Related Manuals for Servomex SERVOPRO 4000 Series
Summary of Contents for Servomex SERVOPRO 4000 Series
- Page 1 SERVOPRO 4000 Series INSTALLATION MANUAL Part Number: 04000005D Revision: Language: UK English...
- Page 3 Transducer I2 Type: Type: Serial No: Serial No: Sample Inlet Position Sample Inlet Position Transducer I3 Transducer I4 Type: Type: Serial No: Serial No: Sample Inlet Position Sample Inlet Position Servomex Order Reference No: Software Revision No: Completed By: Date :...
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Page 5: Table Of Contents
List of Contents SECTION 1 INTRODUCTION ......... 1.1 Introduction . - Page 6 SECTION 6 SPARES ..........6.1 SECTION 7 TECHNICAL SPECIFICATIONS .
- Page 7 List of Tables Table 1.1: Transducer FSD values and availability in product range ..1.6 Table 1.2: Recommended calibration periods ......1.7 Table 3.1: Signal terminal location PL1 to PL4 .
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Page 9: Introduction
AEG-MODICON. General description The Servomex 4000 series analyser is a chassis into which up to four gas sensor modules may be fitted. The chassis provides power, gas connections and other support functions to the sensors and calculates associated sample gas concentrations. These concentrations are then displayed on the analyser display screen and may be directed to the analogue outputs and/or the serial output. - Page 10 A number of optional features are available for the 4000 series. These may include the following, depending upon analyser configuration: • Flow meters and needle valves (on the 4900D only) to monitor and control sample gas flow through the instrument. •...
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Page 11: Location Of Components
Location of components Figure 1.1 identifies the location of the key features of the analyser. Note that the identification label (including serial number information) is located on the underside of the unit towards the rear. Figure 1.1: Key features of 4000 series analyser FRONT VIEW Sample inlet(s) REAR VIEW... -
Page 12: Transducer Site Numbering System
Transducer site numbering system The four internal transducers are assigned site locations represented as I1, I2, I3 and I4 on the display. In the case of the 4100 and the 4200 analysers, each transducer is served by a discrete sample inlet and outlet connection on the rear panel. -
Page 13: Conversion Of Transducer Measuring Units
NOTE The following abbreviations are used throughout this manual: Gas filter correlation infra-red transducer Pulsed infra-red transducer Paramagnetic transducer Zirconia transducer Conversion of transducer measuring units As supplied, the standard transducers within the analyser will measure in the units indicated in Table 1.1. -
Page 14: Table 1.1: Transducer Fsd Values And Availability In Product Range
Table 1.1: Transducer FSD values and availability in product range: Transducer 4100 4200 4900 4210 Gfx1210 CO Standard sensitivity 3000vpm CO Gfx1210 CO High sensitivity 500vpm CO Gfx 1210 SO Standard sensitivity 2500vpm SO Gfx 1210 SO High sensitivity 1000vpm SO... -
Page 15: Calibration - General
Calibration - General For optimum performance, it will be necessary to routinely check the calibration of all of the internal gas sensors within the analyser. The recommended periods for each sensor type are shown in Table 1.2. Table 1.2: Recommended calibration periods Gas sensor module Low calibration High calibration... - Page 16 NOTES...
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Page 17: Installation - General
SECTION 2 INSTALLATION - GENERAL Introduction NOTE Sections 2, 3 and 4 provide all the information required to install any 4000 series analyser. The installer is advised to read all sections completely before commencing installation. Installation will only require the use of standard hand tools. The analyser is suitable for indoor use and may be configured for either bench mount, panel mount or 19"... -
Page 18: Unpacking And Inspection
Lift and remove the analyser from its packing and inspect for any damage incurred during transit. If damage has occurred, inform Servomex or its agent immediately. Retain all packing and shipping information. The shipping carton may be used for future transportion. -
Page 19: Figure 2.1: Panel Mounting Detail
WARNING The rack mounting brackets are not intended to provide the sole means of support. The user must provide additional support. Figure 2.1: Panel mounting detail. Key: Mounting brackets Additional Support (customer supplied) Note: Cut-out dimensions of 447mm x 134mm mounting holes should be M6 or 7mm clearance... -
Page 20: Rack Slide Mounting Installation
Rack slide mounting installation The analyser occupies 3U/5.25"/133mm of rack space. Determine at what height the analyser is to be installed in the rack enclosure. The analyser will occupy nine rack flange cage nut positions. Note that intermediate cage nut positions need not be punched out. If the instrument has been purchased with the rack mounting option then the rack slide inners will already be mounted on the analyser chassis. - Page 21 See Figure 2.2. The 19" optional rack slide mount version is supplied with a mounting kit which includes either long or short slides and rack mounting brackets. Do not attempt to support or carry the analyser by the rack mount brackets. The analyser is suitable for installation in most standard rack types including Schroff and Rittall, thus: •...
- Page 22 NOTES...
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Page 23: Installation - Electrical
SECTION 3 INSTALLATION - ELECTRICAL WARNINGS • The installer must be satisfied that the 4000 series analyser installation conforms to the relevant safety requirements, National Electrical Code and any other local regulations, and that the installation is safe for any extremes of conditions which may be experienced in the operating environment of the analyser. -
Page 24: Signal Connections
• Fit fuse F2 to the right hand side of the voltage selector according to the voltage selected. Voltage selector position 220 to 240V operation fit fuse T3.15A HBC to IEC 127 (Figure 3.1). Voltage selector position 110 to 120V operation fit fuse T5.0A HBC to IEC 127 (Figure 3.2). -
Page 25: Figure 3.3: Signal Socket Assembly
Figure 3.3: Signal socket assembly Key: Screw terminal block Cover End block Cable tie Jacking screw Notes Relay cabling may use either entry Analogue output cabling Mount item 2 by sliding them onto the dovetails in item 1 For compliance with EMC standards connections to current outputs must use screened or shielded cable, with either separately screened pairs or two pairs with an overall screen. -
Page 26: Ma Output And Relay Output Connections
The use of screened signal cables is recommended in all installations After wiring the loose sockets, the covers must be re-fitted for safe operation. To avoid straining the screw terminal connections attach the cable sheath to the cover by trimming and folding out the appropriate section of the cover and securing the cable to it using the cable tie provided. -
Page 27: Table 3.1: Signal Terminal Location Pl1 To Pl4
Table 3.1: Signal terminal location PL1 to PL4 Terminal number (optional) (optional) (optional) Screen Screen Screen Screen Relay 4.5A Relay 3.5A Relay 2.5A Relay 1.5A Relay 4.5A Relay 3.5B Relay 2.5B Relay 1.5B Relay 4.4A Relay 3.4A Relay 2.4A Relay 1.4A Relay 4.4B Relay 3.4B Relay 2.4B... -
Page 28: Analogue Inputs
The standard relay output defaults are as follows: CAL IN PROG (Calibration in progress) MAINTENANCE FAILURE All other relays are unassigned, except (where external autocalibration is fitted): GROUP 1 SAMPLE/CAL GROUP1 CAL1/CAL2 The standard analogue output defaults are: 1.1 TXD (transducer) 1 1.2 TXD 2 2.1 TXD 3 2.2 TXD 4... -
Page 29: External Autocalibration Connection
Table 3.3: Signal terminal location PL5 Terminal Function Terminal Function Analogue input 1 +ve Analogue input 1 -ve Analogue input 1 valid Analogue input 2 +ve Analogue input 2 -ve Screen Auto calibration initiate Screen Analogue input 2 valid Range change 3.2.3. -
Page 30: Serial Data/Modbus Connection
Table 3.4: External autocalibration truth table Gas Required Relay Contacts for Relay Contacts for Valve 1 Valve 2 Sample Gas De-energised (OPEN) De-energised (OPEN) Calibration gas 1 Energised (CLOSED) De-energised (OPEN) Calibration gas 2 Energised (CLOSED) Energised (CLOSED) Depending on the number of autocalibration groups, at total of 2, 4, 6, or 8 relays will be needed to control up to eight external valves. -
Page 31: Continuous Mode
Continuous mode In continuous mode a data frame is transmitted by the serial output port at a user defined interval. The format of the data frame is given in Table 3.6 and 3.7. However, it is a list of process variables (or 'fields') preceded by a start character, separated by semi colons and terminated by carriage return and line feed, i.e.: A;B;C;D;E;F;G;H;I;J;K;L;M;....;N;<CR><LF>... -
Page 32: Modbus Mode
Table 3.7: Serial output data frame, measurement sequences Field Number of Function Entry/format characters measurement identity e.g.: I1 , D1 , E1 measurement name e.g.: Oxygen value e.g.: 20.9 units e.g.: % alarms one character for each alarm, 1,2,3,4 raised = alarm, space = OK failure and maintenance first character F for failure,... -
Page 33: Emc Installation
EMC Installation The chassis must be securely bonded to the local EMC ground. In most installations this will be the back plate, cabinet walls or other access point to the local equipotential common bonding network. Connection to the analyser should be made using the shortest possible length of heavy-gauge braid. - Page 34 NOTES 3.12...
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Page 35: Installation - Gas Connections
SECTION 4 INSTALLATION – GAS CONNECTIONS Introduction Sample and calibration gases pass into and out of the chassis via a gland plate mounted on the rear of the chassis. The sample gland plate with or without external autocalibration provides up to four sample inlets and a corresponding outlet for each inlet, and an optional interface connector, PL 8. -
Page 36: Gfx Transducer Low And High Calibration
Table 4.1: 4900D calibration gas examples Gas components measured Calibration gas 1 Calibration gas 2 CO only or CO+O "zero grade" N CO in air gas mix CO+CO or CO+CO "zero grade" N CO+CO in air gas mix NO only or NO+O NO in N gas mix NO+CO... -
Page 37: Zirconia Transducer Low And High Calibration
This gas can also be used to calibrate the Pm Pressure sensor. NOTE Pure dry air can be used, but not if it has been passed through molecular sieve driers since its composition may have been altered significantly. 4.2.4 Zirconia transducer low and high calibration The low calibration gas must be a high quality certified mixture of pure background gas (usually nitrogen N6.0) containing trace oxygen. -
Page 38: Table 4.2: 4100D And 4200D Sample Port Vs Transducer Type
Table 4.2: 4100D and 4200D sample port vs transducer type Gas sensor Sample inlet Sample outlet Low cal gas High cal gas module type Zirconia 1/8" OD* 1/4" NPT stainless steel female stub 1520 Series IR 1/8" NPT 1/4" NPT female female Paramagnetic... -
Page 39: Reading Flowmeters
Table 4.4: 4900D sample port type Gas sensor Sample inlet Sample outlet Low cal gas High cal gas module type Standard 1/8" NPT 1/4" NPT female female With internal Auto 1/8" NPT 1/4" NPT 1/8" NPT 1/8" NPT Calibration female female female female... - Page 40 In autocalibration two user defined gases (cal gas 1 and cal gas 2) are provided to the instrument. These gases may be either for low or high calibration of the transducers. In some cases the same gas may be used for low calibration of one transducer while being the high calibration of another.
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Page 41: Autocalibration Valve Installation
Autocalibration valve installation As a general guide, two externally powered three way valves are required for each transducer to be calibrated. One switches between sample gas and the second 'calibration' valve (which switches between calibration gas 1 and calibration gas 2). Autocalibration valves may be controlled either by the RS232 output (see Section 3.3) or by relays on the rear panel of the analyser (refer to Section 3.2 and Section 3.6). -
Page 42: Figure 4.3: External Autocalibration - Parallel Systems
Figure 4.3: External autocalibration - parallel systems Key: INLET 1, gas connection to analyser inlet 1 INLET 2, gas connection to analyser inlet 2 SAMPLE A, gas connection to sample gas 1 SAMPLE B, gas connection to sample gas 2 CAL1 (A), gas connection to calibration gas 1 associated with transducer 1 CAL2 (A), gas connection to calibration gas 2 associated with transducer 1 CAL1 (B), gas connection to calibration gas 1 associated with transducer 2... -
Page 43: Figure 4.4: External Autocalibration - Stream Systems
Figure 4.4: External autocalibration - stream systems Key: INLET 1, gas connection to analyser inlet 1SAMPLE, gas connection to sample gas CAL1 (A), gas connection to calibration gas 1 associated with transducer 1 CAL2 (A), gas connection to calibration gas 2 associated with transducer 1 CAL1 (B), gas connection to calibration gas 1 associated with transducer 2 CAL2 (B), gas connection to calibration gas 2 associated with transducer 2 A, wiring to analyser option board, in this example PL8 (external autocal) -
Page 44: Power Up
Power up WARNING Conditions for safe use with flammable samples (4200 and 4210): Do not operate the power switch on the rear panel of the analyser if the unit is known to contain a flammable sample mixture. The 4200 or 4210 must not be used in the event a display failure is observed. The analyser may now be powered up. -
Page 45: Routine Maintenance
SECTION 5 ROUTINE MAINTENANCE Replacing fan filter element The external fan filter element should be checked every six months in laboratory conditions, for environments with a high dust content this period should be reduced. The filter element is washable and in laboratory or light dust conditions may be washed and refitted rather than replaced. -
Page 46: Cleaning
Cleaning The exterior of the analyser should be regularly cleaned using a slightly damp cloth. Remove power before cleaning. Ventilation holes must be kept clear. Do not use solvents or abrasive cleansers to clean the analyser. Toxic/flammable samples - routine leak test WARNING If toxic and /or flammable samples are being analysed it is essential to check the analyser and associated sample lines/system for leaks (every 6 months). -
Page 47: Spares
SECTION 6 SPARES Spare parts may be ordered from Servomex (addresses shown on the back cover of the manual). When ordering spares always give the model and serial number of your analyser. The analyser serial number is on the identification label on the underside of the analyser, and can be displayed via the user interface (refer to Quickstart manual). - Page 48 Part Number Description Quantity S4000976 Kit, four tip up feet. 1 pk S4000978 Mains fuses for 170-264V operation 1 pk S4000979 Mains fuses for 85-132V operation 1 pk S4000986 Kit socket 14W signal 1 ea 2388-1981 Filter element, 80mm Sq fan 1 pk S4000984 Rack mount kit, short chassis...
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Page 49: Technical Specifications
SECTION 7 TECHNICAL SPECIFICATIONS Introduction This section includes the technical specifications for all versions of the 4000. The user must ensure that the relevant sub-sections are used for reference. It may be noted that similar transducer options are available in different analyser variants, in some cases the specifications for these will be application dependent. -
Page 50: Analogue Outputs
EN61326+A1 Electrical equipment for measurement, control and laboratory use - EMC requirements. 7.2.4 Analogue outputs Two isolated 0-20mA/4-20mA output with full zero and span adjustment as standard. The user may define a second range by means of an external contact closure. A maximum total of eight, two range outputs are available by selecting option cards. -
Page 51: Sample Wetted Materials
7.2.9 Sample wetted materials The following tables list sample wetted materials, firstly by sensor type, then by analyser model and configuration. Table 7.1: Sample wetted materials Material Sensor type: Paramagnetic Zirconia 1210 1520 series series Basic Control Purity ... -
Page 52: Table 7.2: Sample Wetted Materials, Continued
Table 7.2: Sample wetted materials, continued Feature Analyser Additional materials Flow driven options 4100 Polypropylene 4200 Pressure driven options 4100 Polysulphone 4200 Polypropylene Stream systems 4900 Polysulphone Polypropylene Nylon* Flowmeters 4100 Borosilicate Glass 4200 Duralumin 4900 Needle valves 4900 Brass Fomblin Grease (suitable for oxygen service) Flow alarm Glass... -
Page 53: 4100D Analyser Performance
4100D analyser performance WARNING This analyser (4102D and 4104D) is not suitable for use with flammable or corrosive samples. Internal autocal is unsuitable for use with toxic samples. If toxic samples are present, the maximum pressure to the analyser must be limited to 8psig by means of a suitable pressure release system. -
Page 54: Table 7.3: 4100D Performance Specification, Oxygen
Table 7.3: 4100D performance specification, oxygen Gases measured Pm1111E O Pm1158 O 4100995 O Zr 704 O Basic Control Purity Trace Range 0-25% 0-100% 0-100% 0-210000 vpm*** Min.rec.o/p range 0-5% 0-5% 0-0.5% 0-5 vpm Intrinsic error <0.15% <0.15% <0.02% <0.1 vpm O Linearity error <0.1% <0.05%... -
Page 55: Table 7.4: 4100D Performance Specification, Gfx
Table 7.4: 4100D performance specification, Gfx * whichever is the larger ** also for O2 background Table 7.5: Gfx trace measurement cross sensitivity information Gfx 1210 CO Gfx 1210 CO Gfx 1210 N Gfx 1210 CH 2% H O ~ 0.5 vpm no effects in target 500vpm CO ~ 0.5 vpm... -
Page 56: Table 7.6: 4100D Performance Specification, Ir
Table 7.6: 4100D performance specification, IR Gases measured 1520 CO 1522 CO Range see Table 7.7 below Min.rec.o/p range 80% of selected range Intrinsic error 1% of selected range Linearity error 1% of selected range Repeatability 1% of selected range Response (T90) <20sec at 200ml/min Zero drift / week... -
Page 57: 4200D Analyser Performance
4200D analyser performance WARNING This analyser (4202D and 4204D) is not suitable for use with hydrogen, acetylene or corrosive samples. The auto-ignition temperature of each flammable gas in the sample must be greater than 135°C. The maximum pressure to the analyser must be limited to 8psig by means of a suitable release system. -
Page 58: Table 7.8: 4200D Performance Specification, Oxygen And Ir
Table 7.8: 4200D performance specification, oxygen and IR Gases measured Pm1158 O Control 1520 CO 1521 CH 1522 CO Range 0-100% see Table 7.9 Min.rec.o/p range 0-5% 80% of selected range Intrinsic error <0.15% 1% of selected range Linearity error <0.05% inherently linear, 1% of selected range dependant on cal. -
Page 59: Table 7.10: 4200D Performance Specification, Gfx
Table 7.10: 4200D performance specification, Gfx Gases measured Gfx 1210 CO Gfx 1210 CO Gfx 1210 N Gfx 1210 CH Trace Trace Trace Trace Range (higher are 0-50 vpm 0-10 vpm 0-50 vpm 0-50 vpm available) Min.rec.o/p range 0-10 vpm 0-5 vpm 0-10 vpm 0-10 vpm... -
Page 60: 4210D Analyser Performance
4210D analyser performance WARNING This analyser (4212D and 4214D) is not suitable for use with corrosive samples. The auto-ignition temperature of each flammable gas in the sample must be greater than 135 ° The maximum pressure to the analyser must be limited to 8psig by means of a suitable release system. -
Page 61: Table 7.12: 4210D Performance Specification, Oxygen And Ir
Table 7.12: 4210D performance specification, oxygen and IR Gases measured Pm1158 O Control 1520 CO 1521 CH 1522 CO Range 0-100% see Table 7.13 Min.rec.o/p range 0-5% 80% of selected range Intrinsic error <0.15% 1% of selected range Linearity error <0.05% inherently linear, 1% of selected range dependant on cal. -
Page 62: Table 7.14: 4210D Performance Specification, Gfx
Table 7.14: 4210D performance specification, Gfx Gases measured Gfx 1210 CO Gfx 1210 CO Gfx 1210 N Gfx 1210 CH Trace Trace Trace Trace Range (higher are 0-50 vpm 0-10 vpm 0-50 vpm 0-50 vpm available) Min.rec.o/p range 0-10 vpm 0-5 vpm 0-10 vpm 0-10 vpm... -
Page 63: 4900D Analyser Performance
4900D analyser performance WARNING This analyser (4902D and 4904D) is not suitable for use with flammable or corrosive samples. If toxic samples are present, the maximum pressure to the analyser must be limited to 5psig by means of a suitable release system. Sample requirements For best performance the flow supplied to the analyser should be kept at a constant value for both normal sampling and for calibration gas input. -
Page 64: Table 7.16: 4900D Performance Specification, Oxygen And Ir
Table 7.16: 4900D performance specification, oxygen and IR Gases measured Pm1111E O Pm1158 O 1520 CO 1522 CO Basic Control Range 0-25% 0-25% see Table 7.17 Min.rec.o/p range 0-5% 0-5% 80% of selected range Intrinsic error <0.15% <0.05% 1% of selected range Linearity error <0.1% <0.05%... -
Page 65: Table 7.18A: 4900D Performance Specification, Gfx
Table 7.18A: 4900D performance specification, Gfx Gases measured Gfx 1210 SO Gfx 1210 SO Gfx 1210 CO Gfx 1210 CO standard high standard high sensitivity sensitivity sensitivity sensitivity Range 0-200 vpm † 0-100 vpm 0-200 vpm 0-50 vpm 0-2500 vpm 0-1000 vpm 0-3000 vpm 0-500 vpm... -
Page 66: Table 7.18B: 4900D Performance Specification, Gfx
Table 7.18B: 4900D performance specification, Gfx Gases measured Gfx 1210 N O Trace Gfx 1210 NO Gfx 1210 CH Trace Trace Range 0-50 vpm 0-100 vpm 0-50 vpm 0-500 vpm 0-1000 vpm 0-500 vpm Min.rec.o/p range 0-10 vpm 0-100 vpm 0-10 vpm Intrinsic error 1% of reading... -
Page 67: Appendix A Effects Of Variations In Sample
Oxygen is a paramagnetic gas, i.e. it is attracted into a magnetic field. Virtually all other gases are diamagnetic, i.e. they are repelled by a magnetic field. Servomex oxygen analysers are calibrated on a scale which is normalised for nitrogen at 0 and oxygen at 100. For high accuracy measurements it may be necessary to introduce a zero offset into the calibration to compensate for the background gas. - Page 68 Formula Molar Zero offset (x 0.01 %) mag.susc x 10 20°C 50°C 60°C 110°C Acetaldehyde -22.70 -0.31 -0.34 -0.35 -0.40 Acetic acid -31.50 -0.56 -0.62 -0.64 -0.74 Acetone COCH -33.70 -0.63 -0.69 -0.71 -0.82 Acetylene HCCH -20.80 -0.25 -0.28 -0.29 -0.33 Acrylonitrile =CHCN...
- Page 69 Formula Molar Zero offset (x 0.01 %) mag.susc x 10 20°C 50°C 60°C 110°C Fluorochlorobromomethane CFClBr -58.00 -1.33 -1.46 -1.51 -1.74 Fluorodichloromethane (Freon 21) CHCl -48.80 -1.06 -1.17 -1.21 -1.39 Fluroxene OCHCH -56.70 -1.29 -1.42 -1.47 -1.69 Freon 114 -77.40 -1.89 -2.08 -2.15...
- Page 70 Formula Molar Zero offset (x 0.01 %) mag.susc x 10 20°C 50°C 60°C 110°C Phosphorous oxychloride POCl -69.00 -1.65 -1.82 -1.87 -2.15 Propane -38.60 -0.77 -0.85 -0.87 -1.00 iso-Propanol CHOH -47.60 -1.03 -1.13 -1.17 -1.34 Propene CH=CH -31.50 -0.56 -0.62 -0.64 -0.74 n-Propyl acetate...
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Page 71: Appendix B Modbus Profile
APPENDIX B MODBUS PROFILE The analyser supports Modbus slave communication through the serial data connector (PL6). This supports an RS232 or RS485 multidrop link to a Modbus master. The implementation of Modbus is based on the “Modicon Modbus Protocol Reference Guide PI-MBUS-300 Rev. J” dated June 1996. - Page 72 30022 – 30023 I4 Measurement Measurement 4 value in IEEE 754 floating point format 30024 – 30026 I4 Name A 6 character string containing the measurement 4 name 30027 – 30028 I4 Units A 3 character string containing the measurement 4 units Derived measurement data Derived measurement data associated with each of the four possible transducer positions is available in a block of input registers that can be read using Modbus function code 04.
- Page 73 Status and alarm information Read-only access to measurement status and alarm information is provided in a block of discrete inputs that can be read with function code 02. + Offset Discrete Description Input 10001 Measurement I1 Fault Maintenance Calibration Warming up Alarm 1 Alarm 2 Alarm 3...
- Page 74 Starting/stopping autocalibration Using the following block of coils, an autocalibration on a specific calibration group may be started, or all calibrations may be stopped. Coil Description 00001 Start Calibration Group 1 00002 Start Calibration Group 2 00003 Start Calibration Group 3 00004 Start Calibration Group 4 00009...
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