600 SERIES MK 3

INDUSTRIAL OXYGEN
TRANSDUCER

OPERATOR’S MANUAL
Version 4.3 2nd June 2015

Illinois Instruments, Inc (U.S.) Systech Instruments Ltd

2401 Hiller Ridge Road 17 Thame Park Business Centre
Johnsburg Wenman Road
Illinois IL Thame
60051 Oxfordshire
OX9 3XA
E: [email protected] E: [email protected]
www.systechillinois.com
 600 Series Operators Manual v4.3

Table of Contents
1.0 PREFACE ..................................................................................................................................1
1.1 Important .......................................................................................................................................... 2
2.0 INTRODUCTION .......................................................................................................................3
3.0 WARRANTY ..............................................................................................................................3
3.1 Instrument Warranty ......................................................................................................................... 3
3.2 Measuring Cells Warranty ................................................................................................................ 3
4.0 INSTALLATION ........................................................................................................................4
4.1 Connection With A Systech Supplied Panel Meter: .......................................................................... 4
4.2 Connection Using 24 VDC: .............................................................................................................. 4
4.3 Cable Length .................................................................................................................................... 5
5.0 CHANGING THE RANGE .........................................................................................................5
6.0 CALIBRATING THE TRANSDUCER .......................................................................................6
7.0 SENSOR REPLACEMENT. ......................................................................................................7
8.0 REPLACEMENT SENSOR ORDERING INFORMATION: .......................................................8
9.0 600 SERIES MONITOR.............................................................................................................9
10.0 MOUNTING AND DIMENSIONS ............................................................................................10
11.0 PROGRAMMING THE ALARMS (OPTION)...........................................................................10
12.0 PROGRAMMING THE RANGES ............................................................................................11
13.0 RS232 COMMUNICATIONS (OPTION) ..................................................................................12
13.1 Pin Connections. PC To 600 Monitor ........................................................................................... 12
13.2 Configuring The Monitor ............................................................................................................... 12
13.3 Data String Format ....................................................................................................................... 13
14.0 RETRANSMISSION OUTPUTS (OPTION).............................................................................13
14.1 Configuring The Outputs .............................................................................................................. 13
Appendix 1 DRAWING No. A 600 071 ...............................................................................................14

Revision History

Issue Issue Date Changes By

3.2 29-09-2006 Current Release Version BC / JD
4.0 08-06-2009 Format changes added warranty info and clarified Nick Stuart
some info with diagrams.
4.1 26-02-2010 Added info regarding cable length. Rebranding Nick Stuart
format changes.
4.2 22-03-2012 Changed the Table, section 11, Process Input Nick Stuart
4.3 03-06-2015 Added Warranty information Bryan Cummings

www.systechillinois.com
 600 Series Operators Manual v4.3

1.0 PREFACE

600 SERIES TRANSDUCER

IMPORTANT

Please read this manual before attempting to install or operate the equipment.

The instrument has been calibrated at our factory and does not need to be re-calibrated prior to
installation.

The transducer is supplied with a sealing cap on the pipe fitting and a sealing screw fitted to the gas
vent. Do not remove until the transducer is ready for use. – see installation section.

The equipment should be electrically connected and grounded in accordance with instructions
connected to the power cord and in accordance with good standard practice.

The specifications are as written on the data label on the sensor. If these do not coincide with your
application or order, please contact your representative or Systech.

Note: For dimensional information see drawing No. A 600 071 (Appendix 1) at the back of this
document.

No responsibility is accepted by Systech Illinois Instruments Limited

for accidents resulting from improper use of this equipment.

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

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 600 Series Operators Manual v4.3

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.) Systech Instruments Ltd

2401 Hiller Ridge Road, 17 Thame Park Business Centre
Johnsburg Wenman Road
Illinois IL 60051 Thame
Tel: +1 815 344 6212 Oxfordshire
OX9 3XA Tel: +44 (0) 1844 216838

For customers outside UK or USA, please contact us for details of your local representative.
Alternatively check out our website:

www.systechillinois.com

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 600 Series Operators Manual v4.3

2.0 INTRODUCTION
The transducer measures oxygen in a gas background. It is loop powered 4-20mA and is powered by
a nominal 24VDC.
It has four measurement ranges, which can be found on the data label fixed to the transducer.

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 measuring cell should have a life of 4+ years. The life is very much
the date of dependent on the moisture in the gas stream. The more humid the gas
supply. (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.
C 36 months The measuring cell should have a life of 5+ years.
from the date
of supply
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

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 600 Series Operators Manual v4.3

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.

MISUSE OF THE CELL IS NOT COVERED BY WARRANTY

4.0 INSTALLATION
The transducer is supplied with 5m of connecting cable. The two core cable should be connected to a
24V (15-35V) DC power source. The optional Panel Meter can supply this power directly as well as
displaying the measurement value and alarms etc.
Should the cable need to be changed or extended it is extremely important to observe the correct
polarity of the DIN socket. The pin numbers are marked on the socket.

Pin No. Signal Name

Pin 1 RED/POWER+/LOOP+
Pin 2 BLACK/POWER-/LOOP-

4.1 Connection With A Systech Supplied Panel Meter:

Refer to Page 5. Connect the cable to the sensor using the plug provided. Connect the free end as
follows: -

Wire Colour Pin No

Red: Pin 3 on the panel meter.

Black: Pin 2 on the panel meter

4.2 Connection Using 24 VDC:

Connect the cable to the sensor using the plug provided. Connect the free end as follows

Wire Colour Pin No

Red: Power supply 15-35 VDC (Nominal 24VDC) +ve (loop +ve)
Black: Power supply -ve (loop -ve).

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 600 Series Operators Manual v4.3

The transducer will generate a 4-20mA output signal in the current loop, proportional to the measured
oxygen and the range selected. This may be used to generate a voltage signal of 1-5Volts by inserting
a 250 ohm resistor in the loop and measuring across the resistor.

Power up the transducer by powering up the Panel meter or by connection to the nominal 24VDC and
make sure that once the reading has settled the oxygen measurement is less than 60 ppm (ppm ranges
only). See below about changing ranges. If not, please contact your representative or Systech.

Power down; remove the sealing cap at the process connection and remove the sealing screw of the
vent to the side of the unit (retain these items to reseal the sensor in the future).

Install the transducer to the measuring point, it can be any orientation, the transducer may be supported
using a bracket provided. DO NOT OBSTRUCT the vent on the side.

Power up the transducer and allow the reading to reach equilibrium with the true oxygen value.

4.3 Cable Length

The 600 sensor requires a minimum voltage and operating current in order to function reliably and
accurately. Therefore; when contemplating the use of a non standard cable these conditions must be
taken into account.

The maximum loop resistance permissible can be calculated as follows: Regarding the cable length for
the model 600:

Rmax = (V1-V2)/0.022

Where:

Rmax is the maximum resistance in the loop which will include the cable resistance and any
resistor drop for any meter that you will have in the loop.

V1 is the power supply you will use, between 35V and lowest V for power

V2 is the minimum voltage for the 600 to function, = 12V

And 0.022 is the maximum current needed for the 600.

5.0 CHANGING THE RANGE

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 600 Series Operators Manual v4.3

600 Series Operators Panel (100ppm selected)

To change the range, press and hold the ‘PAGE’ key until the currently selected range LED flashes.
Use the ‘UP’ and ‘DOWN’ keys to move to the desired range and press the ‘PAGE’ key to accept. The
ranges of oxygen measurement appropriate to the LED’s are found on the data label fixed to the
transducer.
Note that although the transducer has four ranges of measurement, if an optional panel meter is
supplied the panel meter can only be set up for one range only. A label will be found on the panel meter
to show to what range of O2 it was set up.
In order to change the Systech Panel meter range please refer to the section ‘Programming the ranges’.

6.0 CALIBRATING THE TRANSDUCER

The sensor can be calibrated by applying a gas with a known oxygen concentration to the transducer.
Allow the reading to stabilise and press and hold the ‘PAGE’ key until the currently selected range LED
flashes. Press the ‘PAGE’ key again so all the range LED’s flash. Use the ‘UP’ and ‘DOWN’ keys to
increase or decrease the oxygen reading to match the value of the calibration gas.

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 600 Series Operators Manual v4.3

7.0 SENSOR REPLACEMENT.

Sensors should last for a number of years in normal operation before requiring replacement. Sensor
lifetime is a function of the oxygen level and time of exposure hence a sensor continuously used on a
low oxygen gas stream will have the longest lifetime.

To check the sensor expose the inlet to atmospheric air and change the range to 0-25% O2, the reading
should be 20.9%. If 20.9% cannot be achieved with the calibration adjustment then the sensor should
be replaced.

To replace the sensor:

1 Remove the power from the transducer.

Disconnect the transducer from any pipe work
2
connections.

Using the small Allen key supplied with the cell

3 replacement kit remove the three Allen screws
around the side of large body of the transducer.

Gently remove the base revealing wiring to the

4
transducer.

Undo the plug/socket connection from the sensor

5
PCB.

Again using the small Allen key supplied with the

cell replacement kit remove the three Allen
6
screws around the side of small section of the
transducer, and withdraw the sensor.

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 600 Series Operators Manual v4.3

Using the large Allen key supplied remove the

7 three Allen screws at the base of the unit. Gently
remove the sensor and the ‘O’ ring.

Fit the new O ring to the supplied sensor and re-

assemble the unit in the reverse order to that
8 above.
NOTE: You MUST replace the O ring, do NOT
reuse the old one.

Reconnect the transducer to the pipe work

9
connections.
10 Reconnect the power to the transducer.

It should be noted that after replacing the cell, especially ppm cells it may take some time for the cell
reading to stabilise.

8.0 REPLACEMENT SENSOR ORDERING INFORMATION:

ELECTROCHEMICAL CELL WARRANTY (CURRENT INSTRUMENTS)

Part No Used In Application Description Warranty
Code
600 047 EC600 Trace Cell Assy Cell Trace Cell kit A
600 053 EC600 Percent Cell Assy Cell % cell kit C

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 600 Series Operators Manual v4.3

9.0 600 SERIES MONITOR

The 600 Series display monitor may be used in conjunction with the 600 sensor to display oxygen
values in the range of the sensor.

The monitor can power the sensor and it may be fitted with various options.

NOTE: Some newer models of panel are double insulated and as such have no earth connection on
the AC supply.

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 600 Series Operators Manual v4.3

10.0 MOUNTING AND DIMENSIONS

The 600 display can be panel mounted in a cut out 92 mm wide by 45 mm high.
The display will require a minimum of 147 mm of depth behind the panel.

The supply voltage is factory set; however if you require it to run at a different voltage please contact
Systech Instruments.

11.0 PROGRAMMING THE ALARMS (OPTION)

NOTE: 600 Monitor must be specified with retransmission at time of order. Pt No. 600 024.

Menu Change Next digit Enter

Digit / selection

Press and hold the ‘MENU’ button. After two seconds the display will show a series of dashes then
AL1. In order to set the Alarm 1 set point value, press the ‘ENTER’ button. Use the Digit select button
and the Next Digit button to set the desired Alarm 1 value. Press the Enter/Reset button to programme
this value. Press the Menu button to show AL2. Use the same procedure to set up the level-set point
value.

Press the Menu button to show InP - do not touch any buttons while in this menu. Press the Menu
button again to show AL.CO. This is the sub-menu to configure whether each Alarm is hi or low, and
whether its contacts are normally open or normally closed. You may also set a hysteresis level for
each alarm and an alarm activation delay.

At the sub-menu AL.CO press the Enter/Reset button and it will show A1.Lo or A1.Hi, use the change
digit to toggle from one to the other. Always press the Enter/Reset button to accept the change. This
sets the alarm as a high level alarm or a low level alarm. Press the Enter/Reset button again to show
A1.no or A1.nc and again the Change digit button may be used to set the required action. A1.no is
setting a normally open alarm and A1.nc a normally closed alarm.

Further pressing of the Enter/Reset button will enter the Hysteresis menu (Hys1) and the Delay menu
(dEL1). Enter the value of desired hysteresis. Hysteresis is sometimes required to stop the relays
switching on and off when the process value is close to the alarm value. As an example should the
alarm level be set at say 100ppm (100) and the hysteresis set at 10 then the alarm will activate at 100
and deactivate at 90. The value of delay setting is seconds. This is the time delay after which the relay
will activate after the alarm.

Further pressing of the Enter/Reset button will show END and the display will revert to measurement
of oxygen. The time out for entries is 20 seconds – the display will then revert to oxygen measurement.

The same procedure is used to configure Alarm 2.

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 600 Series Operators Manual v4.3

12.0 PROGRAMMING THE RANGES

Menu Change Next digit Enter

Digit / selection

Ranges of Process Decimal point

Transducer Input Position
0-10ppm 1000 00.00
0-100ppm 1000 000.0
0-1000ppm 1000 0000
0-1% 1000 0.000
0-10% 1000 00.00
0-25% 2500 00.00
0-100% 1000 000.0

The transducer is equipped with four ranges. These are shown on the data label fixed to it. The output
from the transducer is always 4-20 mA for each range. Since the Panel Meter is a 4-20mA input device
it must be set up in Engineering units to show the correct range and this can only be for one range. So
when changing ranges on the transducer temporarily you must move the decimal point to another
imaginary position. For permanent changes you should reprogramme the meter according to the table
above.

Press and hold the ‘MENU’ button. After two seconds the display will show a series of dashes then I/P.
Note that if alarms are fitted then it will show AL1. Press the ‘ENTER’ button repeatedly until the meter
shows P FS. Press the enter key again and it will show the current Process Input. Use the Change digit
and Next digit keys to input the new process input.
Continue to use the enter button to move to the P dP, and another press of the ‘ENTER’ key will show
the present decimal point position. It can be changed with the Change digit and Next digit keys.
Do not make any changes to any other programme variables.
When finished continue pressing the Menu key until you see ‘END’

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 600 Series Operators Manual v4.3

13.0 RS232 COMMUNICATIONS (OPTION)

NOTE: 600 Monitor must be specified with RS232 at time of order. Pt No. 600 038.

The 600 monitor can be operated using both ASCIIbus and DIGIbus protocols. Systech Instruments
provide support for the ASCIIbus protocol only.

13.1 Pin Connections. PC To 600 Monitor

600 Monitor
Function PC pin connection
connection
-D (Tx) 2 8
+D (Rx) 3 7
D Gnd 7 9

Important Note: The DGnd connection may need to be connected to the PC case, or other suitable
earth connection. Lack of Earthing will result in no communications.

13.2 Configuring The Monitor

Menu Change Next digit Enter

Digit / selection

Press and hold the MENU button for three seconds to enter the menu. Press the MENU button
momentarily, and repeat until Conn is shown on the display.

Press the ENTER button to enter the menu. The first option is ADD (Address). Select the required
address for the monitor by pressing the DIGIT SELECT and INCREMENT.

The address identifies the monitor to the PC in use. If the address is set to 00, the 600 monitor will
transmit a data string either when the front panel MENU button is pressed or when the PC sends any
ASCII byte to the monitor.

If the address is set between 01 and 99, the monitor will continually transmit a data string, approximately
5 times a second.

Press ENTER to accept the address setting. The display will show the baud rate. Select using
INCREMENT. Pressing enter accepts the baud rate setting.

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 600 Series Operators Manual v4.3

The display will now show ASCI or DIGI for the protocol selection. Using INCREMENT select ASCI,
press ENTER to accept.

Finally the selection for communications on or off. Using INCREMENT select ON and press ENTER.
Press the menu button to exit the setting menu and return to display mode.

13.3 Data String Format

# A A S D D D D D D D D P CR LF

Where # indicates start of message, AA the address, sign (polarity) + or -, data bits (NB first four will
be blank, last four contain the display reading, P is decimal point position.

14.0 RETRANSMISSION OUTPUTS (OPTION)

NOTE: 600 Monitor must be specified with retransmission at time of order. Pt No. 600 029.

The 600 monitor can retransmit 0-10Volts, 4-20mA or 0-20mA, dependant on both hardware and
software selection.

For connections see the ‘series 600 Display Connection Diagram’ above.
For current output 0-20mA or 4-20mA, there are no hardware changes to make, however if 0-10V is
required a hardware change is required. Remove all the output plugs from the rear of the unit and
remove the back panel of the meter using the two lugs on the side of the meter. Withdraw the circuit
cards and locate the hardware links immediately behind output pins 1,2,3,4, 5 and 6. Move the link 3rd
from the right to second from the right if you require 0-10Volts retransmission. Reassemble the boards
and the back panel.

14.1 Configuring The Outputs

Menu Change Next digit Enter

Digit / selection

Press and hold the MENU button for three seconds to enter the menu. Press the MENU button
momentarily, and repeat until OUTP is shown on the display.
Press the enter button and it will display the current setting, 0-10V, or 0-20, or 4-20. If you want to
change the setting then use the ‘Change digit / selection’ key to select an output to your requirements.
When finished press the Enter key.
It is possible to modify the retransmission output by changing the zero and full scale if required by
continuing to press the Enter key to reveal the OU O command and the OUFS command. Use the
Change digit and Next digit keys to modify the output.

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 600 Series Operators Manual v4.3

Appendix 1 DRAWING No. A 600 071

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