OPERATING INSTRUCTIONS ULTRA.sens

Transcription

1 Wi.Tec - Sensorik GmbH Am Kaisershecken Schermbeck GERMANY Phone. : +49 (0) Fax: +49 (0) ge.wiegleb@witec-sensorik.de Web: [1]

2 General Description The ULTRA.sens is based on the selective absorption of ultraviolet radiation in the range from 200nm till 450nm. In this spectral range it is possible to measure a numerous number of important gases like Sulphur dioxide (SO2), Nitrogen dioxide (NO2), Nitrogen oxide (NO), aromatic Hydrocarbons (e.g. Benzene) and Ozone (O3). The radiation source is a special LED (Light Emitting Diode) or an EDL (Electrode less Discharge Lamp). The absorption of radiation in the sample cell is based on the Lambert-Beer-Law. In order to get a stable gas concentration reading it is necessary to have a reference signal. For this purpose the ULTRA.sens has a references channel detecting the LED or EDL radiation I0 without any absorption. The design of the optical bench is shown in Fig. 1. Fig. 1 : Optical design of the ULTRA.sens gas detection module Fig. 2: Demountable design of the ULTRA.sens optical bench. Bracket (1), sample cell tube (2), fastening screws (3), detector unit (4), Source and bema splitter unit (3). [2]

3 The complete ULTRA.sens module is demountable as shown in Fig. 2. Especially in case of contamination it is possible to dismantle the optical bench and clean the surfaces inside. The sample cell (2) is made in stainless steel. After a reassemble the only adjustment is a zero calibration with zero gas (e.g. Nitrogen, N2). Technical data Power supply VDC Supply current <100 ma Power consumption 2-3 W Warm up time < 10 min. Dimensions (W x H x D) 35cm x 7cm x 12cm Weight app. 700g PC requirements Windows 7-10, RS232, CAN Bus Adapter (PEAK etc.) Ambient conditions Temperature: 5 45 C, Relative humidity: < 80% Gas connection/hose Viton or Teflon flexible tube (4mm/6mm) DEVICE DESCRIPTION In Fig. 3 the entire assemble of the ULTRA.sens is shown. The gas input is designated at the right side (detector unit) and the gas output at the left side (source unit). The fittings are suitable for 4mm (inner diameter) and 6mm (outer diameter) flexible tubes (Viton or Teflon). The gas flow direction is not critical, so that it is also possible to change the direction. All connectors on the main board are accessible from the top side accept the program interface (only for production purpose necessary). The optical bench and the main PCG are assembled on a support plate (Aluminium). The dimensions of the support plate are shown in Fig. 4. The 6 holes are suitable for M4 screws. Fig. 3: Entire arrangement of the ULTRA.sens module [3]

4 Fig. 4: Dimensions of the support plate WARNING The UV-source (EDL, LED) emits high intensity ultraviolet radiation. Please do not look directly at light- use eye protection. Eye and skin hazard- avoid exposure to eye/skin. Fig. 5: Warning label shown on the source unit of the ULTRA.sens optical bench (left). International UV Light Hazard Symbol based on ANSI Z535.4 and ISO (right). [4]

5 Important Note Gases like sulphur dioxide (SO2) and nitrogen dioxide (NO2) have the properties to stick at surfaces. This behaviour leads to a hang up effect as shown in Fig. 6. In order to reduce this unwanted effect it recommended using Viton or Teflon for the gas supply. Furthermore it is recommended to wait a sufficient time for zero and span calibration. Fig. 6 : Response behaviour of the gas readings under different circumstances [5]

6 Electrical Connections Fig. 7: Positions of the electrical connections Power connection It s not important to have attention on the polarity, because the detector can powered in both ways. To connect the detector with a power supply please use a 5mm 2 pol. Connector. For example: CAMDENBOSS, CTB9200/2A Wire: 0, 2 2, 5 mm 2 (12AWG 30AWG) Fig. 8: Power socket (connector) [6]

7 Communication connection Fig. 9a: Socket (connectors) for CAN-BUS Interface Fig. 9b: Socket (connectors) for RS232 Interface CAN-BUS (RJ 45) CAN-BUS (6 pol) RJ45 Connector RJ Front view Back view Bottom view terminal RJ45 connector (X1,X4) Alternative connector (X2,X3) PIN SIGNAL PIN SIGNAL 1 GND 1 GND 4 CAN-H 3 CAN-H 5 CAN-L 2 CAN-L [7]

8 RS232 (CON 3) Configuration (from detector) PIN SIGNAL NC 2 TXD 3 RXD 4 NC 5 GND 6 NC RESET Detektor (LowAktiv) 7 8 NC 9 NC 10 NC Channel Description for the different measurements NDUV Low concentration High concentration CH1 CH2 CH3 CH4 NDIR Low concentration High concentration NDUV CH3 CH4 ADCMeas CH1 ADCRef_CH1 ADCMeas CH2 ADCRef_CH2 ADCMeas CH3 ADCRef_CH3 CH1 CH2 NDIR [8]

9 Multi Analyser Software Tool (MAS Tool) General The software tool enables data logging of all relevant parameter from the detector system (chart and data). The main user level of this software can read all parameter and set Zero and Endpoint of the Gas Channels. It is also possible to turn off/on the radiation sources of the detector. Note: To change the calibration coefficients and some other sensible parameter the user can Type a password to entry into an advanced user mode. The password is given after request and only in special cases. Connection In Fig. the connection between the ULTRA.sens module and the PC/Laptop is shown. It is necessary to use the provided adapter cable (Fig. ) and a USB to RS-232DB9 serial adapter cable (Fig.12). Fig. 10: Connection between the ULTRA.sens module and the PC/Laptop [9]

10 Fig. 11: Position (R-Cable10P) of the RS 232 Interface (left) and the adapter cable (right) Fig. 12: USB to RS-232DB9 Serial Adapter Cable [10]

11 Starting the program The program can directly started from the directory it is not necessary to install anything. Right klick on TestCommands.exe and open with administration rights! Fig. 13: Screen shot of the MAS Tool (Host Software) [11]

12 1 Set the serial COM Port 2 Serial Number of the connected Detector 3 Open the selected COM Port and read 4 Measurement Configuration Ser.No. and Configuration 5 Colour for the plotted line (Chart View) 6 Thickness of the plotted line (Chart View) 7 Primary or secondary axis (Chart View) 8 Select/Deselect Channel for logging and Chart View 9 Rename the channel (stored in 10 Measurement Value configuration) 11 Exit the program 12 All Channels become zero (with Inert gas N2,H2) 13 Set all Channels to default names 14 Stop the data logging into *.csv file 15 Start the data logging into *.csv file 16 Time interval for logging the data in milliseconds 17 Received data frames 18 Measurement cycle starts independent from data logging. Useful for Chart View and direct Feedback values 19 Enable Advanced User Mode 20 All values on the different tabs read out 21 Storage path for logging file 22 Enable chart view with extra window Measurement recording into *.csv File No. Description 1 Connect the detector with a serial data cable on the COM Port an Power the detector 2 Select the correct COM Port [1] and click Open [3] 3 Check the boxes [8] if they have to be measured 4 Choose a folder for the new data file [21] 5 Choose the measurement interval [16] min. 100ms 6 Klick the Start Button [15], if the File already exist the user can choose if the file will be overwritten or the new data will attached to the old data 7 For Stop the recording in the data file klick Stop [14] [12]

13 Setup measurement channels The MAS Tool can handle NDUV and NDIR detector electronics separate and together. So it is possible to measure all channels and log the data in one data file. The different channels can be configured separately Fig. 14: Screen shot of the MAS Tool (Host Software) 7 1 Configuration of radiation sources. Parameter Source_Power_xx shows the percent of radiation power. This can be an indicator for aging. 6 Setup the CAN parameter Baudrate and Node ID. All other parameters for production purpose only. 8 By pressing this button the complete detector will restarted. 2-5 Is only necessary for Endpoint Calibration of the measurement signal. All other parameter can only set in Advanced user mode. 7 Read all parameters from the active TAB [13]

14 Zero- and Span Calibration For a high accurate gas measurement it is necessary to check the zero point and span point on a regular basis. Zero Check every 24 h Span Check every week In case of a deviation (e.g. > 2% of span) the MAS Toll has a function to set the zero and span point easily. ZERO Setting Purge the entire gas measurement system with a sufficient volume (1L/Minute) of zero gas (e.g. Nitrogen N2, Argon Ar, or cleaned Air) and wait until the gas concentration reading is stable (<1% of Span). Then press the Write button for Zero Detector (See Fig. 15 below). The Concentration reading is now ppm. Fig. 15: Screen shot of the MAS Tool for ZERO setting [14]

15 SPAN Setting For setting the Span point it is necessary to use a well-known concentration of test gas. If you use a certified test gas bottle (cylinder) you will find the gas concentration value on the label or in the provided certificate (e.g. 480 ppm SO2). Type the applied gas concentration into the box (Endpoint_Calibration_Ch3) as shown in Fig. 16. Purge the entire gas measurement system with a sufficient volume (1L/Minute) of test gas and wait until the gas concentration reading is stable (<1% of Span). Then press the Write button for Span Calibration (See Fig. 16 below). Fig. 16: Screen shot of the MAS Tool for SPAN setting The real behaviour (Process of zero and span setting as a function of the Time) of the gas reading is shown in Fig. 17. [15]

16 Fig. 17: Process of zero and span setting as a function of the Time [16]

17 Digital communication protocol via RS232 (ASCII Mode) Settings Baudrate Baud Databits 8 Stopbit 1 Parity None Data Format LSB First Protocol basic (to detector) [17]

18 Protocol basic (from detector) The detector answer with an ASCII String. For example please note the telegram below. The incoming data from the detector can be displayed with a simple terminal program (Hterm ect.) or with the more comfortable MAS Tool (Wi.Tec) to detector 0x17 0x00 0x00 0x00 0x00 0x00 0x55 0x00 read Concentration CH1 from detector ASCII Data [ppm (Vol. %)] to detector 0x18 0x00 0x00 0x00 0x00 0x00 0x55 0x00 read Temperature CH1 from detector ASCII Data [ C] [18]

19 Command List Normal operating mode This commands are important for the main function of the detector. Description Command Frame Index Data Format Type Unit Access Set UV1 LED on 0x25 0 BOOL Write Set UV1 LED off 0x27 0 BOOL Write Set UV2 LED on 0x26 0 BOOL Write Set UV2 LED off 0x28 0 BOOL Write Set IR Source on 0x29 0 BOOL Write Set IR Source off 0x30 0 BOOL Write Set zero detector [all Channel] 0x08 0 BOOL Write Set Endpoint Calibration Ch3 0x60 2 UINT16 ppm[vol.%] Write Set Endpoint Calibration CH4 0x60 3 UINT16 ppm[vol.%] Write Set Endpoint Calibration CH1 0x60 0 UINT16 ppm[vol.%] Write Set Endpoint Calibration CH2 0x60 1 UINT16 ppm[vol.%] Write Concentration CH3 0x0F 0 FLOAT ppm[vol.%] Read Concentration CH4 0x0F 1 FLOAT ppm[vol.%] Read Concentration CH1 0x17 0 FLOAT ppm[vol.%] Read Concentration CH2 0x17 1 FLOAT ppm[vol.%] Read Temperature CH1 0x18 0 FLOAT C Read Temperature Controller Board 0x1A 0 FLOAT C Read Pressure Sensor (optional) 0x19 0 FLOAT mbar Read [19]

20 Diagnosis mode (read) Description Comman d Fram e Index Data Format Type Unit Acces s Range ADC Raw CH3_4 reference 0x10 0 FLOAT V Read 0-1,25V ADC Raw CH3_4 sensor 0x13 0 FLOAT V Read 0-1,25V Modulation CH3 0x12 0 FLOAT Read 0-1 Modulation CH4 0x12 1 FLOAT Read 0-1 ADC Raw CH1_2 reference 0x14 0 FLOAT V Read 0-1,25V ADC Raw CH1_2 sensor 0x15 0 FLOAT V Read 0-1,25V Modulation CH1 0x16 0 FLOAT Read 0-1 Modulation CH2 0x16 1 FLOAT Read 0-1 LED 1 PWM 0x21 0 UINT16 Read LED 2 PWM 0x22 0 UINT16 Read Filter Depth UV reference 0x35 0 UINT8 rw Filter Depth UV sensor 0x35 1 UINT8 rw Filter Depth IR reference 0x35 2 UINT8 rw Filter Depth IR sensor 0x35 3 UINT8 rw µ LED1 Current 0x36 UINT16 µa rw A µ A 0 LED2 Current 0x38 UINT16 µa rw Linearization UV Low 0x FLOAT rw Linearization UV High 0x FLOAT rw Linearization IR Low 0x FLOAT rw Linearization IR High 0x FLOAT rw Serial Number 0x40 0 UINT16 Read Config ID 0x62 0 UINT32 Read Hardware Revision 0x41 0 UINT16 Read Software Revision 0x0b 0 UINT16 Read UINT16 ppm[vol. Read 0 Range UV Low 0x47 %] UINT16 ppm[vol. Read 1 Range UV High 0x47 %] UINT16 ppm[vol. Read 2 Range IR Low 0x47 %] UINT16 ppm[vol. Read 3 Range IR High 0x47 %] Source Power LED1 0x49 0 UINT8 % Read 0-100% Source Power LED2 0x49 1 UINT8 % Read 0-100% Source Power IR LAMP 0x49 2 UINT8 % Read 0-100% TK Compensation zero point CH1 [ON/OFF] 0x57 3 BOOL write TK Compensation end point CH1 [ON/OFF] 0x58 3 BOOL write TK Compensation zero point CH2 [ON/OFF] 0x59 3 BOOL write [20]

21 TK Compensation end point CH2 0x5A 3 BOOL write [ON/OFF] TK Compensation zero point CH3 [ON/OFF] 0x5B 3 BOOL write TK Compensation end point CH3 [ON/OFF] 0x5C 3 BOOL write TK Compensation zero point CH4 [ON/OFF] 0x5D 3 BOOL write TK Compensation end point CH4 [ON/OFF] 0x5E 3 BOOL write Example for transmitting the Endpoint Calibration for UV low Channel (CAN BUS & RS232) Concentration = 6050ppm (certified Gas bottle) Measured concentration = 6021ppm Write Endpoint Calibration UV Low to detector from detector 0x32 0x00 0xA2 0x17 0x00 0x00 0x7A 0x30 ASCII String: The detector sends the calculated compensation factor back. The compensation factor in this example is 1, This factor is stored in the internal Eeprom. [21]

22 Digital communication protocol via CAN open Settings Baudrate Node ID Trigger Mode PDO Number of PDO s Static PDO 0 Static PDO 1 500kBaud (default), 250kBaud, 125kBaud 4 (default) SYNC [0x80] 2 [16 Bytes] CH3 Concentration [float] CH4 Concentration [float] CH1 Concentration [float] CH2 Concentration [float] Boot up sequence after Restart the detector [22]

23 Object dictionary ro read only wo write only rw read and write Element 0 CH3-CH4 (NDUV) Element 1 CH1-CH2 (NDIR) General Description Object 0x2000 Description Sub-Index Access Detector configuration Device Ident Number [IR,UV] and Gas type 1 ro [UINT32] [SO2,CO2..] Device Serial Number Serial Number [YearofProduction_No.] 2 ro [UINT16] Device Type not implemented yet 3 ro [UINT16] Revision Number Hardware return the electronic revision 4 ro [UINT16] Revision Number Software returns the software revision 5 ro [UINT16] Lightsource alarm values 0x2003 Description Sub-Index Access Status change when power UV-LED 1 minimum power lower % Range 1 rw [UINT8] [uint8] UV-LED 2 minimum power Status change when power lower % Range 2 rw [UINT8] [uint8] IR-LAMP minimum power Status change when power lower % Range [uint8] 3 rw [UINT8] [23]

24 Device Status 0x2004 Description Sub-Index Access PCB Temperature x.xxx [ C] 1 ro [REAL32] System Operation Time 0dxxxxx [hour] 2 ro [UINT16] System Status Light Source Status 0x00 [ Status normal] 0x01 [Source Maintanance REQ.] 3 ro [UINT8] Device Control Object 0x2005 Description Sub-Index Access Zero detector Trigger set 0 ppm(vol.%) [0x01] 1 rw [UINT8] Enable PDO SYNC SYNC Trigger 0x80 [0x01] 2 rw [UINT8] Restart Device complete system restart [0x01] 3 wo [UINT8] Modul Status Object 0x200A Description Sub-Index Access UV-LED 1 [Status] ok/service/ disconnected / off [0x00/0x01 / 0x02 / 1 ro [UINT8] 0x03] UV-LED 2 [Status] ok/service/ disconnected / off [0x00/0x01 / 0x02 / 2 ro [UINT8] 0x03] IR-LAMP [Status] ok/service/ disconnected / off [0x00/0x01 / 0x02 / 0x03] 3 ro [UINT8] [24]

25 Element 0 Concentration CH3 0x2010 Description Sub-Index Access Reading valid YES/NO [1/0] 1 ro [UINT8] Actual Value xxx ppm [Vol.%] 2 ro [REAL32] lower measuring range limit upper measuring range limit in special cases the value is above 0 max. value of production calibration 3 ro [UINT16] 4 ro [UINT16] Data Units [ppm,vol.% ] 0x01 [ppm] 0x02[Vol.%] 5 ro [UINT8] Element 0 Emitter 0x2011 Description Sub-Index Access UV-LED 1 Current [µa] 1 rw [UINT16] UV-LED 2 Current [µa] 2 rw [UINT16] UV LED1 [switch on/off] ON/OFF [1/0] 3 rw [UINT8] UV LED2 [switch on/off] ON/OFF [1/0] 4 rw [UINT8] UV-LED 1 Operating Time 0-xxxx [hour] 5 ro [UINT16] UV-LED 2 Operating Time 0-xxxx [hour] 6 ro [UINT16] UV-LED 1 percent of power 0-100% 7 ro [UINT8] UV-LED 2 percent of power 0-100% 8 ro [UINT8] [25]

26 Element 0 Diagnosis Object 0x2012 Description Sub-Index Access Modulation CH3 raw signal without linearisation 1 ro [REAL32] Modulation CH4 raw signal without linearisation 2 ro [REAL32] ADC Value CH3_4 Reference ADC Output data [15Bit] 3 ro [UINT16] ADC Value CH3_4 Sensor ADC Output data [15Bit] 4 ro [UINT16] Filter Depth CH3_4 Reference Filter Depth CH3_4 Sensor Moving avatage filter depth [1-255] Moving avatage filter depth [1-255] 5 rw [UINT8] 6 rw [UINT8] Element 0 Linearisation CH3 0x201F Description Sub-Index Access Coefficient 1 Linearisation Coefficient x^1 1 ro [REAL32] Coefficient 2 Linearisation Coefficient x^2 2 ro [REAL32] Coefficient 3 Linearisation Coefficient x^3 3 ro [REAL32] Coefficient 4 Linearisation Coefficient x^4 4 ro [REAL32] Element 0 Concentration CH4 0x2020 Description Sub-Index Access Reading valid YES/NO [1/0] 1 ro [UINT8] Actual Value xxx ppm [Vol.%] 2 ro [REAL32] lower measuring range limit upper measuring range limit in special cases the value is above 0 max. value of production calibration 3 ro [UINT16] 4 ro [UINT16] Data Units [ppm,vol.% ] 0x01 [ppm] 0x02[Vol.%] 5 ro [UINT8] [26]

27 Element 0 Linearisation CH4 0x202F Description Sub-Index Access Coefficient 1 Linearisation Coefficient x^1 1 ro [REAL32] Coefficient 2 Linearisation Coefficient x^2 2 ro [REAL32] Coefficient 3 Linearisation Coefficient x^3 3 ro [REAL32] Coefficient 4 Linearisation Coefficient x^4 4 ro [REAL32] Element 1 Concentration CH1 0x2030 Description Sub-Index Access Reading valid YES/NO [1/0] 1 ro [UINT8] Actual Value xxx ppm [Vol.%] 2 ro [REAL32] lower measuring range limit upper measuring range limit in special cases the value is above 0 max. value of production calibration 3 ro [UINT16] 4 ro [UINT16] Data Units [ppm,vol.% ] 0x01 [ppm] 0x02[Vol.%] 5 ro [UINT8] Element 1 Emitter 0x2031 Description Sub-Index Access IR-LAMP PWM ro [UINT16] IR-LAMP [switch on/off] ON/OFF [1/0] 2 rw [UINT8] IR-LAMP percent of power 0-100% 3 ro [UINT8] [27]

28 Element 1 Diagnosis Object 0x2032 Description Sub-Index Access Modulation CH1 raw signal without linearisation 1 ro [REAL32] Modulation CH2 raw signal without linearisation 2 ro [REAL32] ADC Value Reference ADC Output data [15Bit] 3 ro [UINT16] ADC Value Sensor ADC Output data [15Bit] 4 ro [UINT16] Filter Depth CH1_2 Reference Filter Depth CH1_2 Sensor Moving avatage filter depth [1-255] Moving avatage filter depth [1-255] 5 rw [unit8] 6 rw [unit8] Temperature Sensor xx C from the Detektorelement 7 ro [REAL32] Pressure Sensor + yyy mbar (optional) 8 ro [UINT16] Element 1 Linearisation CH1 0x203F Description Sub-Index Access Coefficient 1 Linearisation Coefficient x^1 1 ro [REAL32] Coefficient 2 Linearisation Coefficient x^2 2 ro [REAL32] Coefficient 3 Linearisation Coefficient x^3 3 ro [REAL32] Coefficient 4 Linearisation Coefficient x^4 4 ro [REAL32] [28]

29 Element 1 Concentration CH2 0x2040 Description Sub-Index Access Reading valid YES/NO [1/0] 1 ro [UINT8] Actual Value xxx ppm [Vol.%] 2 ro [REAL32] lower measuring range limit upper measuring range limit in special cases the value is above 0 max. value of production calibration 3 ro [UINT16] 4 ro [UINT16] Data Units [ppm,vol.% ] 0x01 [ppm] 0x02[Vol.%] 5 ro [UINT8] Element 1 Linearisation CH2 0x204F Description Sub-Index Access Coefficient 1 Linearisation Coefficient x^1 1 ro [REAL32] Coefficient 2 Linearisation Coefficient x^2 2 ro [REAL32] Coefficient 3 Linearisation Coefficient x^3 3 ro [REAL32] Coefficient 4 Linearisation Coefficient x^4 4 ro [REAL32] Element 1 T- compensation Zeropoint CH1 0x2050 Description Sub-Index Access Coefficient 0 compensation Coefficient x^1 1 ro [REAL32] Coefficient 1 compensation Coefficient x^2 2 ro [REAL32] Coefficient 2 compensation Coefficient x^2 3 ro [REAL32] Compensation on/off YES/NO [1/0] 4 rw [UINT8] [29]

30 Communication object 0x4000 Description Sub-Index Access set Node ID wo [UINT8] set Baudrate 500(default), 250, wo [UINT16] [30]

31 NOTES: [31]