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LOI Thermprocess GmbH

Tenova Metals Division


Am Lichtbogen 29
Postfach 10 24 51
Tel. +49 (201) 18 91-1
Fax +49 (201) 18 91 321
Service Hotline:
Tel. +49 (201) 18 91 800
Fax +49 (201) 18 91 801

45141 ESSEN GERMANY


45024 ESSEN GERMANY
Internet:
http://www.tenova-loi.de

E-Mail:

service-loi@tenova.com

Operation Manual
O2-Controller
(Rev. D)

We reserve the right to make technical modifications in the interests of progress.

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Table of Contents
1

General............................................................................................................. 4

Important Notes ................................................................................................ 5

2.1
2.2
3

Version ............................................................................................................. 5
CE Mark ........................................................................................................... 5
Introduction....................................................................................................... 6

3.1
3.2
4

Description of Functions ................................................................................... 6


Block diagram................................................................................................... 7
Controls ............................................................................................................ 8

4.1
4.2
4.3
4.4
5

Front View of Unit ............................................................................................. 8


Display.............................................................................................................. 9
Status Display .................................................................................................. 9
Keypad ........................................................................................................... 10
Operation........................................................................................................ 11

5.1
5.2
5.3
5.3.1
5.3.2
6

General .......................................................................................................... 11
Normal operation ............................................................................................ 11
Manual Entry of Parameters ........................................................................... 11
Checking parameters ............................................................................... 11
Changing parameters............................................................................... 11
Parameters ..................................................................................................... 12

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24

Parameter 1: O2-concentration ....................................................................... 12


Parameter 2: probe voltage ............................................................................ 12
Parameter 3: heating current .......................................................................... 12
Parameter 4: temperature of NiCrNi thermocouple (optional) ........................ 12
Parameter 5: terminal temperature (optional) ................................................. 12
Parameter 6: input current at mA input (optional) ........................................... 12
Parameter 9: status word 1 ............................................................................ 13
Parameter 10: status word 2 .......................................................................... 13
Parameter 11: Switch point mV / Vol.% * ....................................................... 13
Parameter 12: hysteresis of O2-setpoint mV / Vol.% *) ................................... 13
Parameter 13: minimum heating current*)....................................................... 13
Parameter 14: maximum heating current*)...................................................... 14
Parameter 15: hysteresis for heating current*) ................................................ 14
Parameter 20: mA output mode*).................................................................... 14
Parameter 21: mA output range*) ................................................................... 14
Parameter 22: O2-concentration [% by volume] at 0/4 mA*) ........................... 14
Parameter 23: O2-concentration [% by volume] at 20mA*) ............................. 15
Parameter 24: mV value of probe voltage at 0/4 mA *) ................................... 15
Parameter 25: mV value of probe voltage at 20 mA*) ..................................... 15
Parameter 26: actual current at mA output ..................................................... 15
Parameter 27: calibration value 1 [mV] of measuring cell*) ............................. 15
Parameter 28: calibration value 2 [C] heating temperature of measuring cell*)16
Parameter 30: option parameter*) ................................................................... 16
Parameter 32: binary inputs ........................................................................... 16

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6.25
6.26
6.27
6.28
6.29
6.30
7

Parameter 33: binary outputs ......................................................................... 16


Parameter 39: mA output test*) ...................................................................... 17
Parameter 40: software version...................................................................... 17
Parameter 97: display and I/O test*) ............................................................... 17
Parameter 99: password ................................................................................ 17
Summary of Parameters ................................................................................ 18
Troubleshooting .............................................................................................. 19

7.1
7.2
7.3
7.4
7.5
7.6
8

General .......................................................................................................... 19
Status Words 1 and 2 ..................................................................................... 19
Error List Status Word 1 - System Errors ...................................................... 20
Error List Status Word 2 Malfunctions ........................................................... 21
Checking the function of the oxygen probe .................................................... 22
Function Control of Evaluating Unit via Control Input E2 ................................ 22
Installation ...................................................................................................... 23

8.1
8.2
8.3
8.4
8.5
8.5.1
8.5.2
8.5.3
8.5.4
8.5.5
8.5.6
8.5.7
8.5.8
8.5.9
8.6
9

General .......................................................................................................... 23
Proper Use ..................................................................................................... 23
Installation Notes and Safety Precautions ...................................................... 23
General .......................................................................................................... 24
Terminal Allocation ......................................................................................... 25
Ground Connection .................................................................................. 25
Power Supply Connections ...................................................................... 25
Binary Control Inputs................................................................................ 26
mA Control Input ...................................................................................... 26
Probe Signal Input.................................................................................... 27
External Temperature Signal Input........................................................... 27
Current Output for Probe Heating ............................................................ 28
mA Control Output ................................................................................... 28
Switching Outputs .................................................................................... 29
O2- Bus Board Terminal Allocation ................................................................. 30
Technical Specifications ................................................................................. 31

9.1
9.2
9.3
9.4
10

O2-Controller .................................................................................................. 31
Power Supply Module .................................................................................... 32
Analyser Cell .................................................................................................. 33
Diagram of Oxygen Probe .............................................................................. 33
Declaration of Conformity ............................................................................... 34

11

General Warranty Conditions ......................................................................... 35

11.1
11.2
11.3
11.4
11.5
11.6

Scope of Warranty.......................................................................................... 35
Warranty Period ............................................................................................. 35
Procedures ..................................................................................................... 35
Exclusions ...................................................................................................... 36
Operating Errors ............................................................................................. 36
General Provisions ......................................................................................... 36

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1 General
This Manual is protected by copyright. All rights to this Manual and any part thereof, especially
the rights of translation, printing, oral presentation, the use of illustrations and tables,
broadcasting or copying in any other manner and storage on data processing systems, are
reserved. Copying of this Manual or any part thereof is only permitted within the limits set by
the Copyright Act of the Federal Republic of Germany of 9 September 1965, as subsequently
amended. All copying shall be subject to the payment of fees. Any infringement of these
restrictions shall be subject to the punishments provided for in the Copyright Act.
The use of any trade name or trade mark in this Manual, even if a trade name or trade mark is
not designated as such in this Manual, shall not be construed as meaning that any such trade
name or trade mark is in the public domain within the terms of the applicable legislation and
may be used without restriction by anyone.
The issuer of this Manual shall not be deemed to have warranted that any reference to or
quotation from any standard or code of practice(e.g. DIN, VDI, VDE) which may be made in
this Manual is correct, complete or up-to-date. Users are recommended to obtain complete
copies of the latest issue of any such standard or code of practice which they may need for
their own work.

The issuer of this Manual does not assert that any information given in this Manual is free from
patents and proprietary rights. This Manual shall not be deemed to grant any implied or other
license under any patent or proprietary right.

The software of the O2 Controller must not be copied or made available to third parties
without our written permission.

All due care has been taken in compiling the information given in this Manual. However, the
information in this Manual shall not be construed as representing performance warranties. Our
warranty obligations shall be governed by our standard conditions.

Errors and the right to make amendments required by technical progress are reserved.

All rights reserved by LOI THERMPROCESS GmbH, Essen 2013

Document Revision D - April 2013

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2 Important Notes
2.1

Version

The O2-Controller, Rev.B, described in this document is not compatible with the preceding
model.
The three components, the O2-Bus, the O2-PSU and the processor module, must not be
installed in combination with components of the previous version.
If it is necessary to replace an O2-Controller, the complete unit, comprising bus board, power
supply unit and processor module, must be replaced.
Before commissioning the unit, always check the model (nameplate), the version and
the parameters set. Otherwise, the unit or the equipment connected may be damaged
or destroyed.

Please read this Manual carefully, even if you are already familiar with the O2-Controller, as
the meanings of some of the parameters and the installation instructions have changed.

2.2

CE Mark

CE marks are applied in accordance with a Directive of the Council of the European
Communities of 29 April 1991 on the approximation of the laws of the Member States relating
to the mutual recognition of conformity.
The O2-Controller described in this Manual is supplied complete with a CE mark, guaranteeing
compliance with the following requirements:

interference emission in accordance with EN 55011:


product standard: high-frequency interference for ISM units

interference immunity to EN 50082-2:


basic standard: interference immunity in the industrial area

Please refer to the notes in Section 8.

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3 Introduction
3.1

Description of Functions

The O2-Controller measures and monitors the mV output signal of a zirconium dioxide probe
within the range from -10 mV to 2500 mV. The oxygen concentration in % by volume is
calculated from this signal.
The O2-Controller is equipped with an LED display for the indication of cell voltage, the oxygen
concentration calculated from this voltage and the current of the probe heating system.
An analogue output (0/4 - 20 mA) is available for the connection of the O2-Controller to other
instruments.
In addition, two limit contacts (one for oxygen concentration and one for heating current
monitoring) can be activated.
The O2-Controller comprises a processor module and a power supply module, both connected
to a bus board.
All connections required are made using the screw-type terminals on the bus board.
The processor module receives the analogue heating current and probe voltage signals from
the oxygen probe and indicates them on the display.
The probe heating and probe monitoring systems can be activated by an external system
either via a control input (E1) or via parameter 30 (option parameter).
If the probe voltage exceeds the switchover point which has been set, the O2-controller
activates the switch output " O2-concentration OK"; if the probe voltage falls below the
setpoint, the output " O2-concentration OK" is deactivated.
The O2-Controller is equipped with a heating current monitoring system which continuously
checks whether the heating current is within the admissible range. If the heating current is
within the limits selected, the switch output "heating current OK" is activated.
The O2-Controller is equipped with an mA output (0/4mA - 20mA module which makes either
the probe voltage (mV) or the oxygen concentration (in % by volume) available for processing
by external systems.

The power supply module supplies power to the processor module and the probe heating
system.
Four relays, controlled by the processor module, are installed on the power supply module.

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3.2

Block diagram

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4 Controls
4.1

Front View of Unit

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4.2

Display

The 4-character display indicates the measured values or, in the case of parameter input, the
value of the parameter concerned. The 2-figure parameter display indicates the parameter
currently selected.

4.3

Status Display

The status display indicates the current status of the O2-Controller.


(see Section 4.1)
O 2-

Probe voltage below setpoint (parameter 11)


This red LED lights up if the probe voltage is below the setpoint and flashes
with a frequency of 1 Hz if the probe voltage is below - 15 mV.
When this LED is lit, the " O2 OK" relay on the power supply module is deactivated.

<1%

Probe voltage above setpoint with basic setting of 1 % by volume (parameter


11)
This green LED lights up if the probe voltage is above the setpoint and flashes
with a frequency of 1 Hz if the probe voltage is above 2000 mV.
When this LED is lit, the " O2 OK" relay on the power supply module is
activated.
This red LED flashes with a frequency of 1 Hz in the event of a wire breakage
in the mA output circuit or the power supply line to the oxygen probe.
Heating current monitor
If the LED flashes with a frequency of 1 Hz, the heating current is outside the
range which has been selected. If the LED is lit continuously, the heating
current is within the selected range and the "heating OK" relay is activated..
Internal malfunction
In the event of a malfunction in the control module, the malfunction relay is deactivated and the LED lights up.

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4.4

Keypad
setting of parameters

selection of parameters and


display of values

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5 Operation
5.1

General

All functions, such as parameter setting, selection of measured value to be displayed and
troubleshooting functions, are operated using the keypad. Parameter setting and
troubleshooting functions can only be accessed after entering a password and should only be
used by the person commissioning the controller.

5.2

Normal operation

In normal operation, the controller indicates the oxygen concentration in % by volume


(parameter 1)

5.3

Manual Entry of Parameters

5.3.1 Checking parameters


During operation, it is possible to check all the parameters without any effect on
measurements in progress.
To check parameters, select the parameter required using the right half of the keypad and the
parameter selected will appear in on the 4-character display.
If no key is pressed within 60 seconds, the program automatically returns the display to
parameter 1 (oxygen concentration).

5.3.2 Changing parameters


Before any parameters can be changed, the password (see parameter 99) must be entered.
To change a parameter, proceed as follows:
Select the parameter to be changed using the right half of the keypad.
The current value of the parameter selected will then appear on the 4-character display.
You can then increase or reduce the value of the parameter using the right half of the keypad.
If you select another parameter, the value which you have set will be stored in an interim
memory.
The changed parameters are not stored on the EEPROM and adopted by the unit until normal
operation (parameter 1) is selected. The storage and adoption of the parameters is indicated
by the text "Stor." on the 4-digit display.
If more than 60 seconds elapse without a key being pressed during parameter editing, the
program interprets this as an incomplete parameter entry, the password is deleted, the data
entered are ignored and the system returns to parameter 1.
Caution: Parameters must not be changed while the controller is in operation.

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6 Parameters
6.1

Parameter 1:

O2-concentration

When this parameter is selected, the current oxygen concentration in % by volume derived
from the probe voltage at a defined temperature of 820C is displayed.
Oxygen concentration is indicated in a range from 0.0 % to 20.9 % with a resolution of 0.1 %
by volume.

6.2

Parameter 2:

probe voltage

When parameter 2 is selected, the voltage of the oxygen probe is displayed (in mV). The
measuring range is -999 mV to 2000 mV with a resolution of 1 mV.

6.3

Parameter 3:

heating current

When parameter 3 is selected, the probe heating current is indicated in Amps; the measuring
range is 0.00 A to 2.50 A with a resolution of 0.01 A.

6.4

Parameter 4:

temperature of NiCrNi thermocouple (optional)

When this parameter is selected, the unit displays the temperature measured by an external
type K thermocouple; the measuring range is 0C to 1250C and the resolution is 1C.

6.5

Parameter 5:

terminal temperature (optional)

When this parameter is selected, the unit displays the terminal temperature of the external
type K thermocouple; the measuring range is 0C to 55C and the resolution is 1C.

6.6

Parameter 6:

input current at mA input (optional)

The O2-Controller is equipped with an mA input designed for measuring current signals in the
range from 0 mA to 20 mA with an accuracy of 0.1 mA.

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6.7

Parameter 9:

status word 1

In the event of a system error in the O2-Controller, status word 1 indicates the cause. If there is
no error, the 4-character display indicates "----" when this parameter is selected (for further
details, see Section 6 "Troubleshooting").

6.8

Parameter 10: status word 2

In the event of a process malfunction, status word 2 indicates the cause. If there is no
malfunction, the 4-character display indicates "----" when this parameter is selected (for further
details, see Section 6 "Troubleshooting").

6.9

Parameter 11: Switch point mV / Vol.%

This parameter determines the probe voltage respectively calculated oxygen concentration at
which the relay O2-concentration OK is activated. The value can be set between 0 mV and
150 mV in steps of 1 mV corresponding to oxygen concentrations between 12.5 % and 0.0 %
by volume (see diagram in section 8.4).
If the option bit 2 is set in parameter 30, the calculated oxygen content will be used as trigger
criterion considering the probe-specific correcting values of the connected measuring cell
stored in parameters 27 and 28.
The set value of parameter 11 is changed from mV to Vol.% oxygen content.
In the range 0,5 Vol.% to 5,0 Vol.% the switch point can be modified in steps of 0,1 Vol.%

6.10 Parameter 12: hysteresis of O2-setpoint mV / Vol.% *)


Parameter 12 determines the switch hysteresis of switch point " O2-contents OK" (parameter
11). The adjusting range is between 1 mV to 25 mV and can be modified in steps of 1mV.
If the option bit 2 is set in parameter 30, the set value of parameter 12 is changed from mV to
to Vol.% oxygen content.
In the range 0,1 Vol.% to 0,8 Vol.% the hysteresis switch point can be modified in steps of 0,1
Vol. %

6.11 Parameter 13: minimum heating current*)


Parameter 13 determines the lower setpoint of the heating current monitoring function. This
parameter can be adjusted between 0.00 A and 1.00 A in 0.01 A steps

*)

These parameters are only accessible after entering a password ( see parameter 99 ).

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6.12 Parameter 14: maximum heating current*)


Parameter 14 determines the upper setpoint of the heating current monitoring function. This
parameter can be adjusted between 1.50 A and 2.50 A in 0.01 A steps

6.13 Parameter 15: hysteresis for heating current*)


Parameter 15 sets the hysteresis of the heating current setpoints. The parameter is adjustable
between 0.00 A and 0.10 A in 0.01 A steps.

6.14 Parameter 20: mA output mode*)


Parameter 20 is used to activate the mA output. The following modes of operation can be set:
"oFF" mA output de-activated (standard setting)
" O2" output of O2-concentration in % by volume
"mV" The probe voltage is converted into a mA signal.

6.15 Parameter 21: mA output range*)


Parameter 21 can be selected only if the mA output module has been activated by parameter
20.
Using parameter 21, the range of the mA output signal can be set to 0-20 mA or 4-20 mA.

6.16 Parameter 22: O2-concentration [% by volume] at 0/4 mA*)


Parameter 22 can be selected only if parameter 20 has been set to " O2" (output O2concentration).
The O2-concentration can be set to any value between 0 % by volume and the value of
parameter 23 in steps of 0.1 %.
If parameter 22 is set to 0 % by volume and parameter 23 to 20 % by volume and the mA
output signal range is 0-20 mA, the rate of change in the output signal is 1 mA per 1 % by
volume.

*)

These parameters are only accessible after entering a password ( see parameter 99 ).

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6.17 Parameter 23: O2-concentration [% by volume] at 20mA*)


Parameter 23 can be selected only if parameter 20 has been set to " O2" (output O2concentration).
The O2-concentration can be set to any value between 20.9 % by volume and the value of
parameter 22 in steps of 0.1 %.

6.18 Parameter 24: mV value of probe voltage at 0/4 mA *)


Parameter 24 can be selected only if parameter 20 has been set to "mV" (output probe
voltage).
Using this parameter, the mV value at 0/4 mA can be set to any value between -10 mV and the
value of parameter 25 in steps of 1 mV.
If parameter 24 is set to 0 mV and parameter 25 to 2000 mV and the mA output signal range is
0-20 mA, the rate of change in the output signal is 1 mA per 1 mV.

6.19 Parameter 25: mV value of probe voltage at 20 mA*)


Parameter 25 can be selected only if parameter 20 has been set to "mV" (output probe
voltage).
Using this parameter, the mV value at 20 mA can be set to any value between 2000 mV and
the value of parameter 24 in steps of 1 mV.

6.20 Parameter 26: actual current at mA output


Parameter 26 can only be selected if the mA output module has been activated using
parameter 20.
When parameter 26 has been selected, the unit displays the actual output current at the mA
output in the range from 0 to 21 mA.

6.21 Parameter 27: calibration value 1 [mV] of measuring cell*)


If the option bit 2 is set in parameter 30, the parameter 27 can be selected.
The probe-specific factor K1 in [mV] is stored in parameter 27 for the use of measuring cells.
In the range of -20.0 mV to +20.0 mV the adjustable correction value can be modified in steps
of 0,1 mV (see parameter 11).
If either the measuring cell or the evaluation unit are replaced, the correction value K1 in
parameter 27 needs to be adjusted.
*)

These parameters are only accessible after entering a password ( see parameter 99 ).

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6.22 Parameter 28: calibration value 2 [C] heating temperature of


measuring cell*)
If the option bit 2 is set in parameter 30, the parameter 28 can be selected.
The probe-specific factor K2 in [C] is stored in parameter 28 for the use of measuring cells
with correction value from -50 C to +50C the adjustable correction value can be modified in
steps of 1 C (see parameter 11).
If either the measuring cell or the evaluation unit are replaced, the correction value K2 in
parameter 28 needs to be adjusted.

6.23 Parameter 30: option parameter*)


Up to four options bits can be set in parameter 30.
Presently only the option bits 1 and 2 (rightmost in 4 digit display) can be edited.
The option bits can be set and deleted by the two buttons on the right side.
If the option bit 1 is set to value "1", the O2-Controller will be permanently activated and the
signal at the binary input 1 or input 2 will be ignored.

6.24 Parameter 32: binary inputs


When this parameter is selected, the condition of the signals at the binary inputs is indicated
on the 4-character display. An "L" corresponds to 0 V DC and an "H" to 12-24 V DC. The
inputs are displayed in ascending order from left to right.
E1
E2
E3
E4

activate O2-Controller
function control O2-Controller (only possible, unless option bit 1 is set)
not used
not used

6.25 Parameter 33: binary outputs


When this parameter is selected, the condition of the signals at the binary outputs is indicated
on the 4-character display. An "L" corresponds to "output not activated" and an "H" to "output
activated". The outputs are displayed in ascending order from left to right.
A1
A2
A3
A4

O2-concentration < setpoint (no malfunction)


malfunction
heating current OK
heating on

*)

These parameters are only accessible after entering a password ( see parameter 99 )

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6.26 Parameter 39: mA output test*)


When this parameter has been selected, the display can be set manually to a value between
0.00 and 20.00 mA using the right half of the keypad. The value set is only valid if this
parameter has been selected.

6.27 Parameter 40: software version


When this parameter has been selected, the software version of the O2-controller is indicated
on the display.

6.28 Parameter 97: display and I/O test*)


When this parameter has been selected, the individual elements of the display, the status
display LED's and the switching relays on the power supply module can be operated manually
for test purposes using the keys on the right half of the keypad. The 4-character display
indicates which output or LED is switched on.

6.29 Parameter 99: password


The parameters marked with an asterisk (*) can be accessed and changed after entering a 4character password.
New parameter values are only stored about 3 seconds after selecting parameter 1; the
password is erased and the parameter changes are adopted by the system.
The storage of the parameters is indicated by the text "Stor." on the 4-digit display.

Warning!

*)

Do not change any parameters while the controller is in operation.

These parameters are only accessible after entering a password ( see parameter 99 )

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6.30 Summary of Parameters


Parameter

Designation

Range

1
2
3
4
5
6
9
10
11
11
12
12
13
14
15
20
21
22
23
24
25
26
27

oxygen concentration
probe voltage
heating current
NiCrNi temp.
terminal temp.
mA input current
status word 1
status word 2
O2-setpoint
O2-setpoint
hyst. O2-setpoint
hyst. O2-setpoint
heating current min
heating current max
hyst. heating current
mA output mode
mA output range
lower O2-value mA
upper O2-value mA
lower mV value mA
upper mV value mA
mA output current
Correction value 1
measuring cell
Correction value 2
measuring cell
option parameter
binary inputs
binary outputs
mA output manual
software version
display and I/O test
password entry

0.0 Vol.% - 20.9 Vol.%


-999 mV - 2000 mV
0.00 A - 2.50 A
0 C - 1250 C
0 C - 55 C
0.0 mA - 20.0 mA
'----' / 0000h - FFFFh
'----' / 0000h - FFFFh
0 mV - 150 mV
0.5 Vol.% - 5.0 Vol.%
1 mV - 25 mV
0.1Vol.% - 0.8 Vol.%
0.00 A - 1.00 A
1.50 A - 2.50 A
0.01A - 0.10A
oFF, O2,mV
0-20mA,4-20mA
0.0 Vol.% -19.9 Vol.%
1.0 Vol.% - 20.9 Vol.%
-10 mV to 1900 mV
90 mV 2000 mV
00.00 mA 20.00 mA
-20.0 mV to 20.0 mV

28
30
32
33
39
40
97
99

Basic setting

50mV
1 Vol.%
10 mV
0,7 Vol.%
1,0A
2,0 A
0,01 A
mV
4-20 mA
0.0 Vol%
20.0 Vol%
0.0 mV
2000 mV

Remarks
display
display
display
display
display
display
display
display
1 % by Vol.%

0.0 mV

1.)
1.)
2.)
2.)
display
3.)

-50 C to 50C

0 C

3.)

0000 / 0011
L/H
L/H
0.0 mA - 21.0 mA

0000

0000 inactive
display
display
Version 08.12

0000 - 9999

4567

1.) Parameters 22 and 23 can only be selected, if parameter 20 was set to O2". (O2-content to be output in Vol.% via
current output)
2.) Parameters 24 and 25 can only be selected, if parameter 20 was set to mV" (probe voltage of measuring cell to be
output in mV, factory setting).
3.) Parameters 27 and 28 can only be selected, if the option bit 2 was set in parameter 30.

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7 Troubleshooting
7.1

General

The software of the O2-Controllers conducts comprehensive cyclical tests of the status of the
unit hardware and software in order to ensure high reliability.
If any errors or malfunctions are detected while the unit is in operation, the program switches
the status display LED's, the relays and the error bits in status words 1 and 2 as appropriate in
view of the type of malfunction or error (see parameters 9 and 10).

7.2

Status Words 1 and 2

Status word 1 indicates errors detected in the system which may have a detrimental impact on
reliable operation.
Status word 2 indicates the status of the sensors connected and the process data calculated.
The malfunctions recorded in this status word can assist service personnel in performing
effective troubleshooting work in the event of a malfunction.
Errors stored in status words 1 and 2 are indicated in hexadecimal notation in the upper
display. If no errors or malfunctions are active, four hyphens ("----") are displayed.
Each error switches one bit in the status word concerned.
If more than one error is recorded, the signals are added to form a hexadecimal number.
Example:

status word 2

"0021"H

According to the table on the following page, this indicates the following error or
malfunctions
"0001"H breakage of wire to oxygen probe
"0020"H breakage of wire in mA output circuit

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7.3

Error List Status Word 1 - System Errors

Error number
"0001" H
"0002" H

Bit
position
Bit 0
Bit 1

"0004" H

Bit 2

"0008" H
"0010" H

Bit 3
Bit 4

"0020" H
"0040" H

Bit 5
Bit 6

"0080" H
"0100" H

Bit 7
Bit 8

"0200" H
"0400" H
"0800" H
"1000" H
"2000" H
"4000" H
"8000" H

Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15

Cause

Remedy

Remarks

not possible to save parameters


standard parameters stored in
EEPROM
parameter copying error;
emergency operation with
standard parameters
error in cyclical test of parameter
data
program stack overflow
processor not initialized or config
register damaged
incorrect software version
error in check sum test of program
data
-

1,2
-

a,b,e
c,e

b,e

b,e

3
2

d,f,i
f,g,h

2
2

f,g,h
f,g,h

not used
not used
not used
not used
not used
not used
not used

1.) Repeat operation.


2.) Replace processor module.
3.) Replace processor module if error recurs.
a.) Emergency operation with old parameter data.
b.) LED (red) flashes.
c.) This error does not occur in normal operation (for service only).
d.) Display: "Fail"
e.) Malfunction relay contact open.
f. ) All relay contacts open.
g.) All LED's on status display flash.
h.) Operation not possible.
i. ) O2-Controller attempts restart (RESET).

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7.4

Error List Status Word 2 Malfunctions

Error number

Cause

Remedy

Remarks

"0001" H

Bit
position
Bit 0

O2-probe wire breakage

b,d,f,h,j,k

"0002" H

Bit 1

probe voltage lower than -25 mV

"0004" H

Bit 2

"0008" H

Bit 3

probe voltage higher than 2000


mV
heating current outside set range

if error persists
for more than
10 minutes 1,2,3
if error persists
for more than
10 minutes 1,2,3
1,2,3

e,i

"0010" H
"0020" H

Bit 4
Bit 5

if error persists
for more than
5 minutes 4,1,2,3
no error
5,2

b,h
d,g

"0040" H
"0080" H
"0100" H
"0200" H
"0400" H
"0800" H
"1000" H
"2000" H
"4000" H
"8000" H

Bit 6
Bit 7
Bit 8
Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15

not used
not used
not used
not used
not used
not used
not used
not used
not used
not used

O2-probe voltage below setpoint


mA output circuit wire breakage (if
active)
-

a,g,h,m

c,l,g

1.) Check oxygen probe wiring.


2.) Replace processor module.
3.) Replace probe.
4.) Check and, if necessary, replace power supply module.
5.) Check wiring of mA output circuit.
a.) O2-LED (red) flashes.
b.) O2-LED (red))
c.) O2<1% LED (green) flashes.
d.)
LED (red) flashes.
e.)
LED (green) flashes.
f. ) LED (red) flashes.
g.) Malfunction relay contact open.
h.) O2-OK relay contact open.
i. ) Heating OK relay contact open.
j. ) Current of 21 mA from mA output.
k.) Parameter 1 indicates "OPEn".
l. ) Parameter 1 indicates "- - - - ".
m) Parameter 1 indicates "- - - - ".

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7.5

Checking the function of the oxygen probe

The check of the oxygen probe can be only execute when the inner cover
is removed from the base.
The O2- Controller indicates an concentration between 20.9 % and 19.0 % by volume when
the outlet oft the base is ventilated with air.
In this state the value of the probe voltage amount of ca. 10 mV.
When parameter 2 has been selected, the actual voltage of the oxygen probe is displayed (in
mV).
In addition the PLC checks the function of the probe at the beginning of every annealing
process. The signal from the oxygen probe must be going below
1% by volume.

7.6

Function Control of Evaluating Unit via Control Input E2

The function of the evaluating unit can be controlled in an automated way by a superior control
system (PLC) via the control input E2.
Conditions:
-

Option bit 1 not set in option parameter 30


(permanent self-activation is switched off; otherwise function control is not
possible).

Control input E1 without signal


(The heating current for the probe heating and - supervision is switched off).

After a switch signal has been placed via the control input E2, the evaluation unit switches its
switch outputs:
A1
A2
A3

O2-contens < operating point (no malfunction)


Malfunction
Heating current OK

In addition a loop current of 12 mA is generated via the analogue signal output (mA-output).

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8 Installation
8.1

General

Some manufacturers do not explain the significance of the CE declaration of conformity for
their products and the legal consequences clearly to their customers. We would like to help
you to install the unit in accordance with the CE requirements.
When installing a unit with a CE declaration of conformity, it should be noted that the
declaration of conformity in connection with EMC legislation only applies to the installation
configuration which has been tested by the manufacturer. On the other hand, it would be
practically impossible for a manufacturer to test every conceivable installation configuration.
The following paragraphs describe the installation configuration which we have selected. In
normal conditions, it is not necessary to take all the action described to ensure reliable
operation. However, in an environment subject to electromagnetic interference, this action is
essential.
It is the responsibility of the user to determine whether the configuration described
should be implemented without conducting separate tests.
You should also note that it may be necessary to follow the requirements of other regulations
(such as the machinery directive) depending on the specific installation configuration.

8.2

Proper Use

The O2-Controller is an electrical component for installation in a switchgear cabinet. It must be


operated in a closed housing providing adequate protection against direct or indirect contact
with live parts (VDE0100). Ideally, the unit should be installed in a grounded 19" metal housing
without any plastic front panels
The O2-Controller is not a domestic appliance but is designed for industrial use. The unit must
not be used in domestic accommodation or on trade or commercial premises without obtaining
the prior written permission of the manufacturer.
Compliance with the specifications concerning supply voltages, control inputs and outputs and
climatic conditions (see Section 9 "Technical Specifications") is essential.

8.3

Installation Notes and Safety Precautions

The user is responsible for ensuring compliance with the EMC legislation in the specific
application.
The O2-Controller contains components which may be damaged by electrostatic charges.
Before handling an open unit or working on or near equipment connections, personnel must
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discharge any electrostatic charges (for example by touching a grounded bare metal screw or
surface).
If any equipment not in accordance with the requirements of European Standard EN50082-2
as regards interference immunity is operated in the vicinity of the O2-Controller, the possibility
of electromagnetic interference on such equipment cannot be excluded. Similarly, the O2Controller may be affected by interference from equipment not meeting the interference
emission limits of European Standard EN500081-2.
The conformity of a plant with CE requirements depends on the installation configuration and
the care taken in installation. Special attention must be paid to shielding and grounding.

8.4

General

The O2-Controller should be operated only in connection with the bus system designed for the
purpose. If the unit is operated in connection with bus systems of other manufacturers, we
cannot give any warranty as we are not in a position to test components produced by other
manufacturers
A decisive factor in protection against electromagnetic interference is the correct shielding and
grounding of cables. Both ends of the shield must be connected to a grounded surface over as
large an area as possible using cable clamps or PG-skin glands.
Where possible, the positive and negative terminals of unused control inputs should be
connected to each other at the terminals of the bus system (shorted).
The various functional units of the O2-Controller are isolated from each other and have no
common ground connection (see O2-bus board terminal allocation). In accordance with the
standards for low-voltage systems, you can therefore set the reference voltages as required
for 1mm creepage and air gaps between functional units and 3mm between each functional
unit and the mains connection.
Please take note of the following paragraphs before commissioning the unit.

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8.5

Terminal Allocation

8.5.1 Ground Connection


To ensure safe operation of the O2-Controller a ground (PE) conductor with a cross section of
at least 0.75mm must be connected to screwed terminal 3 of the bus board (VDE 0100).
The ground conductor may form part of the AC feeder cable.
Ground connection:
Terminal

: PE

(3)

Cross section

: 0.75mm2

Cable type

: non-shielded

8.5.2 Power Supply Connections


The O2-Controller requires an AC power supply with 110,120,220 or 240V, 50 .. 60 Hz at
screwed terminals 1 (N) and 2 (L). If possible, the power supply should be taken from a power
supply network for control equipment (class 3 or better).
The power supply voltage is set at the factory to the value specified by the customer on the
power supply module.
Power supply connection 110,120,220 and 240 VAC, 50 .. 60 Hz:
Terminals

:N
:L

Cross section

: 0.75mm2

Cable type

: non-shielded

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8.5.3 Binary Control Inputs


For connection to the binary control inputs (optocouplers) at screwed terminals 16 to 23,
shielded conductors with a cross section of at least 0.25mm2 must be used. These conductors
may be combined with other control circuit conductors of the same type in cables.
The load on each binary control input is 2.7k.
Binary control inputs 0 / 12 .. 24VDC:
Terminals

: control input 1 +
: control input 1 : control input 2 +
: control input 2 : control input 3 +
: control input 3 : control input 4 +
: control input 4 -

Cross section

: 0.25mm2

Cable type

: shielded

(23)
(22)
(21)
(20)
(19)
(18)
(17)
(16)

8.5.4 mA Control Input


Connections to the mA control input, screwed terminals 24 (mA input) and 25 (GND 3), must
be made using shielded or twisted pair conductors with a cross section of at least 0.50mm2
These conductors may be combined with other control circuit conductors of the same type in
cables where appropriate.
If this option is not installed, screwed terminals 24 and 25 should be shorted using a jumper.
The load on the mA control input is 200.
mA control input 0 / 4 .. 20 mA:
Terminals

: mA input
: GND 3

Cross section
Cable type

: 0.50mm2
: shielded or twisted pair

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8.5.5 Probe Signal Input


The voltage signal from the zirconium dioxide probe must be connected to screws terminals 12
(O2-probe +) and 13 (GND 2a) using shielded conductors with a cross section of at least
1.50mm2.
Terminal GND 2a is connected to the PE conductor via the screwed cap of the oxygen
probe.
Probe signal input : -999 .. +2000 mV:
Terminals

: O2-probe
: GND 2a

Cross section

: 1.50mm2

Cable type

: shielded

(12)
(13)

8.5.6 External Temperature Signal Input


The signal from the NiCrNi thermocouple must be connected to screwed terminals 26 (NiCrNi
+) and 27 (GND 2b) using shielded conductors with a cross section of at least 0.5mm2.
If this option is not installed, screwed terminals 26 and 27 should be shorted using a jumper.
Terminal GND 2b is connected to terminal GND 2a internally, and therefore also to the
PE conductor!
Signal input

: 0 .. 1250C:

Terminals

: NiCrNi +
: GND 2b

Cross section

: 0.50mm2

Cable type

: shielded

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8.5.7 Current Output for Probe Heating


The power supply for probe heating must be connected to screwed terminals 14 and 15
(heating) using shielded conductors with a cross section of at least 1.50mm2.
Heating current output 0 .. 2,5 AC:
Terminals

: heating
: heating

Cross section

: 1.50mm2

Cable type

: shielded

(14)
(15)

8.5.8 mA Control Output


Connections to the mA control output, screwed terminals 10 (mA OUT) and 21 (GND 1), must
be made using shielded or twisted pair conductors with a cross section of at least
0.50mm2.These conductors may be combined with other control circuit conductors of the same
type in cables where appropriate.
The load on the mA control output must not exceed 600 .
mA control output 0 / 4 .. 20 mA:
Terminals

: mA OUT
: GND 1

Cross section

: 0.50mm2

Cable type

: shielded or twisted pair

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8.5.9 Switching Outputs


For connections to switching outputs, i.e. the relay contacts "malfunction" " O2-concentration <
setpoint" and "heating OK", conductors with a cross section of 0.50mm or higher, depending
on the cable length, must be used. These conductors may be installed together with other
similar conductors in a shielded control cable.
Switching outputs

: impressed current, 12 ..24 VDC


: max. current load: 0.5 A

Screwed terminals : O2 < setpoint


: O2 < setpoint
: malfunction
: malfunction

6
7

: heating OK
: heating OK

8
9

Cross section

: 0.50mm2

Cable type

: shielded

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8.6

O2- Bus Board Terminal Allocation

Apart from GND 2a and GND 2b, there are no internal connections between the GND
terminals.
Terminal GND 2a is connected to the PE terminal via the screwed cap of the oxygen probe.

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9 Technical Specifications
9.1

O2-Controller

Operating voltage
Current drain

5 V DC
approx. 600 mA

Analogue inputs

voltage measurement -999 mV to 2000 mV DC


accuracy, typical : 1 mV
accuracy, max.
: 3 mV
current measurement: 0.00 A to 2.50 A 50/60 Hz
current measurement: 0.0 mA to 20.0 mA DC (optional)
temperature measurement using ext. NiCrNi
thermocouple: 0 to 1250 C (optional)
terminal temperature measurement
0C to 55C (optional)

Digital inputs

4 floating inputs 12 - 24 V DC

Analogue outputs

1 analogue mA output
configuration by parameters
galvanically isolated
signal range: 0 mA to 21 mA
accuracy, typical : 0.05 mA
accuracy, max.
: 0.5 mA
load: 600 Ohm

Digital outputs

4 open collector outputs


5 V DC, max. 100 mA per channel

Electrical connection

64-pin male connector, type "D", DIN 41612

Size

Operating temperature

European standard, 100 x 160 mm


with front panel, 50.8 x 128.5 x 2.5 mm (3 vertical, 10
horizontal modules)
0 .. 55 C

Storage temperature

- 25 .. 70 C

Climatic conditions

35 to 75% rel. humidity, no condensation

Front panel

IP 65

CE conformity

EN 50081 / Part 2
EN 50082 / Part 2

Weight

approx. 300g

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9.2

Power Supply Module

Operating voltage

110, 120, 220, 240 V, 50/60 Hz


adjustable using jumpers

Power absorbed

max. 50 VA

Outputs

3 relay contacts
24 V / 0.5 A

Voltage outputs

5 V DC / 2A
12 V AC / 2,5 A

Electrical connection

32-pin male connector, type "D", DIN 41612

Size

European standard, 100 x 160 mm


with front panel, 50.8 x 128.5 x 2.5 mm (3 vertical,
10 horizontal modules)

Operating temperature

0 .. 55 C

Storage temperature

-25 .. 70 C

Climatic conditions

rel. humidity = 35 to 75%, no condensation

Front panel

IP 65

CE conformity

EN 50081 / Part 2
EN 50082 / Part 2

Weight

approx. 1000g

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9.3

Analyser Cell

Type

zirconium dioxide probe

Accuracy

better than 0.1 % O2 by volume

Reaction time

less than 1 sec.

Power supply

12 V AC, 50-60 Hz, approx. 1.4 A

9.4

Diagram of Oxygen Probe

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10 Declaration of Conformity

DECLARATION OF CONFORMITY
in accordance with the EC
electromagnetic compatibility directive (89/336/EEC)
as amended by 91/263/EEC; 92/31/EEC; 93/68/EEC
This Declaration applies to the following product:
Equipment type:
Type designation:

O2 controller
O2 Controller CE

The product was tested in a typical situation.


This Declaration does not apply if any changes not agreed with the manufacturer
are made to the product.
The electromagnetic compatibility of the product was assessed on the basis of
the following harmonized standards:
EN 55011 1991
EN 50082-2 1995
Compliance with the protection requirements of the directives mentioned above
was confirmed by the following test laboratories:
EM-Test, Kamen
EMV-Test NRW, Dortmund (accredited)
This Declaration is made on behalf of the manufacturer/importer
LOI Thermprocess GmbH
Am Lichtbogen 29
45141 Essen
GERMANY
by
Dr.-Ing. Karl Nolte
Managing Director
Essen, 20 September 1996

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__________________
Dr.-Ing. Karl Nolte
Managing Director

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11 General Warranty Conditions


The following warranty is given to purchasers of O2 Controller units in addition to the
warranties provided for by statute, in accordance with the conditions stated below:

11.1 Scope of Warranty


a)

This warranty covers all parts of the unit. Any parts of the unit which may become
defective as a result of defects in materials and workmanship will be replaced free of
charge to the purchaser. This warranty shall only apply if the parts concerned have
demonstrably been used properly and the purchaser has complied with the
appropriate operating instructions. Any manuals and software supplied with the unit
shall be excluded from this warranty.

b)

LOI THERMPROCESS will bear the material and labor cost incurred in repairing
defective parts, but not carriage expenses.

c)

Any parts which are replaced shall become the property of LOI THERMPROCESS.

d)

In addition to repairing or replacing defective parts, LOI THERMPROCESS shall be


entitled to make modifications to the unit (such as firmware updates) in order to adapt
it to the current state of the art. Such modifications will be made at no charge to the
purchaser, but LOI THERMPROCESS shall be under no legal obligation to make
them.

11.2 Warranty Period


a)

The warranty period shall be 6 months.

b)

The warranty period shall commence on the date of delivery of the unit.

c)

Work carried out under this warranty shall not operate to extend the warranty period
or to start a new warranty period. The warranty period for any spare parts installed
shall end on the same date as the warranty period for the entire unit.

11.3 Procedures
a) Units to be repaired under warranty shall be shipped to and from the points where
repairs are to be carried out at the cost, risk and expense of the purchaser.

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11.4 Exclusions
LOI THERMPROCESS shall be under no warranty obligations whatsoever in any case in
which:
a)

a unit is damaged or destroyed by force majeure or environmental conditions


(humidity, lightning, dust, etc.);

b)

a unit has been stored or operated under conditions not in accordance with the
technical specifications;

c)

damage has been caused by improper handling, especially failure to comply with the
system description and the operating instructions;

d)

a unit has been repaired or modified by any person not authorized by LOI
THERMPROCESS;

e)

a unit bears traces of mechanical damage of any type;

f)

a warranty claim is not made in accordance with Section 3 a) above.

11.5 Operating Errors


In the event that it is found that a malfunction of the unit has been caused by defective
hardware supplied by third parties or errors in software supplied or installation work performed
by third parties or by operating errors, LOI THERMPROCESS reserves the right to charge the
cost of inspecting the unit to the purchaser.

11.6 General Provisions


a)

LOI THERMPROCESS shall be under no further warranty obligations to the purchaser


in addition to those stated above. This warranty shall not entitle the purchaser to make
any further claims, including claims for a rescission of the purchase contract or a
reduction of the purchase price for the unit. Any claims for damages by the purchaser
against LOI THERMPROCESS for whatsoever reason shall be excluded, except where
any claim made against LOI THERMPROCESS is based on compulsory provisions of
the applicable law, such as claims for damages in respect of personal injury or damage
to privately used property in accordance with the law concerning product liability or
injury or damage caused by willful act or gross negligence. LOI THERMPROCESS shall
not be liable for any indirect or consequential loss or damage or loss of profit.

b)

This warranty shall only be available to the first owner of the unit and shall not be
transferable to subsequent purchasers.

c)

The venue for any disputes between the purchaser and LOI THERMPROCESS shall be
Essen, if the purchaser is entered in a commercial register. In the event that the
purchaser does not have a general venue for disputes in the Federal Republic of
Germany or relocates its normal place of residence outside the Federal Republic of
Germany following the conclusion of the purchase contract for the unit or the place of

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normal residence of the purchaser is not known at the time when any proceedings are
initiated, the venue for any disputes between LOI THERMPROCESS and the Purchaser
shall be the place where LOI THERMPROCESS has its registered office.
d)

The purchase contract for the unit shall be governed by and construed and interpreted
in accordance with the law of the Federal Republic of Germany.

e)

The international conventions concerning the international sale of goods shall not apply.

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