration of EC-Conformity

ENOTEC GmbH
Höher Birken 6
51709 Marienheide/Rodt
Germany

CE Mark - Conformity
to EC Directive Electromagnetic Compatibility 89/336/EEC

We declare that the OXITEC® Ex Oxygen Analyser System as detailed below as well as the type sold by us, is designed
and constructed to comply with the relevant basic safety and health requirements of the EC Directive. This declaration
becomes invalid if the product is modified without our prior consent.

®
Identifier: OXITEC Ex Oxygen Analyser System
......................................................................................
Electronics Type: OXITEC® 5000 Ex - SME 5
......................................................................................

Relevant
EC-directives: EC Low-voltage Directive (73/23/EEC)
EC Directive Electromagnetic Compatibility (89/336/EEC)
EC Directive Product Liability (85/374/EEC)

Applied
harmonised
generic standards: EN 50082-2 1995 Resistance to interference
.....................................................................................
EN 55011 Cl.B 1992 Emission
.....................................................................................

.....................................................................................

Applied
standards and technical
specification, in particular: EN 61000-4-2 ESD
....................................................................................
EN 61000-4-3 Irradiation E-field
....................................................................................
EN 61000-4-4 Burst
....................................................................................
EN 61000-4-6 Inflow
....................................................................................
EN 61000-3-2 Current Harmonics
....................................................................................
EN 61000-3-3 Flicker
....................................................................................
EN 61326-1 Immunity partly
....................................................................................

Date / Manufacturer’s signature: 31 May 2007 signed. Fred Gumprecht

.....................................................................................
Position: Managing Director
.....................................................................................

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 12

 1.3 Information on the CE-Certification
After having completed and successfully passed EMC-tests, the complete
ENOTEC analyser system - consisting of oxygen measuring probe, electronic
unit and special probe cable - has a conformity certificate. If parts of this sys-
tem are operated with products not supplied or approved by ENOTEC, the
CE-conformity is no longer valid.

Likewise, all warranties are void if the system is operated in a configura-

tion not authorized by ENOTEC!

Note

The enclosed ferrite sleeves must be placed over the ter-

minal leads of the cable (see chapter 7.2.11 on page 46).
The CE-conformity is void if these ferrite sleeves are not
fitted!

Note

The ground (Earth) connection must be installed thoroughly

using the correct cable of at least 1,5mm² minimum. It is
very important that the equipotential bonding is installed
correctly.

Please note that some electrical devices (e.g. frequency

converter etc.) close to the system can create considerable
electrical disturbance and instability. So for normal function
of the OXITEC® 5000 Ex system it is important that these
devices be installed away from the system and in accor-
dance with the manufacturer’s installation notes and guide-
lines.

Please do not lay the probe cable near power supply ca-
bles, or near motors and their cables, as frequency con-
verters control them and this could cause interference ef-
fects. If possible, do not cross the cables because this
could also cause interference effects. However, if this is
unavoidable please make sure that these cables are only
crossed at right angles.

1.4 Notes on this Document

This document describes the design, installation, commissioning, operation,
maintenance and troubleshooting for the OXITEC® 5000 Ex InSitu analyser
system.
Only authorized, qualified personnel may work on this equipment. These per-
sonnel must be familiar with all warnings, safety references and maintenance
tasks in accordance with this instruction manual. The reliable and safe use of
this equipment assumes appropriate transport, professional storage and in-
stallation as well as care with operation and maintenance.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 13

 1.5 Symbols used in this Document
Important information as well as safety instructions are emphasised by the be-
low-mentioned symbols. Please make sure that all safety advices and warn-
ings are observed at all times.

Note

Points out important information, which should be particu-

larly noted.

Important

Warns of the risk of destroying the system or components

or reducing its function.

Warning

Warns of dangers, which emerge by inappropriate han-

dling, and which can result in death, bodily harm and/or
substantial property damage.

Warning – Hot Surface

Warns of the danger of burns, which could occur from hot

system parts.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 14

 2 Intended Use
Note

The OXITEC® 5000 Ex analyser system is a system for

measuring the oxygen concentration in flue gases and
other non-combustible gases. For reasons of safety and
the possibility of accidents, unauthorized conversions and
modifications of the system are prohibited.

Warning

The system must not be used to determine the oxygen

concentration of combustible gases or in a location where
combustible gases are present as the measuring cell tem-
perature of 800°C / 1472°F could generate an explosion
hazard!

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 15

 3 Explosion Protection
The electronic units of OXITEC® 5000 Ex analyser systems are certified for
installation in Zone-1 locations (ATEX Certified ll 2G EExd IIC T6/IP66) and
the probe is certified for installation in Zone-1 locations (ATEX Certified ll 2G
EExd IIC T3). Please take note of the following instructions.

The probe operating temperature is 800°C / 1472°F. For safeguarding the

maximum surface temperature, the probe is switched off if the temperature
exceeds 810°C / 1490°F. The monitoring of the probe operating temperature
is by dual thermocouples. The switch-off is therefore provided by a mecha-
nism which is independent of the control (fail-safe heater switch-off article no.:
HCU-0001). After a deactivation of the heater, the fail-safe heater switch-off
must be reset manually by the user. For further explanations see chapter 9.8
on page 91.

Warning

Under working conditions neither the covers of the probe

connection box nor of the electronic unit may be opened.
Before opening it must be guaranteed that - after the
switch-off of the system - all probe components fulfil the
condition of the temperature class T3 and all components
of the electronic unit fulfil the condition of the temperature
class T6. In both cases the minimum waiting period after
switch-off amounts to 1 hour.

Working on the electronic unit and/or the probe can only be

carried out under operating conditions, if the surrounding
conditions can be classified as non-explosive.

In some applications only the Exd certified measuring probe is located in the
hazardous area, whereas the electronic unit can be installed outside of this
danger zone. For these applications ENOTEC offers an electronic unit in gen-
eral purpose (GP) field housing with fail-safe heater switch-off. Any differences
in design, installation, start-up or maintenance are specified in this manual in
the respective chapter.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 16

 4 Safety Instructions for the Operation of
OXITEC® 5000 Ex Analyser System

4.1 General Safety Instructions

The OXITEC® 5000 Ex analyser systems may only be operated by authorized
trained skilled persons. For reasons of immunity to interference, it must be en-
sured that the connection between the measuring probe and the electronic
unit is only made using the special ENOTEC probe cable and pneumatic tub-
ing.

The ATEX certificated O2 measuring probes supplied by ENOTEC may only

be used with an ENOTEC Electronic Unit with an ATEX certified heater
switch-off or with a compatible electronic unit approved by ENOTEC. All
OXITEC® 5000 Ex probes are operated at 800°C / 1472°F.

Important

Under no circumstance should the measuring probe be

directly connected to the 230V mains power supply, as this
will immediately destroy the probe heater element!

4.2 Maximum Ambient Temperature

Important

The maximum ambient temperature for the electronic unit

is 50°C (122°F) and for the probe terminal box 80°C
(176°F). These ambient temperatures may not be ex-
ceeded in any circumstances. Please contact ENOTEC for
other temperatures.

4.3 Corrosion
The probe may only be used in flue gases whose composition is not critical
regarding the corrosive effect on the materials used. Where there is an in-
creased risk of corrosion, regular checks at suitably short intervals are neces-
sary.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 17

 4.4 Waiting Times
Under working conditions neither covers of the probe connection box or of the
electronic unit may be opened. Before opening it must be guaranteed that -
after the switch-off of the system - all probe components fulfil the condition of
the temperature class T3 and all components of the electronic unit fulfil the
condition of the temperature class T6. In both cases the minimum waiting pe-
riod after switch-off amounts to 1 hour.

Working on the electronic unit and/or on the probe can only be carried out at
operating condition, if the surrounding conditions can be classified as non-
explosive.

4.5 Installation Notes

The probe/protection tube is installed into the wall of a flue gas duct. It may
protrude into the combustion system up to the probe flange at maximum.

The connection box must remain outside the hot flue gas duct up to the probe
flange. For high temperature applications, the probe is installed into the cool
end of the gas cooling tube, outside the duct.

4.6 Safety Hazards

Warning – Hot Surface

During operation, the temperature of the probe filter head

and of other parts exposed to flue gas is 150°C - 800°C
(302°F - 1472°F). Direct contact with the hot parts when
dismantling or maintenance will cause severe burns!

The probe may only be removed with heat-insulated

gloves. Before removing the probe, always switch off the
supply voltage of the electronic system. After removal,
store the probe in a safe, protected place and wait until it
has cooled down below 35°C (95°F).

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 18

 5 General System Description

5.1 Measuring Principle

The oxygen analysing system OXITEC® 5000 Ex measures the net concentra-
tion of oxygen in the flue gas of combustion processes and other non-
combustible gases.

The source voltage Uq (in former times called EMF for “electrical motive force”)
is produced by a temperature-stabilised zirconium cell indicating the amount of
oxygen concentration.

Measurement is made direct and InSitu, i.e. the measuring cell is inside the
flue gas duct at the probe end.

The measuring cell consists of a small zirconium-oxide disc about the size of a
penny, which is coated with porous layers of platinum on both sides and sol-
dered with a gas-tight seal, into the end of a steel tube cell holder.

The temperature of the measuring cell is stabilised by a built-in heater whose

temperature is kept constant by a temperature controller. At a constant tem-
perature the mV-output of the cell is calculated as follows:

 P1 
U q = K • T • log  + C[ mV ]
 P2 
Where:
P1 = Oxygen partial pressure of the reference gas on the inside of the cell (e.g.
Ref. air)
P2 = Oxygen partial pressure of the process gas on the outside of the cell (Flue
gas - O2)
K= Natural constant
T= Temperature (measuring cell)
C[mv] = Cell constant – millivolt air/air
Uq = Source voltage

The reference gas (Instrument Air) is clean, dry and oil-free air (20.95% by
volume O2).

When different oxygen concentrations occur between the measuring and ref-
erence sides of the electrochemical cell, there is a migration of oxygen ions
from the higher to the lower partial pressure side. The mV output signal of the
cell is inversely logarithmically proportional to the oxygen content of the proc-
ess gas. With reducing oxygen content in the process gas the mV signal of the
measuring cell increases. With air on the process gas side, the ZrO2-cell gen-
erates approx. 0 mV ±5 mV (cell constant) and with 2.1% O2 approx. +50 mV
(slope of the characteristic line or decade voltage).

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 19

 The water content which exists in any flue gas, has an influence on the actual
O2 concentration, and is taken into account in this wet measuring process. The
wet process provides a lower measuring value compared to the dry process,
because it refers to the total volume. The difference between both values is in
direct proportion to the water content in the flue gas.

5.2 Design of the complete Analyser System

Every OXITEC® 5000 Ex analyser system consists of the measuring probe,
which detects the oxygen partial pressure direct in the flue gas duct; the elec-
trical connection cable; the pneumatic connection cable and the electronic
unit.

5.3 Design of the OXITEC® 5000 Ex Analyser

System (completely explosion-proof)

®
Figure 1 Design of the OXITEC 5000 Ex analyser system (completely explosion proofed)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 20

 ®
Figure 2 Design of the OXITEC 5000 Ex analyser system (completely explosion proofed) with cooling tube

5.4 Design of the OXITEC® 5000 Ex Analyser

System with explosion-proof Probe and
Electronic Unit in General Purpose (GP)
Field Housing

®
Figure 3 Design of the OXITEC 5000 analyser system with explosion-proofed O2 probe

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 21

 ®
Figure 4 Design of the OXITEC 5000 analyser system with explosion-proofed O2 probe with cooling tube

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 22

 6 Description of the OXITEC® 5000 Ex
System Components

6.1 Design and Function of the Measuring

Probe KEX500x
The probe assembly consists of the connection box (ASK-...); the inner probe
assembly part (SIK-...) complete with heater, thermocouple and signal wire;
the measuring probe tube (MSR-...) with test gas line; the ZrO2 measuring cell
(ZO2-…), the filter head and the protection tube (optional). Please consider
Figure 112 and the following on page 125.

The connection box contains the electrical connectors for the measuring cell,
the thermocouple, the probe heater and additionally the pneumatic connector
for the reference air.

The probe tube with flange provides the negative pole and serves as protec-
tion for the positive measuring line and the reference gas line to the reference
side of the measuring cell.

The filter head has a gas deflector plate referred to as v-shield.

The O2 measuring cell itself consists of three layers: platinum, zirconium oxide
and platinum with the platinum being applied porously. The measuring cell
with its 4-hole connection flange and gasket seal can be field replaceable by
the customer, if required.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 23

 Figure 5 Design of the O2 measuring probes KEX500x

The test gas or flue gas flows through to the filter and fills the flue gas side of
the filter head. On the probe internal side, reference gas (clean, dry and oil-
free instrument air (20.95 percent by volume O2)) continuously flows through
the inner part of the probe to the measuring cell. Because of the two different
gases on each side of the measuring cell, a logarithmic mV output occurs
(high O2 concentration in the test gas = low voltage (e.g. 21% ≈ 0 mV); low O2
concentration in the test gas = high voltage (e.g. 2.1% ≈ 50 mV)). By means of
the electronic unit, this voltage (mV) is converted into a current 4-20 mA (or 0-
20 mA) with a maximum load of 500 Ohm. The current output is then directly
related to the measured oxygen value and available as an electrically isolated
output signal from the terminals (see Figure 21 on page 40 and also Figure 23
on page 42).

The temperature of 800°C / 1472°F required for the O2 measuring cell, is pro-
duced by a heater element installed inside the probe. To keep the temperature
constant, it is measured by a Ni-Cr-Ni (type K) thermocouple, and the heater
voltage is controlled by the SME 5 electronic unit equipped with a built-in tem-
perature reference point to compensate ambient temperature variations (Cold
Junction Compensation).

6.2 Special Probe Cable

Note

Only ENOTEC special cable for the O2 sensor (FEP-0009

or FEP-0010 (armoured)) is to be used between the probe
and the electronic unit. This cable must not be longer than
150m. Other cable length must be technically approved by
ENOTEC in advance.

All ENOTEC special cable must be treated as a measuring signal line.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 24

 Important

The shielding of the special probe cable (FEP-0009 or

FEP-0010) must only be connected at one end - in the
electronic housing - at the ground wire (PE terminal). In no
circumstances should the shield of the special probe cable
be also connected at the probe end.

All cables have PUR insulation and can be used in ambient temperatures from
-40°C (-40°F) up to +90°C (194°F). During the installation only a temperature
range from -5°C (23°F) to +50°C (122°F) is permitted. The minimum bending
radius of the cable amounts to fifteen times the cable diameter.

Important

Please do not run the probe cable near power supply ca-
bles, or near motors and their cables, as frequency con-
verters control them and could cause interference.

If possible, do not cross the cables because this could also

cause interference. However, if this is unavoidable, please
make sure that these cables are only crossed at right an-
gles.

Figure 6 Special probe cable FEP-0009

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 25

 6.3 Special Pneumatic Cable
ENOTEC offers a pneumatic cable (tubing) with two tubes - one for the refer-
ence air supply to the probe (blue tube 30 l/h - 40 l/h continuously) and the
other for the test gas supply (green tube 150 l/h - 180 l/h) for the calibration of
the O2 sensor with test gas.

If the pneumatic unit uses reference air and test air pumps, instead of instru-
ment air, the pneumatic cable must not be longer than 50 m. If longer
lengths are required, an additional external pump must be installed upstream,
to ensure a test air flow of 150 l/h min. even under the worst conditions.

All cables have PUR insulation and can be used in ambient temperatures from
-40°C (-40°F) up to +90°C (194°F). During the installation only a temperature
range from -5°C (23°F) to +50°C (122°F) is permitted. The minimum bending
radius of the pneumatic cable amounts to eight times the cable diameter.

6.4 Design of the Electronic Unit in Ex-Housing

The electronic unit package is supplied in two Ex housings (electronic unit and
power supply) for wall mounting with external pneumatics unit in a GP field
housing. All units are intended for wall mounting.

The cable entries for both Ex housings are bottom entry Ex threaded connec-
tions.

The external pneumatic unit is located in a sheet steel general purpose (GP)
field housing, which does not need certification as it only contains the pneu-
matic unit components and is therefore intrinsically safe.
The instrument air version requires a clean, dry, oil-free instrument air supply
at the installation location.

The housings must be opened for service. The following is therefore abso-
lutely essential.

Warning

Under working conditions neither covers of the probe con-

nection box nor of the electronic unit may be opened. Be-
fore opening it must be guaranteed that - after the switch-
off of the system - all probe components fulfil the condition
of the temperature class T3 and all components of the
electronic unit fulfil the condition of the temperature class
T6. In both cases the minimum waiting period after switch-
off amounts to 1 hour.

Working on the electronic unit and/or on the probe can only

be carried out at operating condition, if the surrounding
conditions can be classified as non- explosive

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 26

 The microprocessor electronic unit possesses a graphic display with back-
ground lighting. For operation, the electronic unit possesses 4 soft keys and a
numeric keyboard. The entire menu structure is laid out in such a way that an
intuitive operation is possible.

Figure 7 Design of the electronic unit in Ex housing

6.5 Design of the Electronic Unit in General

Purpose (GP) Field Housing with fail-safe
Heater Switch-off
The OXITEC® 5000 Ex analyser system with electronic unit in a GP field hous-
ing is available in a version with an integrated pneumatic unit, as well as in a
version without internal pneumatics. As a standard, the electronic unit is sup-
plied in a GP wall mounting housing, with built-in pneumatic system.

Two different pneumatic systems are available:

An instrument air version requiring the supply of clean, dry, oil-free instru-
ment air at the point of installation.
A pump version using the surrounding ambient air for reference air and test
air.

To recognize the type of pneumatic version please look at the valve for adjust-
ing test air. (For details see page 111).

Note

To ensure the full functional range of the electronic unit,

both versions need a test gas supply with pressure reducer
and flow limiter.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 27

 The housing has bottom entry electrical cable glands, and compression fittings
for 6 mm or ¼” tubing, as specified, for the pneumatic lines.

Flow monitoring of the test and/or reference gas is made electronically inside
the electronic unit (only versions with built-in pneumatic unit). No manual con-
trol is necessary.

The microprocessor electronic unit possesses a graphic display with back-

ground lighting. For operation the electronic unit possesses 4 soft keys and a
numeric keyboard. The user friendly operation of the electronic unit takes
place menu-driven.

Figure 8 Design of the electronic unit in field housing with fail-safe heater switch-off

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 28

 Figure 9 Mounting plate with fail-safe heater switch-off (HCU-0001)

6.6 Design of the Electronic Unit in 19 inch

Rack with fail-safe Heater Switch-off
The OXITEC® 5000 GasEx analysing system with electronic unit in19“ rack is
available with two different pneumatic systems:

An instrument air version requiring the supply of clean, dry, oil-free instru-
ment air at the point of installation.
A pump version using the surrounding ambient air for reference air and test
air.

To recognize the type of pneumatic version please look at the valve for adjust-
ing test air. (For details see page 112).

Note

To ensure the full functional range of the electronic unit,

both versions need a test gas supply with pressure reducer
and flow limiter.

The housing has bottom entry electrical cable glands, and compression fittings
for 6 mm or ¼” tubing, as specified, for the pneumatic lines.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 29

 Flow monitoring of the test and/or reference gas is made electronically inside
the electronic unit (only versions with built-in pneumatic unit). No manual con-
trol is necessary.

The microprocessor electronic unit possesses a graphic display with back-

ground lighting. For operation the electronic unit possesses 4 soft keys and a
numeric keyboard. The entire menu structure is laid out in such a way that an
intuitive operation is possible.

6.7 Description of Function of the

Microprocessor Electronic Unit
The SME 5 electronic unit is designed for connection to a single oxygen
measuring probe. The mV signal of the measuring cell is amplified and then
converted into a digital signal in the electronic unit (14 Bit converter). The µ-
processor linearises and corrects the signal of the measuring cell according to
the Nernst equation. The O2 value is then displayed as a percent value and
has a floating transmitted output, either 0 - 20 mA or 4 - 20 mA - keypad se-
lectable.

As a standard, the electronic unit has two measuring ranges. These measur-
ing ranges can be freely defined in their initial and/or final value (within per-
missible system-related limits). The second measuring range can be switched
on remotely (digital input see Figure 23 on page 42) or manually, using the
keyboard of the electronic unit. The second measuring range is signalled re-
motely by a relay contact, and also on the display (chapter 9.5.9 on page 73).

The electronic unit is completely self-controlled. Any system errors are dis-
played as clear text with help function information. The ENOTEC user inter-
face permits intuitive operation by means of a self-explanatory menu structure.

The system is multi-lingual; currently the available languages are: German,

English, French and Spanish. Also a software version in Polish language is
available on request.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 30

 7 Installation of the OXITEC® 5000 Ex
Analyser System
Note

Only qualified and authorized personnel may work on this

instrument. These personnel must be familiar with all warn-
ings, safety instructions and maintenance work in accor-
dance with these operation instructions. The reliable and
safe operation of this equipment requires careful transpor-
tation, professional storage, installation and commission-
ing, as well as careful operation and maintenance.

7.1 Installation of the Measuring Probe

7.1.1 Checking the Location for the Probe Installation

Flue gas temperature, pressure and all other process conditions must be in
accordance with the specification. Allow enough space for insertion/removal of
the probe and protection tube (if supplied) and ensure access to the measur-
ing probe and/or connecting box.

Before cutting the hole in the flue gas duct, make sure that the inside of the
duct has enough space for probe installation, and that no soot is blown
nearby, or any obstructions are in the way.

For probe lengths exceeding 2000 mm, a support must be mounted inside the
duct (every 2 m) to prevent the probe and mounting tube from flexing or bend-
ing.

7.1.2 Installing the Probe

Note

The fastest possible response time is obtained with hori-

zontal installation. We recommend installing the probe
horizontally in preference.

The dimensions for the hole in the flue gas duct and the mounting of the
adapter plate (mating flange) are shown in the dimensional drawing (Figure
111 on page 125). The mating flange is to be fitted by the customer, and when
mounted, ensures an airtight seal.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 31

 Figure 10 Mounting dimensions of the O2 probe KEX500x

All dimensional drawings can be found in chapter 15 on page 123 and the fol-
lowing.

Figure 11 Mounting dimensions of the O2 probe KEX5001 with PROTEC cooling tube

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 32

 Figure 12 Mounting dimensions of the O2 probe KEX5001 with INCOLOY cooling tube

Note

If a cooling tube is used, the part of the protection tube

projecting from the duct wall must be insulated or heated if
necessary, to prevent its temperature from dropping below
the dew point.

Figure 13 Insulation of the cooling protection tube

Electrical heaters are available from ENOTEC as accessories. The bolts of the
probe flange must remain accessible.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 33

 The special cables for pneumatic and electronic systems must be left long
enough (coiled up) so that the probe can be removed out of the protection
tube without disconnecting it.

Important

The ground (earth) connection must be installed thoroughly

using the correct cable of at least 1,5mm² minimum. It is
very important that the equipotential bonding is installed
correctly. In the case of doubt please contact ENOTEC.

Please note that some electrical devices (e.g. frequency

converter etc.) close to the system can create considerable
electrical disturbance and instability. So for normal function
of the OXITEC® 5000 Ex system it is important that these
devices be installed away from the system and in accor-
dance with the manufacturer’s installation notes and guide-
lines.

Please do not run the probe cable near power supply ca-
bles, or near motors and their cables, as frequency con-
verters control them and could cause interference. If possi-
ble, do not cross the cables because this could also cause
interference. However, if this is unavoidable please make
sure that these cables are only crossed at right angles.

Important

The shielding of the special probe cable (FEP-0009 or FEP-

0010 (armoured)) must be connected only at the electronic
unit ground wire (PE) clamp. In no case should the shield of
the special probe cable be also connected at the probe end.

7.1.3 Adjusting the Filter Head

Note

Before installing the probe, the direction of flue gas flow

must be determined and the filter head assembly turned to
such a position that the flue gas flow hits the V-deflector.
The filter head can be turned freely a full 360° for this pur-
pose, by loosening the protection screw, rotating the filter
head/V-shield to the required position (maximum 1 turn),
and then tightening the protection screw.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 34

 Figure 14 Adjusting the filter head

7.1.4 Electrical and Pneumatic Terminations at the

Probe Connection Box
The special ENOTEC probe cable (FEP-0009 and FEP-0010 (armoured)) and
the pneumatic tubing (FEP-0002) must be connected in accordance with
Figure 15 on page 36 and Figure 23 on page 42. Both cables have PUR
sheathing and are designed for a maximum permissible ambient temperature
of +90°C / 194°F.

Note

All special probe signal cables must be treated as measur-

ing lines. Do not connect the shield of the probe cable at
the probe.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 35

 Figure 15 Terminal allocation of the cable connection box

Screwdriver

Step 3

Step 2 Wire
Step 1

Wire

Terminalboard

Figure 16 Handling of the WAGO clamps

All cable glands have to be encapsulated to keep the ATEX conditions. The
pottant (resin) is included in delivery and you may find a detailed instruction of
the procedure on the package of the resin.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 36

 Note

The processing instructions of the manufacturer of the pot-

tant are decisive.

Figure 17 Encapsulated cable glands

Note

Mask the brass sealing sleeve to ensure that no resin im-

pact the sealing. Overflowed resin has to be wiped off im-
mediately, because the material cured very firm.

7.2 Installation of the SME5 Electronic Unit

7.2.1 Requirements for the Location of the Electronic

Unit
Note

When installing the electronic unit, please ensure sufficient

air circulation around the electronic unit housing and make
sure that the permissible ambient temperature is met.

The permissible ambient temperature range for the Ex housing is -20°C/-

4°F to +55°C/+131°F. The permissible ambient temperature range for the
standard steel box field housing with instrument air or without pneumatic
unit is -20°C/-4°F to +55°C/+131°F, and for the unit with built-in reference
air and calibration gas pumps -20°C/-4°F to +50°C/+122°F.
The location of the electronic unit must be selected, so that it is easily ac-
cessible ensuring that the door can be fully opened after installation.
The place should be largely weather-protected to enable inspection even
under the worst weather conditions.

7.2.2 Requirements for Connecting Power Supply and

other Electrical & Pneumatic Cables
For connection of the supply voltages, it is necessary to use cable of min.
1,5mm².

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 37

 Before putting the system into operation, it is essential that all electrical con-
nections, supply voltage and pneumatic connections are checked and, if appli-
cable, the instrument air pressure and quality, too. Special care must be taken
not to mix up the connections for test gas and reference air.

Important

In no case should the shield of the special probe cable be

also connected at the probe end.

The enclosed ferrite sleeves must be placed over the leads

of the stripped cable (see chapter 7.2.11 on page 46). CE-
conformity is invalid if these ferrite sleeves are not fitted!

Important

The ground (earth) connection must be installed thoroughly

using the correct cable size of at least 1,5mm² minimum. It
is very important that the equipotent bonding is installed
correctly.

Please note that some electrical devices (e.g. frequency

converter etc.) close to the system can create considerable
electrical disturbance and instability. So for normal function
of the OXITEC® 5000 Ex system it is important that these
devices be installed away from the system and in accor-
dance with the manufacturer’s installation notes and guide-
lines.

Please do not run the probe cable near power supply ca-
bles, or near motors and their cables, as frequency con-
verters control them and could cause interference. If possi-
ble, do not cross the cables because this could also cause
interference. However, if this is unavoidable please make
sure that these cables are only crossed at right angles.

All cable glands have to be encapsulated to keep the ATEX conditions. The
pottant (resin) is included in delivery and you may find a detailed instruction of
the procedure on the package of the resin.

Note

The processing instructions of the manufacturer of the pot-

tant are decisive.

Figure 18 Encapsulated cable glands

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 38

 Note

Mask the brass sealing sleeve to ensure that no resin im-

pact the sealing. Overflowed resin has to be wiped off im-
mediately, because the material cured very firm.

7.2.3 Connection of the pneumatic connections

1 2 3 4 5
Pneumatic unit Test gas Test gas Reference air Reference air Test air input
with pumps input output input output
Pneumatic unit Test gas Test gas Reference air Reference air
instrument air input output input output

A Regulator Test Air D Test Air Filter

B Regulator Reference Air E Reference Air Filter
C Regulator Test Air
®
Figure 19 Pneumatic connections of the OXITEC 5000 Ex electronic units

Assembly instruction of the pneumatic connections

Nut Support sleeve Clamp ring

Probe side: Art.No.: 0-R-000056 Art.No.: 0-P-000092 Art.No.: 0-R-000055

Electronic side: Art.No.: 0-P-000187 Art.No.: 0-P-000044 Art.No.: 0-P-000188

Attention: Plastic pneumatic tube should only be screwed with support sleeves
Figure 20 Instruction for the mounting of the pneumatic connections

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 39

 7.2.4 Connection Diagram of the OXITEC® 5000 Ex Ana-
lyser System

®
Figure 21 Connection diagram of the OXITEC 5000 Ex electronic unit

Important

The shielding of the special probe cable (FEP-0009 or

FEP-0010 (armoured)) must be connected only at the elec-
tronic unit ground wire (PE) clamp. In no case should the
shield of the special probe cable be also connected at the
probe end.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 40

 7.2.5 Connection Diagram of the OXITEC® 5000 in
General Purpose (GP) Field Housing with Heater
Switch-off

®
Figure 22 Connection diagram of the OXITEC 5000 in field housing with heater switch-off

Important

The shielding of the special probe cable (FEP-0009 or

FEP-0010 (armoured)) must be connected only at the elec-
tronic unit ground wire (PE) clamp. In no case should the
shield of the special probe cable be also connected at the
probe end.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 41

 7.2.6 Terminal Connections of the SME5 Electronic Unit
(both Versions)

®
Figure 23 Terminal connections OXITEC 5000 Ex (both versions)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 42

 7.2.7 Terminal Connections of the SME5 Electronics in
19” 3HE Rack

Figure 24 19“ rack 3HE

At the SME5 electronics in the 19" 3HE rack the terminal strip of the power
board (0-L-000080) is led directly outwards. The terminal diagram is identical
to the terminal diagram described under chapter 7.2.6 on page 42.

7.2.8 Terminal Allocation according to the installed op-

tions
Depending on the selected options, terminals 28 to 30 have the following func-
tions.

7.2.8.1 Terminal Allocation for the Limit Curves Option

Name of Terminal allocation

terminal
28 A + Analogue Input, Burner Load 4 to 20 mA (0...100%)
28 B - Analogue Input, Burner Load 4 to 20 mA (0...100%)
29 A + Digital Input 1, select fuel, current input (0..4mA, 5..20mA)
29 B - Digital Input 1, select fuel, current input (0..4mA, 5.. 20mA)
30 A + Digital Input 2, select fuel, current input (0..4mA, 5..20mA)
30 B - Digital Input 2, select fuel, current input (0..4mA, 5..20mA)
Table 1

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 43

 7.2.8.2 Terminal Allocation for the Process Pressure Correction
Option

Name of Terminal allocation

terminal
28 A Not Used
28 B Not Used
29 A + Analogue Input, process pressure, 4 to 20 mA
29 B - Analogue Input, process pressure, 4 to 20 mA
30 A Not Used
30 B Not Used

Table 2

Important

The external current for the inputs (28 to 30) must be elec-
trically isolated from ground. Otherwise a malfunction or
damage to the electronic unit is possible.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 44

 7.2.9 Terminal Diagram of the Fail-Safe Heater Switch-
Off

Figure 25 Terminal Diagram HCU-0001

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 45

 7.2.10 Instructions for Connection of Probe Special Ca-
ble
Note

The probe special cable contains two white wires. When

connecting the cable it is to be made certain that the col-
ours are assigned to the correct conductors.

One of the white wires is marked with a brown line around to indicate the allo-
cation to the brown wire.

White and green wires→ thermocouple 1 and 2

Brown and white wires → measuring cell

To confuse the white wires may result in a measuring error and the basic ac-
curacy of the equipment can not then be guaranteed.

Polarity of thermo- DIN IEC 584 DIN 43710 (old ANSI MC 96.1
couple German) (US)
+ green red yellow
- white green red
Table 3 International colour codes for NiCrNi Thermocouple wires

7.2.11 Fitting the ferrite sleeves (EMC)

Important

Do not connect the cable shield at the probe.

The enclosed ferrite sleeves

must be put over the leads of
the stripped cable (see Figure
26). Please use all ferrite
sleeves supplied by ENOTEC.

CE-conformity is invalid, if
these ferrite sleeves are not
fitted!

Figure 26 Ferrite sleeves

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 46

 8 Start-up of the OXITEC® 5000 Ex System
Important

Before the OXITEC® 5000 Ex analyser system is powered

up make sure that the conditions comply with the following
points:

Does the supply voltage correspond with the voltage

shown on the type label of your OXITEC® 5000 Ex?

Are all electrical connections made in accordance with the

instructions in this manual?

Is the OXITEC® 5000 probe installed in a flue gas that cor-

responds with the probe specification?

Are all pneumatic connections made correctly and gas tight

to prevent the probe from ingress of ambient air?

8.1 Probe Heating Phase

After switching on the OXITEC® 5000 Ex analyser system, the OXITEC® logo
appears on the display for a short time. During this time, all parameters rele-
vant for faultless functioning and start-up are checked automatically.

If during this check any system errors are found, the electronic unit will show
them in clear text. You will find a detailed error and warning description in
chapter 9.7 on page 89.

If the power-on check is completed without any errors, the heater window ap-
pears as shown in Figure 27. In this heater window the progress of the heating
phase is indicated by a bar in the range 0°C/+32°F to 900°C/1652°F.

Figure 27 Display during the heating phase

When the probe temperature is stable at 800°C/1472°F within ± 0.5°C/0.9°F

(after approx. 20 to 60 minutes, depending on the process conditions), O2
measurement is released and the main window appears on the display.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 47

 Figure 28 Display main window

During the heating phase, all actual values can be called up in the correspond-
ing menu window with the soft key [Actual]. You can also enter the system
menu and the parameter menu by pressing the corresponding soft keys.
Please note that some functions will not be available in heating phase (e.g.
calibrations).

Note

System adjustments may only be made be specially trained

personnel.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 48

 9 Operating Instructions for the OXITEC®
5000 Ex Electronic Unit
Note

Only qualified and authorized personnel may work with this

instrument. These personnel must be familiar with all warn-
ings, safety instructions and maintenance work in accor-
dance with this Instruction Manual.

If not advised differently, the operation of the OXITEC® 5000 Ex electronic unit
in explosion proof housing, is identical to the operation of the electronic unit in
the GP field housing.

The electronic unit is operated by means of four software-configured function

keys (subsequently called soft keys) and a numeric keypad. The functions of
the soft keys always adapt to the current menu window. The numeric keypad
serves only for entering numerical values.

The OXITEC® 5000 ‘user interface’ is designed for intuitive operation of the
electronic unit by a self-explanatory structure of the selection dialogues.

®
Figure 29 Front panel of the OXITEC 5000 Ex electronic unit

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 49

 9.1 General Operating Instructions
By pressing the soft keys [System], [Actual] and [Parameter] (see Figure 29)
the respective selection menus can be obtained. In each of these menus vari-
ous options can be selected from a list (as shown as an example in Figure 30)
with the soft keys [ ] and [ ]. If there are more than 4 options, this is indi-
cated by an arrow on the right hand side of the menu list. This arrow indicates
that there are more options to follow.

The option which can currently be selected has a black background and light
letters and can be confirmed with the soft key [Enter].

Figure 30 Display: system menu

9.2 Main Window

In the main window (see Figure 31) the measured oxygen current value is dis-
played. An additional bar graph below the measured value display represents
the instantaneous value related to the measuring range.

In the left upper corner the current measuring range is indicated. At moisture
of > 0% (see page 56) "oxygen dry" is displayed to indicate that the O2 value is
a corrected value.

Figure 31 Display: main window

This main window branches into four menus:

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 50

 Menu Description
Status resp. MR1/2 If the Measuring Range Switching is set to “local” and
there is no error or alarm, the measuring range can be
selected with this key. In this case the soft key is marked
with "MR1/2". In the case of an error or alarm this soft
key is labelled with "status" and with this soft key the
errors and/or alarms can be called up.
System Calls up the system menu, in which you have access to
calibration functions, system settings, system tests etc.
For a detailed description see chapter 9.5 on page 58
and the following and chapter 9.6 on page 75 and the
following respectively.
Actual Displays all actual values of the system. For a detailed
description see chapter 9.3 on page 51 and the follow-
ing.
Parameter Calls up the parameter menu, in which several parame-
ters are shown. These parameters such as measuring
range, test gas… can also be altered. For a detailed
description see chapter 9.4 on page 53 and the follow-
ing.
Table 4 Branching of the main window

9.3 Actual Value Menu

Figure 32 Display: actual value menu

In the actual value menu the following current actual values of the electronic
unit can be called up:

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 51

 Actual Value Unit Description
Measured cell voltage of the O2 zirconium ox-
cell voltage mV
ide cell
Measured cell temperature of the O2 zirconium
cell temperature °C
oxide cell
Calculated, active O2 value current output de-
pending on the O2 range. The O2 range is set
current output mA
and can be changed in the parameter menu
(for details see chapter 9.4.2 on page 55)
At moisture of > 0% this is the corrected value
oxygen dry vol. % (for details see chapter 9.4.3 on page 56). This
value is also displayed in the main window.
This is the measured and calculated O2 value
oxygen wet vol. %
based on the cell voltage.
lambda Air/fuel ratio (see chapter 9.3.1 on page 52).
cold junction tem- Cold junction temperature of the thermocouple
°C
perature element
Only available on systems with integrated
flow rate reference pneumatic unit. This value shows the meas-
l/h
gas ured flow rate of the reference gas (20.95% O2)
used for the zirconium oxide cell
heater power % Power of the probe heater
process pressure bar Only with process pressure correction option
process pressure psi Only with process pressure correction option
burner load % Only with limit curves option
actual limit1 % Only with limit curves option
actual limit2 % Only with limit curves option
fuel % Only with limit curves option
Table 5 Actual value menu

Note

If, instead of a ‘value’ only underscores are shown, this

means that no valid value for this parameter is currently
available.

9.3.1 Lambda
The air ratio factor Lambda, describes the relationship of air flow supplied ef-
fectively before combustion, to the theoretical amount of air which is neces-
sary for complete combustion. A Lambda value of 1 means the exact relation-
ship of gaseous fuel and air needed for complete combustion, and this mixture
is designated as the stoichiometric gas air mixture. With complete combustion
of the fuel, the oxygen supplied is also completely used at this stoichiometric
point. In practice this value cannot be attained. Which Lambda value here is
considered as acceptable, depends on the respective application.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 52

 The value for Lambda (air relationship) is determined by the electronic accord-
ing to an approximate equation and under no circumstances replaces one,
e.g. in the control room calculated value, which presupposes still further
measured values.

21
λ≈
21 − O2

Approximate equation for Lambda

As a matter of course this approximate equation is not valid for a below-

stoichiometric combustion condition. It applies therefore, only to combustion
with excess air.

9.4 Parameter menu

In the parameter menu, the system parameters as shown in (Figure 33) can
be displayed and altered.

Note

With the limit value curves option, a selection menu ap-

pears between system parameters and limit value curves,
after selection of the parameter menu (see chapter 9.4.4
on page 56).

Figure 33 Display: parameter menu

Having selected a parameter for the first time with the soft key [Enter], a win-
dow appears requesting the entry of a code. If the maintenance code was not
yet changed after installation, then one confirms the inquiry using [Enter] with-
out any input of numbers. To change the system code see chapter 9.5.10 on
page 74.

Note

The system code is factory-set to 0000.

Having entered the valid system code, a window appears where the corre-
sponding value can be selected.

In this menu the following parameters can be changed:

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 53

 Parameter Unit Input limits Comment
O2 cell constant
Note: a successful O2 single point or
constant mV -50mV to 10mV
two point calibration will overwrite this
zirconium oxide cell constant.
O2 cell slope
Note: a successful O2 two point
slope mV/dec +35mV to +55mV
calibration will overwrite this zirconium
oxide cell slope.
O2 concentration of the test gas 1
test gas 1 % 0 % to 99 % Note: only available in systems without
integrated pneumatics unit
test gas 2 % 0 % to 99 % O2 concentration of the test gas 2
measuring 0% to setting of value of
% Start value of the O2 measuring range 1
range 1 from “measuring range 1 to”
setting of value of
measuring
% “measuring range 1 End value of the O2 measuring range 1
range 1 to
from” to 99%
measuring 0% to setting of value of
% Start value of the O2 measuring range 2
range 2 from “measuring range 2 to”
setting of value of
measuring
% “measuring range 2 End value of the O2 measuring range 2
range 2 to
from” to 99%
Limit value 1 for O2 min (alarm is set
when the O2 concentration falls below
the limit value) or max (alarm is set
limit 1 % 0% to 99%, min or max
when the O2 concentration rises above
the limit value) alarm. Not available with
limit value curves option!
Limit value 2 for O2 min (alarm is set
when the O2 concentration falls below
the limit value) or max (alarm is set
limit 2 % 0% to 99%, min or max
when the O2 concentration rises above
the limit value) alarm. Not available with
limit value curves option!
proportion of H2O (water) in the flue
H2O correction % 0 % to 50 %
gas
Table 6 Parameter menu

9.4.1 Changing a Parameter Value using the Alteration

of O2 Limit as an Example
In this chapter the alteration of a parameter will be explained using the exam-
ple of value “O2 limit 1”. For this purpose the downward arrow in the parame-
ter menu is pressed repeatedly until the point "limit 1" is reached. The point is
then called up using [Enter], and the system code entered and confirmed. On
the display the window "Parameter Input" appears.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 54

 Figure 34 Display: parameter input (example limit value 1)

The parameter to be altered is displayed in clear text with the current value. If
special functions are assigned to this parameter (like “min/max” in this exam-
ple), these are also displayed. In addition the permissible input limits of this
value are indicated (in this example 00.0 and 99.0).

With the numeric keypad, the value can be altered. To correct, the cursor can
be moved back with the [] key. The sign can be selected independently of
the cursor position with the [±] key (which would be unreasonable in this
case).

The secondary parameter “min/max” can be changed by the corresponding

soft keys.

Note

If a value cannot be entered, it should be checked whether

this value is outside the permitted limits. In such a case,
the entry of the value is not permitted, but the correspond-
ing limit value is selected.

The altered value has to be confirmed with the soft key [Enter].

Note

When pressing the soft key [Back], the altered value is

cancelled and the old value maintained.

9.4.2 Changing a Parameter Value using the Alteration

of “Measuring Range 1” as an Example
The electronic unit possesses two freely adjustable O2 measuring ranges. The
measuring ranges of the electronic unit can be determined freely. For example
one changes the “O2 Measuring Range 1” as follows:

To reach the menu option "O2 Measuring Range 1" the downward arrow in the
parameter menu is pressed repeatedly until the point "Measuring Range 1" is
reached. The point is then accessed by using [Enter], and the system code is
then entered and confirmed

In the menu option "Measuring Range 1 from", the initial value of the measur-
ing range can be indicated now.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 55

 Note

It is to be noted that the initial value of the measuring range

cannot be larger than the final value. Likewise the final
value cannot be selected as smaller than the initial value.
Otherwise the electronic unit does not permit the entered
values.

The same rule applies for the second measuring range,

which has to be smaller than the first measuring range.
Otherwise the electronic unit will not accept such settings.

After the input of the initial value, this value will be confirmed with [Enter] and
the final value of the measuring range can be entered in the menu option "O2
Measuring Range to". As soon as this value is confirmed using [Enter], the
electronic unit is updated with the new measuring range.

Note

By default, the change-over between the two measuring

ranges is set to "remote". If a manual (“local”) change-over
is required, this can be altered in the system menu (see
chapter 9.5.9 on page 73 and chapter 9.6.9 on page 87
respectively).

9.4.3 H2O Correction

The OXITEC® 5000 Ex oxygen analyser measures InSitu the wet oxygen
value. In the menu item „H2O correction“, the H2O value of the flue gas can be
entered. Then the electronic unit calculates the dry oxygen value (“Oxygen
dry”).

Note

If a moisture value greater than 0% is entered, the elec-

tronic unit indicates in the main window that this is a cor-
rected value - with the text “oxygen dry”.

9.4.4 Limits, Limit Curves (Option)

The standard electronic unit is fitted with two adjustable limits. As an option,
the electronic unit is available with limit curves adjustable for a maximum of 4
different fuels.

9.4.4.1 Fuel Select

In the menu "Select Fuel" there is a submenu for the 4 different fuels. In this
submenu, the four O2 points and the Min or Max function of the limit value
points can be adjusted.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 56

 9.4.4.2 Limit Value Curves

In the menu "Limit Curves for Fuel X" the five O2 points for the corresponding
fuel can be entered. The Min or Max function can also be entered. The elec-
tronic unit calculates the theoretical point for 0% burner load from the points of
20% and 40%.

The burner load signal is connected at the analogue input "Burner Load". This
signal must be 0 to 100% for 4 to 20 mA.

At digital input 1 and 2 the fuel should be selected. This selection is coded as
follows:

Digital Input 2 Digital Input 1

fuel 1 0 0
fuel 2 0 1
fuel 3 1 0
fuel 4 1 1
Table 7

In this connection, logic 0 corresponds to 0..4mA and logic 1 corresponds to

5..20mA.

Important

The external current supply must be electrically isolated

from ground. Otherwise a malfunction or damage to the
electronic unit is possible. Do not exceed the maximum
current of 20mA.

3,5

2,5
Vol % O2

2 limit curve 1
1,5 limit curve 2

0,5

0
20 40 60 80 100
burner load

Figure 35 Limit value curves ((default values for all kind of fuel)

Note

The space between the O2 points is calculated by the elec-

tronic unit. The accuracy of this calculation is ± 0,1Vol%.

The actual burner load and the corresponding limits can be shown in the ac-
tual value menu (see chapter 9.3 on page 51).

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 57

 9.5 System Menu of the OXITEC 5000 Ex* with
explosion proof Electronic Unit
* Since there are clear differences in some parts of the system menu between
the Ex electronic unit and the electronic unit in the GP field housing, the
chapter system menu is doubly available in this manual, one for electronic
units in Ex housing (chapter 9.5) and the other for electronic units in GP field
housing (chapter 9.6).

When selecting the system menu with the corresponding soft key, a code en-
quiry appears, where the system code (factory-set to 0000) must be entered
and confirmed with [ENTER].

Figure 36 Display: request for code input

Note

The system code is factory-set to 0000.

After entering the system code, the system selection menu appears (Figure
37).

Figure 37 Display: system menu

In this menu, the following functions can be called up:

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 58

 Menu Point Description / Remarks
Single point calibration Performs an O2 single point calibration with test air
Performs an O2 two point calibration with test air
Two point calibration
(20.95 % O2) and test gas
Calls menu for the automatic calibration of the O2
Automatic calibration
measurement at fixed time intervals
If the measured value memory is switched on, it
Measured value mem-
"freezes" the last measured value for O2 while in
ory
calibration
System test with test
Performs a measuring verification with test gas
gas
System test with test air Performs a measuring verification with test air
Setting of current out-
Changes between 0-20mA and 4-20mA output
put
Measuring range
Sets the operation mode to either "local" or "remote"
switching
Change code Changes the system code
Allows alteration to the damping time of the mA out-
Damping mA output
put for O2
Call up max./min. val- The lowest and/or highest measured values can be
ues called up here.
Change language Change language to either "English" or "German"
Service Calls the service menu
Shows the software version of the OXITEC® 5000
Software
Ex analyser system
Table 8 System menu

A description of the individual functions is given below:

9.5.1 First Steps for Calibration

Before you begin with the calibration, please make sure that the pneumatic
connections are correct (for details see chapter 16.1 page 128). The require-
ment for the gas supply is described in chapter 16.3/16.4 on page 129/130.

Please control the flow meters for test air / test gas. In systems with the
pneumatic unit option this control is accomplished at the pneumatics unit (see
Figure 38 and Figure 39 respectively). Check whether the flow of test air
and/or the test gas amounts to 150 l/h or more and the flow of the reference
gas amounts to 40 l/h (+/- 10 l/h). If this is not the case, please check the
pneumatic connections and lines.

Two different types of pneumatics units are available. With the semi-automatic
version (see Figure 38) test air and/or test gas must be selected by means of
a rotary switch at the pneumatics unit. An automatic calibration (ACAL) is not
possible with this version.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 59

 In addition a fully automatic version is available (see Figure 39) where the ro-
tary switch is replaced by a solenoid valve. Only with the fully automatic ver-
sion an automatic calibration (ACAL) can be carried out.

Test gas and reference gas control unit

SME-50000030 (Semi.Autocal)
300
260

Measure

440
400
420

Testair Testgas

3/2 way valve

Instrument air
pressure regulator Reference Test gas
MAX air
S ECONDARY

0,1-3,5
Flowmeter
PRESSURE
BAR

1,0
0,5 1,5

2,0
0
bar 2,5

Instrument air
pressure manometer

8,2

Connection 1/4''
218
210

Test Test Instr. Ref.

gas gas air air
in out in out

Figure 38 Front view of the pneumatic unit, semiautomatic

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 60

 Test gas and reference gas control unit
SME-50000060 (Autocal)
300
260

440
400
420

Instrument air
pressure regulator Reference Test gas
air
Flowmeter
MAX
SECONDARY

0,1-3,5
PRESSURE
BAR

1,0
0,5 1,5

2,0
0
bar 2,5

Instrument air
pressure manometer

8,2

Connection 1/4''
218
210

Test Test Instr. Ref.

gas gas air air
in out in out

Figure 39 Front view of the pneumatic unit, fully automatic

The calibration starts from the O2 value display (main window).

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 61

 Figure 40 Display: main window

Press the soft key [System] to select the system menu.

Before you enter the system menu, you are asked to first put in the system
code.

Figure 41 Display: code input request

Normally you have only to confirm the factory default code by pressing the soft
key [Enter]. This only works if the system code has not been changed. Other-
wise put in the 4-digit system code using the keypad on the right side of the
display panel, and then press the soft key [Enter].

After entering the system menu press the soft key [ ] several times until the
menu entry for the required calibration is selected. Confirm with [Enter].

Figure 42 Display: menu entries for calibration

9.5.2 O2 Single Point Calibration (Electronic Unit in Ex

housing)
Please take into account chapter 9.5.1 First Steps for Calibration page 59
which explains how to get to this calibration point.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 62

 Note

If the electronic unit is connected to a probe without sole-

noid valve, the manual test air valve must first be opened
before calibration.

If you have a system with

semi-automatic pneumatics
unit, then change the 3/2 way
valve from position “measure“
to position “testair“.
For systems with fully auto-
matic pneumatics unit the in-
troduction of test air takes
place automatically. With sys-
tems without pneumatics unit Figure 43 Position for the O2-single
please supply test air at the point calibration with test air (semi-
automatic pneumatics unit)
test gas input of the probe
(see Figure 15).

In this menu item, a single point calibration with ambient air can be done. After
selecting this menu item, you are requested to begin calibration with the soft
key [Start]. Before starting the calibration the flow rate of test air and test gas
has to be checked.

Figure 44 Request to start the calibration

The reading on the pneumatics unit (option) shows the current flow of test air.

Please check the flowmeter for test air / test gas on

the pneumatic unit. Verify the flow rate of the test
air amounts 150 l/h - 180 l/h and the flow rate of
the reference air is 40 l/h (+/- 10 l/h). If not please
check the test air supply and path.

Figure 45 Announcement: Measurement of the flow rate (on the left reference air, on the right test gas) only
systems with integrated pneumatic unit

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 63

 If the flow rates are correctly adjusted, please start the calibration with [Start],
and the single point calibration is effectively fully automatic. The progress of
the calibration process is represented by a time-controlled bar and takes
approx. 2 minutes.

Figure 46 Display: O2 single point calibration

During calibration, the cell voltage is checked for stability. This check works
according to the following criteria. The last measured value is temporarily
saved, and when the next value is outside the tolerance (±0.5mV), the internal
timer is reset, and the new value temporarily saved. This means that if the
timer was not reset, the value is stable. In this way, the last measured value
after the timer has lapsed (2 min.) is used to calculate the cell constant or
slope. The moving time bar indicates the internal timer, if the internal timer is
reset, the time bar is also reset.

When the calibration is completed, the display shows a message, which re-
quires an acknowledgement [Ok]. In the case of a successful calibration, the
message will be “Calibration Successfully Completed” (Figure 47); otherwise it
will be “O2 sensor constant out of tolerance”.

Figure 47 Advice for a successful calibration

During calibration, it is possible to accept the value of the cell voltage with
[Accept] and to have the calibration parameters calculated in advance. It
should however be noted that the advanced acceptance of the cell voltage is
not recommended, because in this case the electronic system does not know
if the output is stable, and therefore the value may not be correct.

Note

If you have a version with semi-automatic pneumatics unit,

change the 3/2 way valve from position “testair” to position
“measure” after calibration.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 64

 Note

If the electronic unit is connected to a probe without sole-

noid valve, the test air manual valve must be closed after
calibration.

9.5.3 O2 Two Point Calibration (Electronic Unit in Ex

Housing)
Please take into account chapter 9.5.1 First Steps for Calibration on page 59,
where it is explained how to get to this calibration point.

Please check the flowmeter for test air / test gas

on the pneumatic unit. Verify the flow rate of the
test air is 150 l/h - 180 l/h and the flow rate of
the reference air is 40 l/h (+/- 10 l/h). If not
please check the test air supply and path.

Figure 48 Announcement: Measurement of the flow rate (on the left reference air, on the right test gas) only
systems with integrated pneumatic unit

In this menu item, a two point calibration with air and with a suitable test gas
concentration can be performed (for this see chapter 16.4

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 65

 Requirements for the Gas Supply on page 130). It should be noted that the
concentration of the test gas must correspond to the value shown in the pa-
rameter menu.

For the test gas (test gas 2) a concentration of 2.1% is recommended.

Note

If the electronic unit is connected to a probe without sole-

noid valve, the manual test air valve must first be opened
before calibration.

Note

The oxygen concentration of the test gas used must be first

entered in the parameter menu (see also chapter 9.4 on
page 53).

The calibration is accomplished in two steps.

First step:

If you have a system with semi-

automatic pneumatics unit, then
change the 3/2 way valve from
position “measure“ to position
“testair“. For systems with fully
automatic pneumatics unit the
supply of test air takes place
automatically. With systems with-
out pneumatics unit supply test Figure 49 Position of the valve
air at the test gas input of the for the first step of the O2-two
point calibration with test air
probe (see Figure 15). (semiautomatic pneumatics
unit)

If the flow rates are correctly adjusted, start the calibration with [Start], and the
two point calibration starts fully automatically.

The first part of the calibration uses test air and the process progress is indi-
cated in the display (see Figure 50). In the second step the calibration with the
test gas is accomplished and indicated (see Figure 53). The calibration works
fully automatically and needs two minutes per calibration, which is indicated by
a moving time bar.

Figure 50 Display: Two point calibration 1.step

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 66

 If this time controlled bar reached the centre line, the first part of the calibra-
tion is finished and the following request appears in the display.

Figure 51 Display: Request to start 2. step of two point calibration

Second step:

If the system does not have a fully automatic pneumatics unit, test gas must
be supplied before starting the second part of the two point calibration.

On systems with semi-automatic

pneumatics unit please change
the 3/2 way valve from position
“testair“ to position “testgas”.

On systems without pneumatics

unit, please supply test gas 2 at
the test gas connection of the Figure 52 Position of the valve
probe. for the second step of the two
point calibration (semiautomatic
pneumatics unit)

If the test gas is supplied and the flow rate is controlled, the second part of the
calibration can be accomplished through pressing the soft key [Start].

For systems with fully automatic pneumatics unit, the supply of the test gas
takes place automatically and after the completion of the first part of the cali-
bration the second part can be started immediately.

In the second step, the calibration with test gas is shown on the display and
needs also approx. two minutes for calibration, which is also indicated by the
moving time bar.

Figure 53 Display: O2 two point calibration, 2.step

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 67

 When the calibration is completed the display shows a message, which re-
quires an acknowledgement by pushing the soft key [Ok]. In case of a suc-
cessful calibration, the message will be “Calibration Successfully Completed”
(see Figure 54) otherwise it may be “O2 sensor constant out of tolerance”
and/or “O2 sensor slope out of tolerance”.

During calibration, the cell voltage is checked for stability. This check works
according to the following criteria. The last measured value is temporarily
saved, and when the next value is outside the tolerance (±0.5mV), the internal
timer is reset and the new value temporarily saved. This means that if the
timer was not reset, the value is stable. In this way, the last measured value
after the timer has lapsed (2 min.) is used to calculate the constant or slope.
The moving time bar indicates the internal timer, if the internal timer is reset
the time bar is also reset.

During the Two Point Calibration, the cell voltage can be accepted in advance
with [Accept], but it should be noted that for the Two Point Calibration two cell
voltage values are required. It may therefore occur that after the manual ac-
ceptance of a value, the calibration progress bar jumps to the halfway position.
This is not an error, but means that the electronic unit is now determining the
second value, which can also be accepted manually.

It should, however, be noted that an advance acceptance of the cell voltage is

not recommended, because the electronic system then does not know if the
output is stable and therefore the measuring value may be incorrect.

Figure 54 Advice for a successful calibration

If the parameters determined by calibration are outside the plausibility limits,

this is indicated by an error message. In this case the electronic unit will con-
tinue to work with the old values.

Note

If the electronic unit is connected to a probe without sole-

noid valve, the manual test air valve must be closed after
calibration.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 68

 Note

If you have a version with semi-automatic pneumatics unit,

change the 3/2 way valve from position “testgas“ to position
“measure” after calibration.

9.5.4 Automatic Calibration (ACAL) with Air (20.95% O2)

OXITEC® 5000 Ex offers the opportunity of automatically performing a calibra-
tion procedure at regular intervals. This procedure however requires the ver-
sion with a fully automatic pneumatics unit.

All settings required for an automatic calibration can be made in this menu.

These are:

Type of Calibration (Single Point or Two Point)

At this point, the type of calibration can be selected.

Automatic Calibration On/Off

As a standard, ACAL is off. In this item, ACAL can be activated.

Calibration every xx days (e.g. 90 days)

Indication of the calibration cycle time in days. Note: At a value of 0 days
the calibration starts immediately upon release, this is important for a man-
ual remote calibration.

Authorisation (internal or external)

If External is selected, a calibration is made only when the digital input
Calibration release has a “high” signal and the cycle time has elapsed (see
Chapter 10.5 on page 95). Internal means that independently of the release
input status, calibration will be made when the cycle time has elapsed. If
the cycle time has elapsed, but no release has been given, calibration
starts immediately upon release.

Remaining time xx days and xx hours

The remaining time until the next calibration is indicated under this item.

Note

For automatic calibration it is essential to connect a probe

with solenoid valve and to ensure that the test gas “air” is
always available and under pressure.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 69

 Important

If the calibration time interval in the parameter menu is set

to zero seconds for example - to make a remote calibration
- it is very important that the release signal has a maximum
time of 60 seconds. A release signal of more then 60 sec-
onds could restart the calibration permanently.

Please note that, there is no "real time" clock in the electronic unit. It does not
know time of day, month or year. Only a clock-pulse generator is used for
automatic calibration purposes.

9.5.5 Measured Value Memory

Under this menu item a measured value memory can be switched ‘on’ during
calibration. With the measured value memory ”on” the last measured value be-
fore calibration is saved so that at the current (mA) output, the measured
value, which changes during the calibration, has no effect. The currently
measured value is released again, after an adjustable delay, and when the
calibration is completed.

9.5.6 System Test with Test Gas (Electronic Unit in Ex-

Housing)
In this menu option, a system test with test gas can be accomplished. For sys-
tems with semi-automatic pneumatics unit, the test gas has to be supplied at
the test gas connection on the electronic unit and for systems without pneu-
matic unit; the test gas has to be supplied to the test gas connection of the
probe.

Please check the flowmeter for test air / test

gas on the pneumatic unit. Verify the flow rate
of the test gas is 150 l/h - 180 l/h and the flow
rate of the reference air is 40 l/h (+/- 10 l/h). If
not, please check the test air supply and path.

Figure 55 Announcement: Measurement of the flow rate (on the left reference air, on the right test gas)

Before the System Test, check in the parameter menu, whether the set value
of oxygen concentration of test gas agrees with the actual test gas concentra-
tion. If this should not be the case, the value in the parameter menu has to be
corrected (see chapter 9.4 on page 53).

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 70

 For systems with semi-automatic
pneumatics unit please change
the 3/2 way valve to position
“testgas“.

For systems without pneumatic

unit, please supply test gas 2 to
the test gas connection of the
probe. Figure 56 Position for the sys-
tem test with test gas

Note

If the electronic unit is not connected to a probe with sole-

noid valve, the manual test gas valve must be opened be-
fore System Test.

The System Test starts by pressing the soft key [Start].

Figure 57 Display: request to start the System Test

Now the oxygen concentration of test gas is displayed (see Figure 58).

Figure 58 Display: System Test with test gas

Control the O2 value in the OXITEC® 5000 Ex display.

After successful system test

please set the 3/2 way valve
back to "measure".

Figure 59 Position of the valve dur-

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 71

 ing measurement

Note

If the electronic unit is not connected to a probe with sole-

noid valve, the manual test gas valve must be opened be-
fore System Test, and closed after finishing.

9.5.7 System Test with Test Air (Electronic Unit in Ex-

Housing)
In this menu option a system test with test air can be accomplished.

For systems with semiautomatic

pneumatics unit please change
the 3/2 way valve to position
“testair“.

For systems without pneumatics

unit, please supply test air to the
test gas connection of the probe.
Figure 60 Position for system
test with test air

Please check the flowmeter for test air / test

gas on the pneumatic unit. Verify the flow rate
of the test gas is 150 l/h - 180 l/h and the flow
rate of the reference air is 40 l/h (+/- 10 l/h). If
not, please check the test air supply and path.

Figure 61 Announcement: Measurement of the flow rate (on the left reference air, on the right test gas) at
systems with integrated pneumatics unit

Note

If the electronic unit is not connected to a probe with sole-

noid valve, the manual test gas valve must be opened be-
fore System Test.

Begin the test with [Start].

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 72

 Figure 62 Display: System Test with test air

Control the O2 value in the OXITEC® 5000 Ex display.

After successful system test

please set the 3/2 way valve
back to "measure".

Figure 63 Position of the valve dur-

ing measurement

Note

If the electronic unit is not connected to a probe with sole-

noid valve, the manual test gas valve must be opened be-
fore System Test and closed after finishing.

9.5.8 Setting O2 Current Output

Here, the initial value of the current output of the measured O2 value can be
selected with the keys [ ] and [ ] respectively (0mA or 4mA).

9.5.9 Measuring Range Switching

The electronic unit has two measuring ranges. The switching mode of the
ranges can be made manually from the instrument keypad or by an external
remote 12 - 24 volt input signal. In this menu item it can be determined which
mode of range switching is required – “local” or “remote”.

The factory preset default in the electronic unit is "remote"

range switching. This means that in case of an open digital input, the measur-
ing range 1 is active. At the modus "local“, the measuring range can
be changed in the main menu with the soft key MR1/2 by hand.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 73

 Note

In case of errors and alarms, the soft key MR1/2 in the

main menu is used for status information. The status func-
tion has the highest priority, therefore this means in case of
errors the measuring range cannot be changed manually
(by hand).

9.5.10 Change Code

In this menu item, the system code can be changed.

Important

Note! Make sure that the current system code is well

noted! Loss of the service code would necessitate a Sys-
tem RESET. This RESET is only possible after consulta-
tion with ENOTEC.

9.5.11 Damping of O2 mA Output

The mA-output can be damped if required. There are optional settings, from 0
sec. (without damping) to a maximum of 55 sec. available.

Damping is useful if the electronic unit oxygen output signal is spiky or rough
due to sudden process condition changes. A smooth or damped output can be
obtained with the attenuation setting feature.

9.5.12 Call up max. / min. Values

The electronic unit continuously saves the lowest and highest measured
value. These values can be called up here. After quitting this item, the current
minimum and/or maximum value can be deleted in order to restart recording
minimum and maximum from this point in time.

9.5.13 Change Language

In this menu item the language can be selected.

9.5.14 Service
This menu item is reserved for ENOTEC service personnel only. It is factory-
coded.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 74

 9.5.15 Software
Here information about the software conditions is available.

9.6 System Menu of the OXITEC 5000 Ex* with

Electronic Unit in General Purpose (GP)
Field Housing and 19” Rack
* Since there are clear differences in some parts of the system menu between
the Ex electronic unit and the electronic unit in the GP field housing and in 19”
rack, the chapter system menu is doubly available in this manual. One for
electronic units in Ex housing (chapter 9.5) and the other for electronic units in
GP field housing (chapter 9.6).

When selecting the system menu with the corresponding soft key, a code en-
quiry appears, where the system code (factory-set to 0000) must be entered
and confirmed with [ENTER].

Figure 64 Display: request for code input

Note

The system code is factory-set to 0000.

After entering the system code, the system selection menu appears (Figure
65).

Figure 65 Display: system menu

In this menu, the following functions can be called up:

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 75

 Menu Point Description / Remarks
Single point calibration Performs an O2 single point calibration with test air
Performs an O2 two point calibration with test air (20.95
Two point calibration
% O2) and test gas
Calls menu for the automatic calibration of the O2 meas-
Automatic calibration
urement at fixed time intervals
If the measured value memory is switched on, it "freezes"
Measured value memory
the last measured value for O2 while in calibration
System test with test gas Performs a measuring verification with test gas
System test with test air Performs a measuring verification with test air
Setting of current output Changes between 0-20mA and 4-20mA output
Measuring range switch-
Sets the operation mode to either "local" or "remote"
ing
Change code Changes the system code
Allows alteration to the damping time of the mA output for
Damping mA output
O2
The lowest and/or highest measured values can be
Call up max./min. values
called up here.
Change language Change language to either "English" or "German"
Service Calls the service menu
Shows the software version of the OXITEC® 5000 Ex
Software
analyser system
Table 9 System menu

A description of the individual functions is given below:

9.6.1 First Steps for Calibration

Before you begin with the calibration, please make sure that the pneumatic
and gas connections are correct (for details see chapter 16.2 page 128). You
may find a description of the requirements of the gas supply in chapters
16.3/16.4 on page 129/130.

The calibration starts from the O2 value display (main window).

Figure 66 Display: main window

Press the soft key [System] to select the system menu.

Before you enter the system menu, you are first asked to put in the system
code.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 76

 Figure 67 Display: request of code input

Normally you have only to confirm the factory default code by pressing the soft
key [Enter]. This only works if the system code has not been changed. Other-
wise put in the 4-digit system code using the keypad on the right side of the
display panel, and then press the soft key [Enter].

After entering the system menu press the soft key [ ] several times until the
menu entry for the required calibration is selected. Confirm with [Enter].

Figure 68 Display: menu entries for calibration

9.6.2 Single Point Calibration (Electronic Unit in GP

Field Housing)
Please take into account to chapter 9.6.1 on page 76 which explains how to
get to this calibration point.

Note

If the electronic unit is connected to a probe without sole-

noid valve, the manual test air valve must first be opened
before calibration.

In this menu item, a single point calibration with ambient air can be done. After
selecting this menu item, you are requested to begin calibration with the soft
key [Start]. If the system has no pneumatic unit, test air must be supplied, and
the flow rate adjusted before the start of the calibration.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 77

 Figure 69 Request to start the calibration (system without pneumatic unit)

Figure 70 Request to start the calibration (system with pneumatic unit)

The single point calibration starts immediately and works fully automatically -
no manual intervention is required.

In the version with integrated pneumatics, the quantity of test gas is super-
vised by the electronic Unit. The horizontal bar of the following display shows
the current value of the flow rate of test air. If the gas flow corresponds to the
requirements, then this display appears only for a very short time, and the
calibration starts automatically.

Figure 71 Display: Measuring of the flow rate (only systems with intetrated pneumatic unit)

Should this not occur and the bar does not end at the point marked by an ar-
row (see Figure 71), the flow rate must be adjusted accordingly. You have
some minutes before an error message will be displayed. If an error message
occurs, the message must be confirmed, the correct flow rate adjusted and the
calibration procedure started again.

As soon as the correct flow rate is adjusted, the calibration starts automatically
(if no error message appeared).

In systems without integrated pneumatics unit the calibration starts automati-

cally after pressing the soft key [Start].

A moving time bar indicates the progress of calibration.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 78

 Figure 72 Display: O2 single point calibration (system without pneumatic unit)

Figure 73 Display: O2 single point calibration (system with pneumatic unit)

During calibration, the cell voltage is checked for stability. This check works
according to the following criteria: The last measured value is temporarily
saved, and when the next value is outside the tolerance (±0.5mV), the internal
timer is reset, and the new value temporarily saved. This means that if the
timer was not reset, the value is stable. In this way, the last measured value
after the timer has lapsed (2 min.) is used to calculate the constant or slope.
The moving time bar indicates the internal timer, if the internal timer is reset,
the time bar is also reset.

When the calibration is completed, the display shows a message, which de-
mands acknowledgement [Ok]. In the case of a successful calibration, the
message will be “Calibration Successfully Completed” (Figure 74); otherwise it
will be “O2 sensor constant out of tolerance”. In this case the determined cali-
bration values will not be accepted and the system will continue to work with
the old values.

Figure 74 Advice for a successful calibration

During calibration, it is possible to accept the value of the cell voltage with
[Accept] and to have the calibration parameters calculated in advance. It
should however be noted that the advanced acceptance of the cell voltage is
not recommended, because in this case the electronic system does not know
if the output is stable, and therefore the value may not be correct.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 79

 Note

If the electronic unit is connected to a probe without sole-

noid valve, the test air manual valve must be closed after
calibration.

9.6.3 Two Point Calibration (Electronic Unit in GP Field

Housing and 19” Rack)
Please take into account chapter 9.6.1 on page 76, where it is explained how
to get to this calibration point.

In this menu item, a two point calibration with air and with a test gas with a
suitable test gas concentration can be performed. It should be noted that the
concentration of the test gas must correspond to the value shown in the pa-
rameter menu.

Note

If the electronic unit is connected to a probe without sole-

noid valve, the manual test air valve must first be opened
before calibration.

Note

The oxygen concentration of the test gas used must be first

entered in the parameter menu (see also chapter 9.4 on
page 53).

After selection of this menu option you are requested to start the calibration by
pushing the [Start] key. In systems without integrated pneumatic unit, test air
must be supplied and the flow rate adjusted before the start of calibration.

Figure 75 Display: Request to start two point calibration (system without pneumatic unit)

Figure 76 Display: Request to start two point calibration (system with pneumatic unit)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 80

 The first part of the calibration now starts fully automatically; and manual inter-
ference is not necessary.

With the version with integrated pneumatic unit the quantity of the test gas is
supervised by the electronic unit. The horizontal bar of the following display
shows the current value of the test air flow rate. If the gas flow corresponds to
the requirements this display only appears for a very short time, and the cali-
bration begins automatically.

Figure 77 Display: Flow rate measuring (only systems with integrated pneumatic unit)

Should this not occur and the bar does not end at the point marked by an ar-
row (see Figure 77), the flow rate must be adjusted accordingly. You have
some minutes before an error message will be displayed. If an error message
occurs, the message must be confirmed, the correct flow rate adjusted and the
calibration procedure started again.

If no error message appeared the calibration starts automatically, as soon as

the correct flow rate is adjusted.

The two point calibration takes place fully automatically in two steps. The first
step of the calibration is carried out using test air. The process progress is in-
dicated in the display (see Figure 78 and Figure 79 respectively).

Figure 78 Display: Two point calibration 1.step (system without integrated pneumatic unit)

Figure 79 Display: Two point calibration 1.step (system with integrated pneumatic unit)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 81

 After completion of step 1 for systems without integrated pneumatic unit, the
request to supply and adjust test gas and to start step 2 appears (see Figure
80). For systems with integrated pneumatic unit, the quantity of the test gas is
supervised by the electronic unit.

The horizontal bar of the display in Figure 81 (just for systems with integrated
pneumatic unit) shows the current value of the test air flow rate. If the gas flow
corresponds to the requirements this display only appears for a very short
time, and the calibration begins automatically (see Figure 83).

Figure 80 Display: Request to start 2. step of two point calibration (system without pneumatic unit)

Figure 81 Display: Flow rate measuring (only systems with integrated pneumatic unit)

During the second step, calibration with the test gas is carried out and dis-
played. Also the second part of calibration operates fully automatically and
needs two minutes, which is indicated by a moving time bar (see Figure 82
and Figure 83 respectively).

Figure 82 Display: O2 two point calibration, 2.step (system without integrated pneumatic unit)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 82

 Figure 83 Display: O2 two point calibration, 2.step (system with integrated pneumatic unit)

During calibration, the cell voltage is checked for stability. This check works
according to the following criteria. The last measured value is temporarily
saved, and when the next value is outside the tolerance (±0.5mV), the internal
timer is reset and the new value temporarily saved. This means that if the
timer was not reset, the value is stable. In this way, the last measured value
after the timer has lapsed (2 min.) is used to calculate the constant or slope.
The moving time bar indicates the internal timer, if the internal timer is reset
the time bar is also reset.

During the Two Point Calibration, the cell voltage can be accepted in advance
with [Accept], but it should be noted that for the Two Point Calibration two cell
voltage values are required. It may therefore occur that after the manual ac-
ceptance of a value, the calibration progress bar jumps to the halfway position.
This is not an error, but means that the electronic unit is now determining the
second value, which can also be accepted manually.

It should, however, be noted that an advance acceptance of the cell voltage is

not recommended, because the electronic system then does not know if the
output is stable and may therefore not be correct.

When the calibration is completed the display shows a message, which re-
quires acknowledgement [Ok]. In the case of a successful calibration, the
message will be “Calibration Successfully Completed”; otherwise it may be
“O2 sensor constant out of tolerance” and/or “O2 sensor slope out of toler-
ance”.

Figure 84 Advice for a successful calibration

If one or more of the parameters determined by calibration are outside the

plausibility limits, this is indicated by an error message. In this case the elec-
tronic unit will continue to work with the old values.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 83

 Note

If the electronic unit is connected to a probe without sole-

noid valve, the manual test air valve must be closed after
calibration.

9.6.4 Automatic Calibration (ACAL) with Air (20.95% O2)

OXITEC® 5000 Ex offers the opportunity of automatically performing a calibra-
tion procedure at regular intervals. This procedure however requires the ver-
sion with a fully automatic pneumatics unit.

All settings required for an automatic calibration can be made in this menu.

These are:

Type of Calibration (Single Point or Two Point)

At this point, the type of calibration can be selected.

Automatic Calibration On/Off

As a standard, ACAL is off. In this item, ACAL can be activated.

Calibration every xx days (e.g. 90 days)

Indication of the calibration cycle time in days. At a value of 0 days the cali-
bration starts immediately upon release, this is important for a manual re-
mote calibration.

Authorisaton (internal or external)

If External is selected, a calibration is made only when the digital input
Calibration release has a “high” signal and the cycle time has elapsed. (See
Chapter 10.5 on page 95). Internal means that independently of the release
input status, calibration will be made when the cycle time has elapsed. If
the cycle time has elapsed, but no release has been given, calibration
starts immediately upon release.

Remaining time xx days and xx hours

The remaining time until the next calibration is indicated under this item.

Note

For automatic calibration it is essential to connect a probe

with solenoid valve and to ensure that the test gas “air” is
always available and under pressure (instrument air ver-
sion) or a pneumatic unit with pumps must be installed (for
details see chapter 16.2 on page 128).

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 84

 Important

If the calibration time interval in the parameter menu is set

to zero seconds for example - to make a remote calibration
- it is very important that the release signal has a maximum
time of 60 seconds. A release signal of more then 60 sec-
onds could restart the calibration a second time.

Please note that there is no "real time" clock in the electronic unit. It does not
know time of day, month or year. Only a clock-pulse generator is used for
automatic calibration purposes.

9.6.5 Measured Value Memory

Under this menu item a measured value memory can be switched “on” during
calibration. With the measured value memory ”on” the last measured value be-
fore calibration is saved so that at the current (mA) output, the measured
value, which changes during the calibration, has no effect. The currently
measured value is released again, after an adjustable delay, and when the
calibration is completed.

9.6.6 System Test with Test Gas (Electronic Unit in GP

Field Housing and 19” Rack)
In this menu option, a System Test with Test Gas can be carried out. In sys-
tems without integrated pneumatic unit, the test gas has to be supplied at the
probe. For systems with integrated pneumatic unit, the test gas has to be sup-
plied at the test gas connection on the electronic unit.

Before the System Test, check in the parameter menu whether the set value
of oxygen concentration of test gas, agrees with the actual test gas concentra-
tion. If this should not be the case, the value in the parameter menu has to be
corrected (see chapter 9.4 on page 53).

The System Test starts by pressing the soft key [Start].

Figure 85 Display: request to start the System Test

Now the oxygen concentration of test gas is displayed (see Figure 86 and
Figure 87 respectively).

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 85

 Figure 86 Display: System Test with test gas (system without pneumatic unit)

Figure 87 Display: System Test with test gas (system with pneumatic unit)

In addition, this menu permits the adjustment of the correct flow of test gas re-
quired for two point calibration (only systems with integrated pneumatic unit).
The bar indicating the flow rate of test gas must end close to the vertical ar-
row.

Note

If the electronic unit is not connected to a probe with sole-

noid valve, the manual test gas valve must be opened be-
fore System Test, and closed after finishing.

9.6.7 System Test with Test Air (Electronic Unit in GP

Field Housing or 19” Rack)
In this menu option a System Test with Test Air can be accomplished.

Figure 88 Display: System Test with test air (system without integrated pneumatic unit)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 86

 Figure 89 Display: System Test with test air (system with integrated pneumatic unit)

Note

If the electronic unit is not connected to a probe with sole-

noid valve, the manual test gas valve must be opened be-
fore System Test and closed after finishing.

9.6.8 Setting Current Output

Here, the initial value of the current output of the measured O2 value can be
selected with the keys [ ] and [ ] (0mA or 4mA).

9.6.9 Measuring Range Switching

The electronic unit has two measuring ranges. The switching mode of the
ranges can be made manually from the instrument keypad or by an external
remote 12- 24 volt input signal. In this menu item it can be determined which
mode of range switching is required – “local” or “remote”.

The factory preset default in the electronic unit is "remote"

range switching. This means that in case of an open digital input, the measur-
ing range 1 is active. In the modus "local“, the measuring range can
be changed in the main menu with the soft key MR1/2 by hand.

Note

In case of errors and alarms, the soft key MR1/2 in the

main menu is used for status information. The status func-
tion has the highest priority, therefore this means in case of
errors the measuring range cannot be changed manually
(by hand).

9.6.10 Change Code

In this menu item, the system code can be changed.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 87

 Important

Note! Make sure that the current system code is well

noted! Loss of the system code would necessitate a Sys-
tem RESET. This RESET is only possible after consulta-
tion with ENOTEC.

9.6.11 Damping of O2 mA Output

The mA-output can be damped if required. There are optional settings, from 0
sec. (without damping), to a maximum of 55 sec. available.

Damping is useful if the electronic unit oxygen output signal is spiky or rough
due to sudden process condition changes. A smooth or damped output can be
obtained with the attenuation setting feature.

9.6.12 Call up Max. / Min. Values

The electronic unit continuously saves the lowest and highest measured
value. These values can be called up here. After quitting this item, the current
minimum and/or maximum value can be deleted in order to restart recording
minimum and maximum from this point in time.

9.6.13 Change Language

In this menu item the language can be selected.

9.6.14 Service
This menu item is reserved for ENOTEC service personnel only. It is factory-
coded.

9.6.15 Software
Here information about the software conditions is available.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 88

 9.7 Status Messages (Error Messages)

Figure 90 Display: Example of error messages

If errors or alarms occur during operation, these are displayed as clear text in
the status menu. All errors and alarms must be acknowledged in this menu
display by pressing the soft key [Enter].

A ‘help’ function for the status messages is available in this menu.

Note

If the electronic unit is put into operation without a probe

connected, some system errors will occur. E.g. “System not
heating up”, “O2 sensor signal out of range”, Thermocouple
failure”. When the electronic unit is then connected to a
probe, these errors will be displayed again, because the
microprocessor stores the errors as they occur in a perma-
nent memory (EEPROM). After acknowledgement of each
of these errors, the system operates normally.

With the key [Enter] an error or an alarm can be reset, if the condition does not
exist any longer (e.g. “Limit Value Injury”) or the error is eliminated.

Following status messages are possible:

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 89

 Status Messages / Error Messages LED output
1. O2 sensor constant out of tolerance
LED “Error”
As the result of a calibration check, the calculated cell constant is
outside the tolerance range parameters of the microprocessor
Relay “System
settings. Therefore the electronic unit continues with the previ-
Error” contact
ous/former cell constant value. The microprocessor tolerance
open
range is factory set to: -50mV to +10mV.
2. O2 sensor slope out of tolerance
As the result of a calibration check, the calculated mV/Decade
slope is outside the tolerance range. The electronic unit therefore LED “Error”
continues with the previous/former slope value.
Occurrence: During calibration Relay “System
Tolerance: 35mV to 55mV per decade Error” contact
Possible reasons: Test gas flow to low (⇒ Check the test gas open
tubes, if needed exchange of the test gas and reference gas
tubes), solenoid valve not open, incorrect test gas concentration.
3. Ref.gas flow too low (only with integrated pneumatic unit)
The reference gas flow is too low (min. 5 litre-per-hour).
Occurrence: At any time
Tolerance: Min. 5 l/h, min. 1 bar LED “Error”
Possible reasons: Please test the pressure of the instrument air
supply (min. 1 bar) and if necessary, try to adjust the reference air
(see page 109/110). With the pump version, test the pneumatic LED “Maint.”
tubes for kinks or blockages. If the problem is due to the pump
itself, it is possible to change the pump. Please contact ENOTEC
in this instance.
4. Cal. gas flow too low
Occurrence: During calibration LED “Error”
Tolerance: Min. 150 l/h
Possible reasons: Insufficient instrument air supply, blown fuses,
test gas tube blocked, solenoid valve not open, test gas bottle not LED “Maint.”
open.
5. System not heating up
The probe could not heat to the nominal temperature (800°C /
1472°F).
Occurrence: During heating phase
Possible reasons: Reference air flow rate is too high, blown fuses, LED “Error”
insufficient power supply voltage, broken probe cable, broken
heater wires, heater resistance failure of the probe heater (must Relay “System
be between 37.5 and 47.0 Ohms). Error” contact
open
Warning

Make sure that the power is switched off when

doing this test!

6. Thermocouple failure LED “Error”

The electronic unit has detected an error with the thermocouple.
Occurrence: At any time Relay “System
Possible reasons: Connection failure, broken probe cable, faulty Error” contact
thermocouple open
7. O2 sensor signal out of range
The cell voltage detected by the electronic unit is out of the input
LED “Error”
range.
Occurrence: At any time
Relay “System
Tolerance: -45mV to +265mV
Error” contact
Possible reasons: O2 cell signal wire not connected, bad connec-
open
tion, push the probe inner part assembly, broken probe cable,
faulty thermocouple, large amount of combustibles in the flue gas.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 90

 Status Messages / Error Messages LED output
8. Probe heater power too high LED “Error”
The probe heater is switched off with this error message, if – after
the heating phase – the heater power exceeds 80% (default value) Relay “System
for a period of 60 minutes (default value). Error” contact
open
9. C/J temp. out of specification
The temperature of the electronic unit is outside the allowed oper-
LED “Error”
ating limits
Occurrence: At any time
Relay “System
Tolerance: -20°C (-4°F) to +70°C (158°F) within its housing
Error” contact
Possible reasons: Ambient air temperature is too high. The tem-
open
perature of the electronic unit is outside the allowed operating
limits)
10. Probe temperature too high
LED “Error”
Occurrence: At any time
Tolerance: Max. 820°C (1508°F)
Relay “System
Possible reasons: Flue gas temperature too high (see Chapter
Error” contact
11.3 - on page 106), failure thermocouple, failure heater, wrong
open
connection at terminal box.
11. Probe temperature too low
The temperature of the probe was or is too low. LED “Error”
Occurrence: At any time
Tolerance: Min. 780°C (1436°F) Relay “System
Possible reasons: Reference air flow too high, blown fuses, heater Error” contact
failure, broken probe cable, actual power supply voltage to the open
electronic unit (230V/115V ±10%).
12. Alarm limit 1
Occurrence: At any time, when limit was enabled. Not active,
LED “Alarm”
when measuring value memory is active.
Possible reasons: Oxygen limit 1 out of range
13. Alarm limit 2
Occurrence: At any time, when limit was enabled. Not active,
LED “Alarm”
when measuring value memory is active.
Possible reasons: Oxygen limit 2 out of range
14. Data fault EEProm LED “Error”
A data error has occurred in the microprocessor and the electronic
unit continues with factory default values. Please contact Relay “System
ENOTEC. Error” contact
Occurrence: During commissioning open
15. Memory measuring value active
Occurrence: At any time. Status message. LED “Maint.”
Reason: The measuring value memory is still active.
16. Error: auto cal. failure
LED “Error”
Automatic calibration has failed.
Possible reasons: mV output value/signal from probe not stable,
Relay “System
cell constant or mV/Dec slope outside of microprocessor toler-
Error” contact
ance/range (Note: the corresponding error is shown on the elec-
open
tronic unit display), no calibration air (instrument air version only).
Table 10 Status messages

9.8 Heater Switch-off in Case of Failure

The temperature of the probe is supervised by an additional electronic unit
(part no. HCU-0001) with two thermocouples.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 91

 The electronic unit is designed for fail-safe (redundant) operation. It switches
the heater automatically off if the actual probe temperature exceeds the oper-
ating set temperature. The switch-off temperature is 810°C/1490°F. In addition
the heater is switched off in the case of an error at one of the thermocouples.

Electronic unit goes on hold - this means in case of a disturbance, the elec-
tronic unit must be reset manually by pressing the RESET button. Distur-
bances are signalled by red LEDs on the circuit board. The green LED signals
the error free operating condition.

By lighting up the LED 3 with each restart of the system, as well as with the
first start-up, the system signals that the electronic unit has to be reset by
pressing the RESET button. The RESET button is directly beside the front
panel of SME5 electronic unit.

Note

With SME5 electronic unit in GP field housing, the RESET

button is directly below the display.

LEDs Function
LED 1 Fault thermocouple,
Start-up and/or restart of the system (reset electronic unit with
RESET button)
LED 2 Max. switch-off thermocouple 1
LED 3 Max. switch-off thermocouple 2
LED 4 error free operating condition
Table 11 LED functions of the electronic unit for heater control

Figure 91 Electronic unit for fail-safe heater switch-off

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 92

 10 System Description / Adjustments

10.1 In Case of Loss of the System Code

In case of loss of the system code, it is possible to reset the code to factory
standard (0000). Therefore contact to ENOTEC is required.

10.2 Bridge on the Rear Side of Display Unit

Important

A bridge exists on the rear side of the display unit. This

bridge is used for the first operation in the factory. Don’t
move or remove this bridge, otherwise a fault function of
the electronic unit is possible. In this case contact to
ENOTEC is required.

Figure 92 Rear side of the display unit

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 93

 10.3 Adjustment of Display Contrast
The contrast of the display can be adjusted if necessary. This could be neces-
sary at higher ambient temperatures. The trimming potentiometer is shown on
Figure 93. To adjust the contrast it is necessary to remove the display board
and power ‘on’ the system. Now the contrast can be adjust by a small screw-
driver (type 2.5).

Warning

Working under power is only allowed by authorized, trained

skilled persons in complying with the corresponding safety
instructions (e.g. VDE 0105).

Figure 93 Adjustment display contrast

10.4 Relay Outputs / Functions and Correlation

of the Relays
The relay contacts are designed for 24V and 1A ~, 1A = (Exception: probe
valve)

Relay Contact Function

System error* break contact Signals operation-critical errors
Service make contact Service code was entered, system is
in service mode
Measuring range make contact Closed: Measuring range 1 active
Open: Measuring range 2 active
Probe valve** make contact Activation of the probe valve
Limit value 1 break contact Signals a violation of limit value 1
Limit value 2 break contact Signals a violation of limit value 2
Table 12 Relay outputs and their functions

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 94

 * The relay “system error“ is active also during the heating phase.
** The relay contact for the probe valve is designed for 230V and 1A ≅.

Figure 94 Relay plate with marked relays and LEDS

Relay Mark LED Mark Function Terminal.Contact

A a Main probe heater relay
B b Maintenance X4.18
C c System error X4.19
D d Limit O2 1 X4.21
E e Measuring range X4.20
F f Limit O2 2 X4.22
G g Probe valve X4.23/X4.24
H h Solenoid valve test gas 1 X7
I i Solenoid valve test gas 2 X2
x Probe heater control
Table 13

10.5 Digital Inputs

The digital inputs are designed for a direct voltage of 12 V - 30 V for logical
“High”. Logical “Low” agrees a voltage less than 1 V.

Digital input Function

Calibration release External release for calibration with ACAL
Measuring range shift Switching on the second measuring range
Table 14 Digital inputs and their functions

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 95

 10.5.1 Digital Inputs at Limit Curves Option
These digital inputs are designed for a current of 0..4mA for logical “low”, and
5..20mA for logical “high”.

Terminal names Terminal function

29 A + Digital Input 1, select fuel, current input (0..4mA,
5..20mA)
29 B - Digital Input 1, select fuel, current input (0..4mA,
5.. 20mA)
30 A + Digital Input 2, select fuel, current input (0..4mA,
5..20mA)
30 B - Digital Input 2, select fuel, current input (0..4mA,
5..20mA)
Table 15

Important

The external current for the inputs (28 to 30) must be elec-
trically isolated from ground. Otherwise a malfunction or
damage to the electronic unit is possible.
Do not exceed the maximum current of 20mA.

10.6 Pressure and Flow rates for Test Air and/or

Reference Air
The systems are factory-set to the correct amounts of test air and/or reference
air.

The instrument air versions are designed for an inlet pressure of 1-10 bar.
With a higher inlet pressure than 6 bar, it is necessary to readjust the flow of
reference air and/or test air (see chapter 12.3 on page 109 and chapter 12.4
on page 110 respectively).

The flow rates for air should be in the following range:

Test air: 150l/h - 180l/h

Reference air: 30l/h - 40l/h

The flow of reference air can be checked in the actual value menu. In systems
with integrated pneumatic unit, test air and/or test gas flow can be examined
and adjusted in the system menu under System Test with Test Gas (see page
70 and 85 respectively).

10.7 Stability Criteria for Calibration

During calibration, the cell is checked for stability. This check operates accord-
ing to the following criteria.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 96

 The last measured value is always temporarily saved. When the next value is
outside the tolerance, the internal timer is reset and the new value temporarily
saved. This means that if the timer was not reset, the value is stable. In this
way, the last measured value after the timer has elapsed (2 min.) is used to
calculate the cell constant or slope.

10.8 Reaction Time of the mA Output

The reaction time of the mA output to a change of the O2 cell input voltage is
less than 200 ms.

10.9 Extension Modules

As an option, the electronic unit is available with a RS 232 Interface Module.

10.9.1 RS 232 Interface (option)

Via the RS232 (V24) interface cyclically (approx. every 400ms) operational
data are sent.

10.9.1.1 Global Description

The bidirectional OXITEC®/COMTEC® serial interface protocol is used for

value requests, parameters settings and function executions.

The transmission is frame-oriented; it means that each transmission block is

framed by defined control characters. Within the frame only readable charac-
ters (ASCII) are allowed. The length of each transmission block is dependant
upon the function and also its assigned data.

The serial communication protocol has no address attribute, therefore it is not

possible to use it for a multi-slave communication bus.

Within each transmission frame there are only ASCII characters allowed but
no control characters. Therefore digits and values are transmitted as text.
Memory dumps are transmitted as HEX character strings.

A CRC8 checksum secures each transmission frame and is placed at the end
of each transmission block as a HEX character string.

10.9.1.2 Description of the Transmission Block (Frame)

In principle the structures of the transmission blocks of a master request (e.g.

PC) and of a slave answer (e.g. OXITEC or COMTEC) are identical. Addition-
ally the answers of the slave have a leading ACK control character to identify
a successful transmission. The slave transmits a NAK control character on
any transmission faults or unsupported functions.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 97

 Each transmission block is framed by the control character STX and ETX.

10.9.1.2.1 Definition of the Control Characters

The control characters are transmitted as 8 bit values and they are defined as
follows:

Control Character Value (decimal) Value (hexadecimal)

STX 2 0x02
ETX 3 0x03
ACK 6 0x06
NAK 21 0x15
Table 16 Definition of control characters

10.9.1.2.2 Master Request Slave

Any request is defined as follows:

<STX><C><NN><UUUU><F><D....D><HH><ETX>

Definition Description Count of Characters

<STX> STX control character 1
<C> Operation Mode: 1
’1’ read operation
’2’ write operation
’3’ execute operation
<NN> Function Number (see also the following chapters) 2
’00’ to ‘99’
<UUUU> Dimension (Unit) In Clear Text, e.g.: 4
’ %’
’ mV’
’ mA’
’ °C’
...
<F> Format Character 1
’A’ ASCII (not used yet)
’F’ floating point, single precision
’D’ floating point, double precision (not used yet)
’I’ 16Bit INTEGER, signed
’U’ 16Bit INTEGER, unsigned
’L’ 32Bit INTEGER, signed
’N’ 32Bit INTEGER, unsigned
<D..D> Values as hex character string (memory dump) or as plain 0...22
text (for format ‚A’ only)
<HH> CRC8 checksum, hexadecimal character string 2
e.g. ‚3B’ or ‚04’
<ETX> ETX control character 1
Table 17 Explanation of control characters

10.9.1.2.3 Answer Slave Master

10.9.1.2.3.1 Positive Answer (ACK)

Positive answers will be transmitted to the master if the request block could be
interpreted correctly, and also executed.
The answer transmission block is sent with a leading ACK control character.
<ACK><STX><C><NN><UUUU><F><D....D><HH><ETX>

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 98

 The description of the transmission format definition is described in Table 17
on page 98.

10.9.1.2.3.2 Negative Answer (NAK)

Negative answers will be sent back to the master, if:

• more than 32 characters were transmitted by the master within the

STX and ETX control characters
• the STX control character is missing
• the checksum is not correct
• the operation mode is not defined (in general or not for the desired
function, e.g. a write access to a read-only value)
• less than required characters were transmitted
• invalid characters have been detected within the transmission block
• the function number is not supported

10.9.1.2.4 Timing

tA answer time, min. 0ms, max. 1000ms

tD delay time to the next request after an answer, min. 0ms

10.9.1.2.5 Checksum Calculation

10.9.1.2.5.1 Specification

The checksum is defined as CRC8 with its polynomial

C (x ) = x 8 + x 2 + x + 1

The CRC8 calculation includes all characters within the STX and ETX control
character except the two CRC8 checksum characters itself.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 99

 10.9.1.2.5.2 C Example

unsigned char stxetx_getcrc8(void *src, int count)

{
unsigned crc= 0x00;
int i;
while(count--) {
crc^= *((unsigned char*)src);
((unsigned char*)(src))++;
for(i= 0; i<8; i++) {
if(crc & BIT(7)) {
crc<<= 1;
crc^= 0x07;
} else crc<<= 1;
}
}
return((unsigned char)crc);
}

10.9.1.3 Operation Modes

10.9.1.3.1 Read Operation

10.9.1.3.1.1 Specification

The read operation opcode is 1.

The read operation transmission block consists of at least 5 characters:

Request: <STX>1<NN><HH><ETX>
Answer : <ACK><STX>1<NN><UUUU><F><D....D><HH><ETX>

10.9.1.3.1.2 Example

Request for an oxygen value:

Request: <STX>100E3<ETX>
Answer : <ACK><STX>100 %F9A99A741C8<ETX>

The function returns a floating point (single precision) memory dump which is
interpreted as 20.95% O2.

10.9.1.3.2 Write Operation

10.9.1.3.2.1 Specification

The write operation opcode is 2.

The write operation transmission block consists of a format dependent block
length.

Request: <STX>2<NN><UUUU><F><D....D><HH><ETX>
Answer: <ACK><STX>2<NN><UUUU><F><D....D><HH><ETX>

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 100

 The format characters (<UUUU>) can be set blank on request. The format
character must have the correct function-dependent format. A format charac-
ter which is not supported by the desired function will be acknowledged by a
NAK control character.

The data which must be transferred are defined as HEX character string of the
memory dump.

10.9.1.3.2.2 Value Limitation

Each data can be limited by a function-dependent minimum and maximum

value. If the value exceeds this limits it will be automatically set to its de-
pended limitation value. In this case the answer contains the new limited
value.

10.9.1.3.2.3 Example

The following example shows how the O2 cell constant can be written. The set
value of 50.00mV exceeds the maximum value of 10.00mV; therefore it is lim-
ited to a value of 10.00mV.

Request: <STX>210 F00004842F8<ETX>

Answer: <ACK><STX>210mVF000020411A<ETX>

The set value of 50.00mV is limited to 10.00mV, therefor the limited value is
returned.

10.9.1.3.3 Execute Operation

10.9.1.3.3.1 Specification

The execute operation opcode is 3.

The execute transmission block consists of at least 5 characters:

Request: <STX>3<NN><HH><ETX>
Answer: <ACK><STX>3<NN> U<DDDD><HH><ETX>

The answer contains the execution status which is defined as follows:

0000 normal execution, process running

0001 previous execution process is still running
FFFF not supported

10.9.1.3.3.2 Example

The following example executes a single point calibration. The execution

status is directly returned.

Request: <STX>3201F<ETX>
Answer: <ACK><STX>320 U0000E3<ETX>

In this case the execution progress must be requested by a read operation of

the calibration status variable, function number 05.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 101

 10.9.1.4 Device Dependent Functions

10.9.1.4.1 Specification

Because of supporting different devices, there are some functions which were
only implemented in COMTEC® and OXITEC® respectively.

If a function is not supported by the device, the return value is always 0. Also
the unit definitions contain only space characters. The device type can be re-
quested by function no. 26.

10.9.1.4.2 Example

The following request asks for the COe value on a COMTEC® system. The
COe value is not supported by OXITEC®.

Request: <STX>106F1<ETX>
Answer: <ACK><STX>106 F0000000048<ETX>

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 102

 10.9.1.5 Implementation Table

Fn Operation Description Format Dimension (Unit) min max

00 read only oxygen value F %
01 read only O2 cell voltage F mV
02 read only O2 cell termpature F °C
03 read only O2 current output F mA
04 read only status signals N
05 read only O2 calibration status U
0 last calibration success-
ful
1 last calibration fault
2 calibration still active
3 calibration pending
06 read only COe value F ppm
07 read only COe sensor resistance F Ohm
08 read only COe sensor temperature F °C
09 read only COe heater resistance F Ohm
10 read / write O2 cell constant F mV -50.00 +10.00
11 read / write O2 cell slope F mV +35.00 +55.00
12 read / write O2 limit 1 F % +0.00 +21.00
13 read / write O2 limit 1 function N 0 (min) 1 (max)
14 read / write O2 limit 2 F % +0.00 +21.00
15 read / write O2 limit 2 function N 0 (min) 1 (max)
16 read / write O2 lower range F % 0.00 O2 upper
range
17 read / write O2 upper range F % O2 lower 21.00
range
18 read / write O2 current output average N sec 0 55
time
19 read / write not used
20 execute single point calibration U
21 execute O2 two point calibration U
22 read COe current output F mA
23 read / write COe calibration zero offset F Ohm 0 999999
24 read / write COe calibration span F Ohm 0 999999
25 read / write COe measuring range F ppm 500 10000
26 read only device type U
0 OXITEC
1 COMTEC
27 read only COe calibration status U
0 last calibration success-
ful
1 last calibration fault
2 calibration still active
3 calibration pending
28 execute COe single point calibration U
29 execute COe two point calibration U

Table 18 Description of the function code

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 103

 11 Technical Data*

11.1 Technical Specification Electronic Unit in

Ex-Housing
Dimensions: see dimensional sheets
Mains voltage: 230 V / 50...60Hz Toleranz ±10%
115 V / 50...60Hz Toleranz ±10%
Power consumption: 400 VA during start up
100 - 200 VA during operation
Recommended fuse: 10A
Requirements for the gas supply: See chapter 16.3/16.4 on page 129/130
Working ambient temperature: -20°C / -4°F up to +55°C / 131°F
other temperatures on request
Interference resistance : Electromagnetic compatibility (EMC)
89/336/EWG:
EN 50082-2: 1995
EN 55011 KI.B: 1992
Low Voltage Directive 72/23/EWG:
EN 61010-1: 8 / 2002
Relay outputs, potential-free: 24V 1A
Max. relay output solenoid valve: 230V ~ 1A
Analogue input cell: Re: > 9 MOhm
Ue: -45mV to +265mV
for the active measuring range
Resolution of the digitizers in the active 14 Bits + sign
measuring ranges:
Analogue input thermocouple: Re: > 900 kOhm
Temperature compensation: on the circuit board
Signal output 0/4...20 mA: maximum load 500 Ohm, potential-free, ac-
tive
Reaction time of the mA output: With a change of 100mV on the cell input
<200 ms
Display: LC, LED-lit 240 x 64 dots graphic display
Measuring accuracy: ±0.2% of actual measured value
Protection class: ATEX ll 2G Eex d IIC T6, IP66

*
Technical subject to change without notice! Please contact ENOTEC for further information.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 104

 11.2 Technical Specification Electronic Unit in
GP Field Housing
Dimensions: see dimensional sheets for the different housings
Mains voltage: Instrument air version:
230 V / 50...60Hz Toleranz ±10%
115 V / 50...60Hz Toleranz ±10%
Pump version:
230 V / 50Hz Toleranz ±10%
115 V / 50Hz Toleranz ±10%
230 V / 60Hz Toleranz ±10%
115 V / 60Hz Toleranz ±10%
Power consumption: 400 VA during start up
100 - 200 VA during operation
Recommended fuse: 10A
Requirements for the gas supply: See chapter 16.3/16.4 on page 129/130
Working ambient temperature: Version without pneu- -20°C/-4°F to +55°C/131°F
matic:
Instrument air version: -20°C/-4°F to +55°C/131°F
Version with pumps: -20°C/-4°F to +50°C/122°F
other temperatures on request
Interference resistance : Electromagnetic compatibility (EMC) 89/336/EWG:
EN 50082-2: 1995
EN 55011 KI.B: 1992
Low Voltage Directive 72/23/EWG:
EN 61010-1: 8 / 2002
Relay outputs, potential-free: 24V 1A
Max. relay output solenoid valve: 230V ~ 1A
Analogue input cell: Re: > 9 MOhm
Ue: -45mV to +265mV
for the active measuring range
Resolution of the digitizers in the 14 Bits + sign
active
measuring ranges:
Analogue input thermocouple: Re: > 900 kOhm
Temperature compensation: on the circuit board
Signal output 0/4...20 mA: maximum load 500 Ohm, potential-free, active
Reaction time of the mA output: With a change of 100mV on the cell input <200 ms

Display: LC, LED-lit 240 x 64 dots graphic display

Measuring accuracy: ±0.2% of actual measured value
Protection class: IP66

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 105

 11.3 Technical Specification Probe
Flue gas temperature: KEX500x: max. 500°C/932°F
up to 1400°C/2552°F with cooling
protection tube
Depth of immersion: KEX5001: 464mm
KEX5002: 924mm
Depth of immersion with KEX5001: 500mm
cooling protection tube KEX5001: 1000mm
Measuring principle: Zirconium oxide
Flue gas pressure: -50 to +50mbar
Flow velocity: 0 to 50m/s
Ambient temperature: -40°C/-40°F to +80°C/176°F
Response time (lag time): 0.5 s (flue gas flowing at > 10m/second)
T90 time: 5 s (flue gas flowing at > 10m/second)
Probe material: V4A (1.4571/316SS)
Type of protection:
ATEX II 2G Eex d II C T3
Number of certificate BVS 03 ATEX E 105 X
Detection limit: < 1ppm O2
Voltage supply: via electronic unit
Dimension: see types of probes

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 106

 12 Service and Maintenance

12.1 Switching between 230 V and 115 V

operation
The operating voltage can only be changed after removing the board cover.

Warning

De-energize system first!

The switch for changing the voltage (Figure 95 marked with SW1) can be
made using a screwdriver and rotating to the required voltage.

Figure 95 Switching between 230 V and 115 V operation (SW1)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 107

 Note

It must be noted that the standard pump version of the

OXITEC® 5000 Ex is designed for 50Hz.

For the 60Hz mains pump version a special order is neces-

sary. The mains frequency cannot be changed by the cus-
tomer.

The instrument air version is specified for 50-60Hz power

supply.

12.2 Replacing the Fuses

The electronic unit has four accessible fuses (see Figure 95):

Fuse Nominal Description

Current
F1 6.3 A semi time-lag 5x20mm glass tube fuse – to protect
the entire system
F2 4A semi time-lag 5x20mm glass tube fuse – to protect
the probe heater
F3 1A fast-acting 5x20mm glass tube fuse – to protect the
electronic
F4 1A fast-acting 5x20mm glass tube fuse – to protect the
electronic
F5 1A semi time-lag 5x20mm glass tube fuse – to protect
the solenoid valve, the test gas pump and reference
gas pump
Table 19 Fuses

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 108

 Important

The fuses on the circuit board below the cover (F3 and F4)
protect the electronic unit and should only be replaced by
service personnel. Otherwise error free function of the elec-
tronic unit cannot be guaranteed.

12.3 Adjusting the Flow Rate of Reference and

Test Air (Electronic Unit in Ex-Housing)

Test gas and reference gas control unit

SME-50000030 (Semi.Autocal)
300
260

Measure
440
400
420

Testair Testgas

3/2 way valve

Instrument air
pressure regulator Reference Test gas
MAX air
S ECONDARY

0,1-3,5
Flowmeter
PRESSURE
BAR

1,0
0,5 1,5

2,0
0
bar 2,5

Instrument air
pressure manometer

8,2
Figure 96 Adjustment of reference and test air quantity (semi-automatical)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 109

 Test gas and reference gas control unit
SME-50000060 (Autocal)
300
260

440
400
420

Instrument air
pressure regulator Reference Test gas
air
Flowmeter
MAX
SECONDARY

0,1-3,5
PRESSURE
BAR

1,0
0,5 1,5

2,0
0
bar 2,5

Instrument air
pressure manometer

8,2
Figure 97 Adjustment of reference and test air quantity (fully automatic)

The flow rate of reference air and test gas is been adjusted with the help of the
flow controllers of the respective flow meters in the pneumatics unit.

12.4 Adjusting the Flow Rate of Reference and

Test Air (Electronic Unit in GP Field Housing
with integrated Pneumatics)
In the system version in the GP field housing and with integrated pneumatic
unit, it is possible to adjust the reference and test air at the electronic unit.

In this respect, the pump and instrument air versions are different:

• In the pump version, only the flow rate of test air can be adjusted (see
Figure 98).

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 110

 • In the instrumental air version, both flow rates (test air and reference
air) can be adjusted (see Figure 99).

In systems with integrated pneumatics unit, the flow rate of reference air can
be read in the actual value menu (see chapter 9.3 on page 51). The flow rate
of calibration air can be read in the system menu under the menu point "Sys-
tem Test with Test Air" (see chapter 9.6.7 on page 86).

You may find the flow rates which have to be adjusted in chapter 10.6 on page
96.

Figure 98 Position of valve (pump version)

Figure 99 Position of valves (instrument air version)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 111

 12.5 Adjusting the Flow Rate of Reference and
Test Air (Electronic Unit in 19” Rack 3HE)
At systems in 19“ racks the reference air and test air quantity can be adjusted
at the back side of electronic unit.

There are differences between the pump and the instrument air version:

• In the pump version, only the flow rate of test air can be adjusted.
• In the instrumental air version, both flow rates (test air and reference
air) can be adjusted.

In systems with integrated pneumatics unit, the flow rate of reference air can
be read in the actual value menu (see chapter 9.3 on page 51). The flow rate
of calibration air can be read in the system menu under the menu point "Sys-
tem Test with Test Air" (see chapter 9.6.7 on page 86).

A Regulator Test Air

B Regulator Reference Air
C Regulator Test Air
D Test Air Filter
E Reference Air Filter
Figure 100 Regulating valves for adjustment of reference air and test air quantity (electronic unit in 19” 3HE
racks) left side: instrument air version, right side: version with pumps

12.6 Replacing the Filter Head

Warning – Hot Surface

The probe may only be removed with heat-insulated

gloves. Before removing the probe, always switch off the
supply voltage to the electronic system. After removal,
store the probe in a safe, protected place and wait until it
has cooled down below 35°C.

To change of the filter head, the protection screw on the filter head must be
loosened. The filter head can then be unscrewed and removed. The new filter
head is then screwed onto the probe tube. Before tightening the protection
screw again, the v-shield must be aligned to the flue gas stream (see for this
chapter 7.1.3 Adjusting the Filter Head on page 34).

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 112

 12.7 Exchange of ZrO2 Measuring Cell
Note

An exchange of the measuring cell is only necessary if the

cell is leaking (erratic or incorrect measured values).

Switch off the electronic unit, take the probe out of the protection tube and wait
until it has cooled down.

Warning – Hot Surface

The probe may only be removed with heat-insulated

gloves. Before removing the probe, always switch off the
supply voltage to the electronic system. After removal,
store the probe in a safe, protected place and wait until it
has cooled down below 35°C.

If necessary, clean the probe, removing dirt and dust, after it has cooled down.

Disconnect the wires in the connection head and loosen the two allen screws
which hold the inner parts of the tube. Pull off the thin transparent reference
air pipe from the entry fitting at the connection box.

Pull out probe internal assembly (4-hole ceramic rod with signal measuring
wire, thermocouple element and heater) carefully.

Figure 101 Probe connection box

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 113

 Important

The measuring signal wire may be fused/fixed solid with its

contact net to the inside of the ZrO2-cell.

Pull off the orange insulation from the measuring signal wire but do not pull out
the signal wire with the probe inner parts, as it may be fixed/fused to the inside
of the cell.

Loosen the four allen screws at the flange of the measuring cell and remove
the measuring cell from the measuring cell tube together with signal wire, if
fixed/fused to it.

Figure 102 Measuring cell holder tube in cut

Insert a screwdriver or the like carefully between the measuring cell holder
tube and the contact net of the measuring signal wire and prise the contact
sideways away by turning the screwdriver. Remove the loosened measuring
signal wire. Slide the measuring signal wire back into the 4-hole ceramic rod
and make certain that the round contact net lies in the recess of the heater
support.

Figure 103 Measuring cell assembly

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 114

 Clean the flange at the probe tube with fine sandpaper. Tighten the new
measuring cell with a new metal gasket sealing and four new screws at the
measuring cell flange of the probe tube. Tighten the 4 allen screws firmly with
an allen key.

Insert the probe inner parts and ensure that the inner parts do not bind in the
probe tube. Press the locking bolt against the spring, so that the inner parts
assembly is pressed against the measuring cell with enough spring tension.

Tighten locking bolt and connect wires as follows:

Terminal Colour Description Polarity Unit

1 green/yellow signal wire, measuring cell - mV
2 Orange signal wire, measuring cell + mV
3 Green thermocouple element 1 + mV
4 White thermocouple element 1 - mV
31 Green thermocouple element 2 + mV
41 White thermocouple element 2 - mV
6 Black heating element
7 Blue heating element
8 green/yellow ground/earth heater
Table 20 Connection of the probe inner part

Note

With older probes the colours of the connecting leads of

the thermocouple can be designated according to the old
colour code (see Table 21).

Polarity of thermocou- DIN IEC 584 DIN 43710 (old ANSI MC 96.1 (US)
ple German)
+ green red yellow
- white green red
Table 21 International colour codes for NiCrNi thermocouple wires

Warning – Hot Surface

In addition, the outside surface of the probe is hot

(300°C/572°F).

Install the probe and carry out an O2 two point calibration.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 115

 Figure 104 Construction of the measure cell holder tube

12.8 Exchange of Probe Inner Parts

Proceed as described in paragraph 12.7 on page 113 to dismantle the probe
inner parts assembly. The exchange of the thermocouple element is an excep-
tion, because this can be changed without completely dismantling the probe
inner parts.

12.8.1 Exchange of Thermocouple Element

The thermocouple element is a sheathed thermocouple assembly with an In-
conel-covering and two Ni-Cr-Ni thermocouple elements.

The thermocouple assembly is in one hole of the 4-hole-rod. Disconnect the

thermocouple element at the probe connection box, pull it out and insert a new
thermocouple element. If the probe is very long, it may be necessary to pull
out the complete probe inner parts assembly.

12.8.2 Exchange of Heating Element

Remove the probe inner parts assembly, loosen the clamp, pull out the signal
measuring wire and pull off the heater complete with ceramic support, from the
4-hole ceramic rod.

Assemble the new heater, if necessary with new ceramic support and new 4-
hole ceramic rod.

Insert signal measuring wire and thermocouple assembly; assemble clamps

and connection sleeves (for long probes).

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 116

 Important

The heater support has three drillings, which must corre-

spond with three holes of the 4-hole ceramic rod. Through
one hole the reference air flows, another hole is for the
thermocouple, and the third one is for the signal measuring
wire. Make sure that the grip net lies in the recess of the
heating support.

12.8.3 Exchange of Signal Measuring Wire

The signal measuring wire has a specially shaped contact for taking the mV-
value of the reference electrode of the ZrO2-measuring cell. The contact wire
is pressed against the measuring cell by means of spring tension of the inner
parts assembly.

If there is not enough spring tension or if the wire is broken, the mV-signal can
not be received any longer, and an error signal will occur.

12.8.4 Exchange of 4-Hole Ceramic Rod

Depending on the length, the probe has one or more 4-hole rods. In the case
of long probes, you have to ensure during assembly, that the holes corre-
spond to one another, so that installation can be carried out and the reference
air can be routed to the inner reference air side of the O2 measuring cell.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 117

 13 Trouble Shooting
The following information is intended as a key element to assist trouble shoot-
ing. It is not a comprehensive list of all possible system errors.

If defects cannot be repaired, please contact us or an approved service agent

directly:

ENOTEC GmbH
Marienheide
Höher Birken 6
51709 Marienheide - Rodt
Germany

Phone: (++49) 2264 4578-0

Fax: (++49) 2264 4578-31
Email: [email protected]

If the measured O2 value appears doubtful, first check all system parameters.
If all Parameters are correct, check the system with test gas. If the system
works correctly with test gas and there are no leakages in the area of the
probe (flanges, calibration gas connection), then the measurement is correct.

If for instance, certain system parameters are wrong, then the measured O2
value cannot be correct. With the following instructions, try to localize or repair
the fault.

13.1 Display remains at the Measuring Range

End or is higher than expected
Steps to localize the problem:

1. All system parameters are correct and the ENOTEC O2 analyser system
shows the correct value with test gas.

Action: Check all flanges and screw connections for tightness.

Result 1: O2 value drops to normal level.

Result 2: O2 value remains high

Cause: Leakages at the measuring probe or at the measuring cell flange seal.

Remedy: Exchange measuring cell or replace measuring cell flange metal

gasket seal. In case of a leakage in the area of the zirconium oxide measuring
cell, this must be replaced.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 118

 13.2 O2 Display Indicates 0 %, although the
Process Operation Mode expects a higher
O2 Value
Steps to localize the problem:

1. Check the measuring cell temperature (set value 800°C/1472°F)

A cell temperature below 600°C/1112°F may lead to a 0% display.

Result 1: Cell temperature okay, next check.

Result 2: Wrong measuring cell temperature.

Causes:
a) Measuring probe heater defective (resistance must be approx. 35-42 Ohm,
disconnect probe and check). Note: De-energize probe first.
b) Thermocouple defective (check resistance, approx. 2-80 Ohm)
c) Fuse for heater voltage defective.
d) Transformer (230/115V) defective, check voltages.
e) Triggering for temperature control or electrical load relay defective.

2. Check the mV value of the O2 measuring cell

Result 1:
The mV value is outside the usual range (see characteristic line) e.g. above
267 mV or below - 45 mV.

3. Check the mV value directly on the probe

De-energize electronic system.

Disconnect the probe cable from the probe on terminals 1 + 2 and switch on
the electronic system. After the heating phase, measure the cell voltage with a
high-resistance voltmeter on the probe strip terminal.

Result 1:
If the mV value measured at the probe is a probable O2 value according to the
cell slope and at the correct measuring temperature, the error lies between the
probe and the electronic unit.

Possible causes:
a) Cable short circuit
b) Electronic units input defective
c) Wire break

Remedies:
a) Check wiring
b) Measure probe cable

Result 2:
A mV value is measured at the probe, which is outside the usual range from -
45 mV to 267 mV.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 119

 Possible causes:
a) There is no mV contact in the probe (measuring signal wire) or it is inter-
rupted.
b) Combustibles in the flue gas.
c) Measuring cell defective

Remedy: Check whether the probe reacts to test gas. If it does, there may be
a high proportion of combustibles in the flue gas. In this case, there are reduc-
ing conditions on the probe cell, which reduce the oxygen content on the cell
surface. Caution: Explosion hazard!
If the probe does not react, check the inner parts assembly.

13.3 Local Displays correct, Output not correct

Steps to localize the problem:

1. Check measuring range. Check whether the current value is outside the
measuring range
2. Measure the mA output on the strip terminal.

Result 1: mA value present, problem is outside the electronic unit

Result 2: no mA value

Possible causes: Electronic unit is defective.

13.4 Unsteady, widely varying Measuring Value

Steps to localize the problem:

1. Check the measuring cell temperature (set value 840°C/1544°F or

800°C/1472°F EExd)
2. Intermittent contact in the probe - internal mV connection.

Action:
Measure the mV value at the terminals on the board.

Result 1: Voltage values jump rapidly like the display

Causes:
a) Intermittent contact caused by wire break.

Remedies:
a) Repair intermittent contact.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 120

 14 Dimensional Drawings of the Electronic
Unit

Figure 105 Dimensions of the electronic unit in Ex housing and the pneumatics unit

Figure 106 Dimensions of the electronic unit in GP field housing with heater switch-off (not visible)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 121

 Figure 107 Electronic unit in 19 inch rack 3HE (aluminium IP20)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 122

 15 Dimensional Drawings of Probes

Figure 108 Dimensions of the probes KEX5001 and KEX5002

Figure 109 Dimensions of the probes KEX5001 and KEX5002 with cooling protection tube made of
PROTEC

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 123

 Figure 110 Dimensions of the probes KEX5001 and KEX5002 with cooling protection tube made of
INCOLOY

Type of Flange/ ANSI4” 150 ANSI3” 300 ANSI3” 150 DIN 2527 DIN 2527
Dimensions LBS FF LBS LBS DN80/PN6 DN80/PN16
equivalent
D 228,6 (9,00) 209,5 (8,28) 190,5 (7,50) 190 (7,48) 200 (7,87)
B 12,5 (0,50) 28,6 (8,25) 23,9 (0,94) 18,0 (0,71) 20,0 (0,79)
K 160,5 (7,50) 168,3 (6,63) 152,4 (6,0) 150 (5,91) 160 (6,29)
D2 19 (0,70) 22,2(0,874) 19,1 (0,75) 18 80,71) 18 (0,71)
Number of Holes 8 8 4 4 8
Letter in the A F J K L
Order Code
Table 22 Dimensions of the protection tube flanges, all dimensions in mm (inch)

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 124

 Figure 111 Dimensions of adapter plate ADP-2000

15.1 Probe Components

Figure 112 Probe components

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 125

 Figure 113 Probe components with work steps

Figure 114 Probe inner parts assembly

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 126

 15.2 Parts List of Probes
No. Designation For Probe Type: Article-No.
1 Probe inner part assembly, KEX5001 SIK-5001EX2T
complete KEX5002 SIK-5002EX2T
2 Connection box KEX500X 0-R-000996
3 Test gas valve/ KEX500X KEX500001000/
solenoid valve KEX500007000
4 Probe measuring tube KEX5001 MSR-5001EX
KEX5002 MSR-5002EX
5 Measuring cell KEX500X Z02-0002EX
MLT measuring cell Z02-0012EX
6 Filter head KEX500X KEX500010000
7 Protection tube please contact ENOTEC

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 127

 16 Pneumatic Connection and
Requirements for the Gas Supply

16.1 Pneumatic Connections of the Ex Electronic

Unit

Figure 115 Gas plan of the pneumatics unit at Ex electronic unit (semiautomatic (left) and fully automatic
(right))

16.2 Pneumatic Connections of the Electronic

Unit in GP Field Housing

Figure 116 Gas plan of the pneumatic connections at electronic unit in field housing

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 128

 16.3 Requirements for the Gas Supply
(Systems with Instrument Air Supply)
The analyser system uses the piped/connected instrument air during the
whole operation time for the supply of reference air, and during the calibration
and system test respectively, for the supply of test air (test gas 1).

Instrument air For reference air supply and for calibration / sys-
tem test as test gas 1 (test air)

Specification: According to ISO 8573-1 class 2

(Particle size max. 1µm,
Particle density max. 1mg/m³,
Oil content max. 0,1mg/m³,
Pressure dew point max. -20°C)

Input pressure: minimum 4 bar (58 psi),

maximum 10 bar (145 psi)

Consumption:* continuously 40 l/h maximum during measure-

ment (for reference air supply),
additionally 180 l/h maximum during calibration /
system test (test air and reference air supply)

Test gas for calibration / system test as test gas 2

Specification: 2.1 Vol.-% O2 in N2 (accuracy +/- 2%)

(recommended)

Input pressure: 1,1 +/- 0,1 bar

Consumption:* 180 l/h maximum during calibration / system test

* The consumption depends on the effective adjusted quantities. It can be seen in chapter 12.3 and
the following on page 109 and the following how to adjust the reference air and test gas quantity.
The quantities, which have to be adjusted, can be seen in chapter 10.6 on page 96.

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 129

 16.4 Requirements for the Gas Supply (Systems
with Pumps)
For systems with pneumatic unit with pumps the system supply with reference
air and with test air (test air 1) is provided by the built-in pumps.

Test Gas (Test gas 2) For calibration / system test as test gas 2

Specification: 2.1 Vol.-% O2 in N2 (accuracy +/- 2%)

(recommended)

Input pressure: 1.1 +/- 0.1 bar (14.5 +/- 1.45 psi)

Consumption*: 180 l/h maximum during calibration / system

test

*
The consumption depends on the effective adjusted quantity. It can be seen in chapter 12.3 and
the following on page 109 and the following how to adjust test gas quantity. The quantity, which
has to be adjusted, can be seen in chapter 10.6 on page 96

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 130

 17 Mounting Overview of the Electronic
Unit

17.1 Mounting Overview of the Electronic Unit in

Ex Housing

Figure 117 Mounting plate Ex electronic unit

Parts List
Mounting plate Ex electronic unit
1 pc 0-L-000080 SME-5 power board
1 pc 0-L-000035 SME-5 OXITEC Display and microprocessor unit

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 131

 Parts List
Mounting plate power supply unit
1 pc TRA- toroidal trans-
00017 former 2x115V;
sec. 115 V / 330
VA
1 pc HCU- separate heater
0001 switch-off
1 pc X3 terminal strip

Figure 118 Mounting plate power

supply unit

Parts List
Display and microprocessor unit
1 pc 0-L-000035 Display and mi-
croprocessor unit

Figure 119 Display and micro-

processor unit

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 132

 17.2 Mounting overview of the Electronic Unit in
GP Field Housing

Parts List
Test gas and reference air unit with two
internal pumps
1 pc DFM-00001 internal flow meter for
reference air and test
gas SME5
1 pc 0-P-000751 solenoid valve 3/2
ways, 110V/50Hz;
G1/8; for SME 5
1 pc TRA-00017 toroidal transformer
2x115V; sec. 115 V /
330 VA
1 pc 0-P-000757 female elbow fitting
G1/8 for 6 mm hose
1 pc 0-P-000755 screw in union G1/8"
for 6 mm hose
1 pc 0-P-000658 Miniature filter 9933-
05-AAQ elimination
rate 99,999%
1 pc PLU-0026 Test air pump for
SME5 720 l/h
115V/50Hz cable 40
cm
1 pc 0-P-000743 angle fitting 6/6mm
LF3000-W-STA-6
1 pc PLU-0025 Reference air pump
for SME5 30 l/h,
115V/50Hz cable 40
cm
Figure 120 Mounting plate 1 5 pc 0-P-000758 plug in connection
(design with pumps)
G1/4 for 6mm hose
5 pc 0-P-000759 fitting G1/4 for 6 mm
hose
1 pc 0-P-000763 female elbow fitting
M5 for 6 mm hose
1 m 0-R-001045 PU-hose 6x4 mm
, black
5
1 pc 0-P-000777 one-way-restrictor,
6mm, for 6mm hose

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 133

 Parts List
Test gas and reference air unit for instrument
air
1 pc 0-A-000154 Mounting plate 1
1 pc DFM-00001 internal flow meter for
reference air and test
gas SME5
2 pc 0-P-000751 solenoid valve 3/2 ways,
110V/50Hz; G1/8; for
SME 5
1 pc TRA-00017 toroidal transformer
2x115V; sec. 115 V /
330 VA
2 pc 0-P-000757 female elbow fitting
G1/8 for 6 mm hose
2 pc 0-P-000755 screw in union G1/8" for
6 mm hose
4 pc 0-P-000758 plug in connection G1/4
for 6mm hose
4 pc 0-P-000759 fitting G1/4 for 6 mm
hose
1 pc 0-P-000753 nut for pressure control
valve
1 pc 0-P-000752 Pressure control valve
G 1/8”, 0.1 - 3.5 bar
2 pc 0-P-000745 angle screw-in fitting R
1/8"- G 1/8"
Figure 121 Mounting plate 1
2 pc 0-P-000760 one-way-restrictor G1/8
(design with instrument air) for 6mm hose
1 pc 0-P-000757 female elbow fitting
G1/8 for 6 mm hose
1 pc 0-P-000763 female elbow fitting M5
for 6 mm hose
1,5 m 0-R-001045 PU-hose 6x4 mm black

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 134

 Parts List
Mounting plate 2
1 pc 0-A-000155 mounting plate 2
1 pc 0-L-0000080 SME-5 power board
1 pc HCU-0001 separate heater
switch-off
2 pc 0-P-000658 miniature filter
1 pc 0-X-000351 micro terminal PE
clip
1 pc 0-X-000353 cover for micro ter-
minal
2 pc 0-X-000352 end clip E/MK
3 cm 0-X-000355 mounting rail NS15,
punched
6 pc 0-X-000350 Micro terminal clip
1,5
6 cm 0-X-000355 mounting rail NS15,
punched

Figure 122 Mounting plate 2 with

fail-safe heater switch-off

Parts List
Display and microprocessor unit
1 pc 0-L-000035 Display and micro-
processor unit
WITHOUT Pneu-
matic
1 pc 0-L-000036 Display and micro-
processor unit
WITH Pneumatic

Figure 123 Display and micro-

processor unit

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 135

 18 Table of Figures
Figure 1 Design of the OXITEC® 5000 Ex analyser system (completely explosion proofed) ......... 20
Figure 2 Design of the OXITEC® 5000 Ex analyser system (completely explosion proofed) with
cooling tube .................................................................................................................... 21
Figure 3 Design of the OXITEC® 5000 analyser system with explosion-proofed O2 probe ............ 21
Figure 4 Design of the OXITEC® 5000 analyser system with explosion-proofed O2 probe with
cooling tube .................................................................................................................... 22
Figure 5 Design of the O2 measuring probes KEX500x .................................................................. 24
Figure 6 Special probe cable FEP-0009 ......................................................................................... 25
Figure 7 Design of the electronic unit in Ex housing....................................................................... 27
Figure 8 Design of the electronic unit in field housing with fail-safe heater switch-off .................... 28
Figure 9 Mounting plate with fail-safe heater switch-off (HCU-0001) ............................................. 29
Figure 10 Mounting dimensions of the O2 probe KEX500x............................................................. 32
Figure 11 Mounting dimensions of the O2 probe KEX5001 with PROTEC cooling tube................. 32
Figure 12 Mounting dimensions of the O2 probe KEX5001 with INCOLOY cooling tube ............... 33
Figure 13 Insulation of the cooling protection tube ......................................................................... 33
Figure 14 Adjusting the filter head ................................................................................................. 35
Figure 15 Terminal allocation of the cable connection box............................................................. 36
Figure 16 Handling of the WAGO clamps....................................................................................... 36
Figure 17 Encapsulated cable glands............................................................................................. 37
Figure 18 Encapsulated cable glands............................................................................................. 38
Figure 19 Pneumatic connections of the OXITEC® 5000 Ex electronic units ................................. 39
Figure 20 Instruction for the mounting of the pneumatic connections ............................................ 39
Figure 21 Connection diagram of the OXITEC® 5000 Ex electronic unit ........................................ 40
Figure 22 Connection diagram of the OXITEC® 5000 in field housing with heater switch-off......... 41
Figure 23 Terminal connections OXITEC® 5000 Ex (both versions)............................................... 42
Figure 24 19“ rack 3HE................................................................................................................... 43
Figure 25 Terminal Diagram HCU-0001 ......................................................................................... 45
Figure 26 Ferrite sleeves ................................................................................................................ 46
Figure 27 Display during the heating phase ................................................................................... 47
Figure 28 Display main window ...................................................................................................... 48
Figure 29 Front panel of the OXITEC® 5000 Ex electronic unit ...................................................... 49
Figure 30 Display: system menu..................................................................................................... 50
Figure 31 Display: main window ..................................................................................................... 50
Figure 32 Display: actual value menu............................................................................................. 51
Figure 33 Display: parameter menu................................................................................................ 53
Figure 34 Display: parameter input (example limit value 1) ............................................................ 55
Figure 35 Limit value curves ((default values for all kind of fuel) .................................................... 57
Figure 36 Display: request for code input ....................................................................................... 58
Figure 37 Display: system menu..................................................................................................... 58
Figure 38 Front view of the pneumatic unit, semiautomatic............................................................ 60
Figure 39 Front view of the pneumatic unit, fully automatic ............................................................ 61
Figure 40 Display: main window ..................................................................................................... 62
Figure 41 Display: code input request ............................................................................................ 62
Figure 42 Display: menu entries for calibration............................................................................... 62
Figure 43 Position for the O2-single point calibration with test air (semiautomatic pneumatics
unit)................................................................................................................................. 63
Figure 44 Request to start the calibration ....................................................................................... 63
Figure 45 Announcement: Measurement of the flow rate (on the left reference air, on the right
test gas) only systems with integrated pneumatic unit ................................................... 63
Figure 46 Display: O2 single point calibration ................................................................................. 64
Figure 47 Advice for a successful calibration.................................................................................. 64

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 136

Figure 48 Announcement: Measurement of the flow rate (on the left reference air, on the right
test gas) only systems with integrated pneumatic unit ................................................... 66
Figure 49 Position of the valve for the first step of the O2-two point calibration with test air
(semiautomatic pneumatics unit) .................................................................................... 66
Figure 50 Display: Two point calibration 1.step .............................................................................. 66
Figure 51 Display: Request to start 2. step of two point calibration ................................................ 67
Figure 52 Position of the valve for the second step of the two point calibration (semiautomatic
pneumatics unit) ............................................................................................................. 67
Figure 53 Display: O2 two point calibration, 2.step ......................................................................... 67
Figure 54 Advice for a successful calibration.................................................................................. 68
Figure 55 Announcement: Measurement of the flow rate (on the left reference air, on the right
test gas) .......................................................................................................................... 70
Figure 56 Position for the system test with test gas........................................................................ 71
Figure 57 Display: request to start the System Test ....................................................................... 71
Figure 58 Display: System Test with test gas ................................................................................. 71
Figure 59 Position of the valve during measurement...................................................................... 71
Figure 60 Position for system test with test air ............................................................................... 72
Figure 61 Announcement: Measurement of the flow rate (on the left reference air, on the right
test gas) at systems with integrated pneumatics unit ..................................................... 72
Figure 62 Display: System Test with test air................................................................................... 73
Figure 63 Position of the valve during measurement...................................................................... 73
Figure 64 Display: request for code input ....................................................................................... 75
Figure 65 Display: system menu..................................................................................................... 75
Figure 66 Display: main window ..................................................................................................... 76
Figure 67 Display: request of code input ........................................................................................ 77
Figure 68 Display: menu entries for calibration............................................................................... 77
Figure 69 Request to start the calibration (system without pneumatic unit) ................................... 78
Figure 70 Request to start the calibration (system with pneumatic unit) ........................................ 78
Figure 71 Display: Measuring of the flow rate (only systems with intetrated pneumatic unit)......... 78
Figure 72 Display: O2 single point calibration (system without pneumatic unit).............................. 79
Figure 73 Display: O2 single point calibration (system with pneumatic unit)................................... 79
Figure 74 Advice for a successful calibration.................................................................................. 79
Figure 75 Display: Request to start two point calibration (system without pneumatic unit) ............ 80
Figure 76 Display: Request to start two point calibration (system with pneumatic unit) ................. 80
Figure 77 Display: Flow rate measuring (only systems with integrated pneumatic unit) ................ 81
Figure 78 Display: Two point calibration 1.step (system without integrated pneumatic unit).......... 81
Figure 79 Display: Two point calibration 1.step (system with integrated pneumatic unit)............... 81
Figure 80 Display: Request to start 2. step of two point calibration (system without pneumatic
unit)................................................................................................................................. 82
Figure 81 Display: Flow rate measuring (only systems with integrated pneumatic unit) ................ 82
Figure 82 Display: O2 two point calibration, 2.step (system without integrated pneumatic unit)..... 82
Figure 83 Display: O2 two point calibration, 2.step (system with integrated pneumatic unit).......... 83
Figure 84 Advice for a successful calibration.................................................................................. 83
Figure 85 Display: request to start the System Test ....................................................................... 85
Figure 86 Display: System Test with test gas (system without pneumatic unit).............................. 86
Figure 87 Display: System Test with test gas (system with pneumatic unit)................................... 86
Figure 88 Display: System Test with test air (system without integrated pneumatic unit) .............. 86
Figure 89 Display: System Test with test air (system with integrated pneumatic unit) ................... 87
Figure 90 Display: Example of error messages .............................................................................. 89
Figure 91 Electronic unit for fail-safe heater switch-off ................................................................... 92
Figure 92 Rear side of the display unit ........................................................................................... 93
Figure 93 Adjustment display contrast............................................................................................ 94
Figure 94 Relay plate with marked relays and LEDS ..................................................................... 95
Figure 95 Switching between 230 V and 115 V operation (SW1)................................................. 107
Figure 96 Adjustment of reference and test air quantity (semi-automatical)................................. 109
Figure 97 Adjustment of reference and test air quantity (fully automatic) ..................................... 110

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 137

Figure 98 Position of valve (pump version)................................................................................... 111
Figure 99 Position of valves (instrument air version) .................................................................... 111
Figure 100 Regulating valves for adjustment of reference air and test air quantity (electronic
unit in 19” 3HE racks) left side: instrument air version, right side: version with pumps 112
Figure 101 Probe connection box ................................................................................................. 113
Figure 102 Measuring cell holder tube in cut ................................................................................ 114
Figure 103 Measuring cell assembly ............................................................................................ 114
Figure 104 Construction of the measure cell holder tube ............................................................. 116
Figure 105 Dimensions of the electronic unit in Ex housing and the pneumatics unit .................. 121
Figure 106 Dimensions of the electronic unit in GP field housing with heater switch-off (not
visible)........................................................................................................................... 121
Figure 107 Electronic unit in 19 inch rack 3HE (aluminium IP20) ................................................. 122
Figure 108 Dimensions of the probes KEX5001 and KEX5002.................................................... 123
Figure 109 Dimensions of the probes KEX5001 and KEX5002 with cooling protection tube
made of PROTEC......................................................................................................... 123
Figure 110 Dimensions of the probes KEX5001 and KEX5002 with cooling protection tube
made of INCOLOY........................................................................................................ 124
Figure 111 Dimensions of adapter plate ADP-2000 ..................................................................... 125
Figure 112 Probe components...................................................................................................... 125
Figure 113 Probe components with work steps ............................................................................ 126
Figure 114 Probe inner parts assembly ........................................................................................ 126
Figure 115 Gas plan of the pneumatics unit at Ex electronic unit (semiautomatic (left) and fully
automatic (right))........................................................................................................... 128
Figure 116 Gas plan of the pneumatic connections at electronic unit in field housing ................. 128
Figure 117 Mounting plate Ex electronic unit................................................................................ 131
Figure 118 Mounting plate power supply unit .............................................................................. 132
Figure 119 Display and microprocessor unit................................................................................. 132
Figure 120 Mounting plate 1 (design with pumps) ....................................................................... 133
Figure 121 Mounting plate 1 (design with instrument air) ............................................................ 134
Figure 122 Mounting plate 2 with fail-safe heater switch-off......................................................... 135
Figure 123 Display and microprocessor unit................................................................................. 135

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 138

 OXITEC® Distribution & Service:
ENOTEC GmbH
Höher Birken 6
D-51709 Marienheide
Germany

Phone: +49 (0) 2264 / 4578-0

Fax: +49 (0) 2264/ 4578-31
Email: [email protected]

ENOTEC National:
Sales Office North/East Sales Office West
Mr. Dirk Jeworowski Mr. Thomas Bechstein
Broistedt Str. 26 Zum Stollen 4
D - 21423 Winsen D - 51674 Wiehl
Phone: ++49 (0) 4171 6672 70 Phone: ++49 (0) 2262 7527 97
Fax: ++49 (0) 4171 7876 400 Fax: ++49 (0) 2262 7528 01
Email: [email protected] Email: [email protected]

Sales Office Middle Sales Office South

Mr. Dieter Rieß Mr. Dr. Claus Gumprecht
Oderstraße 44 Gössmannsreuth 1
D - 64546 Mörfelden-Walldorf D - 95326 Kulmbach
Phone: ++49 (0) 6105 9462 38 Phone: ++49 (0) 9221 9050 20
Fax: ++49 (0) 6105 9462 85 Fax: ++49 (0) 9221 9050 41
Email: [email protected] Email: [email protected]

ENOTEC International:
ENOTEC UK Limited ENOTEC Inc.
PO BOX 9026 6206 Sandy Ridge Circle NW
DUMFRIES North Canton
DG1 3YH Ohio 44720
United Kingdom USA

Phone: +44 8703500102 Phone: +1 330 498 0202

Fax: +44 8703500302 Fax: +1 330 497 9802
Email:[email protected] Email:[email protected]

ENOTEC ASIA PTE. Ltd. Your Distribution:

Pasir Panjang Distripark
Block 1
Please contact:
#02-11 Pasir Panjang Road
ENOTEC GmbH
Singapore 118480
(++49) 2264 / 4578-0
or your ENOTEC Regional Office
Phone: +65 6100 2188
Fax: +65 6399 2780
Email : [email protected]

O2 Analysing System OXITEC® 5000 EX Version 09.150 Page 139