Installation and Operation Manual

O2 Analyzer System

®
OXITEC 5000
Version 22
for Software Version: 4.06

Doc.-ID: OXI-16052012-EN
Preface
Dear Customer,

Thank you for selecting OXITEC® 5000 as your InSitu Flue Gas Oxygen Analyzer System.
For more than 30 years now our OXITEC® Oxygen Analyzer Systems have been operating in numerous applications in more
than 10.000 units around the world. ENOTEC are committed to total quality and performance and we have continuously
enhanced our products to integrate various 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 all OXITEC® measuring probes you will find that the Zirconium Oxide Sensor is soldered in place using a special process and
technique developed by ENOTEC. This results in a considerably increased service life compared to „glued or cemented“
competitors measuring cells, which have a tendency to leak or crack during operation. The OXITEC® sensor is a proven gas
gas-tight design, providing greater measuring accuracy, durability and longer working life time.
All ENOTEC instruments are thoroughly tested in the factory and are subject to a strict ISO9001 Quality Assurance Procedure.
Therefore, with the correct installation, the operation of the OXITEC® 5000 is very straightforward and user friendly and will
provide you with many years of trouble free operation with perfect measuring results.

Notes concerning this Manual

This manual contains important information about the design, installation, commissioning, operation, maintenance and trouble-
shooting. Safe work with the OXITEC® 5000 requires the users to become familiar with all warnings, safety instructions and
maintenance aspects of this manual.

Symbols used in this Manual

All symbols listed beneath, attached to the analyzer or noted in this manual show important information as well as safety instruc-
tions for installation, operation and maintenance, to protect the personnel and the equipment.

Warning Consider Information

Follow all instructions of this manual Points out important information which must be
considered before execution

Warning hot Surface Note

Warns of danger of burns which could occur from Contains further detailed information
hot system parts

Caution
Warns of risks of destroying the system or its Ground earth electrical protection
components or its functionality
The content of this manual, including all written content, pictures and illustrations is protected by copyright.

Safety Instructions
The OXITEC® 5000 System is operated with line voltage. After removal of terminal covers some parts of this system may be
accessible which are under high line voltage.
Only well trained and authorized personnel are allowed to work on this system. The personnel must know and understand all
precautions, safety instructions, installation and maintenance instructions of this manual. The trouble free and safe operation
of the OXITEC® 5000 requires safe transportation, professional storage, installation, operation and maintenance.
Furthermore all local safety requirements at the point of installation and operation must be considered.
OXITEC® 5000 may not be used to measure oxygen in combustible gases or in an environment with combustible gases. Parts
of this system may cause an explosion risk.

ENOTEC GmbH Höher Birken 6 Tel.: +49 (0) 2264 - 45 78 0

Process and Environmental D-51709 Marienheide Fax: +49 (0) 2264 - 45 78 31
Measuring Technology Germany Internet: [Link]
DIN EN ISO 9001 E-mail info@[Link]
Installation and Operation Manual OXITEC® 5000 Table of Contents

Table of Contents
5.1  Exchange fuses ................................................ 27 
1  System Description 2  5.2  Flow rates for Test Air and Reference Air ......... 28 
1.1  System Overview ................................................ 2  5.3  Adjusting Flow Rate (SME 53 with integrated
1.2  Intended use ....................................................... 3  Pneumatics) ...................................................... 28 
1.3  Safety Hazards.................................................... 3  5.4  Position of the adjustment valves ..................... 29 
1.4  Disruption of the Process .................................... 3  5.5  Adjusting Flow Rate (SME-57) .......................... 29 
1.5  Name Plates ....................................................... 4  5.6  Replacing the Filter ........................................... 30 
5.6.1  Remove old Filter .............................................. 30 
2  Installation 5  5.6.2  Cement in new Filter ......................................... 30 
2.1  Installation Requirements for Electronic Unit ...... 5  5.7  Replacing the O2 Sensor .................................. 31 
2.2  Installation of Probe Signal Cable FEP-0001 ...... 6  5.8  Exchange of Probe Inner Parts ......................... 32 
2.3  Access to the Terminals ...................................... 7  5.9  Exchange of Thermocouple Element ................ 32 
2.4  Ferrite Sleeves (EMC)......................................... 7  5.10  Exchange of Heating Element .......................... 33 
2.5  Wiring Diagram of the Electronic Unit ................. 8  5.11  Exchange of Signal Measuring Wire ................. 33 
2.6  OXITEC® 5000 Wiring diagram .......................... 9  5.12  Exchange of 4-Hole Ceramic Rod .................... 33 
2.7  Installation of the probe ..................................... 10  5.13  Relay Outputs / Functions and Correlation ....... 34 
2.8  Mounting of the Probe ....................................... 10  5.14  Digital Inputs ..................................................... 35 
2.9  Mounting a probe with Cooling Protection Tube 11  5.15  Stability Criteria for Calibration ......................... 35 
2.10  Adjusting the V-shield ....................................... 11  5.16  Reaction Time of the mA Output ....................... 35 
2.11  Electrical Connections of the Probe .................. 12  5.17  Extension Modules............................................ 35 
2.12  Requirements for Pneumatic Cable FEP-0002 . 12 
2.13  Preparation of the pneumatic Cable .................. 13  6  Status Messages 36 
2.14  Gas plans .......................................................... 13 
6.1  Error Messages ................................................ 36 
2.15  Pneumatic Connections of the Probe ................ 14 
6.2  Alarm Messages ............................................... 37 
2.16  Pneumatic Connections of Electronic Units ...... 14 
6.3  Maintenance Messages .................................... 37 

3  Initial Operation 16 

7  Troubleshooting 38 
3.1  System Power Up ............................................. 16 
3.2  Display - Probe Heating Phase ......................... 16  A  Technical Data 39 
3.3  Display - Measuring Mode ................................ 16 
A.1  Technical Specifications - Electronic Unit ......... 39 
3.4  Keypad and Display .......................................... 17 
A.2  Technical Specifications - Probe ....................... 40 
3.7  System Code..................................................... 17 
A.3  Gas Supply - Systems with Instrument Air ........ 41 
4  Menu Overview and Explanations 18 
B  Dimensional drawings 42 
4.1  Menu Overview - SYS-MENU ........................... 18 
B.1  Dimensions of Electronic Unit Housing versions42 
4.2  Menu Explanations - SYS-MENU...................... 21 
B.2  Probe Dimensions ............................................ 43 
4.2.1  O2 Measuring Ranges (Scaling) ........................ 21  B.3  Counter Flange Dimensions ............................. 46 
4.2.2  Measuring value averaging for .......................... 21  B.4  Dimensions of protection tube flanges .............. 48 
4.2.3  mA output on system errors .............................. 21 
4.2.4  O2 limit alarm settings ....................................... 21  C  Spare Parts 49 
4.2.5  O2 Sensor calibration values ............................. 22  C.1  Probe Components - KES-132X ....................... 49 
4.2.6  Time per test gas apply ..................................... 22  C.2  Probe Components - KES-200X ....................... 50 
4.2.7  Delay time to process........................................ 22  C.3  Probe Components - KES-500X ....................... 51 
4.2.8  Automatic Calibration (ACAL) ........................... 22  C.4  Probe inner parts assembly .............................. 52 
C.5  Mounting Plates of the Electronic Unit .............. 53 
4.2.9  Automatic Calibration Settings .......................... 22 
C.6  Display Board ................................................... 54 
4.2.10  Measuring units ................................................. 23 
4.2.11  Language .......................................................... 23  D  Declaration of Conformity 55 
4.2.12  Change system code ........................................ 23 
4.2.13  Load factory settings ......................................... 23  Index 56 
4.2.14  Service (Factory Service Settings) .................... 23 
4.3  Calibration Menu ............................................... 24 
4.3.1  Calibration Menu - Display Overview ................ 24 
4.3.2  1-point calibration (manual) ............................... 25 
4.3.3  2-point calibration (manual) ............................... 25 
4.4  System Checks ................................................. 26 

5  Service and Maintenance 27 

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System Description Installation and Operation Manual OXITEC® 5000

1 System Description
1.1 System Overview
Info

Depending on the system configuration ordered by the customer, the electronic unit and / or probe may vary. Refer to
chapters B and B.2 for different versions of electronic units and probes.

®
Figure 1 - OXITEC 5000 (probe without cooling tube for flue gas temperatures of up to 500°C)

®
Figure 2 - OXITEC 5000 (probe with cooling tube for flue gas temperatures of up to 1400°C)

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Installation and Operation Manual OXITEC® 5000 System Description

1.2 Intended use

Info

The OXITEC® 5000 analyzer 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 cannot be used to determine the oxygen concentration of combustible gases or in a location where
combustible gases are present as the measuring cell temperature of 800°C could present an explosion hazard!

Info
The minimum concentration of O2 in flue gas should under normal process conditions, not be less than 0,5%.
If the O2 concentration is regularly below 0,5%, we recommend the option of CSP (Cell Surface Protection) to pro-
tect the O2 sensor.

Caution
Under no circumstance should the measuring probe be directly connected to the 230V main power supply, as this will
immediately destroy the probe heater element!

1.3 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).

1.4 Disruption of the Process

The analyzer system has to be kept in operation also in the event of the process being disrupted or if the plant is
powered off temporarily (e.g. at night or during the weekend). Frequently cooling down and heating up of the probe
results in thermal stress of the hot probe parts (heater, thermocouple and sensor) and reduces their product life.
ENOTEC will not accept any responsibility for resultant damage.

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System Description Installation and Operation Manual OXITEC® 5000

1.5 Name Plates

The name plate contains information about the line voltage, the nominated current, frequency, protection class, year
of manufacture, serial number, order number and system order code.
The system order code refers to information which is detailed in the system test report and supplied with the system.

SME-53 Electronic Unit

Probe Connection Box

SME-57 Electronic Unit

Figure 3 - Position of the name plates

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Installation and Operation Manual OXITEC® 5000 Installation

2 Installation
Warning
The device must be provided with an external power-off switch. The line voltage switch/fuse/breaker must be in ac-
cordance with the local technical standards and should be near to the electronic unit and must be clearly marked as
such. The probe cable is suitable for an ambient temperature range from -40°C to +90°C. All other installed cables
must be suitable for the ambient temperature range at side and must have the required size. All electronic unit termi-
nals are specified from 0,08 mm² (AWG 26) to 2,5 mm² (AWG 14). If wire end ferrules are used the next smaller size
is required. Before removal of the electronic terminal cover the line voltage must be switched off. The line voltage to
the electronic unit must be switched on again after the cover is back in position. After installation power conducting
parts may not be accessible.

2.1 Installation Requirements for Electronic Unit

Keep the minimum distance to adjacent objects Install at eye level

Avoid vibrations greater than 2g Mind the IP code

Ambient temperatures
Min.: -20 °C / Max.: +55 °C
Min.: -4 °F / Max.: +131 °F

(Pump version
20°C - +50°C)

Drilled holes for the electronic unit

Use suitable screws

Electronic unit

Figure 4 - Installation of the Electronic unit

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Installation Installation and Operation Manual OXITEC® 5000

2.2 Installation of Probe Signal Cable FEP-0001

Abide by the maximum cable length (max. 150m)

Note the minimum bending radius.

FEP-0001 Rmin = 96 mm

+50 °C +90 °C
Max. Max.
-5 °C Temp. during installation -40 °C Temp. during operation
Min. Min.

Cross the probe signal cable (FEP-0001) at right angle

to power supply cables

Probe Cable FEP-0001 (FEP-0004 armored version)

No. Function Diameter Colors Additional info.

Measuring cell 2 x 0,75 mm2 white-brown / brown With shield

Thermocouple 2 x 0,75 mm2 green / white With shield

black / blue / green-

Probe heating 3 x 1,5 mm2
yellow

Solenoid valve 2 x 0,75 mm2 grey / grey-blue

Figure 5 - Probe cable FEP-0001

Caution
Probe cables must be treated as measurement cables. In no case should the shield of the probe cable be
connected to the probe.

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2.3 Access to the Terminals

Warning

Before removing the terminal covers, switch off the mains voltage to the system. Switch the mains voltage on only
after attaching the terminal cover. After the installation has been completed, live parts may no longer be accessible.

Figure 6 - Access to the Terminals

2.4 Ferrite Sleeves (EMC)

Caution

In order to avoid cable related disturbances to the electronic unit, the supplied ferrite sleeves must be used.
CE-conformity is invalid if these ferrite sleeves are not fitted!

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Installation Installation and Operation Manual OXITEC® 5000

2.5 Wiring Diagram of the Electronic Unit

Figure 7- Wiring diagram of the Electronic Unit

Ferrite sleeves (Enclosed) Analogue output cable (customer)

Power supply cable (customer) Status signal cable (customer)
Probe signal cable
Internal Power supply
1 L phase Relay contacts for status signals -
2 N neutral wire Potential free

3 PE grounding conductor 18 A/B Maintenance

1
Internal Power supply 19 A/B System Error

4 L phase 20 A/B Output A O2 measuring range

5 N neutral wire 21 A/B O2 Limit Alarm 1
6 PE grounding conductor 22 A/B O2 Limit Alarm 2
Shielding Probe solenoid valve
Power supply probe heater (115V) 23 A Internal Power supply for probe solenoid
valve (115VAC)
8 L black 23 B
9 N blue 24A L grey
10 PE green/yellow 24B N grey/blue
O2-sensor signal Measuring Range O2 (12..24V DC- External supply)
12 + brown 25A +
13 - brown/white 25B -
Thermocouple (O2 sensor) Calibration release (12..24V DC - External supply)
14 + green 27A +
15 - white 27B -
Analogue outputs (active 4-20mA) 1
The output voltage of these contacts (4…6) always have the
17A + O2 same voltage as on the power supply input on contacts (1…3)
17B - O2

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2.6 OXITEC® 5000 Wiring diagram

Figure 8 - Wiring diagram of the OXITEC 5000 Analyzer system

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Installation Installation and Operation Manual OXITEC® 5000

2.7 Installation of the probe

The flue gas temperature, pressure and all other process conditions must be in accordance with the specification.
Leave enough space for insertion/removal of the probe and protection tube (if supplied) and ensure access to the
measuring probe and/or connecting box. Before cutting a 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 out nearby or any obstacles are in the way.
For probe lengths exceeding 2000 mm, a support must be mounted inside the duct (every 2m) to prevent the probe
and mounting tube from flexing or bending. ENOTEC recommends installing the probe horizontally for the
fastest possible response time.

The ambient temperature at the connection box and

the process temperature must not be exceeded. Avoid vibrations greater 2g

Maintain the protection class

2.8 Mounting of the Probe

Figure 9 - Mounting dimensions of the O2 probe KES/KIS-200x with ADP-2000

Figure 10 - Mounting dimensions of the O2 probe KES-132x with ASR-1320

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2.9 Mounting a probe with Cooling Protection Tube

Info
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 11 - Insulation of the cooling protection tube

2.10 Adjusting the V-shield

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 V-shield faces the oncoming flue gas. The filter head can be turned freely a full 360° for
this purpose, by loosening the counter nut, loosening the Allen screw and rotating the filter head / V-shield to the
required position, and then tightening the Allen screw and counter nut.

Flue gas direction

V-shield (KES-132X/KES-200X)
V-shield ( KES500X)
Screws to secure filter head
Filter head
Rotation of filter head
Probe

Figure 12- Adjustment of the V-shield

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Installation Installation and Operation Manual OXITEC® 5000

2.11 Electrical Connections of the Probe

Info
The probe cable (FEP-0001) has to be connected to the terminal board in the probe terminal box. Please do not
attach the shield to the probe.

1 : - mV O2 sensor (white-brown)

2 : + mV O2 sensor (brown)

3 : + mV thermocouple 1 (green)

4 : - mV thermocouple 1 (white)

6 : L 115VAC heater (black)

7 : N 115VAC heater (blue)

8 : PE Protection earth (green yellow)

9 : L 115VAC solenoid valve (grey)

10: N115VAC solenoid valve (grey-blue)

Figure 13 - Electrical Connections of the Probe

connections box

2.12 Requirements for Pneumatic Cable FEP-0002

Note the minimum bending radius.

FEP-0002Rmin = 138 mm

+50 °C +90 °C
Max. Max.
-5 °C -40 °C
Min. Min.

Temp. during installation Temp. during operation

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Installation and Operation Manual OXITEC® 5000 Installation

2.13 Preparation of the pneumatic Cable

Pneumatic tubing of the pneumatic
cable FEP-0002
Nut

Clamp ring

Support sleeve

Both, the pneumatic tubing for the reference air (blue)

and the test gas (green) have to be prepared with
support sleeves , clamp rings and nuts .

Figure 14 - Preparation of pneumatic tubes

2.14 Gas plans

Figure 15 - Gas plans

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Installation Installation and Operation Manual OXITEC® 5000

2.15 Pneumatic Connections of the Probe

Reference air in (FEP-0002: blue tube)

Test gas in ( FEP-0002: green tube)

Figure 16 - Pneumatic connections of the probe

2.16 Pneumatic Connections of Electronic Units

Figure 17 - Bottom view of SME-53 with pneumatic

unit

Nr. Tube Pump version Instrument air version

1/4“ Testgas in Testgas in

1/4“ Testgas out Testgas out

1/4“ Reference air input Instrument air in

1/4“ Reference air output Reference air out

1/4“ Testair input

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Instrument air version Pump version

Figure 18 - Back view of SME-57 showing pneumatic connections

Nr. Tube Pump version Instrument air version

1/4“ Testgas in Testgas in

1/4“ Testgas out Testgas out

1/4“ Reference air input Instrument air in

1/4“ Reference air output Reference air out

1/4“ Test air input

Regulator Test Air Test Air Filter

Regulator Reference Air Reference Air Filter

Regulator Test Air

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Initial Operation Installation and Operation Manual OXITEC® 5000

3 Initial Operation
3.1 System Power Up
Switch on the line voltage to the system. After a short power up information, the user is prompted to
Select language, set the System date and System time.
The probe heating phase now begins which is followed by the measuring mode.

Figure 19 - System Power up. Note the software

version at the bottom right of the display.

3.2 Display - Probe Heating Phase

The probe heating phase begins with the heating

up of the O2 sensor.

Rising probe temperature

(or) waiting period

(or) heater error

Last access with corresponding date

Current temperature
Figure 20 - O2 sensor heating phase
Analogue temperature bar

Setpoint probe temperature

Softkey title: e.g. System menu

3.3 Display - Measuring Mode

Measured component

Measured value

Active measuring range

Blinking indicators showing under or over

measuring range
Analogue bar showing measured value
and measuring range start and end
Softkey titles

Limit alarm indicators

min-Alarm / max-Alarm *

Figure 21 - Measuring mode

* Only if the O2 limit alarms are switched on

and the limits are within the set measuring range.

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Installation and Operation Manual OXITEC® 5000 Initial Operation

3.4 Keypad and Display

The controls and display of the
COMTEC® 6000 are housed in the
electronic unit and are
comprised of:

Three LED indicators depicting

active status
reports for limit alarms, mainte-
nance and system faults
Graphic enabled, back-lit dis-
play

Four softkeys with varying

layout
(softkeys)
Numeric number bloc
Figure 22 - Keypad and display

3.5 Status LEDs 3.6 Softkey Symbols

Moves the selection one position upwards
Alarm, - orange - is lit when an
alarm has been activated (e.g.
Moves the selection one position down-
O2 limit alarm)
wards
Maint. - Orange - a function has Leave an area
been accessed which may
affect the measurement Abort a function or entry

Select or confirm a function/value

Error - red - is lit when a system
error has occurred

3.7 System Code

Info

The system code on delivery is 0000. In this state, entry into the system is granted without having to enter the
system code. The system code protects the system from unauthorized use. Functions which may alter the
measurement of O2 are therefore also protected.
Caution: If the system code has been altered, it must be kept in a safe place!

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Menu Overview and Explanations Installation and Operation Manual OXITEC® 5000

4 Menu Overview and Explanations

4.1 Menu Overview - SYS-MENU
SYS-MENU
System Information
Actual measured values
O2 measured value (% O2) {may be ppm}
O2-mA output 17A/B (mA)
O2 sensor input (mV)
Flow rate reference air (l/h)
O2 probe temperature (°C / °F)
O2 probe heater power (%)
Thermocouple input (mV)
Terminal temperature (°C / °F)
Internal temperature (°C / °F)
O2 sensor life (%)
Lambda

Calibration results
e.g. 2012-05-11 (Choose date/time)
Executed at
Calibration method
O2 sensor calibration
~~ Calibration results ~~
O2 value at test air (20,95 % O2)
♦ calibrated to (% O2)
O2 value at test gas (% O2)
} only if determined
♦ calibrated to (% O2)
~~ Calibration data ~~
O2 sensor offset (mV)
O2 sensor slope (mV / dec) } only 2 point calibration
~~ Test gas data ~~
Test air (20,95 % O2)
Test gas (e.g. 2,1 % O2)
~~ Sensor raw data~~
O2 voltage at test air (mV)
O2 voltage at test gas (mV) } only if determined
O2 response to test gas (s) } only if determined
O2 response to process (s) } only if determined
O2 sensor life

Software version and options

Software OXITEC 5000

~~ Options ~~
♦ .....

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Installation and Operation Manual OXITEC® 5000 Menu Overview and Explanations

SYS-MENU
System configuration
O2 Measuring ranges
[Link] 1 from (% O2, ppm O2)
[Link] 1 to (% O2, ppm O2)
[Link] 2 from (% O2, ppm O2)
[Link] 2 to (% O2, ppm O2)
[Link] select by ([Link] / keypad)
[Link] averaging for (s)
Conversion wet → dry (% H2O)
mA output type (0-20 mA / 4-20 mA)
mA output on system error (mA)

O2 limit alarms
O2 limit alarm 1 (OFF/ON)
♦ at
} visible when set to “ON”
♦ hysteresis
O2 limit alarm 2 (OFF/ON)
♦ at
} visible when set to “ON”
♦ hysteresis

O2 sensor calibration values

O2 [Link] - offset (mV)
O2 [Link] - slope (mV/dec)

Calibration settings

Time per test gas apply (Min.)

Delay time to process (Min.)
Measurement value hold on calibration (ON/OFF)
[Link] (ON/OFF)
♦ Calibration method (O2 1-Point / 2-Point ) } visible when set to “ON”
♦ Test gas (bottle value % O2) { when preset to 2-point} } visible when set to “ON”
♦ Start by (Time, dig. Input, both) } visible when set to “ON”
♦ Interval (days)
} not applicable with [Link]
♦ next ACAL at (set date)

System date/time

System date (jjjj-mm-tt)

System time (hh:mm:ss)

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Menu Overview and Explanations Installation and Operation Manual OXITEC® 5000

Measuring units

Temperature (°C / °F)

Pressure (mbar / psi)

Language

Choose language (Deutsch / English / Spanish / Polish)

Change system code

Load factory settings

Service

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Installation and Operation Manual OXITEC® 5000 Menu Overview and Explanations

4.2 Menu Explanations - SYS-MENU

4.2.1 O2 Measuring Ranges (Scaling)

The O2 Measuring range is linearly scaled and converted to a

linear current output (0/ 4-20 mA).
The parameter „O2 Measuring range from“ is the start value of the
O2 range, leading to an analogue output of 4,00 mA.
„O2 measuring range to“ is the end value of the O2 range, leading
to an output of 20,00 mA.
If a measured value is lower than the start value of the O2 measuring
range, the current output signal drops to 3,60 mA.
(If the current output is set to 0- 20 mA the output is 0 mA)
If the measured O2 value is higher than the end value of the O2
measuring range end, the analogue output rises to 20,40 mA.
If during normal operation the measured O2 value is under, or over
Figure 23 - O2 Measuring Ranges the programmed measuring range, an error message appears on
the display (in measuring mode).

4.2.2 Measuring value averaging for

This entry sets the duration for the continuous average measurement (flowing average). During a calibration or
sensor verification, the measurement average is not shown, though still active for the analogue output.

4.2.3 mA output on system errors

Here the mA output value is set corresponding to a measurement error. The measurement output range for the shown
value (3,60 mA .... 20,40 mA) cannot be defined in this case.

4.2.4 O2 limit alarm settings

The entry “by” sets the value at which the O2 limit alarm is activated.
The O2 limit alarm function “min” defines a value by which the
limit alarm is activated if the measured O2 value falls below the
set limit.
If the hysteresis is set to greater than 0,00,
the limit alarm is reset when the measured O2 value rises above the
set O2 limit plus the hysteresis value .
The O2 limit alarm function “max” defines a value by which the
limit alarm is activated if the measured O2 value rises above the
limit.
If the hysteresis is set to greater than 0,00,
the limit alarm is reset when the measured O2 value falls below the
O2 limit minus the hysteresis value.
Figure 24 - O2 limit alarm settings
If the hysteresis is set to 0,00 % O2, the triggered limit alarm must be
manually reset.

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Menu Overview and Explanations Installation and Operation Manual OXITEC® 5000

4.2.5 O2 Sensor calibration values

Info

The sensor calibration values can be altered through a 1 or 2 point calibration. Manual entry of values is only
necessary after replacing the O2 sensor. (The sensor calibration values, “cell constant” and “cell slope” can be
found on the probe test protocol for new probes.)

4.2.6 Time per test gas apply

Here the maximum duration of time for the application of test gas or test air is set. If sensor stability is not reached within the
maximum time, the following error message is displayed: “O2 Sensor calibration failed - O2 sensor
signal instable” This problem can be offset by setting a longer duration. The factory setting for maximal duration is 10
Minutes. If necessary, the time can be adjusted between 5 minutes and 30 minutes.

4.2.7 Delay time to process

Here the delay time showing the last measured O2 value from the data storage is frozen after test air or test gas has been
applied (only when “Meas. value hold on cal. is set to on) This value also sets the time for showing the trend representation
on the display after test air or test gas application after a sensor calibration is set.

4.2.8 Automatic Calibration (ACAL)

Automatic calibration enables a cyclic, time-based or remote controlled calibration (using the digital input) of the O2 sensor.
The ACAL can be globally switched on or off and can only be started from the main screen of the display.

When a 2 Point ACAL is set, a test gas bottle must be permanently connected and turned on.

Info
Make sure that the test air and test gas volume and flow settings needed for calibration are correct.
For systems with flow monitoring: The flow rates can be checked under
System Checks  O2 sensor check
For systems without flow monitoring: Check the flow rates through an external flow meter and adjust to
150 - 180 l/h via an external throttle valve.

4.2.9 Automatic Calibration Settings

Only when the ACAL is switched on, are the ACAL settings visible. The calibration method determines whether the ACAL
is carried out as a 1 point calibration only with test air (instrument air or ambient air) or as a 2 point calibration with test air
and test gas. Ambient air is preset to a fixed O2 concentration of 20.95% and this value is not shown nor can it be changed.
The ACAL can be started by:
Time: Time based start with set intervals in days and the corresponding time
Time + Digital Input: Same as “Time”, additionally a control voltage of 12-24V DC must be applied to the “calibration re-
lease” so that an automatic calibration can be started.
Digital Input: A control voltage of 12-24V DC must be applied to the “calibration release” so that an automatic
calibration can be started. If the control voltage is still present after the calibration has ended, the calibration will immediately
restart

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4.2.10 Measuring units

Measuring units can be set for temperature (°C / °F) and pressure (mbar / psi).

4.2.11 Language
Set the language for all text shown on the display. One can choose between English, German, Spanish and Polish.

4.2.12 Change system code

Info
The system code on delivery is 0000. In this state, entry into the system is granted without entering the
system code. For security reasons, change the code and store it in safety. In case of loss of the system
code, a system reset has to be carried out. The reset process may only be carried out by trained service
technicians.

4.2.13 Load factory settings

Loading factory settings will restore all original settings and values to the default values programmed in the factory. If acti-
vated, all set parameters and also values such as sensor calibration values and calibration results are lost. Take note of the
sensor calibration values beforehand and re-enter them after the loading the factory settings. If this is not done, a calibration
has to be carried out.
.

4.2.14 Service (Factory Service Settings)

The service functions are password protected and are only accessible by trained service personnel. These functions are
protected with a code, different to the system code.

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4.3 Calibration Menu

CAL MENU

1 point calibration, O2
2 point calibration, O2

4.3.1 Calibration Menu - Display Overview

The max. adjustable measuring range

Trend representation of measured O2 value

and O2 target value

………………
The target value is determined by the O2
concentration in the test gas / test air
Time scale showing the elapsed time of the
Figure 25 - display of a 1 Point Calibration current calibration process. The
amount in seconds (here 120 s) refers to the
end of the time scale
The flow rate currently measured

Current measured value of O2

Abort the calibration

Progress bar

Figure 26 - The 3 phases of a 2 point calibration,

Test Gas apply, Test Air apply and Return to
Process gas.

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Info
The oxygen concentration in test air needs not be entered as it is known (20,95 % O2).
During calibration, entry of the test gas concentration value takes place after test gas has been applied.

4.3.2 1-point calibration (manual)

During the 1-point calibration of the sensor, the calibration offset is determined. Test air is hereby applied to the sensor. In
systems without an integrated pneumatic unit, test gas needs to be applied manually and the flow control also may need to
be checked and adjusted if necessary.
Course of events
(1) Enter System Code
(2) Maintenance LED is lit
(3) Prompt to apply test air (only for systems without flow monitoring)
(4) The calibration process is carried out with test air
(5) Prompt to end the test air application. (only for systems without flow monitoring)
(6) Display of the return to process if the difference between the measured concentration in the process and
the O2 concentration with test air is more than 3.00%.
(7) Enter the O2 concentration of test gas (does not apply to test air)
(8) Display of the calibration results (max. 1 minute)
(9) Maintenance LED switches off (is delayed by the set value in “Delay time to process” if “Meas. Value hold
on cal” is set ON)
(10) Revert to main display

4.3.3 2-point calibration (manual)

During the 2-point calibration of the sensor, the calibration offset and slope is determined. Hereby two gases are
applied to the sensor (test air and test gas. In systems without integrated pneumatic units, test gas needs to be applied
manually and the flow control also may need to be checked and adjusted if necessary.

Course of events
(1) Enter System Code
(2) Maintenance LED is lit
(3) Prompt to apply test gas (only for systems without flow monitoring)
(4) The calibration process is carried out
(5) Prompt to apply test air (only for systems without flow monitoring)
(6) The calibration process is carried out with test air
(7) Prompt to end the test air application. (only for systems without flow monitoring)
(8) Display of the return to process if the difference between the measured O2 concentration in the process and
the concentration with test air (test gas 1) is more than 3.00%.
(9) Prompt to enter test gas concentration(s)
(10) Display of the calibration results (max. 1 minute)
(11) Maintenance LED switches off (is delayed by the set value in “Delay time to process” if “Meas. Value hold
on cal” is set ON)
(12) Revert to main display

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4.4 System Checks

O2 Sensor checks
Source: Testair
O2 sensor .. mV = .. %
Flow rate .. l/h

Source: Testgas
O2 sensor .. mV = .. %
Flow rate (3 bar max) .. l/h

Source: Process
O2 sensor .. mV = .. %
Flow rate .. l/h

Check mA outputs
Set mA output 17A/B (mA)

Check relay outputs

Relay contact at 18A/B (opened / closed)
Relay contact at 19A/B (opened / closed)
Relay contact at 20A/B (opened / closed)
Relay contact at 21A/B (opened / closed)
Relay contact at 22A/B (opened / closed)

Check digital inputs

Input status at 25A/B
Input status at 27A/B

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Installation and Operation Manual OXITEC® 5000 Service and Maintenance

5 Service and Maintenance

5.1 Exchange fuses
Warning

De-energize system first!

Figure 27 - Position of the fuses

Part Current Type of Fuse Task

F3 1A fast-acting 5x20 mm glass tube fuse Protection of the electronic unit
F4 1A fast-acting 5x20 mm glass tube fuse Protection of the electronic unit
Protection of the solenoid valve and ref. air and
F5 1A semi time-lag 5x20 mm glass tube fuse
test air pumps
F1 6.3 A semi time-lag 5x20 mm glass tube fuse Protection of the entire system
F2 4A semi time-lag 5x20 mm glass tube fuse Protection of the probe heater

Nr. ENOTEC Article nr. Description

0-F-000069 F1, Main Unit fuse 6,3A Semi time lag
5x20 mm (glass-tube fuse)
0-F-000083 F2, Probe heater fuse 4A Semi time lag
5x20 mm (glass-tube fuse)

Figure 28 - Electronic unit main fuses

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5.2 Flow rates for Test Air and 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 of 6 bar, it is necessary to readjust the flow of
reference air and/or test air.
The flow rates for air should be in the following range:
Test air: 150l/h - 180l/h
Reference air: 30l/h - 40l/h

5.3 Adjusting Flow Rate (SME 53 with integrated Pneumatics)

In the instrument air version in the Safe Area housing with an 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 ambient air is used. Only the flow rate of test air can be adjusted (Figure 29 - Adjust
flow of test air here - (pump version)).
 The instrument air version requires an external supply of clean, dry and oil free air (instrument air) Both flow
rates (test air and reference air) can be adjusted (Figure 30 - Adjust flow of test air and reference air
here -
(instrument air version)
In systems with integrated pneumatics unit, the flow rate of reference air can be seen in the menu actual measured
values.

Figure 29 - Adjust flow of test

air here - (pump version)

Figure 30 - Adjust flow of test

air and reference air here -
(instrument air version)

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5.4 Position of the adjustment valves

Figure 31 - Terminal cover of the SME-53 Electronic Unit

showing the position of the reference air and test air valves below

5.5 Adjusting Flow Rate (SME-57)

With systems in 19“ racks the reference air and test air quantity can be adjusted at the back of the 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 seen in the menu “Actual measured
values”.

Instrument air version Version with pumps

Figure 32 - SME-57 - Adjusting the flow rate

A Regulator Reference Air

B Regulator Test Air

C Regulator Test Air

D Reference Air Filter

E Test Air Filter

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Service and Maintenance Installation and Operation Manual OXITEC® 5000

5.6 Replacing the Filter

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/95°F.

Note

Only cemented ceramic, basalt and sintered metal filters can be replaced

5.6.1 Remove old Filter

Loosen the holding screws.

Clamp the filter head in a vice.
Free the filter by using a hammer and a metal
extension to force it from the filter head

Figure 33 - Remove old filter

5.6.2 Cement in new Filter

Mix the supplied glue with water according to the

instructions. Spread the glue into the grooves of the seat
and onto the filter part which comes into contact with the
seat. Push - turn the filter into the seat. Evenly
smooth the glue between the filter and seat and remove
all excess glue.

Figure 34 - Cement new filter in

Note

The cement dries at room temperature within 24 hours. Using the cement supplied by ENOTEC, all types of ceramic,
basalt and sintered metal filters supplied by can be inserted and fixated.

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5.7 Replacing the O2 Sensor

Warning Hot Surface

The probe may only be removed with heat-insulated gloves. Before removing the probe, always switch off the sup-
ply 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/ 95°F.

Note

An exchange of the measuring cell is only necessary if the cell is leaking (erratic or incorrect measured values).

Disconnect the wires in the connection head

and loosen the 2 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 carefully

(4-hole ceramic rod with signal measuring
wire, thermocouple element and heater)

Unscrew the 4 allen screws at the measuring

cell holder with flange and remove the
measuring cell.

Figure 35 - O2 sensor replacement

Clean the flange at the probe tube with fine sandpaper. Tighten the new measuring cell with a new metal gasket seal-
ing and four new screws at the measuring cell flange of the probe tube. 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 assem-
bly is pressed against the measuring cell with enough spring tension.
Tighten locking bolt and connect wires as follows:

Terminal Color Description Polarity Unit

1 green/yellow signal wire, measuring cell - mV
2 Orange signal wire, measuring cell + mV
3 Green thermocouple element + mV
4 White thermocouple element - mV
6 Black heating element
7 Blue heating element
8 green/yellow ground/earth heater
9 Black solenoid valve (optional)
10 Black solenoid valve (optional)

Install the probe, wait for the system to reach its operating temperature. Carry out an O2 two point calibration after
2 hours of operation.

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Figure 36 - Construction of the O2 sensor

5.8 Exchange of Probe Inner Parts

Proceed as described in chapter 5.7 to dismantle the probe inner parts assembly. The exchange of the
thermocouple element is an exception, because this can be changed without dismounting the probe inner part as a
whole.

5.9 Exchange of Thermocouple Element

The thermocouple element is a covered thermocouple element with an Inconel-covering and a Ni-Cr-Ni
thermocouple. The thermocouple element is in one hole of the 4-hole-rod (beside the reference air tube).
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.

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5.10 Exchange of Heating Element

Remove the probe inner part assembly, loosen the clamp, pull out the signal measuring wire and the thermocouple
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 (from the measuring sensor side) and thermocouple element (from the connection side);
assemble clamps and connection sleeves (for long probes).

Caution

The heater support has three drilled holes, which must correspond with three holes of the 4-hole ceramic rod. The
reference air flows through the medium hole, the thermocouple is fitted in the larger hole at the side and the third
(smallest) hole is for the signal wire. Make sure, that the tap of the signal wire lies in the depression of the heater
support.
After the insertion of a thermocouple in a new heater support, this hole will be sealed with cement. This avoids the
thermocouple touching the signal wire and causing a short circuit. If the heater support is changed, the hole of the
thermocouple in the heater support has to be sealed with cement after the insertion of the thermocouple as well.

5.11 Exchange of Signal Measuring Wire

The signal measuring wire has a specially shaped contact for taking the mV-value of the reference electrode of O2
sensor. It is possible that a small metal net is fixed on the signal measuring wire which has been pulled out. This net
has no effect on the function of the probe and it need not to be replaced.
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 cannot be received any longer, and an error
signal will occur.

5.12 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, during assembly, one
has to ensure that the holes correspond 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 sensor.

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5.13 Relay Outputs / Functions and Correlation

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

Relay Contact Function Terminal

System error* Normally closed Signals operation-critical errors X5 (19A/B)

Maintenance Normally open System code entered, system in maintenance mode X5 (18A/B)

Measuring range Normally open Closed: Measuring range 1 active X5 (20A/B)

Probe valve** Normally open Triggering of the probe valve X5 (24A/B)

Limit value 1 Normally closed Signals a violation of limit value 1 X5 (21A/B)

Limit value 2 Normally closed Signals a violation of limit value 2 X5 (22A/B)

Relay outputs and functions
• The relay „system error“ is active also during the heating phase.
** The relay contact for the probe valve is designed for max. 230V and 1A .

Figure 37 - Relay plate with marked relays and LEDS

Relay marking LED Marking Function

A a Probe heater relay
B b Maintenance
C c System error
D d Limit O2 1
E e Measuring range
F f Limit O2 2
G g Probe valve
H h Solenoid valve test gas 1
I i Solenoid valve test gas 2
x Probe heater control

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5.14 Digital Inputs

The digital inputs are designed for a direct voltage of 12 V - 24 V DC for logical “High”. Logical “Low” corresponds to
a voltage less than 1 V.

Digital input Function

Calibration release External release for calibration with ACAL

Measuring range switch Switching on the second measuring range

5.15 Stability Criteria for Calibration

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

5.16 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.

5.17 Extension Modules

As an option, the electronic unit is available with several interfaces (RS232, RS485, HART, Fieldbus). If one of these
options is ordered you will find a separate manual/specification for the respective interface together with the
shipment.

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Status Messages Installation and Operation Manual OXITEC® 5000

6 Status Messages
6.1 Error Messages
Error Relay O2 signal
Description
Message contact output
The error can occur at any time and signalises a failure of one of the electronic
Hard- System 2.00 mA,
components. The O2 sensor heater is turned off and can be switched on by the
ware error, when not set
user, once the fault has been corrected. Contact one of the ENOTEC service
error 1-7 open differently
points, if the error returns after restarting the system.
The error can occur at any time and signals a break in the circuit of the
Open
System 2.00 mA, thermocouple. The O2 sensor heater is turned off and can be switched on by the
circuit
error, when not set user, once the fault has been corrected. Possible causes: contact problems of the
thermo-
open differently thermocouple wire to the terminal points of the electronics or the sensor, sensor
couple
cable is damaged or the thermocouple is defective.
The error can occur during the heating of the O2 sensor. The O2 sensor heater is
turned off and can be switched on by the user, once the fault has been corrected.
O2 probe
System 2.00 mA, Possible causes: F2 fuse malfunction, contact problem of the O2 sensor heater
set temp.
error, when not set wire to the terminal points of the electronics or the sensor, sensor cable is dam-
not
open differently aged, short-circuited thermocouple, reference air flow greater than 60 l / h, power
reached
supply too low, flow rate too high and / or temperature in the process too low ,
electronic failure.
The error can occur during measurement, indicating that the O2 sensor tempera-
ture drops 20 ° C (68 ° F) below the set temperature. The O2 sensor heater is
O2 probe turned off and can be switched on by the user, once the fault has been corrected.
System 2.00 mA,
tempera- Possible causes: F2 fuse malfunction, contact problem of the O2 sensor heater
error, when not set
ture too wire to the terminal points of the electronics or the sensor, sensor cable is dam-
open differently
low aged, short-circuit thermocouple, reference air flow greater than 60 l / h, power
supply too low, flow rate too high and / or temperature in the process too low,
electronic failure.
The error can occur during measurement, indicating that the O2 sensor tempera-
O2 probe
System 2.00 mA, ture has risen 20 ° C (68 ° F) above the set temperature. The O2 sensor heater is
tempera-
error, when not set turned off and can be switched on by the user, once the fault has been corrected.
ture too
open differently Possible causes: Process temperature too high, O2 sensor heating line to the
high
transmitter connected incorrectly, electronic failure.
The error can occur at any time and signals a break in the circuit of the O2 sensor.
Open System 2.00 mA, It can be reset by the user, once the fault has been corrected.
circuit O2 error, when not set Possible causes: contact problem of the O2 sensor wire to the terminal points of
sensor open differently the electronics and the probe, probe cable is defective, contact problem of the
probe the inner part of the O2 sensor.
O2 sen-
System
sor cali- O2 sensor calibration has failed for one of the following reasons. A reset can be
error,
bration carried out by the user, all corresponding entries are then reset as well.
open
failed
The error can occur during an O2 sensor calibration and signals an insufficient test
Test gas System gas flow. A reset can be carried out by the user. A successful re-calibration also
flow rate error, remedies the error. Possible causes: test gas bottle empty, test gas flow incorrect-
too low open ly set, test air flow incorrectly set, instrument air supply to the system does not
exist.
The error can occur during an O2 sensor calibration and signals a test gas flow
Test gas System which is too high. A reset can be carried out by the user. A successful re-
flow rate error, calibration also remedies the error. Possible causes: test gas bottle empty, test
too high open gas flow incorrectly set, test air flow incorrectly set, instrument air supply to the
system does not exist.
The error can only occur only during an O2 sensor calibration. A reset can be car-
O2 sen- System
ried out by the user. A successful re-calibration also remedies the error. Possible
sor offset error,
causes: inadequate reference air supply, process pressure is too high, incorrect
too low open
test gas (not with test air), O2 sensor defective.

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Error Messages (cont.)

Error Relay O2 signal

Description
Message contact output
The error can only occur during an O2 sensor calibration. A reset can be carried
O2 sensor System
out by the user. A successful re-calibration also remedies the error.
offset too error,
Possible causes: defective false test gas (not test air), test gas flow too low, O2
high open
sensor defective.
The error can only occur only during an O2 sensor calibration. A reset can be
O2 sensor System carried out by the user. A successful re-calibration also remedies the error .
slope too error, Possible causes:
low open Incorrect calibration gas, test gas flow too low, probe filter damaged, filter head
missing, faulty O2 sensor.
The error can only occur only during an O2 sensor calibration. A reset can be
O2 sensor System
carried out by the user. A successful re-calibration also remedies the error .
slope too error,
Possible causes: Incorrect
high open
calibration gas, O2 sensor defective.
The error can only occur only during an O2 sensor calibration. A reset can be
O2 sensor System
carried out by the user. A successful re-calibration also remedies the error. Pos-
signal error,
sible causes: test gas flow too low, probe filter is damaged, process pressure
instable open
Changes too high.
Unlisted errors: Other errors cannot be remedied by the customer.
Please contact an ENOTEC service point

6.2 Alarm Messages

Error Mes- Relay
Description
sage contact
Reference air Possible Cause: reference air flow set incorrectly, instrument air supply is inadequate, reference air
flow too low pump is faulty.
Reference air
Possible Cause: reference air flow is set incorrectly
flow too high
O2 limit alarm
O2 limit alarm 1 Possible Cause: Over or under range of the O2 limit alarm.
1, open
O2 limit alarm
O2 limit alarm 2 Possible Cause: Over or under range of the O2 limit alarm.
2, open
Electronic temp. Possible Cause: The ambient temperature of the transmitter is lower than the specified lower limit. The
too low specified measurement tolerances are no longer guaranteed.
Electronic temp. Possible Cause: The ambient temperature of the transmitter is higher than the specified upper limit.
too high The specified measurement tolerances are no longer guaranteed.
The alarm can only be reset by the user after replacing the clock battery (Lithium type 2032). As long
Clock battery
as the system is connected to AC power, the alarm has no impact. Only after restarting system will the
low
time / date be incorrect. A possible timed automatic calibration can no longer work correctly.

Unlisted alarm messages: Other messages cannot be remedied by the customer.

Please contact an ENOTEC service point

6.3 Maintenance Messages

Maintenance Relay
Description
message contact
Measured Service, When measured values held is set to on, the determined O2-mA output remains saved for a
value(s) held closed duration before a calibration.

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Troubleshooting Installation and Operation Manual OXITEC® 5000

7 Troubleshooting
Unsteady, widely varying measuring value (O2)

Possible reasons Procedure

Intermittent contact caused by wire breakage
Intermittent contact inside the probe - internal mV Eliminate bad/loose contact
connection
Broken filter element
Visual inspection by dismounting the probe
Wrongly installed V-shield
Probe has been installed without filter head
Intermittent contact inside the probe – low spring tension for Check the spring tension
the O2 signal contact wire internally

O2 display remains at the end of the measuring range or is higher than expected

Possible reasons Procedure

Leakages at the measuring probe or at the O2 sensor flange Check all flanges and screw connections for tightness.
seal. Exchange O2 sensor or replace O2 sensor flange seal. In
case of a leakage in the area of the O2 sensor, the O2
sensor must be exchanged.
Probe flange not welded gas tight. Tighten flange bolts with required torque, possible renew
the gasket.

Local Displays correct, Output not correct

Possible reasons Procedure

Check measuring range. Check whether the current value
Electronic unit is defective is outside the measuring range
Measure the mA output on the strip terminal.

O2 Display Indicates 0 %, although the Process Operation Mode expects a higher O2 Value

Possible reasons Procedure

Measuring probe heater defective (resistance must be ap- Check the measuring cell temperature (set value
prox. 37.5-47.5 Ohm, disconnect probe and check). 800°C/1472°F. A lower temperature could have the effect
of showing a value of 0 %.
Thermocouple defective (check resistance, approx. 2-80 Check the mV value of the O2 measuring cell
Ohm).
Fuse for heater voltage defective. Replace the fuse
Cable short circuit. Electronic units input defective. Wire Check wiring. Measure probe cable.
break
Transformer (230/115V) is defective Check the fuse
There is no mV contact in the probe (measuring signal wire) Check whether the probe reacts to test gas. If it does,
or it is interrupted. Combustibles in the flue gas. Measuring there may be a high proportion of combustibles in the flue
cell defective gas. In this case, there are reducing conditions at the
probe sensor, which reduce the oxygen content at the
sensor surface. Caution: Explosion hazard!

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Installation and Operation Manual OXITEC® 5000 Technical Data

A Technical Data
A.1 Technical Specifications - Electronic Unit

Housing: Sheet steel ST37

RAL6029
(SME-57, 19” rack optional)
(GRP optional)

Safe Area Housing: IP66

IP Code: GFK cabinet: IP66
19“ housing: IP20

Display: LC Dot Matrix 240 x 64

LED backlit

Keypad: Membrane keypad

Signal LEDs: Alarm, Maintenance, Error

O2 measuring ranges: 2 x 0,00 to 25,00 Vol.% O2

Accuracy: ± 0,2 % of measured value

Response time: Change of 100mV at sensor input < 200ms

Manual or ACAL
1 or 2 point (automatic calibration)
(Automatic calibration):

Mains Voltage: 230V ±10 % 50 to 60 Hz

115V ±10 % 50 to 60 Hz
(see Name Plate)

Power consumption: 400 VA (heating phase)

200 VA (typical measuring mode)

Recommended fuse: 10A

Output signal O2: Active, 0/4 to 20 mA

max. load 500 Ω

Relay contact: 24 V AC/DC, 1 A

Relay contact solenoid valve: 230 V AC/DC, 1 A

Dimensions: 300 x 440 x 240 mm (B x H x T)

Weight: ca. 19 kg

Temperature range - storage: * -40 °C to +80 °C

Temperature range - operation: * -20 °C to +55 °C

* Other temperature ranges on request

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Technical Data Installation and Operation Manual OXITEC® 5000

A.2 Technical Specifications - Probe

KES-132x: up to 400°C
Process gas temperature: KES-200x: up to 600°C
KIS-200x: up to 800°C
KES500x: up to 600°C
(For all probes up to 1400°C with cooling protection tube)

Immersion depth: KES-1321: 385 mm

KES-1322: 475 mm
KES-1323: 615 mm

KES-2001: 495 mm
KES-2002: 925 mm
KES-2003: 1835 mm
KES-2004: 2768 mm
KES-2005: 3682 mm

KES5001: 520 mm
KES5002: 950 mm
KES5003: 1865 mm

500 mm / 1000 mm
Immersion depth with cooling tube:
Others on request

Measuring principle: Zirconium oxide

Operating temperature O2 sensor: 800 °C

Air (20,95 % O2: 0 mV ± 1mV

Raw signals from O2-sensor:
2,1 % O2: 50 mV ± 1 mV

Instrument air 40 l/h

O2-Sensor Reference Air:
Adjustment at SME-53

Process gas pressure: -50 to +50mbar

Flow Velocity: 0 to 50m/s

Ambient temperature: -40°C to +80°C

Reaction Time: 0,5s (Process flow velocity > 10m/sec.)

T90: 5s (Process flow velocity > 10m/sec.)

V4A (DIN 1.4571 / SS316Ti)

Probe material:
Others on request

IP Code: IP65

Detection limit: < 1ppm O2

Power supply: Through electronic unit

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Installation and Operation Manual OXITEC® 5000 Technical Data

A.3 Gas Supply - Systems with Instrument Air

The analyzer system uses the connected instrument air continuously for the supply of
reference air, and during calibration and system test respectively, for the supply of test air (test gas 1).

Instrument air supply for reference air / test air

Specification: According to ISO 8573-1 class 2

(Particle size max. 1m,
Particle density max. 1mg/m³,
Oil content max. 0,1mg/m³,
Pressure dew point max. -20 °C)
Constant 20,95 Vol % O2

Input pressure: 2-10 bar

Flow rate continuously maximum 40 l/h (for reference air supply)

180 l/h during calibration

Test gas (test gas bottle) for calibration / system test

Input pressure: max. 3 bar

Specification
21 Vol. % O2 in N2 (synthetic air – in case instrument air is not available)
test gas 1 (optional):

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

Flow rate 180 l/h at 1,1 bar (+/- 0,1).

Note

The flow rate of the test gas bottle is set via the bottle pressure regulator.

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Dimensional drawings Installation and Operation Manual OXITEC® 5000

B Dimensional drawings
B.1 Dimensions of Electronic Unit Housing versions

Figure 38 – Dimensions in mm of the SME-53

Figure 39 – Dimensions in mm of the SME-57

Figure 40 - Dimensions in mm of the SME-56 (optional)

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Installation and Operation Manual OXITEC® 5000 Dimensional drawings

B.2 Probe Dimensions

Figure 41 - Dimensions of the KES-132X probes

Figure 42 – Dimensions in mm of the KES-132X probes with cooling protection tube

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Dimensional drawings Installation and Operation Manual OXITEC® 5000

Figure 43 - Dimensions of the KES-200X probes

Figure 44 - Dimensions in mm of the KES-200X probes with cooling protection tube

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Installation and Operation Manual OXITEC® 5000 Dimensional drawings

Figure 45 - Dimensions in mm of the KES-500X probes

Figure 46 - Dimensions of the KES-500X probes with cooling protection tube

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Dimensional drawings Installation and Operation Manual OXITEC® 5000

B.3 Counter Flange Dimensions

Figure 47 - Dimensions of counter flange for KES 132X

Figure 48 - Dimensions of counter flange ADP-2000

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Installation and Operation Manual OXITEC® 5000 Dimensional drawings

Figure 49 - Dimensions of counter flange ADP-2000-S02

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Dimensional drawings Installation and Operation Manual OXITEC® 5000

B.4 Dimensions of protection tube flanges

Figure 50 - Dimensions of protection tube flanges

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Installation and Operation Manual OXITEC® 5000 Spare Parts

C Spare Parts
C.1 Probe Components - KES-132X

Figure 51 - KES-132X Probe Components

No. Part Part No.

1 Connection Box ASK-1001
2 Measuring probe tube MSR-132X
2a Probe flange gasket FLD-132X
3 Probe inner part SIK-132X
4 Oxygen measuring cell ZO2-00(0/1)1
4a Measuring cell gasket MZD-0001
5 Filter head KES-1320X00
6 *)Test gas valve / *) Solenoid valve KES-13200X0

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Spare Parts Installation and Operation Manual OXITEC® 5000

C.2 Probe Components - KES-200X

Figure 52 - KES-200X Probe Components

No. Part Part No.

1 Connection Box ASK-1001
2 Measuring probe tube MSR-200X
2a Probe flange gasket FLD-200X
3 Probe inner part SIK-200X
4 Oxygen measuring cell ZO2-00(0/1)1
4a Measuring cell gasket MZD-0001
5 Filter head KES-2000X000
6 *)Test gas valve / *) Solenoid valve KES-20000X00
7 Protection Tube KES-200000X0
7a Protection tube flange gasket SRD-200X

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C.3 Probe Components - KES-500X

Figure 53 - KES-500X Probe Components

No. Part Part No.

1 Connection Box ASK-1001
2 Measuring probe tube MSR-200X
2a Probe flange gasket FLD-200X
3 Probe inner part SIK-200X
4 Oxygen measuring cell ZO2-00(0/1)1
4a Measuring cell gasket MZD-0001
5 Filter head KES5000X0000
6 *)Test gas valve / *) Solenoid valve KES50000X000
7 Protection Tube KES500000X00
8 Protection tube flange KES5000000X0
8a Protection tube flange gasket(“A”) SRD-200X

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Spare Parts Installation and Operation Manual OXITEC® 5000

C.4 Probe inner parts assembly

Figure 54 - Probe inner parts assembly

Article Number (depends on probe type)

Nr. Description
KES-1321-2 KES-1323 / KES-2001 KES-200X / KES-500X
1 Heater support tube HZH-00002 HZH-00002 HZH-00002
2 Heater HEI-132X HEI-2001 HEI-200X
3 heater clamp 0-R-000474 0-R-000474 0-R-000474
4 Distance sleeve - 0-R-000201 0-R-000201
5 Ceramic rod KER-132X KER-2001 KER-200X
6 Tube clamp 0-R-000500 0-R-000500 0-R-000500
7 Spring 0-R-000044 0-R-000044 0-R-000044
8 Thermocouple MT2-132X MT2-2001 MT2-200X
9 Reference air hose RLS-0001 RLS-0001 RLS-0001
10 Signal wire MSD-132X MSD-2001 MSD-200X
Repair kit RSI-132X * RSI-2001 * RSI-200X *

* consists of pos. 3,4,6,7

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Installation and Operation Manual OXITEC® 5000 Spare Parts

C.5 Mounting Plates of the Electronic Unit

Parts List
Test gas and reference air unit with internal pumps
TRA-0017 Transformer prim. 2*115V, sec. 115V

PLU-0028 Test air pump for SME5 720 l/h

Test gas solenoid valve P01 for SME53 -

PGM-0001
with pneumatic unit and fittings

0-P-000777 Restrictor one way - 6 mm

Internal flow meter for reference air and

DFM-00001
test gas SME5

PLU-0025 Reference air pump for SME5 30l/h

Figure 55 - Mounting plate 1 (version with pumps)

Parts List
Test gas and reference air unit for instrument air

TRA-0017 Transformer primary 2*115V, sec. 115V

Test gas solenoid valve P01 for SME53 -

PGM-0001
with pneumatic unit and fittings

Test gas solenoid valve P02 for SME5 - with

PGM-0002
instrument air unit and fittings

DFM-00001 Internal flow meter

0-P-000780 Pressure regulator

Figure 56 - Mounting plate 1 (version with instrument air)

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Spare Parts Installation and Operation Manual OXITEC® 5000

Parts List
Mounting plate 2
0-L-000047 Optional mA-output board.

0-L-000080 SME5 power board

Filter for reference air and test air -
PLF-0003
for version with internal pumps

Figure 57 - Mounting plate 2

C.6 Display Board

Parts List
Display Board
0-L-000035 SME5 OXITEC display board without
pneumatic
0-L-000036 SME5 OXITEC display board with pneu-
matic
0-L-000108 SME5 OXITEC display board with CSP
with pneumatic
0-L-000110 SME5 OXITEC display board with RS232
with pneumatic

Figure 58 - Display board

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Installation and Operation Manual OXITEC® 5000 Declaration of Conformity

D Declaration of Conformity

Manufacturer:
ENOTEC GmbH
Höher Birken 6
D-51709 Marienheide

EC Declaration of Conformity

We hereby declare that the product OXITEC® oxygen analyzer system, based on its conception and design as well as in the
equivalent execution which we have brought into circulation, complies to the EC-directives as follows. Compliance with the
guidelines requires that the system is used in accordance to the manufacturer’s data, and no unauthorized changes are made.

Identifier OXITEC® 5000 oxygen analyzer system

Type of Electronic Unit SME 5

Relevant EC Directives EC Low Voltage Directive 2006/95/EC

EC EMC Directive 2004/108/EC
EC Product Liability Directive 85/374/EWG

Applied Harmonized Standards EN 55011 Kl. A:2007 Emission

EN 61000-6-2:2005 Immunity
EN 61000-3-2:2006 Current Harmonics
EN 61000-3-3:1995+A1,A2 Flicker
EN 61010-1:2001 Safety Requirements for Electrical
+Corrigendum 1:2002-08 Equipment for Measurement, Control
+Corrigendum 2:2002-08 and Laboratory Use – Part 1: General
Requirements

Applied Standards and Technical EN 61000-4-2:2001 Electrostatic Discharge

Specifications in Particular
EN 61000-4-3:2006 Rad. Immunity E-Field
EN 61000-4-4:2005 Burst
EN 61000-4-5:2001 Surge
EN 61000-4-6:2001 Immunity to Cond. RF
EN 61000-4-1:2005 Voltage Dips and Interrupts
EN 61000-3-2 Current Harmonics
EN 61000-3-3 Flicker
CISPR 16-1 Conducted Emission cl. A
CISPR 16-1 Rad. Emission E-Field cl. B

Date / Manufacturer signature 2008-08-02 sgd. Fred Gumprecht

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

Information of Signatory Managing director

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

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Index Installation and Operation Manual OXITEC® 5000

Index

A  M 
Access to the Terminals ..................................................... 7 Mounting Plates of the Electronic Unit ............................. 53
Adjusting the Flow Rate.................................................... 28
Adjusting the V-shield ....................................................... 11
N 
C  Name Plate ........................................................................ 4
Cooling Protection Tube ................................................... 11
Counter Flange ................................................................. 10
P 
Pneumatic Connections
D  Probe .......................................................................... 14
Position of the adjustment valves ..................................... 29
Declaration of Conformity ................................................. 55 Pressure and Flow rates .................................................. 28
Dimensional drawings ...................................................... 42 Probe Components .......................................................... 49
Dimensions Probe inner parts ............................................................. 52
Adapter Plate Dimensions .......................................... 46 probe tube ........................................................................ 31
Dimensions of protection tube flanges ........................ 48
Electronic Unit Housing .............................................. 42
Probe Dimensions ...................................................... 43
R 
Display Board ................................................................... 54 Relay outputs ................................................................... 34
Disruption of the Process ................................................... 3 Replacing the Filter .......................................................... 30
Replacing the Filter Head................................................. 30
E  Replacing the O2 Sensor .................................................. 31
Requirements for the Gas Supply .................................... 41
Electrical Connections of the Probe ................................. 12
Exchange fuses ................................................................ 27
Exchange of Heating Element .......................................... 33
S 
Status Messages
F  Alarm Messages ......................................................... 37
Error Messages .......................................................... 36
Ferrite Sleeves ................................................................... 7 Service Messages ...................................................... 37

I  T 
Installation Technical Specifications
Electronic Unit............................................................... 5 Electronic Unit ............................................................ 41
Pneumatic Cable ........................................................ 12 Troubleshooting ............................................................... 38
Probe signal cable ........................................................ 6
Installation of the probe .................................................... 10
W 
L  Wiring Diagram of the Electronic Unit ................................ 8
Language settings ............................................................ 23

56 Doc.-ID: OXI-16052012-EN
Manufacturer
ENOTEC GmbH
Höher Birken 6
D-51709 Marienheide
Germany

Tel.: ++49 (0) 2264 / 45 78 – 0

Fax: ++49 (0) 2264 / 45 78 – 31
E-Mail: info@[Link]
Internet: [Link]

ENOTEC Sales and Service Germany

North West
Mr. Dirk Jeworowski Mr. Thomas Bechstein
Broistedtstr. 26 Zum Stollen 4
D - 21423 Winsen/Luhe D - 51674 Wiehl
Telefon: ++49 (0) 4171 6672 70 Telefon: ++49 (0) 2262 7527 97
Fax: ++49 (0) 4171 7876 400 Fax: ++49 (0) 2262 7528 01
E-Mail: jeworowski@[Link] E-Mail: bechstein@[Link]

Rhein/Main South/ East

Mr. Dipl.-Ing. Dieter Rieß Dr. Claus Gumprecht
Oderstraße 44 Gössmannsreuth 1
D - 64546 Mörfelden-Walldorf D - 95326 Kulmbach
Telefon: ++49 (0) 6105 9462 38 Telefon: ++49 (0) 9221 9050 20
Fax: ++49 (0) 6105 9462 85 Fax: ++49 (0) 9221 9050 41
E-Mail: riess@[Link] E-Mail: drgumprecht@[Link]

ENOTEC International
ENOTEC UK Limited ENOTEC Inc.
PO BOX 9026 6206 Sandy Ridge Circle NW
DUMFRIES North Canton
DG1 3YH Ohio 44720-6686
United Kingdom USA
Telefon: ++44 8442470102 Telephone: ++1 330 498 0202
Fax: ++44 8442470302 Fax: ++1 330 497 9802
E-Mail: [Link]@[Link] E-Mail: [Link]@[Link]

ENOTEC ASIA PTE. Ltd. Your ENOTEC Representative:

151, Pasir Panjang Distripark
#02-19 Pasir Panjang Road Please contact for details:
Singapore 118480 ENOTEC GmbH
Telephone: ++65 6100 2188 Tel.: ++49 (0) 2264 / 45 78 – 0
Fax: ++65 6399 2780 Fax: ++49 (0) 2264 / 45 78 – 31
E-Mail: enotec@[Link] E-Mail: info@[Link]