United Process Controls Probe Buddy User manual

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USER MANUAL
Probe Buddy
Smart O2 Probe Simulator & Tester

PROBE BUDDY – USER MANUAL Page 2 of 27
UPC_MAN013_R7
Copyright © United Process Controls. All rights to copy, reproduce and transmit are reserved.
MANUAL #: 013
Revision #
Revision Date
Revision Description
007
August 16, 2018
Instrument Cables included.
006
May 23, 2018
Foil revision, process values, cable types, cal and
factory mode
005
May 8, 2018
Updated process equations and factor menus
004
April 25, 2018
003
April 2, 2018
002
March 22, 2018
001
September 20, 2017
000
September 17, 2017
COPYRIGHT(C)
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language or computer language, in any form or by any means,
electronic, mechanical, magnetic, optical, chemical, manual, or otherwise, without prior written
permission of United Process Controls Inc.
DISCLAIMER:
The PROBE BUDDY is to be used by the industrial operator under his/her direction. United
Process Controls Inc. (UPC) is not responsible or liable for any product, process, damage or
injury incurred while using the PROBE BUDDY. United Process Controls Inc. makes no
representations or warranties with respect to the contents hereof and specifically disclaims any
implied warranties or merchantability or fitness for any purpose.
TECHNICAL ASSISTANCE
For all questions or concerns regarding the operation of the PROBE BUDDY, please consult
the last page of this manual for contact information.

PROBE BUDDY – USER MANUAL Page 3 of 27
UPC_MAN013_R7
Copyright © United Process Controls. All rights to copy, reproduce and transmit are reserved.
Table of Contents
1DESCRIPTION.................................................................................................................. 5
LCD Graphic Display .................................................................................................... 5
Signal Connectors ........................................................................................................ 5
Keyboard ...................................................................................................................... 6
1.3.1 Single Key Functions ............................................................................................. 6
1.3.2 Dual Key Functions................................................................................................ 7
Normal Operation ......................................................................................................... 7
Standby Mode .............................................................................................................. 8
Input Mode ................................................................................................................... 9
1.6.1 Using Input Mode................................................................................................... 9
Output Mode................................................................................................................. 9
1.7.1 Using Output Mode .............................................................................................. 10
Probe Test Mode........................................................................................................ 11
1.8.1 Why Measure Sensor Impedance?...................................................................... 11
Alarm Display ............................................................................................................. 12
2SETUP MENU................................................................................................................. 13
3PROCESS FORMULAS ................................................................................................. 17
Carbon Formula.......................................................................................................... 17
Dew Point Formula ..................................................................................................... 17
Oxygen Formula......................................................................................................... 18
4CALIBRATION ............................................................................................................... 19
Calibration Displays and Keyboard Operation............................................................ 20
Preparing for Input Calibration.................................................................................... 21
4.2.1 Calibration of Inputs ............................................................................................. 21
Preparing for Output Calibration................................................................................. 22
4.3.1 Calibrating the Outputs Signals............................................................................ 22
Calibration of Cold Junction........................................................................................ 22
5DIAGNOSTIC ALARMS ................................................................................................. 23
6BATTERY REPLACEMENT ........................................................................................... 23
7TECHNICAL DATA......................................................................................................... 24
LCD Graphic Display .................................................................................................. 24
Analog Signals............................................................................................................ 24
General....................................................................................................................... 25

PROBE BUDDY – USER MANUAL Page 4 of 27
UPC_MAN013_R7
Copyright © United Process Controls. All rights to copy, reproduce and transmit are reserved.
Standards Conformity................................................................................................. 25
8REFERENCES................................................................................................................ 25
Available Cables:........................................................................................................ 25

PROBE BUDDY – USER MANUAL Page 5 of 27
UPC_MAN013_R7
Copyright © United Process Controls. All rights to copy, reproduce and transmit are reserved.
1 DESCRIPTION
The United Process Controls Sensor Simulator and Tester (PROBE BUDDY) has been
designed for the maintenance or system engineer in mind. The PROBE BUDDY gives the
operator a valuable tool for testing any UPC oxygen sensor as well as the ability to simulator a
working sensor connected to process control systems.
The important features of the tester are:
•Operates as sensor test/meter or sensor signal simulator
•Accepts selectable TC and mV inputs from any oxygen sensor
•Outputs selectable TC and mV signals to simulate an oxygen sensor
•Performs a sensor impedance test when connected to the sensor
•Computes carbon, dewpoint or oxygen in input or output mode
•Low power LCD display for HMI
•Small hand-held package
•Easy access connections on the top panel
•Operates on standard 9V battery
LCD Graphic Display
The LCD display is a low power 132x32 Pixels graphic display, equivalent to 4x22 characters.
Signal Connectors
There is a sensor millivolt and sensor thermocouple connector located on the top of the
PROBE BUDDY. The standard T/C connector is a B type standard mini-thermocouple plug
with alligator clips. The millivolt connector is a standard banana plug with alligator clips.
Optional cables are available that provide mating connectors for UPC probes – Carbonseer,
Quicksilver, AccuCarb, AtmoProbe – and other sensors and installed cables. See the table in
the reference section of this manual for a list of available cables.

PROBE BUDDY – USER MANUAL Page 6 of 27
UPC_MAN013_R7
Copyright © United Process Controls. All rights to copy, reproduce and transmit are reserved.
Keyboard
The PROBE BUDDY keyboard has eight keys that operate as individual keys or in
combinations of two keys.
These keys are separated into two groups, the mode group and the navigation group.
Figure 1 Mode Group Keys
Figure 2 Navigation Group Keys
Each key has a principal function, but combo keys can be used for additional operations.
1.3.1 Single Key Functions
TC / mV toggles between the TC and mV selection when configured for output mode.
It also serves to move the cursor from the TC to the mV values. Use the arrow keys to
position the cursor and change the digit value.
IN / OUT selects the IN/OUT mode. Both the millivolt and T/C signals shift from input
to output when this button is toggled. Output levels for either signal can be adjusted, if
ramp mode is not active. When input mode is selected, the actual signal levels are
displayed and are not adjustable.
Setup allows access to the setup menu. Press and hold for 5 seconds to enter Setup
mode.

PROBE BUDDY – USER MANUAL Page 7 of 27
UPC_MAN013_R7
Copyright © United Process Controls. All rights to copy, reproduce and transmit are reserved.
Enter / ON starts up the simulator and allows data entry in the setup mode. Press and
hold the Enter key for 1 second to turn on and 5 seconds to turn off. The Enter key
sets values or parameter selections, once required changes have been made. The
Enter key will shift to different display windows when the PROBE BUDDY is in output
mode.
Left Arrow moves the digit cursor to the left in output mode or moves left through the
main menu selection in setup mode.
Down Arrow deceases the selected digit value in output mode or moves down the
selected setup menu.
Up Arrow increases the selected digit value in output mode or moves up in the
selected setup menu.
Right Arrow moves the digit cursor to the right in output mode or moves right through
the main menu selection in setup mode.
1.3.2 Dual Key Functions
Enter / ON + Right Arrow
Pressing the Enter and Right Arrow keys simultaneously starts or stops the sensor test.
Enter / ON + Left Arrow
Pressing the Enter and Left Arrow keys simultaneously opens the Service mode on the
PROBE BUDDY.
Normal Operation
The following figure shows the PROBE BUDDY display layout.

PROBE BUDDY – USER MANUAL Page 8 of 27
UPC_MAN013_R7
Copyright © United Process Controls. All rights to copy, reproduce and transmit are reserved.
1. SIGNAL DIRECTION ICON - Changes the signal direction of both the thermocouple and
millivolt signal by pressing the IN/OUT key. Left arrow (pointing out) indicates output mode.
Right arrow (pointing in) indicates input mode.
2. TEMPERATURE – Display of thermocouple signal is based on the thermocouple type and
temperature scale (°C/°F) selected in the setup menu.
3. TEMPERATURE SCALE – Indicates the temperature scale
4. PROCESS VALUE – Selected process is displayed here based on the temperature and
millivolt signals, either inputs or outputs. The scale will change according to the process.
5. RAMP – Indicates that the selected output signal is ramping from a selected start and stop
range. The ramp function is enabled in the SETUP / OUTPUTS menu. One or both outputs
will ramp if enabled. Changing values are displayed.
6. PROCESS – Indicates the selected process: DPT for dewpoint, %C for carbon, %O2 for
oxygen, and PPM for %O2 values below 00.01% oxygen.
7. SENSOR MILLIVOLTS – Shows the measured or set sensor millivolt output.
8. DIGIT CURSOR – Cursor indicates the digit selected to change. The cursor shifts from
temperature to millivolts when the TC/MV key is pressed. The arrow keys change the
cursor position and digit value. The cursor is only available when the signal output mode is
selected.
9. BATTERY LOW ICON– Indicates when the battery power is low and should be replaced.
Standby Mode
The PROBE BUDDY is in standby mode when the display is blank. The unit will turn on when
the Enter key is pressed for 5 seconds. The unit has an adjustable wake state time that can be
selected in the SETUP / DISPLAY / SLEEP MODE SHUTDOW parameters. This setting

PROBE BUDDY – USER MANUAL Page 9 of 27
UPC_MAN013_R7
Copyright © United Process Controls. All rights to copy, reproduce and transmit are reserved.
determines how long the unit will remain on, without any key being pressed, during the
specified period of time. This feature is available to minimize power drain on the battery.
Input Mode
The input function has been selected with the calculated oxygen
display for the thermocouple and millivolt input signals.
Pressing the Enter key cycles between the available displays
1.6.1 Using Input Mode
Input mode is used to check or test the outputs of a sensor in a working furnace. The sensor
should be at or above its minimum temperature range 1100°F (600°C). Disconnect the sensor
from the monitoring or control system and connect the PROBE BUDDY to the TC and mV
signal connections from the sensor.
If you are using the cable set with alligator clips, there will be a cold junction error introduced to
the temperature measurement, but the intention here is to confirm operation of the TC and
confirm the process value.
Output Mode
The output function has been selected with the calculated oxygen
display for the selected thermocouple and millivolt outputs.
Pressing the TC/mV key cycles between the TC/mV output
values. The ◄ or ► keys move the cursor on the digits of the
value selected.
1600° F 1.12%
72.0 mV %O2
IMPEDANCE 1.20K
RECOVERY 10 SEC
→
TC TYPE - K
COLD JUNC 65
Enter
Enter
Enter
1600° F 1.12%
72.0 mV %O2
→

PROBE BUDDY – USER MANUAL Page 10 of 27
UPC_MAN013_R7
Copyright © United Process Controls. All rights to copy, reproduce and transmit are reserved.
Output mode only displays the signal screen but allows the
operator to cycle between the TC setting and the mV setting.
The position of the cursor is indicated by the flashing cursor
under the selected digit.
This method is much more efficient then the ‘press and wait’
method and allows the operator to instantly change the
magnitude of the output.
The flashing cursor indicates which digit can be changed by pressing the up or down arrows to
increase or decrease the value. The digit will change with each key press. Each digit value
cycles from 0 to 9 or 9 to 0 when the arrow keys are continually pressed.
The operator can change the position of the cursor with the
discrete right or left arrow key presses. The cursor will continually
shift from LSD to MSD or MSD to LSD if the arrow keys are
continually pressed.
This scheme allows the operator to change the output values
quickly without having to wait for fixed or dual speed value
changes and the need to time the key release. The output signal
changes and settles to the selected value as soon as the Enter
key is pressed. The displayed process value is recalculated with
the new output values and displayed.
1.7.1 Using Output Mode
The PROBE BUDDY is used in output mode to test and verify that the monitoring or control
instruments are working or to simulate changes in the sensor signals using the ramp mode for
either or both signals. To modify the process, it is generally more useful to ramp only the mV
signal and set the temperature output to the typical operational level.
To set up for output mode:
•Change PROBE BUDDY to output mode by pressing the IN/OUT key until the signal
direction icon points left (out).
•Using the correct TC cable, connect the TC leads to the instrument thermocouple
inputs. Observe the polarity of this connection. The negative lead of thermocouples is
typically the red wire. NOTE: B type TC connections can be made with standard copper
wire.
•Connect the mV cable to the instrument millivolt inputs. Observe the polarity of this
connection.
•Move the digit cursor to the TC display by pressing the TC/mV key if it is not already
flashing under the TC value.
•Press the ◄ or ► keys to move the cursor, and use ▲ or ▼ keys to change digit value.
1600°F
←
TC/mV
1100 mV
TC/mV
1600°F
Left Right
Cursor Shift
Value Change
Up/Down Arrow