O X I T E C® 5000

O2 Analyser system
with SME 5 Electronics

Installation & Operating

Manual

version 8.129-116np

Please note: The photograph shows as an example the KES5001 probe with a
standard IP65 SME 5 electronics package. Your order may have a different style
of probe and electronics housing selected.

ENOTEC GmbH Höher Birken 6

Process and Environmental D-51709 Marienheide / Germany
Phone +49 (0) 2264 - 4578 - 0
TÜV approved for
Measuring Technology Fax +49 (0) 2264 - 4578 - 31
13. BImschV and 17. BImschV

DIN EN ISO 9001 Email: [email protected]

Internet: www.enotec.de
www.enotec.com
Table of contents

0 OXITEC® 5000 certificate

1 INTENDED USE...................................................................................................................................7

2 HAZARDOUS AREA CENELEC CERTIFIED OPTIONS ...................................................................7

3 SAFETY INSTRUCTIONS FOR THE OPERATION OF O2 ANALYSER SYSTEM/PROBES ...........7

3.1 GENERAL SAFETY INSTRUCTIONS .....................................................................................................7
4 SAFETY HAZARDS ............................................................................................................................8

5 INFORMATION ON THE CE-CERTIFICATION ..................................................................................8

6 GENERAL SYSTEM DESCRIPTION ..................................................................................................9

6.1 MEASURING PRINCIPLE ....................................................................................................................9
7 DESIGN OF THE OXITEC 5000 OXYGEN ANALYSER SYSTEM ..................................................10

8 DESCRIPTION OF THE SYSTEM COMPONENTS..........................................................................11

8.1 DESIGN AND FUNCTION OF THE MEASURING PROBE .........................................................................11
8.2 SPECIAL PROBE CABLE AND PNEUMATIC CABLE ...............................................................................12
8.3 DESIGN OF THE ELECTRONICS ........................................................................................................12
9 INSTALLATION OF THE O2 ANALYSER SYSTEM.........................................................................13
9.1 CHECKING THE LOCATION FOR O2 PROBE INSTALLATION .................................................................13
9.2 INSTALLING THE O2 PROBE ............................................................................................................13
9.3 ADJUSTING THE FILTER HEAD .........................................................................................................15
9.4 ELECTRICAL AND PNEUMATIC CONNECTIONS ...................................................................................16
9.5 INSTALLING THE SME5 ELECTRONICS UNIT .....................................................................................17
10 DESCRIPTION OF THE SME 5 MICROPROCESSOR ELECTRONICS......................................19
10.1 DESIGN OF THE ELECTRONICS ....................................................................................................19
10.2 FUNCTIONAL DESCRIPTION OF THE MICROPROCESSOR ELECTRONICS............................................19
10.3 TERMINAL CONNECTIONS FOR THE SME 5 ELECTRONICS ............................................................20
10.3.1 Terminal connection at installed options ............................................................................................ 20
10.4 CONNECTION DIAGRAM ...............................................................................................................22
10.5 ATTENTION! IMPORTANT CHANGE OF COLOUR CODE ELECTRIC CABLE FEP-0001..........................22
10.6 FITTING THE FERRITE SLEEVES (EMC) ........................................................................................23
11 FUNCTION OF THE SME5 MICROPROCESSOR ELECTRONICS.............................................24
11.1 OPERATION OF THE UNIT ............................................................................................................24
11.2 GENERAL OPERATING INSTRUCTIONS ..........................................................................................24
11.3 THE HEATING PHASE ..................................................................................................................25
11.4 MAIN WINDOW ...........................................................................................................................25
11.5 ACTUAL VALUE MENU .................................................................................................................26
11.5.1 Lambda.............................................................................................................................................. 26
11.5.2 proces pressure (option) .................................................................................................................... 26
11.6 PARAMETER MENU .....................................................................................................................27
11.6.1 Altering parameters ........................................................................................................................... 28
11.6.2 Measuring ranges .............................................................................................................................. 28
11.6.3 H2O correction................................................................................................................................... 28
11.6.4 limits, limit curves (option).................................................................................................................. 29
11.6.5 max range pressure (option).............................................................................................................. 30
11.7 SYSTEM MENU ...........................................................................................................................31
11.7.1 Single point calibration....................................................................................................................... 32
11.7.2 Two point calibration.......................................................................................................................... 32
11.7.3 Automatic calibration (ACAL) with air (20.95 % O2) .......................................................................... 33
11.7.4 Measuring value memory................................................................................................................... 34
11.7.5 System test with test gas ................................................................................................................... 34
11.7.6 System test with test air (Only in Systems with integrated pneumatic) .............................................. 34
11.7.7 Setting current output ........................................................................................................................ 34

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 2
 11.7.8 Measuring Range Shift ...................................................................................................................... 35
11.7.9 Alter code........................................................................................................................................... 35
11.7.10 Damping mA output ....................................................................................................................... 35
11.7.11 Call up max./min. values................................................................................................................ 35
11.7.12 Change language........................................................................................................................... 35
11.7.13 Service........................................................................................................................................... 35
11.7.14 Software ........................................................................................................................................ 35
11.8 STATUS MESSAGES ....................................................................................................................36
12 SYSTEM DESCRIPTION / ADJUSTMENTS .................................................................................38
12.1 IN CASE OF LOSS THE SYSTEM CODE ...........................................................................................38
12.2 BRIDGE ON BACK OF DISPLAY UNIT ..............................................................................................38
12.3 ADJUSTMENT DISPLAY CONTRAST ...............................................................................................39
12.4 RELAY OUTPUTS / FUNCTIONS ....................................................................................................40
12.5 DIGITAL INPUTS..........................................................................................................................40
12.5.1 Digital inputs at Option limit curves .................................................................................................... 40
12.6 AMOUNTS OF TEST AIR AND/OR REFERENCE AIR...........................................................................40
12.7 STABILITY CRITERIA FOR CALIBRATION.........................................................................................41
12.8 REACTION TIME OF THE MA OUTPUT............................................................................................41
12.9 EXTENSION MODULES ................................................................................................................41
12.9.1 RS 232 Interface (option)................................................................................................................... 41
13 TECHNICAL SPECIFICATION ......................................................................................................42
13.1 TECHNICAL SPECIFICATION ELECTRONIC UNIT ............................................................................42
13.2 TECHNICAL SPECIFICATION PROBE .............................................................................................43
14 SERVICE AND MAINTENANCE ...................................................................................................44
14.1 SWITCHING BETWEEN 230 V AND 115 V OPERATION ...................................................................44
14.2 REPLACING THE FUSES ..............................................................................................................44
14.3 ADJUSTING THE FLOW RATE OF REFERENCE AND TEST AIR ...........................................................45
14.4 REPLACING FILTER ....................................................................................................................46
14.5 EXCHANGE OF ZRO2-MEASURING CELL .......................................................................................46
14.6 EXCHANGE OF PROBE INNER PARTS ............................................................................................49
15 TROUBLE SHOOTING ..................................................................................................................49
15.1 O2 DISPLAY 0 %, ALTHOUGH THE OPERATION MODE INDICATES A HIGHER O2 VALUE ......................50
15.2 LOCAL DISPLAYS CORRECT, OUTPUT NOT CORRECT .....................................................................51
15.3 UNSTEADY, WIDELY VARYING MEASURING VALUE .........................................................................51
15.4 DISPLAY REMAINS AT THE END OF THE MEASURING RANGE OR IS HIGHER THAN EXPECTED .............52
16 DIMENSIONAL SHEETS OF THE EVALUATION ELECTRONICS .............................................53

17 DIMENSIONAL SHEETS FOR PROBES ......................................................................................54

17.1 PROBE COMPONENTS.................................................................................................................57
18 PNEUMATIC CONNECTION AND MOUNTING OVERVIEW.......................................................58

19 INDEX.............................................................................................................................................62

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 3
Introduction

Dear customer,

Thank you for selecting our OXITEC® 5000 as your in-situ Flue Gas Oxygen measuring system.

For many years now, our OXITEC® oxygen analyser systems have been operating in numerous
applications with over 1000 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 electronics uses the very latest Microprocessor
Technology, making the SME5 electronics one of the most advanced and up-to-date monitoring units
permitting you to reduce your maintenance & fuel costs to achieve an increased measuring accuracy with
more operational reliability due to new monitoring functions.

In our oxygen measuring probes you will find the Zirconium Oxide measuring cell is soldered in place
using a special process and technique developed by our company. This leads to a considerably
increased service life as compared to "glued or cemented" measuring cells, that have a tendency to leak
or crack during operation. The OXITEC cell is a proven gas-tight design providing 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 oxygen
analyser system is very easy and user friendly. It will provide you with many years of operation with
perfect measuring results.

Please read this manual carefully and follow the instructions as directed. If you have any questions or are
unclear about any aspect of the installation or operation, our Service Department, regional sales office or
approved distributor 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 http://www.enotec.de or http://www.enotec.com or
contact us by e-mail: [email protected] or [email protected].

Dipl.-Ing. Fred Gumprecht,

Managing Director
ENOTEC GmbH

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 4
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® Oxygen Analyser System as detailed below due to its design and construction as well
as the type sold by us complies with the relevant basic safety and health requirements of the EC Directive. This
declaration becomes invalid if the appliance is modified without our prior consent.

Identifier: Oxitec® Oxygen Analyser System

......................................................................................
Evaluation electronics Type: OXITEC 5000 - 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 Kl.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: 30.09.99 sgd. Fred Gumprecht

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

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 5
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
purchaser, 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 deterioration. Corrosive gases and
solid particles may cause damages and make a repair 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 necessary 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.

________________________________________________________________________________________

MANUFACTURER:

ENOTEC GmbH
Höher Birken 6
D-51709 Marienheide
Germany
TEL: +44(0)2264/45780
FAX: +44(0)2266/457831
Email: [email protected] and
[email protected]

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 6
1 Intended use

The OXITEC Oxygen Analyser System is a system for measuring the oxygen
concentration in flue gases and other non-combustible gases. For reasons of safety and
the possible occurrence of accidents, unauthorized conversions and modifications of the
system are prohibited.

The system must not be used to determine the oxygen concentration of

combustible gases or in the surroundings of combustible gases. As the measuring
cell has a temperature of 840°C, there could be an explosion hazard!

2 Hazardous Area CENELEC Certified Options

OXITEC Oxygen Analyser Systems are available in an explosion-proof design for zone-1-installation. The
electronic system is certified EExd IIC T6 and the probe EExd IIC T3.
Please note the corresponding annexes.

3 Safety instructions for the operation of O2 analyser system/probes

3.1 General safety instructions

The OXITEC Oxygen Analyser System may only be operated by authorized, trained skilled persons. For
reasons of immunity to interfering it must be ensured that the connection between measuring probe and
electronic system is only made with the special ENOTEC probe cable and pneumatic tubing.

The O2 measuring probes supplied by us may only be used with ENOTEC electronics or with compatible
electronics approved by ENOTEC. All probes operated at 840°C.
Exception: The explosion-proof probes are approved only for the operating temperature as per Ex-
certification. All OXITEC SME 5 electronics are factory set to 840°C operating temperature (with the
exception of explosion-proof electronics).

Note!
Under no circumstance may the measuring probe be directly connected to the 230
V mains power, as this will immediately destroy the probe heater element!

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 7
4 Safety hazards
During operation, the temperature of the probe filter head and of all parts
exposed to flue gas is 150°-840°C. Direct contact with the hot parts for
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.

5 Information on the CE-certification

After having completed and successfully passed EMC-tests, the complete ENOTEC analyser system -
consisting of oxygen measuring probe, electronics and special probe cable - has a conformity certificate.
If parts of this system 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 configuration not authorized by
ENOTEC!

The enclosed ferrite sleeves must be put over the terminal leads of
the cable.
(see Figure 11)
CE-conformity is void if these ferrite sleeves are not fitted!
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 equipotential
bonding is installed correctly.
Please note that some electrical devices (eg. frequency converter etc.) close to the
system can create considerable electrical disturbance and instability. So
for normal function of the OXITEC 5000 System it is important that these devices
be installed away from the system and in accordance with the manufacturers
installation notes and guidelines.

Please do not lay the probe cable near power supply cables, or near motors and
their cables, as they are controlled by frequency converters because this could
cause interference effects. If possible don’t cross the cables because this could
cause interference effects. However, if this is unavoidable please make sure that
this cables are only crossed at right angles.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 8
6 GENERAL SYSTEM DESCRIPTION

6.1 Measuring principle

The OXITEC 5000 measures the net concentration of oxygen in the flue gas of combustion processes
and other non-combustible gases.

The EMF (electrical motive force) produced by a temperature-stabilised Zirconia cell indicates the amount
of oxygen concentration.

Measurement is made direct and in-situ, i.e. the measuring cell is inside the flue gas duct at the end of a
probe in the middle third of the gas stream.

The water content existing in any flue gas and which has an influence on the actual O2 concentration, 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.

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 soldered 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 temperature the mV-output of the cell is calculated as
follows:

EMF = RT Logn P1 + C(mv)

4F 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)
R = Gas constant
F = Faraday’s constant
T = Absolute temperature = (273 + t °C)
C(mv) = Cell constant - mill volt

The reference gas (Instrument Air) is clean, dry and oil-free air (20.95% by volume O2).
When different oxygen concentrations occur between measuring and reference side 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
process gas. With reducing oxygen content in the process gas the mV signal of the measuring cell
increases. Air on the process gas side, the ZrO2-cell generates approx. 0 mV ± 5 mV (cell constant) and
with 2.1% O2 approx. + 50 mV (rise of the characteristic line or decade voltage).

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 9
7 Design of the OXITEC 5000 Oxygen Analyser System

Every OXITEC 5000 Oxygen Analyser System consists of the measuring probe, which detects the
oxygen partial pressure direct in the flue gas duct, the electrical connection cable, the pneumatic
connection cable and the electronics. In the following paragraphs, the individual components will be
explained in detail.

Electronic unit SME 5

control cable FEP-0003 for solenoid valve

ENOTEC

OXITEC oxygen measuring probe

(only with option solenoid valve)

OXITEC 5000

OXITEC
Sauerstoffanalysensysteme

ENOTEC GmbH
51709 Marienheide / Germany

Modell

Zell-Nr.

Ser.- Nr.

test gas pneumaticcable FEP-0002 flue gas duct

instrument air (*) length 150m max.
Power supply
mA output insulation
probe special cable FEP-0001
signals
(*) only pneumatic unit with instrument air

Figure 1

electronic unit SME 5 OXITEC oxygen measuring probe with cooling protection tube
control cable FEP-0003 for solenoid valve (option)

ENOTEC

gas outlet

OXITEC
Sauerstoffanalysensysteme
ENOTEC GmbH
OXITEC 5000 51709 Mari enheide / Germany

Mod ell

gas entry
Zell- Nr.

Ser.- Nr.

succing/blow back
connection
cloosed gastight

insulation
flue gas duct

instrument
air in* pneumatic cable FEP-0002 length 150 m max.

testgas in probe special cable FEP-0001 length 150 m max.

power supply
mA output
instrument air in* : only pneumatic unit with inst.air
signals output
instrument air in: dry and oilfree ; max. 10 bar
testgas in : max. 3 bar

Figure 2

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 10
8 DESCRIPTION OF THE SYSTEM COMPONENTS

8.1 Design and function of the measuring probe

The probe assembly consists of the connecting box (ASK-...), the inner probe assembly part (SIK-...) with
heater, thermocouple and signal wire, the measuring probe tube (MSR-...) with test gas line, the ZrO2
measuring cell, the filter head and the protection tube (optional for model KES/KIS200x). Refer to drawing
on page 57.

The connecting box contains the electrical connectors for the measuring cell (terminals {-1/+2}), the
thermocouple (terminals {+3/-4}), the heater (terminals 6-8) and additionally the pneumatic connector for
the reference air.

The probe tube with flange is itself the negative pole and serves as protection 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 measuring cell itself consists of several 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 as required.

Optional protection tube for KES/KIS 200X - 500X only!!

Figure 3
The test gas flows through to the filter and fills the flue gas side of the measuring cell. On the other 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-value in the test gas = low voltage (e.g.
21% ≈ 0 mV); low O2-value in the test gas = high voltage (e.g. 2.1% ≈ 50 mV)). By means of the
electronics, 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 a direct relationship with the measured Oxygen value and available
as an electrically isolated output signal from the terminals (see terminal drawing, page 16 ).

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 11
The temperature of 840°C required for the measuring cell is generated by a heater element installed
inside the probe. To keep the temperature constant, it is measured by a Ni-Cr-Ni thermocouple and the
heater voltage controlled. The SME 5 electronics is equipped with a built-in temperature reference point
to compensate ambient temperature variations (Cold Junction Compensation).

8.2 Special probe cable and pneumatic cable

Between probe and electronics, only the ENOTEC O2 special 7-core cable may be used,
which contains the conductors for the heater power, measuring signal, thermocouple,
ground/earth and compensation wire. This cable must not be longer than 150 m. Other
cable lengths must be technically approved with ENOTEC in advance.
The ENOTEC special cable must be treated as a measuring signal line.

ENOTEC offers a pneumatic cable with 2 tubes for the reference air supply to the probe (30 l/h
continuously) and the test gas supply (150 l/h - 200 l/h).

Both cables have a PUR insulation and can be used with ambient temperatures up to 90°C.

Please do not lay the probe cable near power supply cables, or
near motors and their cables, as they are controlled by frequency
converters because this could cause interference effects. If possible
don’t cross the cables because this could cause interference
effects. However, if this is unavoidable please make sure that this cables are only
crossed at right angles.

8.3 Design of the electronics

As a standard, the electronics are supplied in a housing for wall mounting, with pneumatic system.
Two different pneumatic systems are available:
• an instrument-air version requiring the supply of clean, dry, oil-free instrument air at the point of
installation.
• a pump version using the surrounding ambient air.

To recognize the type of pneumatic version look at the valve for adjust Testair. (see Figure on page 45)

To ensure the full functional range of the electronics, one of the above pneumatic
units is required.

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

Optionally, the electronic unit SME 5 is also available in a 19” sub-rack, in a weather-resistant glass fibre
reinforced plastic housing or in an EExd housing for hazardous areas.
With the EExd housing, the pneumatic unit is mounted in a separate sheet steel field housing that does
not require certification since it only contains the pneumatic components.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 12
9 INSTALLATION OF THE O2 ANALYSER SYSTEM
Only qualified and authorized staff may work with this appliance. This staff must
be familiar with all warnings, safety instructions and maintenance work in
accordance with these operating instructions. The faultless and safe operation of
this equipment requires proper transportation, professional storage, setup and
installation as well as careful operation and maintenance.

9.1 Checking the location for O2 probe installation

Flue gas temperature, pressure and all other process conditions must be in accordance with the
specification. Leave enough space for insertion/removal of the O2 probe and protection tube (if supplied)
and ensure access to the measuring 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 out nearby, or any obstacles 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 bending.

9.2 Installing the O2 probe

The dimensions for the hole in the flue gas duct and the mounting of the adapter plate (mating flange) are
shown in the dimensional sheet, pages 57. The mating flange is fitted by the customer and when
mounting, ensure an air tight seal.

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.
Electrical heaters are available from ENOTEC as accessories. The bolts of the probe flange must remain
accessible.
The special cables for pneumatic and electronic systems must be left long enough (coiled up) so that the
probe can be drawn out of the protection tube without disconnecting it.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 13
 mounting O2-probes with adpater plate ADP-2000
gas kets
weld the adapterplate bolts
duct wall so that the probe M16 x 45
O2-probe get the declare
KES/KIS-200X flue gas duct incline.

ca. 1-2ø

min. opening
in the duct wall: í 80 mm
max. opening:
the protection tube í 150 mm
must be insulated in the adapterplate í76,1
this ara to avoid has to be welded
condensation. gastight to the outside diameter protection tube
flu gas duct.
mounting O2-probes with adapter plate ASR-1320
duct wall bolts
gas ket M8 x 29
flue gas duct

ca. 1-2ø
O2-probe
KES-132X min. opening in the
weld the adapterplateduct wall: í 72 mm
so that the probe í76,1
max. opening: í 76,1 mm
the adapterplate the adapterplate get the declare
must be insulated in has to be welded incline.
this ara to avoid gastight to the
condensation. flu gas duct.
Figure 4

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 equipotential
bonding is installed correctly.
Please note that some electrical devices (eg. frequency converter etc.) close to the
system can create considerable electrical disturbance and instability. So
for normal function of the OXITEC 5000 System it is important that these devices
be installed away from the system and in accordance with the manufacturers
installation notes and guidelines.

Please do not lay the probe cable near power supply cables, or near motors and
their cables, as they are controlled by frequency converters because this could
cause interference effects. If possible don’t cross the cables because this could
cause interference effects. However, if this is unavoidable please make sure that
this cables are only crossed at right angles.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 14
9.3 Adjusting the filter head

Before installing the probe, the direction of flue gas flow must be determined and
the filter head assembly turned so that the flue gas flow hits the V - deflector. The
filter head can be freely turned a full 360° for this purpose, by loosening the holding
screws and lock nuts on the filter head, rotating the filter head/V-shield to the
required position, and then tightening both holding screws and lock nuts.

test gas line

2 securing screws for

the filter head

filterhead

filter

V-shield
flow direction
of flue gas
Figure 5

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 15
9.4 Electrical and pneumatic connections

The special ENOTEC probe cable (FEP-0001) and the pneumatic tubing (FEP-0002) must be connected
in accordance with Figure 1 and Figure 6. Both cables have a PUR sheathing and are designed for a
maximum permissible ambient temperature of +90°C.

The special probe cables must be treated as measuring lines.

Don't connect the shield of the probe cable.

test gas valve (option) test gas line measuring cell filter head
test gas supply
filter

OXITEC
Sauerstoffanalysensysteme
ENOTEC GmbH
51709 Marienheide / Germany
Modell

Zell-Nr.
V-shield
Ser.- Nr.

connection box Attention:

reference air supply
plastic pneumatic tube should only be
screwed with support sleeves

nut clamp ring support sleeve

Figure 6
probe connection box
measuring cellsolenoid valve
wh-br/br gr-bl/gr
thermocouple 2 * 0.75 ý 2 * 0.75 ý
2 * 0.75 ý probe heating
SoNiCr/SoNiCr
wh/gr bla/blu/gr-ye
3 * 1.5 ý

Attention !
Do not connect shieldings at
the probe side and ensure,that
these do not have a conductive
1 2 3 4 6 7 8
connection with the cabinet or
wh/br brown greenwhite black blue gr.ye. the PG - screwing.
- mV+ +mV- L N
115 V ~
cell thermocouple probe heating

PUR-covering

í 11,7 mm

to electronic unit

Figure 7

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 16
9.5 Installing the SME5 electronics unit

When installing the electronic unit, please ensure sufficient air circulation around the
electronics housing.

The permissible ambient temperature range for the standard steel box field housing with
instrument air is –20°C to +55°C, and for the unit with built-in reference air and calibration gas pumps,
-20° to +50°. For the 19” rack mounting version, the permissible ambient temperature is 0°C to +60°C.

The location of the electronics unit must be chosen so that it is easily accessible ensuring that the door
can be fully opened after installation.
The place should be largely weather-protected so as to enable inspection even under the worst weather
conditions.
Before putting the system into operation, it is essential that all electrical connections, supply voltage and
pneumatic connections are checked, and, if applicable, the instrument air pressure and quality.

Special care must be taken not to mix up the connections for test gas and reference air.

Do not connect the cable shield at either the probe or electronics.

The enclosed ferrite sleeves must be put over the leads of the stripped cable.
(see Figure 11)
CE-conformity is invalid if these ferrite sleeves are not fitted!

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 equipotential
bonding is installed correctly.
Please note that some electrical devices (eg. frequency converter etc.) close to the
system can create considerable electrical disturbance and instability. So
for normal function of the OXITEC 5000 System it is important that these devices
be installed away from the system and in accordance with the manufacturers
installation notes and guidelines.

Please do not lay the probe cable near power supply cables, or near motors and
their cables, as they are controlled by frequency converters because this could
cause interference effects. If possible don’t cross the cables because this could
cause interference effects. However, if this is unavoidable please make sure that
this cables are only crossed at right angles.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 17
 back view electronic unit with pneumatic unit (19" rack)
testgas testgas
output input X1 X2 X3

PE
0 1

reference air reference air

input output
instrument air test air
input input (only design with pumps)
bottom view electronic unit with pneumatic unit (field housing) bottom view pneumatic unit (field housing)

cable glands
PG11 PG13,5 blind covers

pneumatic connectors pneumatic connectors

1/4" connection 1/4" connection

pneumatic unit testgas testgas reference air reference air test air pneumatic unit testgas testgas instrument air reference air
reference air pumpinput output input output input instrument air input output input output
pneumatic unit testgas testgas instrument air reference air
instrument air input output input output

Attention:
plastic pneumatic tube should only be
screwed with support sleeves
nut support sleeve clamp ring

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 18
10 Description of the SME 5 microprocessor electronics

10.1 Design of the electronics

As a standard, the electronics are supplied in a housing for wall mounting, with pneumatic system.
Two different pneumatic systems are available:
• an instrument-air version requiring the supply of clean, dry, oil-free instrument air at the point of
installation.
• a pump version using the surrounding ambient air.

To ensure the full functional range of the electronics, both versions require a test
gas unit with pressure reducer and flow limiter.

Flow measurement of the test and reference gases is performed electronically in the SME5 unit, and no manual
control or adjustment is required.
The electronics unit has an LED graphic display with back lighting.
To operate the electronics, there are softkeys and a numeric keypad.
The entire menu structure of the electronics is laid out for a simple user-friendly interface.

The bottom of the housing has screw connectors for the cables and pneumatic lines.
Optionally, the SME 5 electronics are also available in a 19” rack or in an EExd housing.

10.2 Functional description of the microprocessor electronics

The SME 5 electronics unit is designed for connection to an oxygen measuring probe. The mV signal of
the measuring cell is amplified and then converted into a digital signal in the electronics (14 Bit
converter). The µ-processor linearises and corrects the signal according to Nernst’s equation of the
measuring cell. The O2 value is then displayed as a percent value and the output has an isolated output,
either 0 - 20 mA or 4 - 20 mA - keypad selectable.

As a standard, the electronics has two measuring ranges. These measuring ranges can be freely defined
in their initial and/or final value (within permissible system-related limits).
The second measuring range can be switched on from outside (digital input see side 20 )
To the outside the second measuring range is signalled by a relay contact.
The electronics is completely self-controlled. Occurring system errors are displayed as clear text with on-
line help function information.

The ENOTEC user interface permits intuitive operation by means of a self-explanatory menu structure.
The system is multi-lingual, presently the languages German and English are available. Spanish, Italian
and French are presently in preparation.

Until the O2 measuring probe has reached its set temperature, the System Error contact is open and the
display shows that the probe is heating up. The progress of the heating phase is shown by a bar
indicating the current probe temperature.
During the heating phase, all system parameters, as well as actual values in the corresponding menus,
can be selected on demand from the key pad.

When the probe has reached its operating temperature and is stable within ± 0.5°C, actual
measurements are read, the System Error contact closes and the standard actual value display appears
on the screen.

The system is now ready for oxygen measurement.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 19
 10.3 Terminal Connections for the SME 5 Electronics

17 18 19 20 21 22 23 24 25 26 27 28 29 30

Input Output Output Cell T/C G

115/230V heater Input Input
Supply N
115/230V * probe
D
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

white/brown
brown

green
gn/ye

white
black

blue

L N P L N P L N P + - + -
E E E
Current output 0 (4) …

Calibration permission

terminal function is different

terminal function is different

terminal function is different

Measurement range make

Limit 1 break contact

Limit 2 break contact

Measurement range

According to options the

According to options the

According to options the

System error break

Supply probe valve

Maintenance make

* Attention. the output

voltage of this terminal is
always the actual power

Input 12-24V

Input 12-24V
Probe valve
supply.
contact

contact
20mA

contact

Figure 8 Terminal
Connection 17 18 19 20 21 22 23 24 25 26 27 28 29 30
AB AB AB AB AB AB AB AB AB AB AB AB AB AB

B - N - - - - -
A + L + + + + +
10.3.1 Terminal connection at installed options
Where options are selected, terminals 28 to 30 have different functions depending on the option chosen.

10.3.1.1 Terminal connections for the limit curves option.

Terminal Terminal function
names
28 A + Analog Input, Burner Load 4 to 20 mA (0..100%)
28 B - Analog 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)

10.3.1.2 Terminal connections for the process pressure correction option.

Terminal Terminal function
names
28 A Not Used
28 B Not Used
29 A + Analog Input, process pressure, 4 to 20 mA
29 B - Analog Input, process pressure, 4 to 20 mA
30 A Not Used
30 B Not Used

WARNING: The external current for the inputs (28 to 30) must be electrically Isolated
from Ground. Otherwise a malfunction or damage to the electronics is possible.
Do not exceed the max. current of 20mA.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 20
 X1 X2 X3

PE
0 1

X1 X2 status signals
1 - probe solenoid valve L 1 - maintenance
2 - probe solenoid valve N 2 -
3 - PE 3 - system fault
4 - probe heater L (black) 4 -
5 - probe heater N (blue) 5 - measure range
6 - PE 6 -
7 - cell + (brown) 7 - limit 1
8 - cell - (white) 8 -
9 - thermocouple + (green) 9 - limit 2
10 - thermocouple - (white) 10 -
11 - 11 - Dig.Input calibration release12-24V +
12 - output 0/4 - 20 mA + 12 - Dig.Input calibration release 12-24V -
13 - output 0/4 - 20 mA - 13 - Dig.Input measure range switch 12-24V+
14 - 14 - Dig.Input measure range switch 12-24V-

Figure 9 Terminal connections 19" housing

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 21
10.4 connection diagram
Terminal OXITEC 5000 - Elektronic
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

The supply of solenoid valve is connected

internal to115V. To use not ENOTEC
specific solenoid vave a modification
L N PE is necassary, contact to ENOTEC is
yellow/green

white/brown
required.
Power Supply
brown

green
white
230V~ bzw.115V~
black
blue

10A

PE
N
L
+
-
Current output 0(4)..20mA

Probe Connection Box

1 2 3 4 5 6 7 8

Probe Special Kabel - + + - L N

Solenoid valve
mV mV 115V~
cell thermocouple heater
yellow/green
white/brown

brown

green

black
white

blue

Figure 10

10.5 Attention! Important change of colour code electric cable FEP-0001

The colour code of the wires for the thermocouple has changed from the old
German standard : (+) red and (–) green to the European standard DIN / IEC 584:

(+) green
(-) white

The result is that there are two white wires in our special cable FEP-0001.
Don’t mix up the two white wires. For differentiation on of the white wire is marked with a brown line, this
wire belong to the brown wire.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 22
Table 1 International colour codes for NiCrNi thermocouple wires

polarity of thermocouple DIN IEC 584 DIN 43710 (old german) ANSI MC 96.1(US)
+ green red yellow
- white green red

10.6 Fitting the ferrite sleeves (EMC)

In the electronics (see Figure 11) the enclosed

ferrite sleeves must be put over all stripped
cables

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

Figure 11

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 23
11 FUNCTION OF THE SME5 MICROPROCESSOR ELECTRONICS

11.1 Operation of the unit

The electronics are operated by means of four soft-keys and a ten-key keypad. The functions of the
softkeys always adapt to the current menu window. The ten-key keypad serves only for entering
numerical values.
The ENOTEC user interface is designed for intuitive usage of the electronic unit. This means that as a
rule there is no need for the instruction manual during operation.

Figure 12

11.2 General operating instructions

Figure 13

Various options can be selected from a list (as in Figure 13) with the softkeys [Up] and [Down]. If there
more than 4 options, this is indicated by an arrow on the right hand side of the menu list. This arrow
indicates that there are more options to follow. To select one of the options, it is highlighted and the
selection confirmed with the softkey [Enter].

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 24
11.3 The heating phase

Figure 14 display heating phase

After switching on the electronics, the OXITEC logo will appear on the display for a short time. During this
time, all parameters relevant for a 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. (see 11.8)
If the check shows no problems, the heater window appears. In this heating window the progress of the
heating phase is indicated by a bar (0°C to 900°C).
When the probe temperature is stable within ±0.5°C (after approx. 20 to 60 minutes, depending on the
process conditions), O2 measurement is released and the main windows appears on the display.
During the heating phase, all system parameters as well as actual values can be called up in the
corresponding menu windows.

System adjustments may only be made be specially trained staff..

11.4 Main window

Figure 15
In the main window (Figure 15) the currently measured oxygen value is displayed. A bar graph shows the
measuring range of the output signal. At a moisture of > 0% "oxygen dry" is displayed to indicate that the
O2 Value is an corrected Value.

This main window branches into four menus:

• Status resp. MR1/2 : With this key in faultless operation the measure range can be selected.
Otherwise display possible errors or alarms.
• System : System menu, where system settings, calibrations, system tests etc. can be
made
• Actual values : Display of all actual values of the system
• Parameters : In this menu, parameters are shown and can be altered.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 25
11.5 Actual value menu

Figure 16

In the actual value menu the following current actual values of the electronics unit can be called up:
• cell voltage [mV]
• cell temperature [°C]
• current output [mA]
• oxygen dry [%]
• oxygen wet [%]
• lambda
• reference point temperature [°C]
• reference gas flow [l/h]
• proces pressure [bar] (only at option process pressure correction)
• proces pressure [psi] (only at option process pressure correction)
• burner load [%] (only at option limit curves)
• actual limit1[%] (only at option limit curves)
• actual limit2 [%] (only at option limit curves)
• fuel (only at option limit curves)

If instead of a value only underscores are shown, this means that presently no valid value for this
parameter can be shown.

11.5.1 Lambda
The value of lambda (air ratio) is be calculated by an approximate equation and is only valid by
combustible free of own CO2 or N2 content.

21
λ≈
21 − O2
Approximate equation

11.5.2 proces pressure (option)

Here the actual proces pressure can be shown. (correspond to pressure input)

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 26
11.6 Parameter menu

Figure 17

In the parameter menu the system parameters can be displayed and altered.

After having selected a parameter for the first time with the softkey [Enter] a window appears requesting
the entry of a code. After having entered the valid service code, there appears a window where the
corresponding value can be altered.

Following parameter can be altered in the parameter menu

Parameter unit Input-limits comment

constant mV -50mV to 10mV
slope mV/dec +35mV to +55mV
test gas 1 % 0% to 99%
At a system with integrated
pneumatic unit only one test gas can
test gas 2 % 0% to 99%
be altered, because for the second
test gas is used ambient air.
measure range 1 from 0% to setting of end of
%
(start of measure range) measure range
measure range 1 till setting of start of measure
%
(end of measure range) range to 99%
measure range 2 from 0% to setting of end of
%
(start of measure range) measure range
measure range 2 till setting of start of measure
%
(end of measure range) range to 99%
limit 1 % 0% to 99% not at option limit curves
limit 2 % 0% to 99% not at option limit curves
H2O correction % 0% to 50%
table 2

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 27
11.6.1 Altering parameters

By means of the parameter “Limit value 1” the entry of parameters will be explained.

Figure 18

In the window Parameter Entry, the parameter to be altered is displayed in clear text with the current
value. If special functions are assigned to this parameter (as in this example), these are displayed, too.
Further, the permissible entry limits of this parameter are indicated.
With the ten-key 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.

Note: If a value cannot be entered, it should be checked whether this value is

outside the permitted limits, because in such a case the entry of the value is not
permitted, but the corresponding limit value is selected.

The altered value is confirmed with the softkey [Enter].

When pressing the [Back] key, the altered value is cancelled and the old value
maintained.

11.6.2 Measuring ranges

The measuring ranges of the electronics can be keypad entered. In the menu item “Measuring range
from” the initial value of the measuring range can be entered.

It should be noted that the initial value of the measuring range cannot be greater
than the final value. Also, the final value cannot be smaller than the initial value.
Therefore the electronics will not accept any such values.
Also, the second measuring range must always be smaller than the first one.
Therefore, the electronics will not accept such settings, either.

The final value of the measuring range can be entered in the menu item “Measuring range up to”.

11.6.3 H2O correction

About the constructive design of the oxitec oxygen measurement the wet oxygen value is measured. In
the menu item "H2O correction" the H2O value of the emission can be entered. Then the electronic
calculated the dry oxygen value.

If an moisture value greater than 0% entered, the electronic indicated in the main
window that this is an corrected value.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 28
 11.6.4 limits, limit curves (option)
The standard electronic unit is fitted with two adjustable limits.
The limits can be configured as min- or max-alarm. An exceed of a limit will be signalised by relay
(brake contact). This means that the contact is closed in "normal" use, if a limit exceed the contact
opened.
As an option, the electronic unit is available with limit adjustable curves for a maximum of different 4
fuels.

11.6.4.1 fuel select

In the menu "select fuel" there is a submenu for the 4 fuels. In this submenu, the four O2 points and the
Min. or Max function and be adjusted as required.

11.6.4.2 limit curves

In the menu "limit curves for fuel X" the five O2 points for the corresponding fuel can be changed.
The Min. or Max. function can also be selected. The electronics calculates the theoretical point for 0%
burner load from the points of 20% and 40%.
At the analogue input "burner load" the burner load signal should be connected. This signal must be 0 to
100% at 4 to 20 mA.

At digital input 1 and 2 the fuel should be selected. This selection has following coding:

Digital- Digital-
Input 2 Input 1
fuel 1 0 0
fuel 2 0 1
fuel 3 1 0
fuel 4 1 1

This corresponds to logical 0 -> 0..4mA and logical 1 -> 5..20mA

WARNING: The external current for the inputs must be electrically Isolated from
Ground. Otherwise a malfunction or damage to the electronics is possible.
Do not exceed the max. 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

picture 19 limut curves (default values)

The space between the O2 points is calculated by the electronics. The accuracy of
this calculation is ± 0,1Vol%.

The actual burner load and the corresponding limits could be shown in the actual value menu.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 29
11.6.5 max range pressure (option)
In most applications the process pressure will be negative relative to ambient conditions. However, If the
process pressure is positive and has a greater than 50mbar differential to ambient, then a process partial
pressure correction will be necessary.
The electronics has an analogue input for the actual process pressure using a standard 4-20mA input
signal. The maximum range of this input signal, corresponding to 20mA, can be adjusted here. Note the
relative pressure differential. The starting value for the 4-20 mA input is always Zero (0) bar standard
gauge pressure.

WARNING: The external current for this input must be electrically Isolated from
ground. Otherwise a malfunction or damage to the electronics is possible.
Do not exceed the max. current of 20mA.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 30
11.7 System menu

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

The system code is factory-set to 0000

Figure 20

After having entered the system code, the system selection menu appears. Figure 21

Figure 21
In this menu, the following functions can be called up:
• Single point calibration
• Two point calibration
• Automatic calibration
• Measuring value memory
• System test with test gas
• Setting current output
• Measuring range shift
• Change code
• Damping mA output
• Call up max./min. values
• Change language
• Service
• Software version

A description of the individual functions is given below.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 31
11.7.1 Single point calibration

Figure 22

In this menu item, a single point calibration with air can be made. After selecting this menu item you are
requested to begin the calibration with the softkey [Start]. The single point calibration is fully automatic, no
manual intervention is required.* The progress of calibration is indicated by a moving time bar.
The amount of test air is monitored by the electronics, if it is insufficient, an error message appears.(only
by integrated pneumatic unit)
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 advance acceptance of the cell voltage is not recommended,
because the electronic system then does not know if the output is stable, and therefore may not be
correct.

* If the electronics are not connected to a probe with solenoid valve, the test gas
valve must be opened prior to calibration.

11.7.2 Two point calibration

Figure 23

In this menu item, a Two point calibration with air and 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 parameter menu.
After having selected this menu item, you are requested to begin the calibration with the softkey [Start].
Like the single point calibration, the Two point calibration is fully automatic.* The progress is indicated by
a moving time bar.
If the amount of test gas seems insufficient during calibration, the message “Test gas flow insufficient”
appears. In this window then the amount of test gas can be adjusted by means of a bar graph display.
After having adjusted the test gas flow, calibration is continued with [OK]..(only by integrated pneumatic
unit)

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 32
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 acceptance of a value, the calibration progress bar is reduced to half. This is not an
error, but means that the electronics are now determining the second value, which can 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.

If the parameters determined after calibration are outside the plausibility limits, this is indicated by an
error message. In case of errors during calibration the electronics will continue to work with the old
parameters.

* If the electronics are not connected to a probe with solenoid valve, the test gas
valve must be opened prior to calibration.

11.7.3 Automatic calibration (ACAL) with air (20.95 % O2)

OXITEC 5000 offers the possibility of automatically performing a calibration at regular intervals.
All settings that are required for an automatic calibration can be made in this menu.
These are:
• Type of calibration Single Point/Two Point
In this point the type of calibration can be selected. (Only in Systems with integrated Pneumatic)
• 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 an value of 0 days the calibration starts immediately
upon release, this is important for an calibration from the outside.
• Release internal/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 12.5
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
The remaining time until the next calibration is indicated under this item.

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 version) or a pneumatic unit with pumps must be installed (for details see Annex
.... Gas plans).

WARNING: If the Calibration Time Interval in the parameter menu is set to zero Secs,
for example to make a remote calibration, it is very important that the Release Signal
has a minimum time setting of 15 seconds and a maximum time of 60 sec. A short
Release Signal (<15 Secs) the calibration will not start, and with too long Release
Signal (>60 Secs) it could be that the calibration function restarts for a second
time, or more.

NOTE: There is no "real time" clock in the electronics. It does not know time of day, month or
year. Only a clock counter in electronically used for automatic calibration purposes.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 33
11.7.4 Measuring value memory

Under this menu item a measuring value memory can be switched on during calibration.
With the measuring value memory on, the last measured value prior to calibration is saved so that at the
current output the measuring value which changes because of the calibration, has no effect. The
currently measured value is released again after an adjustable delay, when the calibration is completed.

11.7.5 System test with test gas

Figure 24

To perform a system test, in this menu the test gas on the probe can be entered.*
This function therefore permits a system test.
Furthermore, this menu permits to adjust the correct amount of test gas required for Two point calibration.

* If the electronics are not connected to a probe with solenoid valve, the test gas
valve must be opened prior to calibration.

11.7.6 System test with test air (Only in Systems with integrated pneumatic)

To perform a system test with test air, in this menu the test air on the probe can be entered.*
This function therefore permits a system test.
Furthermore, this menu permits to adjust the correct amount of test air required for calibration.

* If the electronics are not connected to a probe with solenoid valve, the test gas
valve must be opened prior to calibration.

11.7.7 Setting current output

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

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 34
11.7.8 Measuring Range Shift

The electronics 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 voltage input signal. This microprocessor
parameter location is used to determine which mode of range switching is required - Manual or Remote.

The factory preset default in the electronics is "Remote" range switching. This means that in the case of
an open digital input, the measuring 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. In case of errors or alarms, the soft key
MR1/2 in the main menu is occupied by status information. The status function has the highest
priority, Therefore this means in case of errors the measuring range can not be changed by hand.

In case of errors or alarms, the soft key MR1/2 in the main menu is occupied by
status information. The status function has the highest priority, Therefore this
means in case of errors the measuring range can not be changed by hand.

11.7.9 Alter code

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

11.7.10 Damping 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. are possible.
Damping is useful if the electronics 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.

11.7.11 Call up max./min. values

The electronics continuously save the smallest and greatest measured values. These values can be
called up here. After quitting this item, the current min. and/or max. values can be deleted in order to
restart recording minima and maxima from this point.

11.7.12 Change language

Menu item to select the language.

11.7.13 Service

This menu item is reserved for Enotec service personnel only, it is factory-coded.

11.7.14 Software

To obtain information about the software status and level.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 35
11.8 Status messages

Figure 25

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

If the electronics is put into operation without a probe connected, some system errors
will occur. E.g.. heating system don’t work, error cell signal out of range, error wire
breakage thermoelement. When the electronics is then connected to a probe, these
errors will be shown again, because the microprocessor stores the errors as they occur
in a permanent memory (EEPROM). After acknowledgement of each of these errors,
the system operates normally."

Following status messages are possible:

1. constant out of tolerance

As the result of a calibration check, the calculated cell constant is outside of the tolerance
range parameters on the microprocessor settings. Therefore the electronics continues with
the previous/former cell constant values. The microprocessor tolerance range is factory set
to: -50mV to +10mV.
2. slope out of tolerance
As the result of a calibration check, the calculated Mv/Decade slope is outside of the
tolerance range. The electronics therefore continues with the previous/former slope values.
The microprocessor range is factory set to: 35mV to 55mV per decade.
3. ref.gas flow to low (only at installed pneumatic unit)
The reference gas flow is too low (min. 5 litre-per-hour) Please test the pressure of the
instrument air supply (min. 1Bar) and if necessary, try to adjust the reference air (see page
40). With the pump version test the pneumatic tubes for kinks for 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 to low ((only at installed pneumatic unit)
The calibration gas flow during the calibration test was too low (min 150 litre-per-hour),
please see point 3 above.
5. heating system dont work
The probe could not heat to the nominal temperature (840°C). Test the heater fuses (see
page 40), then measure the resistance of the probe-heater to ensure that it is between 37.5
and 40.0 Ohms. WARNING: Make sure the power is off when doing this test
6. wire breakage thermoelement
The electronic unit has detected an error with the thermocouple. Possible reasons: reverse
connection of thermocouple - check wire connections, wire breakage, faulty thermocouple.
7. error cell signal out of range
The cell voltage detected by the electronic is out of the input range (-45mV to +265mV)
Possible reasons: wire breakage, extra large amount of combustibles products in the
measured flue gas (CO, etc.) or the mechanical breakage cell.
8. temp. of electronic out of spec

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 36
 The temperature of the electronic is outside the allowed operating limits (-20°C to +70°C
within its housing)
9. probe temperature to high
The indicated temperature of the probe is over 890°C. Please test the temperature of the
flue gas (maximum 890°C, without cooling tube) Please contact ENOTEC.
10. probe temperature to low
The temperature of the probe was or is too low (<820°C) Please look at the heater fuse and
measure the actual power supply voltage to the electronics unit(230V/115V ±10%).
11. alarm limit1
Oxygen limit 1 out of range.
12. alarm limit2
Oxygen limit 2 out of range.
13. data fault EEProm
A data error has occurred in the microprocessor and the electronics continues with factory
default values. Please contact ENOTEC.
14. measuring value memory active
The measuring value memory is still active.
15. error by trying ACAL
Automatic Calibration has failed. Possible reasons: mV output value/signal from probe not
stable, cell constant or Mv/Dec slope outside of microprocessor tolerance/range. (Note: the
corresponding error is shown on the electronics display), no Calibration air (instrument air
version only) System descriptions / Settings

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 37
12 System description / Adjustments

12.1 In case of loss the system code

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

12.2 Bridge on back of display unit

On the back side of the display unit an bridge exist. This bridge is use for the first
run in factory. Don’t move or remove this bridge, otherwise an fault function of the
electronic is possible. Therefore contact to ENOTEC is required.

Postion bridge
for working

Figure 26

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 38
12.3 Adjustment display contrast

The contrast of the display can be adjusted if necessary. This could be necessary at higher ambient
temperatures. The trimming potentiometer is shown on Figure 27. To adjust the contrast it is necessary to
dismount the display board and power on the system. Now the contast can be adjusted by a small screw
driver (type 2.5)

Attention, working under tension is only allowed for authorized, trained skilled
persons in keep to the corresponding safety instructions. (eg VDE 0105)

trimming
potentiometer
Adjust contrast

Figure 27

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 39
12.4 Relay outputs / Functions
The relay contacts are designed for 230 V and 10A ~ , 5A =.

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 Open: Measuring range 1 active
Closed: Measuring range 2 active
Probe valve make contact Triggering 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

12.5 Digital inputs

The digital inputs are designed for a direct voltage of 12 V-30 V for logical high.
Logical "Low" agree an 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

Where option limit curves selected, there are folowing additional digital inputs

12.5.1 Digital inputs at Option limit curves

This digital inputs are designed for a current of 0..4mA for logical low, and 5..20mA for logical high.

Terminal Terminal function

names
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)

WARNING: The external current for the inputs (28 to 30) must be electrically
Isolated from Ground. Otherwise a malfunction or damage to the electronics is
possible.
Do not exceed the max. current of 20mA.

12.6 Amounts of test air and/or reference air

As a rule, the systems are factory-set to the correct amounts of test air and/or reference air.

The instrument air versions are designed for an admission pressure of 1-10 bar, with a higher admission
pressure as 6bar it is necessary to readjust the amount of reference air and/or test air.(see Chapter 14.3)
The amount of air should be in the following range:
Test air: 150l/h - 180l/h
Reference air: 30l/h - 40l/h

The amount of reference air can be checked in the Actual value menu.
To adjust the amount of calibration air, the test air line must be disconnected from the electronics housing
and a flow meter can be connected to the test air output.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 40
12.7 Stability criteria for calibration

During calibration, the cell voltage is checked for stability. This check works according to the following
criteria.
Always the last measured value is 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 lapsed (2 min.) is used to
calculate the constant or slope.

12.8 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 175 ms.

12.9 Extension modules

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

12.9.1 RS 232 Interface (option)

12.9.1.1 transfer protocol

The transfer protocol contains a timer index, this timer is increased every second after power on. It is
possible to count the time of one year.
The oxygen is shown by the protocol only in a ppm range.

The transfer protocol has following format:

......[STX]tim:+0000000.0secoxi:+0000000.0ppmcell+0000003.9mVtemp+0000006.9°Cout:+000
0000.0mA[ETX][chk][CR][LF][STX]tim:+0000001.0secoxi:+0014846.3ppmcell+0000012.0mVte
mp+0000014.3°Cout:+0000021.3mA[ETX][chk][CR][LF][STX]tim:+0000001.0secoxi:+0003061.8
ppmcell+0000009.1mVtemp+0000022.1°Cout:+0000021.3mA[ETX][chk][CR][LF]......

The character "STX" is the beginning of the following ACII string, the character "ETX" is the end of the
ACII string.
One data sequence beginns always with a short description (for example : oxi) by following the value (for
example: +0003061.8) the end of the data sequence is the measure unit (for example: ppm).
For example a complete sequence "oxi+0003061.8ppm".

12.9.1.2 protocol commands

ASCII Decimal Hexadecimal Description

STX 2 02h start ascii text
ETX 3 03h end ascii text
LF 10 0Ah line feed
CR 13 0Dh carriage return

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 41
13 Technical Specification

13.1 Technical Specification Electronic Unit

Dimensions: see dimensional sheets for the different housings

Mains voltage: 230 V / 50...60Hz tolerance ±10%

115 V / 50...60Hz tolerance ±10%

Power consumption: 400 VA during start up

100 - 200 VA running
Recommended fuse: 10 A
Ambient temperature: -20° C to +55° C
other temperatures on request
Resistance to interference: to EMC regulations
& Low Voltage Regulation 73/23 EEC
EN 50081-2: July 1993
EN 50082-2: March 1995

Relay outputs, potential-free: 230V~ , 5 A resistive load

Analog input cell: Re > 9 MOhm

Ue: 45mV to +265mV
for the active measuring range

Resolution of the digitizer in the active

measuring range: 14 Bits + sign
Analog input thermocouple: Re: > 900 kOhm

Temperature compensation: on the circuit board

Signal output 0/4...20 mA: max. load 500 Ohm

potential-free

Reaction time of the mA output: With a change of 100 mV on the cell input < 175 ms

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

Measuring accurance: ±0.2% of measuring value

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 42
13.2 Technical Specification Probe

Flue gas temperature: KES-132x: up to 600°C

up to 1400°C mit Kühlschutzrohr
KES/KIS-200x: up to 800°C
up to 1400°C mit Kühlschutzrohr
KES500x: up to 760°C
up to 1400°C mit Kühlschutzrohr
KEX500x: up to 500°C
up to 1400°C mit Kühlschutzrohr

Depth of immersion: KES-1321: 385mm

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

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

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

KEX5001: 520mm
KEX5002: 950mm

Measuring principle: zirconium oxide

Flue gas pressure: -50 to +50mbar

Flow velocity: 0 to 50m/s

Ambient temperatur: -40°C to +80°C

Response time (lag time): 0,5s (flue gas flowing at > 10m/second)

T90 time: 5s (flue gas flowing at > 10m/second)

Probe material: V4A (1.4571/316SS)

Type of protection: IP65

Detection limit: less than 1ppm

Voltage supply: via electronic unit

Dimension: see types of probes

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 43
14 Service and Maintenance

14.1 Switching between 230 V and 115 V operation

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

!! Note: De-energize first !!

The switch for changing the voltage (Figure 28) can be made with a screwdriver and rotating to the
voltage required.

selection of
power supply
F3

F1 F2 F4

Figure 28

It must be noted that the standard version with instrument air of the OXITEC 5000
is designed for 50/60 Hz.
For the pump version on 60 Hz mains, a special order is necessary. The mains
frequency cannot be changed by the customer.

The Instrument Air Version is specified for 50-60Hz Power Supply.

14.2 Replacing the fuses

The electronics have two accessible fuses:

• F1 6.3 A, semi time-lag 5x20mm glass tube fuse - to protect the entire system
• F2 4 A, semi time-lag 5x20mm glass tube fuse - to protect the probe heater.
• F3 & F4 1A semi time-lag 5x20mm glass tube fuse - to protect the electronic.

The fuses on the circuit board below the cover protect the electronics and should
only be replaced by service personnel, because otherwise a damage of the
electronics cannot be excluded.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 44
14.3 Adjusting the flow rate of reference and test air

At a System with a pneumatic unit it is possible to adjust the reference and test air.
In this point the pump and instrumental air versions distinguished.
• At the pump version only the flow rate of test air can adjusted. (see Figure 29)
• At the instrumental air version both flow rate (test air and reference air) can be adjusted. (see
Figure 30)
The flow rate of reference air can be read in the actual menu (see page 26)
The flow rate of calibration air can be read in the system menu under the menu point "system test with
test air" (see page 34)

Figure 29 position of valve by pump

version

Figure 30 position of valve by instrument air version

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 45
14.4 Replacing Filter

1. Loosen V-band or both fixing screws at the filter head

and pull off the filter head from the probe.

Attention! Probe may be hot!

Clamp the filter head into a vice.

Completely remove the old filter. Also clean the

grooves in the metal fixing.

Figure 31
2. Insert new filter with cement as follows:

Mix cement thoroughly and coat both the grooves in the seat and the filter around the seat at
the outside. Press the filter into the seat by turning it. Wipe the cement between filter and seat
and remove excess material inside as well.

The cement dries at room temperature within 24 hours.

With the cements supplied by ENOTEC all types of filters of the ENOTEC-
delivery program can be inserted.

EExd IIC3 probes have a sintered metal filter that is welded to the filter head
assembly.

14.5 Exchange of ZrO2-measuring cell

Take the probe out of the protection tupe and wait until it has cooled down

Attention: 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.

If necessary, clean the probe from dirt and dust etc., after it is cooled down!
Pull out the probe inner parts (4-hole-ceramic-rod with signal -measuring wire, thermocouple element and
heater) by disconnection the wires in the connection head and by loosening the two screws which hold
the inner parts at the tube.
Pull off the thin transparent reference air pipe from the wall entrance screwing at the connection cabinet.
Carefully pull out probe internal part.

ATTENTION ! The measuring signal wire can be fixed solid with its
contact net to the inner part of the ZrO2-cell.

Pull off the orange isolation from the measuring signal wire and do not pull out the platinum wire with the
probe inner parts, if it is fixed solid to the internal cell contact side.
Loosen the 4 screws at the flange of the measuring cell and remove the measuring cell from the
measuring cell tube (with signal wire, if caked solid)

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 46
 measuring cell holder tube
measuring cell
measuring signal wire

screwdriver blade

place twist

Figure 32 measure cell holder tube in cut

Anyhow, if the measuring cell is defect, the ZrO2-ceramic plate should be carefully broken in
order to loosen the platinum wire, if it is caked solid inside.
Lead the platinum wire into the 4-hole-rod and make sure, that the round platinum net lies in the
recess of the heating sleeve.

protection cap

measuring cell holder

with flange

measuring cell flange gasket

probe tube with

flange

4 screws M5x12
figure 33 mounting measure cell holder tube

Clean the flange at the probe tube with fine sandpaper.

Tighten the new measuring cell with a new sealing and 4 new screws at the measuring cell
flange of the probe tube.

Insert the probe inner parts and ensure, that the inner parts do not clamp in the probe tube.

Press the locking bolt against the spring, so that the inner parts are pressed against the
measuring cell with enough spring load.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 47
Tighten locking bolt and connect wires as follows:

Terminal 2: platinum wire, orange + mV-measuring cell

Terminal 3: thermo-couple element, green + mV
Terminal 4: thermo-couple element, white - mV
Terminal 5: free
Terminal 6: heating phase
Terminal 7: heating MP blue
Terminal 8: heating ground green/yellow

Table 3 International colour codes for NiCrNi thermocouple wires

polarity of thermocouple DIN IEC 584 DIN 43710 (old german) ANSI MC 96.1(US)
+ green red yellow
- white green red

Now heat up probe outside the process to operating temperature and tighten the 4 screws of
the measuring cell flange-sealing.

ATTENTION!
Also at the outside the probe is hot (300°C).

Install the probe and take up a curve with test gases (see 11.7.2).

1 2 3 4 5 6 7 8 9 10 11 12

13
figure 34 construction of the measure cell holder tube

1. protection cap 8. fixing clamp

2. cell 9. spacer
3. signal wire pad 10. air connection tube
4. thermocouple 11. flange gasket
5. heater 12. measuring probe heater
6. cell holdering tube 13. screws M5
7. ceramic rod

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 48
14.6 Exchange of probe inner parts
Proceed as described in paragraph 14.5, apart from exchange of thermo-couple element.

1. Exchange of thermo-couple element:

The thermo-couple element is a covered thermo-couple element with an Inconel-

covering and a NiCrNi-thermopair.
The thermo-couple element is in one hole of the 4-hole-rod. Disconnect the thermo-
couple element at the probe head terminals, pull it out and insert a new thermo-couple
element. If the probe is very long, it may be necessary to pull out the probe inner part
completely.

2. Exchange of heating

Disassemble probe inner part, loosen clamp, pull out platinum wire and pull off heating
with support from the 4-hole rod.

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

Insert platinum wire and thermo-couple element, assemble clamps and connection
sleeves (for long probes).

ATTENTION:
The heating support has 3 drillings, which must correspond with 3
holes of the 4-hole ceramic rod. One hole is for the reference air and
the other for the platinum measuring wire, so that the platinum net
lies in the recess of the heating support.

3. Exchange of platinum measuring wire:

At the end of the measuring cell the platinum measuring wire has a platinum net for
taking the mV-value of the reference electrode of the ZrO2-measuring cell. The platinum
net is pressed against the measuring cell by means of spring load via the 4-hole rod.

If there is not enough spring load or if the wire is broken, the mV-signal can no longer be
taken.

4. Exchange of 4-hole ceramic rod

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

15 Trouble shooting

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 49
The following information is intended as a key element to assist trouble shooting. It is not a
comprehensive list of all possible system errors.

If disorders cannot be repaired, please contact us or an approved service agent directly:

Manufacturer and Factory

ENOTEC GmbH
Marienheide
Höher Birken 6
D-51709 Marienheide - Rodt
Germany

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

Fax: +49 (0) 2264 - 4578-31
e-mail: [email protected]

If the measured O2 value appears doubtful, first the ENOTEC-O2 analyser system should first be checked
with test gas, if all system parameters are o.k.. 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 and
with the following instructions it should be tried to localize or repair the disorder.

15.1 O2 display 0 %, although the operation mode indicates a higher O2 value

Steps to localize the problem:

1. Check the measuring cell temperature (set value 840°C, or optionally 750 °C).
A cell temperature below 600°C may lead to a 0% display.

Result 1: Cell temperature o.k., 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.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 50
Result 1:
If on the probe a mV value is measured that according to the characteristic line and at the right measuring
temperature yields a probable O2 value, then the error is on the way to the electronics.

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

Remedies:
a) Check wiring
b) Measure probe cable

Result 2:
On the probe a mV value is measured which is outside the usual range from -45 mV to 267 mV.

Possible causes:
a) There is no mV tap in the probe (measuring signal wire) or it is interrupted.
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 portion of
combustibles in the flue gas. In this case, there are reducing 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 part.

15.2 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 existent, problem is outside the electronics

Result 2: no mA value

Possible causes:
Electronics defective.

15.3 Unsteady, widely varying measuring value

Steps to localize the problem:

1. Check the measuring cell temperature (set value 750°C or 840°C)

2. Intermittent contact in the probe - internal mV tap.

Measures:
Measure the mV value on 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.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 51
15.4 Display remains at the end of the measuring range 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 seal. In case of a leakage in the
area of the zirconium oxide measuring cell, this must be exchanged.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 52
 16 Dimensional sheets of the evaluation electronics

300 í8,2
240

ENOTEC

400
420

OXITEC 5000

All dimensions in mm

260
Figure 35 Field housing IP65
177 (4HE)

483 360

Figure 36 19 inch housing IP20

510 310
330
150

M10

ENOT EC
450

OXITEC 5000
660

All dimansions in mm

Figure 37 GFK housing

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 53
17 Dimensional sheets for probes
test gas valve KES-1320010 filter head filter

A
OXITEC
Sauerstoffanalysensysteme
ENOTEC GmbH
51709 Marienheide / Germany
Modell

Zell-Nr.

Ser.- Nr.

V-shield
A (immersion depth)
A

View A - A
connection box * note: í 9
by mounting with the
148 adapter plate ASR-1320
the immersion depth
decrease around 100 mm

probe typ filter head *immersion depth A

KES-132100 KES-1320100 a) 385 mm 52
KES-132200 KES-1320300 a) 475 mm 99
KES-132300 KES-1320300 a) 615 mm 127

Alle Maáe in mm a) with ceramic filter

all dimensions in mm flow direction
Figure 38 Dimension sheet probe KES 132xx

Adapter plate
for KES132.1-3 Mating flange mounting kit
with stand off tube; length 100 mm(4");diameter 76,1x2 mm
Article-No.: ASR-1320 45

the adapter plate has to be welded M8

gastight to the flue gas duct

adapter plate
í76,1*2

with 4 bolts
M8 * 29
ST 37-2
DN40/PN6

99 16
130 100

Figure 39 Adapter plate for KES132xx

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 54
test gas valve (option)
A 120 B (immersion depth )
protection tube flange A
protection tube filter

í76,1
OXITEC
Sauerstoffanalysensysteme

ENOTEC GmbH
51709 Marienheide / Germany
Modell

Zell-Nr.

Ser.- Nr.

C V-shield

connection box D A
View A - A
18
dimensions in mm
type A B C D protection tube flange
4" ASA 150 LBS
KES/KIS 2001 135 495 380 615
KES/KIS 2002 150 925 800 1045

76,1

191

230
KES/KIS 2003 150 1835 1720 1955
KES/KIS 2004 150 2768 2648 2888
KES/KIS 2005 150 3682 3562 3802
KES/KIS 2006 150 4602 4482 4722
KES/KIS 2007 150 5522 5402 5642
flue gas direction all dimensions in mm

Figure 40 Dimension sheet KES 200x

Typ B (immersion depth)

KES5001 520
KES5002 950 view A - A
90.0ø
150 (5002-5003)
135 (5001) 120
KES5003 1865 d2
test gas
all dimensions in mm
A
connection
B (immersion depth)
1/4"
í 57

filterhead with sinter k

reference air metal filter
connection
b protection tube flange A D
1/4" protection tube flange
Mat.: 1.4571
dimensions of the protection tube flange in mm (inch)
article no.: 0-R-000974 0-R-000972 0-R-000973 0-R-000971 0-R-000975 0-R-000976 0-R-000977
type of flange
ANSI 4 B 150 LB DIN 2527 DIN 2527 ANSI 2" DIN 2527 ANSI 3" for 1 ; 1.5 ; 2 m
FF equivalent DN65/PN16 DN65/PN6 150lbs DN50/PN16 300 lbs ZFG2 standard probes
dimension
D 228,6 (9.00) 185 (7.28) 160 (6.27) 153 (6.00) 165 (6.47) 209,5 (8.22) 165 (6.47)
b 12,0 (0.47) 12,0 (0.47) 12,0 (0.47) 12,0 (0.47) 12,0 (0.47) 12,0 (0.47) 12,0 (0.47)
k 190,5 (7.50) 145 (5.708) 130 (5.118 ) 121 (4.75) 125 (4.902 ) 168,3 (6.6) 140 (5.49)
d2 19 (0.70) 18 (0.706) 14 (0.549) 20 (0.75) 18 (0.706) 22,2 (0.87) 12,5 (0.50)
number of holes 8 4 4 4 4 8 6
letter in A D E F
order formular
B C G

Figure 41 Dimension sheet KES 500x

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 55
 adapter plate
mating flange mounting kit
Article-No.: ADP-2000
M16 18 45

adapter plate
with 8 bolts
M16 * 45
ST 37-2
4" ASA 150 lbs

90 the adapter plate has to be welded

gastight to the flue gas duct
191
230

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 56
17.1 Probe components

1 probe flange protection tube

gasket flange gas ket 9
8

f h
3

measuring cell 7
g 4 6 d
2 flange gas ket 5

a b c e

working cycle require following additional working cycles

a install/remove probe inner parts switch system voltage free
parts list: b install/remove connection box j g switch system voltage free
1 probe inner part compl. c change measuring cell j f e a switch system voltage free
2 connection box compl.
d change ceramic filter j f e switch system voltage free
3 test gas valve
4 probe tube e install/remove filter head j f switch system voltage free
5 measuring cell compl. f install/remove probe j switch system voltage free
6 filter head
g install/remove test gas valve
7 ceramic filter
8 protection tube h instal/remove protection tube j f switch system voltage free
9 adapter plate j switch system voltage free
connect/disconnect probe electrical/pneumatically

require every time a new corresponding gas ket !!

probe inner part complete

article-no.: SIK-132X (for KES 1321-2)
SIK-2001 (for KES 1323 and KES 2001)
SIK-200X (for KES 200X)

measuring wire
Reference air tube article-no.: RLS-0001 article-no.: MSD-132X (for KES 1321-2
MSD-2001 (for KES 1323 a. 2001)
measuring wire MSD-200X (for KES 200X)
4-hole ceramic rod heater
article-no.: KER-132x (for KES 1321-1 article-no.: HEI-132x (for KES 1321-1
KER-2001 (for KES 1323 a. 2001) HEI-2001 (for KES 1323 a. 2001)
KER-200X (for KES 200X) HEI-200X (for KES 200X)
heater connection
heater support
article-no.: HZH-00001

spring reference
holding pins clamp spacer air
assy. thermocouple
article-no.: MT2-132X (for KES 1321-2
MT2-2001 (for KES 1323 a. 2001)
thermocouple connection screw kit for inner part MT2-200X (for KES 200X)
article-no.: RSI-1320 (for KES 1321-2)
RSI-2001 (for KES 2001)
RSI-200X (for KES 200X)
consisting of: holding pins with screws,spring
clamps,spacer assy.

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 57
18 pneumatic connection and mounting Overview

pneumatic unit SME5

instrument air design with pumps

Flowmeter Flowmeter

2 2
solenoid 1 solenoid 1
valve valve
3 3

reference test air

choke choke air pump pump
reference test air
air choke
test air

filter filter
pressure
regulator
reference air out

reference air out

max. 2 bar

reference air in
test gas out
test gas in

max. 2 bar

test gas out

test gas in
instrument air in

test air in
max. 6 bar

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 58
 mounting plate 1 (design with pumps)
0-A-000154

TRA-0017

0-P-000763

0-P-000757

PLU-0026
0-P-000751

0-P-000755
0-P-000777
Abstand zur MP : 15mm
0-A-000171
í 3,2 í 3,2

PLU-0025
í 3,2 í 3,2

DFM-00001

0-A-000158

0-P-000743

0-P-000758

0-P-000759

Test gas Test gas Ref.-Air Ref.-Air Test-Air

In Out In Out In

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 59
 mounting plate 1 below (instrument air)
0-A-000154

TRA-0017

0-P-000763
0-P-000757

0-P-000751

0-P-000755

Abstand zur MP : 15mm

í 3,2 í 3,2

0-P-000745
0-P-000760

í 3,2 í 3,2 0-P-000757

DFM-00001

0-P-000752
0-P-000753
0-A-000158

0-P-000758

0-P-000759

test gas test gas instr.air ref.-air

in out in out

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 60
 mounting plate 2 middle

0-L-000001

í 15
46.2 hoch

í10

0-P-000658
0-P-000658 test air
refrence air only at design
only at design with pumps
with pumps
0-A-000155

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 61
19 Index
µ-processor 19 mains voltage 42
19 19 maintenance 44
4-hole rod 49 measuring accurance 42
4-hole-rod 47, 49 measuring cell 46
actual values 25 measuring range 28, 42
adapter plate 13 measuring range shift 31, 35
altering parameters 28 measuring signal line 12
ambient temperature 17 measuring signal wire 46
amount of reference air 40 measuring value memory 31, 33
amounts of test air 40 oxygen 26
analog input 42 parameters 25
attenuation mA output 31 pneumatic cable 12
automatic calibration 31, 33 pneumatic tubing 16
calibration progress bar 33 power consumption 42
calibration release 40 probe inner part 49
call up max./min. values 31, 35 probe internal part 46
CE-certification 8 probe tube 47
CE-conformity 17, 23 probe valve 40
cell temperature 26 protection tube 11
cell voltage 26 pump version 12, 44, 45
change code 31 reaction time 41
change language 31, 35 recommended fuse 42
code 35 reference air 40
codes 48 reference point temperature 26
colour codes 23 relay outputs 40
conformity 5 replacing filter 46
connecting box 11 resistance to interference 42
connection diagram 22
resolution 42
current output 26, 34
service 31, 35, 44
digital inputs 40
Service 40
dimensions 42 setting current output 31
display 19 shield 16, 17
display unit 38
signal output 42
EExd housing 12
single point calibration 31, 32
electronics 19, 44
softkeys 19
electronics unit 17
software 35
extension modules 41
software version 31
external 33
stability criteria 41
factory-set 31
status 25
ferrite sleeves 8, 17, 23
status messages 36
field housing 17
switch for changing the voltage 44
filter head 11, 46
flow measurement 19 system 25
flue gas duct 13 system code 38
fuses 44 System error 40
heater 11 system menu 25
heating phase 25 system test 34
system test with test gas 31
heating support 49 technical specification 43
inner probe assembly part 11
instrument Air Version 44
temperature compensation 42
instrument-air 12 ten-key keypad 24
instrumental air version 45 terminal connections 20
internal 33 thermocouple 11, 23, 48
lambda 26 two point calibration 31, 32
limit value 1 40 underscores 26
limit value 2 40 valve 45
mains frequency 44 zirconium-oxide 9

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 62
 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 UK Limited
The Red House
84 High Street
Buntingford
Herts SG9 9AJ
England

Phone: +44 1763 272069

Fax: +44 1763 273594
Email: [email protected]

ENOTEC Inc.
6206 Sandy Ridge Circle NW
North Canton
Ohio 44720
USA

Phone: +1 330 498 0202

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

Your Distribution:
ENOTEC ASIA PTE. Ltd.
Pasir Panjang Distripark
Block 1 Please contact:
#02-11 Pasir Panjang Road ENOTEC GmbH
Singapore 118480

Tel : +65 270 6020

Fax : +65 270 6029
Email : [email protected]

OXITEC® 5000 O2 Analyser System with SME 5 Electronics Version 8.129-116np Page 63