Dansensor ISM-3 User manual

PBI-200114-D
04/2013
ISM-3
User Manual
EN

Dansensor A/S COPYRIGHT © PBI-200114-D 04/2013
ISM-3 EN User Manual
ISM-3
User Manual
Published by:
Dansensor A/S
Rønnedevej 18, DK-4100 Ringsted
Denmark
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.dansensor.com
EN

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2 User Manual EN ISM-3

Dansensor A/S COPYRIGHT © PBI-200114-D 04/2013
ISM-3 EN User Manual 3
Table of Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2. Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Start up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General use of buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Start and stop of measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
External/manual start and stop of measuring . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Set-up of alarm limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Output of sensor flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Flow alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Sub menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Setting up of options, relay and external measurement control . . . . . . . . . . . . 16
5. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
6. Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Offset adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7. Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Current output/voltage output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8. Error indication/error correction . . . . . . . . . . . . . . . . . . . . . . . . . . .23
9. Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Standard accessories (included). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Accessories (extra) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10. Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Flow system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Operation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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4 User Manual EN ISM-3

Dansensor A/S COPYRIGHT © PBI-200114-D 04/2013
ISM-3 EN User Manual 5
1. Introduction
ISM-3 is a microprocessor controlled oxygen analyser which automatically controls the concentration of
oxygen (O2) in a given measuring point. The measured O2concentration is shown in a large, easy
readable display.
ISM-3 can via a simple menu structure be programmed to give alarm in case of a too high or too low O2
concentration. Besides that alarm is given in case of insufficient flow of measuring gas, or in case of
other faults in the ISM-3.
ISM-3 is equipped with a relay for alarm in case of too high/low O2concentration, insufficient measuring
gas flow or other vital faults.
ISM-3 is specially developed for being incorporated/mounted on nitrogen generators etc. where the
control of the O2concentration is a vital part of the process.
Fig. 1. ISM-3 Analyser for incorporation
Fig. 2. ISM-3 Analyser designed for retrofitting

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The following makes ISM-3 an unique O2analyser:
• Precise and quick measuring
• Covers all measuring ranges from 100% to 0 ppm with automatic range shift
• Facultative external control of measuring
• Long term stable sensor - long intervals without calibration
• Automatic control of measuring gas flow
• Programmable current oulet/voltage outlet (extra accessories) 0/4-20mA/0/2-10 Volt with galvanic
separation
• 2 alarm limits programmable for O2content
• Calibration with up to 4 calibration gases plus atmospheric air (20.946 % O2)
• Supplied as stand-alone or for incorporation.
ISM-3 is specifically built for measuring on clean dry gases and gas mixtures where a great measuring
precision, reliability and long term stability and alarm control of flow and content of oxygen are required.
As examples of application the following areas can be mentioned:
• Control of gas
• Atmospheric control under industrial or laboratory conditions
• Control of gas mixtures
• Environmental measurements
• Measuring of oxygen within the chemical, metallurgical and medical industry and
research

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ISM-3 EN User Manual 7
2. Safety precautions
Read and understand this manual for your own safety’s sake and for the quality of the work carried out
using this equipment.
The following terms are used:
"DANGER" to designate a condition which MAY involve mortal danger of serious injury
"CAUTION" to designate a condition which MAY involve serious injury
"NOTE" to designate a condition which MAY involve faulty operation of the equipment
thus causing fault measuring results
Follow the below instructions carefully:
DANGER: Opening ISM-3 may involve mortal danger or serious injury as live high-
voltage leads may be exposed. By opening the ISM-3, the mains supply must
always be switched off. By connecting the net ground must always be
connected.
CAUTION: If ISM-3 is moved or transported, make sure it is note exposed to shocks or
impact.
Only use water or a mild soap lather to clean the front panel. Make always
sure that there is at least 5 cm of free air behind the ventilation holes on the
back of ISM-3.
Our warranty does not cover unless the above instruction is strictly adhered
to.
NOTE: Install always a hose on the "Gas out" connection and make sure that the
measuring gas is transported away from the ISM-3, as the surrounding
atmospheric air is used as reference. In order to observe the CE`s EMC
regulation all connections to the ISM-3 (not mains connections) must be
protected. The screen must end in a PG sleeve on the back of ISM-3.
Recommendations
• In order to prolong the life of the analyser it is recommended to let ISM-3 be constantly connected to
the mains voltage.
• Every 6 months it is recommended to control ISM-3`s calibrations by measuring on gases with known
content of O2.
• Recommended control - and calibration interval is 12 months.

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ISM-3 EN User Manual 9
3. Connection
• Measuring control signal for external control of measuring (10-32 VDC)
• Relay output
• Current output/voltage output (optional)
ST1: Gas alarm and system alarm output. Relay connection. Max. 48V, 1A
pin 1: Common terminal (COMMON)
pin 2: Contact set with switch on function (normally connected) (N.C.)
pin 3: Contact set with switch on functions (normally open) (N.O.)
pin 4: Not connected
ST2: Connection to current output/voltage output
pin 1: +0/4 to 20mA (0/2-10Volt)
pin 2: -/GND
ST3: Connection for measuring control signal
pin 1: +10 to 32VDC
pin 2: -/GND
Fuse 0.63 AT (1.6 AT at 115V AC). Placed inside.
Fan
Gas out
Gas in (For ISM-3 without a build-in pump, 2 - 10 bar is labelled upon request)
Cable inlet for mains connection
Cable inlet for display (only for model for incorporation)
Cable inlet for signal cable. The cable is internally connected to ST1, ST2 and ST3.
Current output/voltage output. Yellow + (plus) and Green -(minus)
Alarm relay output Grey and Pink. Switch is open in case of an alarm.
Measuring control input signal (10 to 32 VDC). Brown +(plus) and White-(minus)
RS232C serial communication port.
13
12
11
GAS IN
GAS OUT
3 41 2
1 21 2
103
2
1
14
5
7
6
8 94

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ISM-3 EN User Manual 11
4. Operation
ISM-3 is equipped with four keys and a large LED display for indication of the O2concentration.
Fig. 3. ISM-3 operation panel
Start up
ISM-3 starts up with a self-test lasting about 10 seconds. After the self-test the heating which takes 10
minutes begins. If ISM-3 only has been switched off shortly the heating time is reduced. Minimum
heating time is 2 minutes.
The rest of the heating time in minutes is indicated in the display as H 10 (H for heating). When the time is
counted down to zero the ISM-3 is ready. After 10 minutes ISM-3 has a read-out difference of max 3 % of
the read value. I takes the total heating time of 20 minutes until the ead-out difference is below the
specified 1 % for the shown value.
If the measuring had been activated when the ISM-3 was switched off, the measuring is automatically
started when ISM-3 is turned on. If an external measuring control has been chosen, the measuring will
start when the measuring control signal is set to ON.
Module ISM-3
Gas analyser
PBI Dansensor
%

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General use of buttons
The functions of the single buttons are only activated when you release the button. When a parameter is
displayed, first the parameter name appears, for example FLO for flow AL.HI for high oxygen alarm etc.
for about 1 second. Then the actual value is displayed.
With the button it is easy to scroll between FLO, AL.HI. and AL.LD and return to the output of the actual
O2(20.9)
No matter which parameter is currently displayed, the device automatically returns to display the actual
O2when there has been no activation of any button for about 5 seconds (the sensor flow can be read
constantly. See "Output of sensor flow" on page 13).
Start and stop of measuring
In the set-up menu it is selected whether the measuring is controlled via the button, via external
pump control signal, button as well as external control signal or if the measuring is always activated. If
only an external control of measuring has been chosen or the measuring is always activated, the button
is inactive. If either of the two other set-up possibilities has been chosen, the measuring can be
started and stopped using the button .
1. Press and the measuring starts. As soon as the measuring has started, the measured O2
concentration is read out on the display.
2. Press again and the measuring stops and the displays turns off (only % will be lit).
External/manual start and stop of measuring
If an external and manual control of measuring has been chosen in the set-up menu, the measuring will
start when the external measuring control signal is set to ON and stop when the signal is set to OFF. It is
only when the external control signal is changing condition that the measuring starts/stops. Every time
the key is pressed the conditions change, meaning that if the measuring has been started by the
external control signal the measuring stops when is activated. Now measuring can only be started by
the external signal if signal is set to OFF and the ON again.
flo.
20.9 Al.Lo
Al.Hi

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Set-up of alarm limits
ISM-3 has two programmable alarm limits, AL.HI (high oxygen alarm) and AL.Lo (low oxygen alarm).
In case of measurements above or below the alarm limits the relay is activated.
In order to change one of the alarm limits, the following procedure must be followed:
1. Press 2 or 3 times depending on whether it is a high alarm or a low alarm which must be changed.
2. The alarm value is displayed. Press and hold the button for 3 seconds in order to change the
alarm.
3. With and it is possible to switch between % and ppm.
After choosing % or ppm press and the first digit will flash.
4. Use and to set the flashing digit.
5. Press in order to set the next digit.
6. When the last digit has been set, press the button to store the value.
The set alarm limit is active immediately.
Output of sensor flow
1. Press and FLO. will appear in the display followed by the actual sensor flow value in ml/min.
2. If you wish a continuous display of the flow, press and hold the button for 3 sec. while the flow is
displayed. After about 3 seconds the display will flash shortly.
3. The gas flow value will be displayed until the button is activated again.
Flow alarm
A flow alarm appears if the flow is below or above the min. and max. values as set in the set-up menu. In
case of a flow alarm, display will change in 2 secs. turns between FL.ER and O2value until the flow error
stops. The relay is activated for min. 4 seconds independently of the duration of the alarm.
The flow alarm has a higher priority than the oxygen alarms. If a flow alarm and an oxygen alarm occurs
at the same time, only the flow alarm appears in the display.

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Sub menus
ISM-3 is equipped with 3 sub menus as shown in Figure 4.
Fig. 4. ISM-3 sub menus
• Press and hold and simultaneously for 3 seconds (ISM-3 must not be in a sub menu).
• Now you have access to the 3 sub menus:
Set-up menu (SET.)
Diagnostic menu (DIA.)
Calibration menu (CAL.)
No matter which menu you are in, the device will return to display the actual O2when no key has been
activated for about 20 seconds.
The parameters in the diagnostic menu can be set to permanent readout.
SET.
flo.h
flo.l
del.
flo.
pa.
20.9
DIA.
emf.
tpt.1
tpt.2
offs
CAL.
cal1
cal2
CAL3
CAL4
CAL5
3 sec.+
Al.Lo
Al.Hi
prg.
ti.FL
ti.po
ti.ca

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• Use to display the next sub menu.
The setup menu SET.
1. Press when SET. appears on the display.
2. Use and to set required value.
3. Press and hold for 3 seconds to change the value. (for typing in values, see "Set-up of alarm
limits" on page 13).
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
•FLO.L 100 Flow alarm limit. Alarm limit for min. flow in ml/min.
•FLO.H 150 Flow alarm limit. Alarm limit for max. flow in ml/min.
•DEL. 3 Gas flushing time in seconds before activation of alarms.
Valid area 0 to 250.
•PA. 1001 Setting up of options, relay function and external measurement control.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
When typing in values for FLO.L and FLO.H, error ER.1 appears, if FLO.L is set to a higher value than
FLO.H.
Diagnostic menu DIA.
1. Press when DIA. appears in the display.
2. Use and to set required value. For a permanent readout of the chosen value press and hold
for about 3 seconds. The value wil now be displayed until you press , or again.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
•EMF. 165.0 Present sensor EMF in mV.
•TPT.1 33 Present internal ISM-3 temperature in °C.
•TPT.2 0 Present difference in heater temperature in °C. Difference between present
temperature and ideal temperature.
•OFFS -0.12 Sensor offset. Result of latest off set adjustment in mV.
•TI.PO 1234 Hour counter in number of 10 hours. Number of hours in which ISM-3 has
been switched on.
•TI.CA 678 Hour counter in numbers of 10 hours. Number of hours since the last
calibration of ISM-3.
•TI.FL 983 Hour counter in number of 10 hours. Number of hours in which the flow has
passed through the sensor (flow >30ml/min).
•PRG. 1.0 Installed program version.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Calibration menu CAL.
See the chapter about calibration

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Setting up of options, relay and external measurement control
In the set-up menu the PA. parameter is defined as follows:
• The first digit (from the left) determines from where and how the measurement can be started and
stopped.
• The second digit must be 0 and is reserved for future use.
• The third digit determines how the relay works.
• The last digit indicates if there has been installed options as current output/ voltage output.
0: Press Measurement activated only via button (manual control)
1: Press/Ext. Measurement controlled via button and external
measuring control signal
2: Ext. Measurement activated only via external measuring
control signal.
3: None Measurment is constantly connected and cannot be
disconnected
0: No current output / voltage output
1: Current output (0-20mA/4-20mA) or
voltage output (0-10Volt/2-10volt)
Measurement 0Current
output
Relay
0
Off
Off
Off
Off
Off
Off
ISM-3 mode
When heating
System error
High oxygen alarm
Low oxygen alarm
Flowalarm
Measurement off
1
-
Off
Off
Off
Off
-
2
On
On
On
On
On
On
3
-
On
On
On
On
-
Do not change
Current output / voltage output
Effect of ISM-3 relay
Measurement controlled by:

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5. Maintenance
ISM-3 requires for a minimum of maintenance and as the oxygen-sensor itself is very long term stable,
no calibration of the analyser in a normal application situation is needed between the obligatory 12
months service control intervals.
See "Recommendations" on page 7 for details.
If ISM-3 is installed in places with more dust than normal, it may be necessary to change the cooling air
filter between the obligatory 12 months service control intervals.
When cleaning the front panel, use only water or a mild soap lather.

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6. Calibration
Besides atmospheric air, you can calibrate with up to 4 calibration gases. If an offset adjustment has
been made after the last calibration, a calibration of ISM-3 must always be started from the beginning
again, meaning that calibration with 20.946% O2must be carried out initially. If an off set adjustment has
been made and calibration is attempted with another gas than 20.946 % O2the error message ER.8 will
appear (cannot calibrate after the offset adjustment).
When calibrating with 20.946 % O2the result is compared with the latest 20.946 % O2calibration. All
other calibrations are adjusted using the difference between the new and the preceding 20.946 % O2
calibration. If an offset adjustment has been carried out, it is reset. After the calibration with 20.946 % O2,
calibration must be performed with the selected calibration gases. See below.
Besides the calibration with 20.946% O2it is recommended to calibrate ISM-3 with minimum 2 gases in
the range in which you will measure later on. The calibration gas values should lie above and below the
range in which you will measure later on.
Note: ISM-3 must warm up for at least 1 hour before making the calibration.
Calibration
The following procedure must be used in order to calibrate ISM-3:
1. Before the calibration is started, it must be assured that the measurement can be started via the 
button and that the measurement cannot be started/ stopped via an external measurement control
signal during the calibration. You can choose manual start/stop measurement alone, by setting the
first digit in the PA parameter in the set-up menu to "0 - - - -". Make a note of the setting before
making the change.
2. If ISM-3 is not equipped with an internal pump: Connect the calibration gas to gas in and adjust the
input pressure in order to produce a flow of 125±5ml/min.
If ISM-3 is equipped with an internal pump: Establish a gas overflow of approx. 0.5 l/min and let ISM-
3 suck the calibration gas from here.
3. Start the measurement with .
4. Let ISM-3 measure on the gas for at least 4 minutes. When calibrating with gases of less than 1000
ppm it is recommended to measure for about 10 minutes. Then check that the output of O2in the
display is stable for about 1 minute before carrying out the calibration.
When the output is stable check that the output O2value corresponds to or is very close to the
analysis value of the calibration gas. If this is not the case, check for leaks in the measurement gas
hose and for a sufficient gas supply pressure.
5. Go to the calibration menu
- Press and hold the buttons and about 3 seconds until display shows set.
- Press twice and the calibration menu CAL. is shown.
6. Press and the value for the first calibration gas CAL1 will appear. The calibration gas number 1 is
reserved for calibration with 20.946 % O2(atmospheric air) and cannot be changed. In case of
calibration with 20.946 % O2choose this field. If the calibration gas is different from 20.946% O2,
press button until an empty field appears (a field for the readout of 0 ppm) or a field with an old