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United Process Controls Probe Buddy User Manual

Smart o2 probe simulator & tester
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USER MANUAL
Probe Buddy
Smart O2 Probe Simulator & Tester
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Summary of Contents for United Process Controls Probe Buddy

  • Page 1 USER MANUAL Probe Buddy Smart O2 Probe Simulator & Tester CONNECT WITH US...
  • Page 2 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.

  • Page 3: Table Of Contents

    PROBE BUDDY – USER MANUAL Page 3 of 27 UPC_MAN013_R7 Table of Contents DESCRIPTION ........................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 ......................
  • Page 4 PROBE BUDDY – USER MANUAL Page 4 of 27 UPC_MAN013_R7 Standards Conformity ....................25 REFERENCES ........................ 25 Available Cables: ......................25 Copyright © United Process Controls. All rights to copy, reproduce and transmit are reserved.

  • Page 5: 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.

  • Page 6: Keyboard

    Page 6 of 27 UPC_MAN013_R7 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.

  • Page 7: Dual Key Functions

    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.

  • Page 8: Standby Mode

    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.

  • Page 9: 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.

  • Page 10: Using Output Mode

    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.

  • Page 11: Probe Test Mode

    To run a probe impedance test it is necessary to setup the probe testing parameter in the SETUP Probe Menu, and the PROBE BUDDY is configured for signal inputs. Please refer to Probe parameters table for an explanation of these setup parameters. You may choose to accept the defaults for the other parameters in this menu or change them to suit your applications.

  • Page 12: Alarm Display

    - CHANGE TO OUTPUT MODE. Alarm Display Alarm display alerts the operator about a fault in the PROBE BUDDY or signals exceeding the limits of the inputs. A major fault or alarm screen must be acknowledged using the ALARM Enter key.

  • Page 13: Setup Menu

    PROBE BUDDY – USER MANUAL Page 13 of 27 UPC_MAN013_R7 Low value displays when the signal exceeds the display or lower 800° C 0.00% → limit of the signal input. LLLL mV 2 SETUP MENU Holding the Setup key for 5 seconds opens the Setup Menu.
  • Page 14 SLEEP MODE 1, 5, 10, 30, Select number Sets the time the PROBE BUDDY ALWAYS ON values (mins) or will stay on after the last key ALWAYS ON to press. If there is no key press...
  • Page 15 0 to disable. Set MV output offset and span for ramp range. Ramps can be enabled for TC, MV, or both. If any ramp time is > 0, then ramp(s) start as soon as the PROBE BUDDY is returned to normal operation. Output Menu...
  • Page 16 PROBE BUDDY – USER MANUAL Page 16 of 27 UPC_MAN013_R7 Parameter Name Units or Options Range Description TC RAMP 0, 30, 45, 60 Ramp rate in 0 disables ramp function. Ramp is seconds a sawtooth with ramp from offset to span and drop back to offset.

  • Page 17: Process Formulas

    CO correction variable allows for adjustment of the carbon calculation based on actual %CO readings or results from material tests. The PROBE BUDDY’s sensor millivolt output simulates the signal from an in-situ zirconia sensor. The T/C output simulates the integrated temperature T/C in the oxygen sensor.

  • Page 18: Oxygen Formula

    PROBE BUDDY – USER MANUAL Page 18 of 27 UPC_MAN013_R7 PROBE BUDDY’s sensor millivolt output simulates an in-situ zirconia sensor. The T/C output simulates the integrated temperature T/C in the oxygen sensor. The result of the calculation is dew point in °F.

  • Page 19: Calibration

    Make sure the PROBE BUDDY is turned off. Then follow the steps listed in the following figure. Press and hold the Left Arrow and then the Enter key until the PROBE BUDDY turns on.

  • Page 20: Calibration Displays And Keyboard Operation

    PROBE BUDDY – USER MANUAL Page 20 of 27 UPC_MAN013_R7 Both the TC and mV values show the input signals in mV. If these values match the mV signal inputs then only the cold junction calibration may be necessary. Change to Output mode and enter typical values for the TC mV and mV outputs. Make sure the TC and mV connections are plugged into mV meters to verify the output signals.

  • Page 21: Preparing For Input Calibration

    The TC zero and span calibration is done with the mV source. The cold junction calibration is done with the TC source and set to the same thermocouple type as the PROBE BUDDY. 4.2.1 Calibration of Inputs Calibration procedure: 1.

  • Page 22: Preparing For Output Calibration

    3. Use a millivolt meter with copper wire and an uncompensated TC connector. 4. Connect to the TC connector to the PROBE BUDDY. 5. Adjust the number displayed on the second line of the PROBE BUDDY to read 0mV on the meter. Allow the reading to stabilize between adjustments.

  • Page 23: Diagnostic Alarms

    This prompt displays temporarily when at sensor test is attempted but the PROBE BUDDY is in the output mode. The sensor test can only run when the PROBE BUDDY is connected to a valid sensor mV signal. The front panel display will show LLLL if the process value is below the display resolution or signal range.

  • Page 24: Technical Data

    PROBE BUDDY – USER MANUAL Page 24 of 27 UPC_MAN013_R7 7 TECHNICAL DATA LCD Graphic Display The LCD display is based on the Electronic Assembly EA DOGM132W-5 display module: • Resolution: 132x32 Pixels • Viewing Area: 48mm x 13mm • Text Color: Black •...

  • Page 25: General

    PROBE BUDDY – USER MANUAL Page 25 of 27 UPC_MAN013_R7 • Full Scale Temperature Coefficient: 10 ppm/°C • Input Impedance: >100 MΩ Millivolt Output: • Range: 0-2000Mv • Resolution: 16 bit • Accuracy: 0.05% of FS (at 25’C) • Full Scale Temperature Coefficient: 10 ppm/°C •...
  • Page 26 PROBE BUDDY – USER MANUAL Page 26 of 27 UPC_MAN013_R7 Sensor Cables Oxyfire NitroCarb CS87 T/C Type No TC Adapter for converting to signal source is included Copyright © United Process Controls. All rights to copy, reproduce and transmit are reserved.
  • Page 27 PROBE BUDDY – USER MANUAL Page 27 of 27 UPC_MAN013_R7 Reach us at www.group-upc.com United Process Controls brings together leading brands to the heat treating industry including Atmosphere Engineering, Furnace Control, Marathon Monitors and Process-Electronic, and Waukee Engineering. We provide prime control...

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