Scantronic OC 2010 - LSU User manual

User guide OC 2010 (UK 07/2011 CE) page 1 of 16
Oxygen Control
OC 2010 - LSU
Technical Information and User Guide

User guide OC 2010 (UK 07/2011 CE) page 2 of 16
Oxygen Control OC 2010
Technical Information and Installation
Table of contents
1.0. General information ...........................................................................3
1.1. Introduction...........................................................................3
1.2. Principle of function..............................................................3
  1.3.Technicalspecications.........................................................4
1.3.1.Wide Band Lambda Sensor ..................................4
1.3.2. Scan Tronic LSU-cable .......................................4
   1.3.3.Signalamplier ...................................................5
2.0. Installation..........................................................................................6
2.1. Control at delivery.................................................................6
  2.2.Instrumentidentication .......................................................6
2.3. Place of installation...............................................................6
2.4. Installation of the oxygen probe............................................7
  2.5.Installationofthesignalamplier.........................................8
2.6. Cable connections. ................................................................8
3.0. Operation............................................................................................9
  3.1.Functionofthesignalamplier.............................................9
3.2. Testing prior to use................................................................9
3.3. Start up. .................................................................................9
3.4. Stops of operation. ................................................................9
4.0. Adjustments and settings..................................................................10
4.1. Routine calibration.............................................................10
4.2. Setting of alarm limits........................................................11
4.2.1. Alarms with normally closed contacts...............11
4.2.2. Alarms with normally open contacts. ................12
4.3. Selecting 0 - 20 or 4 - 20 mA output..................................13
4.4. Connecting OC 2010-LSU to other equipment..................13
4.4.1. Active loop ........................................................13
4.4.2. Passive loop.......................................................14
5.0. Maintenance.......... ............................................................................14
6.0. Scalation............................................................................................15
7.0. EU Declaration of conformity.............................................16
Warning!: Because of the internal heating of the probe, the probe is hot and
can cause severe burnings to personnel if not handled with care.

User guide OC 2010 (UK 07/2011 CE) page 3 of 16
1.0. General Information
1.1. Introduction
The oxygen control OC 2010-LSU is designed to measure the contents of oxygen directly in the
ue-gas.Themeasurementisdoneusingaheatedcellmadeofzirconiumdioxide(ZrO2) sitting
withitsactivesurfaceindirectcontactwiththeue-gas-herebyilliminatingtheuseoflters
andpumpsduringue-gassampling.Futhermoretheinstrumentisunaffectedbychangesinthe
ue-gastemperature.
The probe
Theprobeismountedintheue-gaschannel
wall.Theue-gasisledtothemeasuringcell
surface via a protective shield.
The probe is heated, and therefore contains an
electric heating elment apart from the measur-
ing cell probe.
Scan Tronic LSU-cable
Thiscablehasbeenspecicallydevelopedfor
connectingtheprobewiththesignalamplire
Measuring/signal/amplier
The signal coming from the probe is ampli-
ed,liniarizedandshowninpercent[%]ofO2
on the build -in display. Futhermore, the
signal is forwarded as current signal for
external use and used to activate two
alarm relays,when two preset limits are
exceeded.
Beyondthat,themeasuringampliersupplies
power to the heating of the probe.
1.2. Principle of function
Concept:
The measuring instrument does not take an absolute but rather a relative measurement. The
sensor constantly measures the contents of O2intheuegasandinthiswaythecombustionis
controlledandthecontentsoftheharmfulsubstancesintheuegaswillbeminimized.
Function:
The wide band sensor is a complex and therefore very precise sensor, built as two tightly con-
nectedcells.ThewallofthemeasuringcellsconsistsofzirconiumdioxideZrO2, which is heated
to about 600o C with the help of a heating element. When the concentration of oxygen on the
cell surfaces differs, there is a migration of oxygen Ions through the cell wall, thereby releasing
electrons and forming electrical voltage.
Thereisaspecialbuilt-intrimmingresistorinthesensor’sconnectorthatdenesthesensory
properties which are necessary for the sensor’s function.
Only in combination with the specially de-
veloped Scan Tronic cable can the wide band
sensor function. This cable controls the power
supply to the probe’s heating element. In this
way the sensor has optimal operating condi-
tions. The signal from the sensor is trans-
mitted through the cable to the signal repeater.
The probe must be mounted minimum 100in
relationtothehorizontalplane,bestmounted
vertically to avoid the possible accumulation
of water inside the probe.

User guide OC 2010 (UK 07/2011 CE) page 4 of 16
1.3. Technical specications
1.3.1. Measuring Probe.
Insertion length 29 mm
Cable length 850 mm
Thread........................... ...........M18x1,5
Exhaust gas pressure <1,5 bar
Working temperature
Exhaust gas temperature 0-900o C
Ambient temperature 0-60o C
Calibration interval 6 month
1.3.2. Scan Tronic LSU- cable
Acontrolcablespecicallydevelopedtoconnecttheprobewiththesignalrepeater.Oneend
of the cable has a 4-pin multiplug that connects to the signal repeater, while the other end of
the cable has a 6-pin multiplug that connects to the probe.
Cable length.......................................... 1500 mm
Elektroniks box.. .l x b x h = 112 x 60 x 31 mm
Ambirnt temperatur..........................00- 60o C

User guide OC 2010 (UK 07/2011 CE) page 5 of 16
1.3.2. Signal amplier
Indication
1.0%-20.9%O2
Displayed on a three digit seven segment
display with light-emitting diodes.
A switch setting (inside the cabinet)
selects displaying setpoints for two
alarm relays.
Output signal
0(4) - 20 mA
 Correspondingto0-20%O2
0 - 4 mA switch selectable.
Maximum series resistor 600 Ohm.
Maximum isolation voltage to ground
300 V DC.
Alarms
Potential free contacts, which are
able to carry 6 A at 250 V AC.
 The rst relay contact opens below
the O2setpoint (LO-alarm).
The second relay contact opens
above the O2setpoint (HI-alarm).
Mains voltage connection
230V-10%/+15%50/60Hz
Power consumption
50 VA in the heating period of the
probe (approx. 2 min) hereafter
max. 30 VA.
Probe connection
4-pole multi-connector
Cable connections:
2pcs. M 16 cable glands
1pcs. M 20 cable gland
Ambient temperature
0-60 o C
Tightness
IP 54 (IP 64 on request).
Dimensions
Height: 244 mm
(280 mm incl. multiplug)
With: 157 mm
Depth: 64.3 mm
Accuracy
Display: ± 1 on last digit
   Currentoutput:    ±0,2%ofmax.
signal

User guide OC 2010 (UK 07/2011 CE) page 6 of 16
2.0. Installation
2.1. Control at delivery
Afterunpacking,pleaseconrmthatthedelivereditemsareinaccordancewiththepackinglist.
Possible inconsistencies should be reported to the supplier immediately. If some parts are dam-
aged please contact the shipping company.
2.2. Instrument identication
The oxygen control system OC 2010-LSU, as standard, consists of a measuring probe OS 2014,
andsignalamplierOC2010-LSU,aguidetubeincludingagasketand4mountingscrewsare
optional.
Measuring probe
The measuring probe contains a measuring cell,
a heating element and a connection cable with
a multipole connector.
Signal amplier
Themeasuringamplierisbuiltintoanalu-
minium cabinet, and contains a power-supply,
ameasuringamplier,alinearizationunit,an
alarm circuit and a current loop output circuit.
2.3. Place of installation
Satisfactory operation, faultless function and
minimal maintenance is achieved by paying
attention to the following notes:
1)The tting place for the probe should
be chosen in a way that protects the probe
 againstmechanical damage.Theuegas-
temperature has to lie within the given
limits of the probe at the measuring point.
2) The gas, which passes the probe, must
be representative.At large crosssections it is
recommended to use the guide-tube (which
leads the gas to the probe).
3)The ue-gas channel must be controlled
 forholesandleakages.Oozingofsurroun-
ding air into the channel, before and
 after the probe, inuences the accuracy
af to the oxygen measurement in an
unwanted direction.
4) The zirkoniumdioxide measuring cell re-
acts on changes in the concentration
of oxygen (e.g. the partial pressure of the
oxygen), and on changes in the negative
pressure at the measuring point.
To keep this effect at a minimum, the
probe must not be installed between id-
fans and their regulation valves or in the
immedate vicinity of these. The pressure
difference must be kept under 100 mm
water column (H2O).
5) The installation place of the signal
 ampliermustbechosensothattheambient
temperature at any time lies over 0 o C,
and below 60 o C.
6) The distance between measuring probe
 andsignalampliercannotexceed2,0m.
7) At high gas-temperatures a special guide
 tube to be welded into the ue channel
wall can be delivered.
Attention
Mounting of the probe itself should not take
place before the completion of all pipe- and
ue-worksattheboiler,andtheburnerisready
to start.
Care should be taken to assure that the system
is constantly powered and the probe is heated
also when the boiler is out of service.

User guide OC 2010 (UK 07/2011 CE) page 7 of 16
2.4. Installation of the oxygen probe
The drawing shows the tting of the probe
inthe ue wall.Inminor ues, the probeis
mounted in a M 18 x 1,5 mm thread hole. In
largeruestheguide-tubeisused.Theange
of this guide tube is mounted onto the wall of
theue.Ifpossibletheprobemustbemounted
on the topside of the ue, assuring that any
possible dust and oil carbon are not deposited
around the probe.
The below drawing is scale 1 : 1 and shows the
cutoutintheue-channelwallforthesupplied
guide tube. The drawing can be taken out of
thismanualandttedontotheuewallwith
an adhesive and be used as a guide to mark
the necessary holes before drilling and cutting.

User guide OC 2010 (UK 07/2011 CE) page 8 of 16
2.5. Installation of the signal amplier
Thesignalamplierismountedineye-levelimmediatelybeloworneartheprobe.Theunit
cannot be installed more than 2,0 meters away from the probe.
2.6. Cable connections
Access to the connection terminals of the signal
amplierisobtainedbyremovingthetop-and
front plate of the cabinet and pushing the front
printed circuit board half a length out of the
cabinet.
A) Connection between the probe and the signal
 amplierisestablishedasthemultipolecon-
nector of the probe is mounted in the socket
 ofthesignalamplier.
B) Mains connection, phase, neutral and
ground are established through a cable gland
(M20), max. pre-fuse 10 A.
C) Signal connection is made through the ot-
her (M16) cable gland. Low voltage
screened cable (2 conductors with shield)
is to be used.
D) Alarm connection is made through the
third (M16) inlet (3 conductors).
Urgent
TheunitfullltheEULowVoltagedirective,thismeansthatallcableconnectionsmustbedone
accordingly. It is mandatory to use the cable clamps to secure the wires of the cables leaving no
excess cable length between clamps and terminals, and to use terminal-tubes/core-protectors)
if using multi cord wires. Supply wires to OC 2010-LSU must be disconnectable by a separate
switch in the panel.

User guide OC 2010 (UK 07/2011 CE) page 9 of 16
3.0. Operation
This paragraph describes normal operation, testing prior to use and procedure at operation stop.
3.1. Function of the signal amplier
1. Current-loop output (0(4)-20mA)
Gives a current loop signal rising
with the O2 %inaccordancewiththeout-
put signal of the probe. The mA-signal
is typically used as input sinal for
an O2-regulator, but it can also be
used for a pen recorder for instance.
The output is galvanically isolated up
to 300 V DC. If higher common mode vol-
tages occur provisions must be taken to
avoid higher common mode voltages be-
tweenOC2010-LSUchassisandthenegative
 outputterminalofthesignalamplier.
2. Alarm switches.
Two alarmswitches are available as a nor-
mally-closed contact.
3. Display.
The signal amplifier is provided with
a digital display. At normal operation the
 oxygenconcentrationisshowninpercent[%]
at the instrument. By means of 3 switches
(which are accessed by removing the top plate
of the cabinet) two set-points for the O2-alarm
are shown.
3.2. Testing prior to use.
1. Check that the probe and the signal am-
plierareinstalledinaccordancewiththe
notes in paragraph 2.3.
2. Checkthatthesignalamplierareinsta-
led in accordance with paragraph 2.4.
3. Check that the probe and the signal am-
 plierareinstalledinaccordancewiththe
notes in paragraph 2.5.
4. Check that wire connections are carried out
in accordance with the instructions given in
paragraph 2.6.
3.3. Start up.
1. Mains voltage is connected to signal
amplifier. The display will indicate
„LLL“while the probe is heaing up.
Note: Because of smal quan-
ties of oil from the prodution smoke
may appear from the probe for a
couple of minutes, but it is of no
importance
2. While the probe (during approx. 2 min.)
reaches its operation temperature, the oxy-
genmonitor will show a number of various
oxygen concentrations, which will be stabi-
 lizedwhentheprobehasreacheditsopera
tion temperature.
3. Optional recalibration, or test of calibration
can be performed after 60 minutes. Calibra
tion is carried out as described in para-
graph 4.1.
3.4. Stops of operation.
Short stops of operation (less than 14 days):
The mains voltage may remain connected if
the operation stop does not imply any pollution
of the probe, as i.e. when the boiler is cleaned
by white washing or high-pressure cleaning.
Long stops of operation (more than 14 days).
The mains voltage is disconnected and the probe
isdismountedfromtheueandstoredinpro-
tected surroundings.
Warning!: Because of the internal heating of the probe, the probe is hot and
can cause severe burnings to personals if not handled with care.

User guide OC 2010 (UK 07/2011 CE) page 10 of 16
4.0. Adjustments and settings
4.1. Routine calibration
The following paragraph describes routine calibration of the OS/OC 2010-LSU system. The
unitsarecalibratedpriortoshipmentandneednosupplementarycalibrationbeforetherst
rutine calibration. Calibration is generally done every 6 months.
Introduction
On calibration the measuring cell OS 20140 is
removedfromtheuechannelandttedintoa
special adapter and exposed to atmospheric air
„AIR“andtocalibrationgas„GAS“(lor2%
of Oxygen in Nitrogen) and the corresponding
adjustmentsaredoneintheSignalAmplier
by removing its topplate.
Warning!:
Because of the internal heat-
ing of the probe, the probe
is hot and can cause severe
burnings to personnel if
not handled with care.
Needed tools:
1. Cross-headedscrewdriverPZDno.2
2. Screwdriverforadjusting(3mmat).
3. Spanner for dismounting the probe(22mm
  xedforkspanner)
4. Calibrationgas1%O2in N2(1)(2)
5. Air pump (3).
6. Flowmeter 0.2 - 1.0 l/min (4).
7. Calibration adaptor (5).

User guide OC 2010 (UK 07/2011 CE) page 11 of 16
6. Apply reference gas from the reduc-
tion valve of the calibration gas-bottle
 (10)and adjust theowto0.6 l/min (4).
7. When the display is stabilised, the
„GAS“ potmeter is adjusted until the display
 isinaccordancewiththetestcerticateof
the calibrationgas.
8. Repeat step 4 to 7 if needet.
9.RettheOS2014sensor.
10.RetthetopcoveroftheOC2010-LSU
cabinet.
Procedure.
1. The multipole connection of the probe is
 removedfromthesignalamplier. 
2. The probe is removed from the guide tube
 orue-wallandplacedinthecalibration 
adapter.
3. The multipole connection is remounted
and the top cover is removed from the
 signalamplier. 
4. Apply calibration air from the pump (9)
 andadjusttheowto0.6Vmin. 
5. After 10 minutes the „AIR“ potmeter is
adjusted, as it is slowly turned to the right
 ifthedisplayshowslessthan20.9%,and
correspondingly left if the display shows
 „HHH“untilthedisplayshows20.9%.
4.2 Setting of alarm limits
4.2.1. Alarms with normally closed contacts
Alarm setting can be accessed removing the top plate of the electronic unit. The display can
be used as an indicator selecting the value to be displayed switching the „FUNC.“ switchs ac-
cordingly.

User guide OC 2010 (UK 07/2011 CE) page 12 of 16
High Alarm
Theoutputrelaywillremainenergizedaslong
as the Oxygen value remains below the adjusted
setpoint.
Setting
Slide switch 1 and 3 to „OFF“ position. Slide
switch 2 to „ON“ position. Adjust the poten-
tiometer marked „HI“ until the display reads
the wanted value.
Low Alarm
Theoutputrelaywillremainenergizedaslong
as the Oxygen value remains above the adjusted
setpoint. The output contact will remain closed
aslongastherelayremainenergized.
Setting
Slide switch 2 and 3 to „OFF“ position. Slide
switch 1 to „ON“ position.
Adjust the potentiometer marked „LO“ until
the display reads the wanted value.
Warning
Please remember to slide switch 1 and 2 to
„OFF“ position and to slide switch 3 to „ON“
position to enable the display to indicate the
measured Oxygen value.
Internal alarms.
When an internal error occur in OC 2010-LSU or power is not supplied to the unit both
„HIGH“and„LOW“alarmcontacts open. OC 2010-LSU is monitoring the OS 2014 measuring
cell and at cell error the „LOW“ alarm relay contact will open.
4.2.2. Alarms with normally open contacts
Alarms with opening contacts are not adapted in the OC 2010-LSU.
When using alarms with normal open contacts -„HIGH“ and „LOW“ alarm can be
interchanged. Please observe that no internal alarms can be given and no proper cell error
alarm can be expected

User guide OC 2010 (UK 07/2011 CE) page 13 of 16
Example 1
4.3. Selecting 0 - 20 or 4 - 20 mA output.
The current loop output signal from OC 2010 can - by sliding the „FUNC.“ switch - be selected
either as 0 - 20 mA or as 4 - 20 mA. The „FUNC.“ switch can be accessed by removing the top
coveroftheSignalAmplier.
Sliding switch 4 to „ON“ position selects the
current loop to be 4 - 20 mA
Sliding switch 4 to „OFF“ position selects the
current loop to be 0 - 20 mA
4.4. Connecting OC 2010-LSU to other equipment.
The current loop output of OC 2010-LSU is either 4 - 20 mA or 0 - 20 mA selected in accord-
ance to chapter 4.3.
The loop is galvanically isolated from the internal circuits of OC 2010-LSU within a range of
maximal 300 VDC.
Pending is shown two ways to connect
OC 2010-LSU to other equipment.
4.4.1. Active loop:
In example 1 OC 2010-LSU is supplying the
loop with power (active loop).
If in doubt whether to use an active or passive
loop connection it is recommended to use an
activeloopastherstalternative.

User guide OC 2010 (UK 07/2011 CE) page 14 of 16
5.0. Maintenance
To obtain the best possible results using the OC 2010-LSU Oxygen control it is recommended
to maintain the instrument as listed below:
1) Every 6 or 12 months a routine calibrations
performed according to paragraph 4.1.
If calibration is no longer possible or feasible
the cell must be exchanged.
 Itisrecommendedtoletacertiedtech-
nician (having the necessary special tools)
perform this calibration.
2) When using the OC 2010-LSU on very dusty
fuels (i.e. straw) it is recommended to
dismount the OS 2014 measuring cell
at intervals and inspect the four holes
at the base of the protective shield of
the cell. If the holes are blocked they can
be opened with a small needle. The cham-
ber between the shield and cell wall can
 thencleanedusingpressureizedair.
Example 2
4.4.2. Passive loop
In example 2 the receiver is supplying loop
power (passive loop).
If in doubt whether to use an active or pas-
sive loop connection it is recommended to use
anactiveloop(seepreviouspage)astherst
alternative.
Passive loop is normally only used on installa-
tions where a larger number of loop powered 4
- 20 mA transmitters are used (i.e. Pt100 sensors
withintegratedamplier)
Warning.
Avoid connecting a power source from both ends - or connecting the input of the
receiver directly to both the + and - terminal of the OC 2010-LSU. This will destroy
the internal fusing circuit of the OC 2010-LSU.
The cell is heated -therefore the
power to the unit has to be dis-
connected and the cell needs
to cool down by itself before
any attempt to handle the
cell is made.
Warning!:
Small
Protection shield
Holes 12 pcs.
needle
OS 2014 S/N nnnn

User guide OC 2010 (UK 07/2011 CE) page 15 of 16
6.0. Scalation
The current loop output of OC 2010-LSU is either 4 - 20 mA or 0 - 20 mA selected according
to chapter 4.3.
Selectingthe0-20mAoutputone%ofoxygenequalsonemA(1:1).
Selecting4-20mAone%ofoxygenequals0.81mA(nx0.81)+4.
Actualmeasuringrangeislimitedto0.5%through20.9%usingtheunderrangebelow0.5%
aserrorindication"LLL"andoverrangeabove20.9%"HHH"forambientaircalibration.
Signal conversion of the logaritmic signal from the sensor to a linear output signal is done
digitallyandtheoutputcomesfroman8bitD/Aconverter.Thisgivesaniteresolutionof
81.6 µA per step of the output signal and forms a staircase step increasing output.
The corresponding output mA to oxygen values are shown in the graph below:

User guide OC 2010 (UK 07/2011 CE) page 16 of 16
7.0. EU Declaration of conformity
ScanTronic
Sverigesvej 16
DK - 8700 Horsens
Danmark
According to the requirements set out by directive 93/68/EEC
declare in sole responsibility that the products:
Oxygen control OC 2010 -LSU
to which this certicate applies, conform to the
EMC directive 2004/108/EEC and its
amendments and conform to the Low voltage directive 2006/95/EEC
To effect correct application of the EMC directive the standards
EN 61000-6-4 and EN 61000-6-2 have been consulted.
To effect correct application of the Low voltage directive the standard
EN 61010-1 has been consulted.
Comply with EU Directive 2011/65/EU (RoHS II).
Ove Kudahl Munch, Director
April,2014
_____________________ ____________________
signature date
Sveriesvej16Phone+4589614555
8700HorsensMobile+4521660085
Danmark CVR no. 25015886
www.scan-tronic.dk
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