Systech Instruments EC900 series Assembly instructions

Illinois Instruments, Inc. (U.S.)
2401 Hiller Ridge Road
Johnsburg
Illinois IL
60051
Systech Instruments Ltd
17 Thame Park Business Centre
Wenman Road
Thame
Oxfordshire
OX9 3XA
E: [e-mail]
E: [e-mail]
www.systechillinois.com
SERIES EC900
OXYGEN ANALYZERS
(Covers MK3 USB models)
OPERATOR’S INSTRUCTION
MANUAL
Version 4.7 5th February 2014

EC900 Series Operation Manual V4.7
www.systechillinois.com
Table of Contents
1.0 PREFACE..................................................................................................................................1
1.1 Important..........................................................................................................................................2
2.0 INTRODUCTION.......................................................................................................................3
3.0 WARRANTY..............................................................................................................................4
3.1 Instrument Warranty.........................................................................................................................4
3.2 Measuring Cells Warranty................................................................................................................4
4.0 ISOLATION VALVE OPERATING ORDER..............................................................................5
5.0 PRINCIPLE OF OPERATION...................................................................................................5
6.0 TECHNICAL SPECIFICATIONS...............................................................................................6
7.0 INSTALLATION ........................................................................................................................8
7.1 Instrument Installation......................................................................................................................8
7.2 Gas Installation ................................................................................................................................9
7.3 Electrical Installation ......................................................................................................................10
8.0 USING THE INSTRUMENT.....................................................................................................10
9.0 INSTRUMENT OPERATION...................................................................................................11
10.0 CHANGING PROGRAMME CODES......................................................................................12
10.1 Front Panel Guide........................................................................................................................13
10.2 Data Table Programmable Functions...........................................................................................14
11.0 PROGRAMME CODES...........................................................................................................17
13.0 CALIBRATION........................................................................................................................20
13.1 Calibration with Atmospheric Air ..................................................................................................20
13.2 Calibration with Certified Gas.......................................................................................................21
13.3 Automatic Calibration option ........................................................................................................22
14.0 USB and RS485 COMMUNICATIONS...................................................................................24
14.1 Installing the USB Driver Software...............................................................................................24
14.2 Installing the COMMS UTILITY SOFTWARE...............................................................................25
14.3 Determining the installed Comms Port.........................................................................................28
14.4 Running the COMMS Utility Software. .........................................................................................30
14.5 USB Commands For Use with the EC900....................................................................................32
14.6 RS485..........................................................................................................................................33
15.0 OPTIONAL FACILITIES..........................................................................................................34
15.1 Analogue Outputs (Option)...........................................................................................................34
15.2 Alarm Trip (Option).......................................................................................................................34
15.3 Sample Pump...............................................................................................................................35
16.0 FAULT MESSAGES/ALARMS...............................................................................................36
17.0 REPLACING THE MEASURING CELL..................................................................................37
17.1 Resetting the Calibration Range and Life Counter.......................................................................38
18.0 SPARE PARTS .......................................................................................................................39
19.0 SERIAL NUMBER SUFFIX DETAILS ....................................................................................41
Appendix 1 Drawing Number B900-176.........................................................................42

EC900 Series Operation Manual V4.7
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Appendix 2 Drawing Number 920 043_B .......................................................................43
Appendix 3 Drawing Number B 900 180 ........................................................................44
Revision History
Issue
Issue Date
Changes
By
1.1
09-05-2008
Current Release Version
Jon Dawson
2.0
18-08-2009
Format changes, updated some drawings
Nick Stuart
4.0
09-08-2010
Updated to the USB comms model
Nick Stuart
4.1
19-08-2010
Added 0-10V output details.
Nick Stuart
4.2
02-06-2011
Added details for mk 6 PCB, also corrected p16.
Nick Stuart
4.3
20-12-2011
Added info regarding Auto Cal initiation. Re: CI 4162
and SPn2# value.
Nick Stuart
4.4
25-04-2012
Clarified “Delay” for alarm settings. Ref CI 4176
Nick Stuart
4.5
24-08-2012
Amended the flowmeter part numbers
Nick Stuart
4.6
15-11-2013
Added Warranty and other information regarding cells.
Updated Wall mount dimensions 920 043.
Bryan Cummings
4.7
5-02-2014
ECN 1404s, All RACEcell instruments now have
dual life displays.
Bryan Cummings

EC900 Series Operation Manual V4.7
www.systechillinois.com
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1.0 PREFACE
The EC900 series of oxygen analyzers exist with a number of variations, with different cabinet types
and different measuring cells, these variations are covered in this manual.
We are always trying to improve our product, of which this manual is part, so we would greatly
appreciate any information you can give us of any difficulties you may encounter with the analyzer or
the manual.
This symbol is known as the ‘Crossed-out Wheelie Bin Symbol’. When this symbol is marked
on a product it means that consideration should be given to the disposal of the product, parts
or accessories. Only discard electrical/electronic items in separate collection schemes which
cater for the recovery and recycling of the materials contained within. Your co-operation is
vital to ensure the success of these schemes and for the protection of the environment.

EC900 Series Operation Manual V4.7
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1.1 Important
Please read this manual before attempting to install or operate the equipment.
The equipment should be electrically connected and grounded in accordance with the instructions
attached to the power cord and in accordance with good standard practice.
No responsibility is accepted by Systech Illinois
for accidents resulting from improper use of this equipment.
All service and technical enquiries are covered from our factories in Thame, Oxfordshire, and
Johnsburg, Illinois where we will endeavour to give a quick and helpful response to all queries.
The factory addresses are:
Illinois Instruments, Inc (U.S.)
2401 Hiller Ridge Road,
Johnsburg
Illinois IL 60051
Tel: [phone]
Systech Instruments Ltd
17 Thame Park Business Centre
Wenman Road
Thame
Oxfordshire
OX9 3XA Tel: [phone]
For customers outside UK or USA, please contact us for details of your local representative.
Alternatively check out our website:
www.systechillinois.com

EC900 Series Operation Manual V4.7
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2.0 INTRODUCTION
The EC900 Series of instruments may be supplied in three types of cabinet/housing and may use any
one of four measuring cells, suitable for different applications.
The instrument may also be fitted with other customer specified options.
Please refer to Table 1 below, for the configuration code and an explanation of the instrument
numbering system.
When particular attention should be given in this manual to a particular configuration the paragraph
will be preceded with a configuration specification i.e.
EC91x
=
Panel/Bench mounting
EC92x
=
Wall mounting
EC9x1
=
Trace analysis
Series EC900 Oxygen Analyzers
Cabinet - Mounting
EC9
Panel or bench mounting
1
Wall mounting IP66
2
Rack mounting (*Note 1)
3
Cell type / range
% analysis
0
Trace analysis
1
Ultra low trace analysis
2
RACE
3
Configuration code =
EC9
x
x
Table 1 Configuration codes
* Note: 1 A rack mounting case is 19" wide, 4U high. This provides a housing suitable for 1 or 2
analyzers.

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3.0 WARRANTY
3.1 Instrument Warranty
This Instrument is guaranteed for a period of one year from its delivery to the purchaser covering
faulty workmanship and replacement of defective parts. This assumes fair wear and tear and usage
specified on the data sheet. It does not cover routine calibration and housekeeping.
Warranty covers parts and labour on a “return to base” basis. Any on-site warranty visits may be
chargeable in terms of travel and expenses.
We maintain comprehensive after sales facilities and the instrument should be returned to our factory
for repair, servicing or routine calibration if this is necessary. Service agreements are available and
can include routine maintenance at the customers site, please contact Systech / Illinois Instruments
for more details.
The warranty does not extend to sensors overexposed to oxygen during the warranty period, or to
those whose elements have been damaged by surges of undue pressure.
The type and serial number of the instrument should always be quoted, together with full details of
any fault.
3.2 Measuring Cells Warranty
Please note the Warranty code against the part number of the measuring cell installed by referring to
the Spare Parts section.
Code
Warranty
Typical Life and Notes
A
6 Months from
the date of
supply.
The measuring cell should have a life of 4+ years. The life is very much
dependent on the moisture in the gas stream. The more humid the gas
(as long as it is non-condensing) the longer the life. The primary reason
for premature failure is exposing the cell to air, or to subject the cell to
high pressure.
B
12 months from
the date of
supply.
The measuring cell should have a life of 3+ years. Cells measuring
Oxygen concentrations of less than 10% should have a lifetime of 5+
years. The life is very much dependent on the moisture in the gas stream.
The more humid the gas (as long as it is non-condensing) the longer the
life. The primary reason for premature failure is exposing the cell to high
pressure.
C
36 months from
the date of
supply
The measuring cell should have a life of 5+ years.
D
Cells have a full
warranty of 6
months from
the date of
supply.
Between 6
months and 36
months a
partial warranty
applies.
A credit will be given for complete calendar months remaining up to 36
months. The credit is calculated from (36 - months in use)/30. A cell for
instance that has failed after 25 months will be credited (36-25)/30 =
0.366 * the current list price. The measuring cell should have a life of 4+
years. The life is very much dependent on the moisture in the gas stream.
The more humid the gas (as long as it is non-condensing) the longer the
life. The primary reason for premature failure is exposing the cell to air, or
to subject the cell to high pressure.

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WARRANTY EXCLUSION
In some instances cells do not achieve their expected lifetime, failing early due to misuse: isolation
valves on the analyser left open causing ingress of high oxygen levels, or cell rupture caused high
pressure being applied across the cell. Misuse of the measuring cell in this way is not covered by the
warranty.
3.2 Measuring Cells Warranty - continued
NOTE
Most cells that do not last their expected lifetime fail because:-
1. The isolation valves on the analyzer are left open, causing ingress of high ambient
oxygen levels.
2. The cell has been ruptured caused by high pressure, usually caused by the isolation
valves being operated in the wrong order. Ruptured cells can be confirmed by
electrolyte solution seeping from the inlet/outlet pipes or by blackening of the same
pipes.
4.0 ISOLATION VALVE OPERATING ORDER.
For analyzers sampling from pressurised supplies:
When opening the cell, open the OUT valve first, followed by the IN valve
When closing, close the IN valve first, followed by the OUT valve.
For analyzer fitted with a pump:
When opening the cell, open the IN valve first, followed by the OUT valve
When closing, close the OUT valve first, followed by the IN valve.
MISUSE OF THE CELL IS NOT COVERED BY WARRANTY
5.0 PRINCIPLE OF OPERATION
The detector contains an anode, electrolyte and an air cathode to which the diffusion of Oxygen is
limited by a diffusion barrier. At the air cathode Oxygen is reduced to Hydroxyl ions which in turn
oxidise the metal anode.
The following reaction takes place at the cathode:
O2+ 2H2O + 4e 4(OH)-
and at anode
2Pb + 4(OH)- 2Pb(OH)2+ 4e
and the complete chemical reaction is represented by
2Pb + O2+ 2H2O 2Pb(OH)2

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6.0 TECHNICAL SPECIFICATIONS
Measuring Ranges:
(All Auto-ranging)
EC9x0
0.3% - 100%
EC9x1
EC9x3
0.1ppm - 30%
EC9x2
0.01ppm - 30%
Calibration
Ranges:
EC9x0
0.3% –100%
EC9x1
EC9x3
0.1ppm –30%
EC9x2
0.01ppm –30%
Response Time:
EC9x0
EC9x1
90% indication in less than 30 seconds
EC9x2
90% indication in less than 30 seconds
EC9x3
Air to less than 20ppm in 2 minutes
Accuracy:
EC9x0
± 0.2% of calibrated value at 20oC
± 1% of calibrated value over temperature range
EC9x1
EC9x3
>10ppm
± 2% of reading at 20oC
± 5% of reading over temperature range
<10ppm
± 2% of reading +0.4ppm at 20oC
± 5% of reading + 0.6ppm over temperature range
EC9x2
>10ppm
± 2% of reading at 20oC
± 4% of reading over temperature range
<10ppm
± 2% of reading +0.2ppm at 20oC
± 4% of reading + 0.3ppm over temperature range

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Technical Specification contd.
Suitable Gases:
EC9x0
All gases except corrosive gases
EC9x1
EC9x2
EC9x3
All gases except corrosive and/or
acidic gases
Display:
4 Digit high visibility LED
Sample connections:
1/8” OD compression (Swagelok)
Ambient Temperature:
-5°C to 50°C (Instrument and sample gas)
Sample Gas Inlet
Pressure:
3.5 –29 PSI (0.25 Bar - 2 Bar)
Ambient (for pump equipped systems)
Power:
90-260 VAC, 40VA
Area Classification:
General Purpose
Communications:
USB 1.0 / 2.0 and RS485
Dimensions:
Refer to the drawing B900 176 at the rear of the manual Appendix 1.
OPTIONS
High / Low Alarms:
Two with volt free c/o contacts fully
configurable over the complete oxygen range,
one fault alarm.
Contact rating 5A @ 250VAC/30VDC
Analogue outputs:
Software configurable over the entire oxygen range for either :
Current: 4-20mA isolated
Current 0-20mA isolated
Flow Alarm:
Thermal Mass Flow sensor
Auto Calibration
(option):
Allows connection to a cylinder of gas with a certified level of oxygen.
Analyzer will correct to recorded level at programmed intervals.
Bypass Flowmeter:
Improves the response time of the analyzer due to sample transport lag by
adding a fast side stream.
Sample Pump
Allows the instrument to be used in situations where there is no pressure to
the sample gas.
Stainless Steel
Fittings
Allows the instrument to be used in situations where the sample gas will
react with either brass or copper fittings and pipes. Note: stainless steel
flowmeter and regulator will also be required.