GE Sensing OptiSonde Operating Manual
GE
Sensing
OptiSonde™
General Eastern Chilled Mirror Hygrometer
User’s Manual
GE
Sensing
OptiSonde™
General Eastern Chilled Mirror Hygrometer
User’s Manual
910-282A
October 2007
The OptiSonde Chilled Mirror Hygrometer is a General Eastern Instruments product. General Eastern
Instruments has joined other GE high-technology sensing businesses under a new name—GE Sensing.
October 2007
Warranty Each instrument manufactured by GE Sensing, Inc. is warranted to be
free from defects in material and workmanship. Liability under this
warranty is limited to restoring the instrument to normal operation or
replacing the instrument, at the sole discretion of GE Sensing, Inc.
Fuses and batteries are specifically excluded from any liability. This
warranty is effective from the date of delivery to the original
purchaser. If GE Sensing, Inc. determines that the equipment was
defective, the warranty period is:
• one year for general electronic failures of the instrument
• one year for mechanical failures of the sensor
If GE Sensing, Inc. determines that the equipment was damaged by
misuse, improper installation, the use of unauthorized replacement
parts, or operating conditions outside the guidelines specified by GE
Sensing, Inc., the repairs are not covered under this warranty.
The warranties set forth herein are exclusive and are in lieu of
all other warranties whether statutory, express or implied
(including warranties of merchantability and fitness for a
particular purpose, and warranties arising from course of
dealing or usage or trade).
Return Policy If a GE Sensing, Inc. instrument malfunctions within the warranty
period, the following procedure must be completed:
1. Notify GE Sensing, Inc., giving full details of the problem, and
provide the model number and serial number of the instrument. If
the nature of the problem indicates the need for factory service,
GE Sensing, Inc. will issue a RETURN AUTHORIZATION number (RA),
and shipping instructions for the return of the instrument to a
service center will be provided.
2. If GE Sensing, Inc. instructs you to send your instrument to a
service center, it must be shipped prepaid to the authorized repair
station indicated in the shipping instructions.
3. Upon receipt, GE Sensing, Inc. will evaluate the instrument to
determine the cause of the malfunction.
Then, one of the following courses of action will then be taken:
• If the damage is covered under the terms of the warranty, the
instrument will be repaired at no cost to the owner and returned.
• If GE Sensing, Inc. determines that the damage is not covered
under the terms of the warranty, or if the warranty has expired, an
estimate for the cost of the repairs at standard rates will be
provided. Upon receipt of the owner’s approval to proceed, the
instrument will be repaired and returned.
iii
October 2007
Table of Contents
Chapter 1: Features and Capabilities
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Electronics Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Input/Output Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Dew Point Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Chapter 2: Installation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Benchtop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mounting the Benchtop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Wiring the Benchtop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Wall-Mount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Mounting the Wall-Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Wiring the Wall-Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Analog Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Alarm Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Serial Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Sensor Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Sampling Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Ensuring Heat Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Filter Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Model 1111H Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Model D-2 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Model 1211H Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Connecting the Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
v
October 2007
Table of Contents (cont.)
Chapter 3: Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operating the OptiSonde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Status Line Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Sensor Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Helpful Hints For Operating the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Supercooled Dew Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Mirror Flooding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Sample Line Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Pressure Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Chapter 4: Programming the OptiSonde
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Programming Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Programmable Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Logging OptiSonde Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
OptiSonde Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Automatic Cleaning and Balance Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Service Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Locking the System Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Chapter 5: Maintenance
Minor Maintenance of Sensor Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cleaning and Balancing the Sensor Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Procedure for Cleaning and Balancing the Sensor Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Field Replacement of Sensor Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Replacing the Sensor Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Test and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
The Display Doesn’t Light Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
“Service” Appears on the STATUS Display Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Incorrect Dew Point Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
“Balance” Remains on the Status Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
No Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
No Serial Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
vi
October 2007
Table of Contents (cont.)
Appendix A: Specifications
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Accuracy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Measurement Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Update Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Operating Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Physical (Bench Mount) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Physical (Wall Mount) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Appendix B: Humidity Equations and Conversion Chart
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Vapor Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Appendix C: Configuring the Serial Interface
Wiring to a Personal Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Appendix D: Chilled Mirror Sensors
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Depression. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Measurement Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Comparing OptiSonde Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Appendix E: Theory of Operations and Glossary
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Hygrometer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Hygrometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Other Hygrometer Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
The PACER Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
vii
Chapter 1
Features and Capabilities
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Electronics Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
October 2007
Introduction The GE Sensing OptiSonde™ is a multi-purpose chilled-mirror
hygrometer, suitable for use in a wide variety of applications. The
OptiSonde can function with the GE Sensing one and two-stage
chilled-mirror sensors to provide the following measurement ranges
(depending on the sensor selected):
• one-stage 45° depression @25°C and 1 ATM
two-stage 65° depression @25°C and 1 ATM
(depending on sensor, as shown in Figure 1-1 below)
• relative humidity from 0.02% to 100%
• moisture content from 0.9 ppm
to over 5.8 × 105 ppm
v
• temperature from -100° to +100°C (-212°F to +212°F)
(a)
(b)
v
(c)
Figure 1-1: Mirror Depressions at Various Temperatures for
1111H (a), D2 (b) and 1211H (c) Sensors
Features and Capabilities 1-1
October 2007
Introduction (cont.) The OptiSonde simultaneously measures and displays any two
parameters with a wide variety of units of measurement. You can use
the data logging function to record and upload weeks of data. When
the data is uploaded to a PC, PanaView software enables graphing
and data reduction. You can also export the data in ASCII text file
format for use in spreadsheets such as Excel, or view screen captures
in HyperTerminal.
Electronics Enclosure The OptiSonde is available in two configurations:
• a benchtop model, AC powered with DC option
• a wall-mount unit, housed in an IP65 enclosure
See Chapter 2, Installation, for details on how to mount the
OptiSonde.
Front Panel The OptiSonde’ s fron t panel is shown in Figure 1 -2 below. The panel
includes: a 128 X 64 graphical display,
arrow keys to the right of the display screen.
ENTER and ESC keys, and four
3.30
3.70
Figure 1-2: OptiSonde Benchtop Version
1-2 Features and Capabilities
Input/Output Capability Available inputs and outputs include the following:
• 1111H, 1111H-GE, D2 or 1211H chilled mirror sensor input
• 4-wire Resistance Temperature Detector (RTD) input
• two simultaneous analog outputs, each with a programmable 0-20
mA or 4–20 mA DC signal
• one independent alarm relay (7 A, 30 VDC)
• RS-232 serial communications port
The OptiSonde uses the GE Sensing patented Programmable
Automatic Contaminant Error Reduction (PACER) system for
automated self-cleaning and optics rebalancing.
Detailed specifications for the OptiSonde are given in Appendix A.
The System
October 2007
System Components A complete OptiSonde system consists of the following items:
• Electronic monitor • Temperature sensor
• Dew point sensor • Maintenance kit
• Interconnecting sensor cable • User’s Manual
• AC line cord (for benchtop)
• Certification that the unit is traceable to the National Institute
of Standards and Technology (Certificate of Conformance)
Sensors The OptiSonde is configured with a chilled-mirror dew point sensor.
The specific sensor is chosen according to the expected dew point
range and the environment in which the dew point is to be
determined. In addition, the OptiSonde is supplied with a temperature
sensor. GE Sensing provides the following sensors for various
applications:
Dew Point Sensors • Model 1111H — Dew point single-stage sensor with 1” M-NDT
• Model 11 1 1H-GE — Dew point single-stage sensor with flange for
duct mounting
• Model 1211H — Two-stage sensor; high pressure and temperature
• Model D-2 — Two-stage sensor
Temperature Sensor • Model T-100E
Features and Capabilities 1-3
Chapter 2
Installation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Benchtop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Wall-Mount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Sensor Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
October 2007
Introduction This chapter explains the installation of the benchtop and wall-mount
versions of the OptiSonde, the various sensors used with the system,
and the I/O and power wiring.
Benchtop Installation
Mounting the Benchtop
Note: All dimensions are in inches.
The OptiSonde benchtop dimensions are shown in Figure 2-1 below.
A wire bale on the bottom of the case can be unfolded to raise up the
front for easier viewing, if desired.
3.30
3.70
8.0
8.84
Figure 2-1: OptiSonde Benchtop Dimensions
Installation 2-1
October 2007
Wiring the Benchtop
Input Power The OptiSonde operates with input power from 100 to 240 VAC
±10%. (See Figure 2-2 below.) The OptiSonde’s voltage and
frequency rating are listed on the product label. A DC option offers a
minimum of 18 to a maximum of 32 VDC operation (See Figure 2-3
below.)
Sensors Connect the dew point sensor cable to the 25-pin connector on the
OptiSonde’s rear panel (see Figure 2-2 below). Connect the optional
temperature sensor cable to the 9-pin temperature connector on the
rear panel. Other I/O wiring connects to the appropriate terminal
block. Tighten all connector thumbscrews to prevent disconnection s.
LINE
180-240VAC
TEMP
COMM
FUSE: 1A
TYPE T
50-60 Hz
80 VA MAX
Analog
OUTB
DP-SENSOR
OUTA
ANALOG SHIELD
Figure 2-2: OptiSonde Benchtop Rear Panel
TEMP
DP-SENSOR
COMM
Analog
OUTBOUTA
NO NC C
7A, 30V
DC POWER
18-32 VDC/1A
RELAY
NO NC C
7A, 30V
RELAY SHIELD
ANALOG SHIELD RELAY SHIELD
Figure 2-3: OptiSonde DC Option Rear Panel
2-2 Installation
October 2007
Wall-Mount Installation The OptiSonde Wall-Mount unit is designed to mount on a flat,
vertical surface, such as a wall or panel. To mount the wall-mount
version, see Figure 2-4 and Figure 2-5 below.
Mounting the Wall-Mount
8.17
4.49
10.479
Note: All dimensions are in inches.
4X
Ø
.38
Figure 2-4: OptiSonde Wall-Mount Dimensions
4X
Ø
.38
2.86
2.86
7.80
7.80
Note: All dimensions are in inches.
Figure 2-5: OptiSonde Wall-Mount - Mounting Hole Locations
For mounting, secure the unit to a wall or panel using all four
mounting holes. Use stainless hardware, a minimum of 2 inches long,
#8 screws with washers. Screws should go directly into wood studs.
If no stud is available, use suitable hardware for the application, such
as with plasterboard or cement.
Installation 2-3
October 2007
Wiring the Wall-Mount Caution!
The wall-mount unit meets IP65 rating for water ingress
when tested with solid plugs. In order to maintain this
rating, installation personnel must ensure that each of the
two wiring ports use a single cable with a minimum
diameter of 0.24 in (6 mm) and a maximum diameter of
0.47 in (12 mm). Recommended wire nuts torque is 37 in-
lbs (4.2 Nm). Any unused wiring port shall be plugged with
a supplied solid plug.
All connections to the wall-mount unit are made through the panel at
the bottom of the case as shown in Figure 2-6 below. Any I/O cabling
is brought into the unit through glands at the lower right of the case
and connects to the terminal blocks inside the case. Wiring for these
connections is shown below and in Figure 2-8 on page 2-5. The dew
point sensor and temperature sensor cable connectors are located on
the black mounting block.
IMPORTANT: AC and signal wiring must be done in accordance
with local codes. Wire size cannot exceed 14 AWG
2
(2.08 mm
to being inserted into the connection block.
). Insulation shall be stripped 6 mm prior
ANALOG OUTPUTS
PIN
OUTA +1.
2.
OUTA -
3.
OUTB +
OUTB -4.
TEMP. SENSOR
PIN WIRE COLORS
RED
1.
WHITE2.
GREEN
3.
4.
BLACK
SHIELD
5.
NOTE: CUSTOMER MUST INSTALL
SUPPLIED FERRITE (P/N 222-028)
OVER THE END OF TEMPERATURE
SENSOR ON LOCAL AND REMOTE.
DESCRIPTION SUPPLY VOLTAGE
EARTH GROUND CONNECTION
(TIE TO A COMMON PROTECTIVE EARTH
RELAY
USING THE SAME SIZE , OR GREATER,
PIN
WIRE AS AC POWER.)
NO1.
NC
2.
3.
COMM
SHIELD
A/C POWER
FERRITE
LOCAL SHOWN
COVER ASSEMBLY NOT SHOWN
5 1
1 4 1 3
J1
J11
2 1
J13
J2
J9
1 2 3
A/C POWER TERMINAL BLOCK
PIN
1 L1 LINE POWER CONNECTION 100-240VAC
2 L2/ N LINE/NEUTRAL CONNECTION
RS232
PIN
TX1.
2.
RX
RTN3.
I/O
Figure 2-6: Wall-Mount Wiring Entrance Locations
CHASSIS GROUND
2-4 Installation
October 2007
S
Input Power Power wiring enters the case through a gland fitting at the lower right
of the unit and connects to a screw terminal block mounted on the
right side of the case. The voltage, frequency and power ratings are
listed on the bottom of the unit.
shown in Figure 2-7 below. The external ground screw must connect
the unit to protective earth using a wire that is sized equal to or great
then the wire used for input power connectio ns. Groun ding should b e
done in accordance with local codes.
Wiring of this terminal block is
2 1
J13
J9
1 2 3
A/C POWER TERMINAL BLOCK
PIN DESCRIPTION
1 L1 LINE POWER CONNECTION
2 L2/ N LINE/NEUTRAL CONNECTION
Figure 2-7: Wall-Mount AC Power Wiring
Output Wiring The benchtop outputs are connected to removable terminal blocks o n
the rear panel. Figure 2-2 on page 2-2 shows the location of the
benchtop terminal blocks and Figure 2-8 below shows the wall-mount
connections.
The Wall-Mount OptiSonde input/output terminal blocks are located
inside the front door as shown in Figure 2-6 on page 2-4. Cabling is
brought in through the glands on the bottom of the unit and wired to
the terminal blocks shown in Figure 2-8 below. Terminal block
screws must be torqued between 0.4 - 0.5 Nm.
Output programming is described in Chapter 4.
TEMP. SENSOR
PIN WIRE COLORS
RED
1.
WHITE2.
GREEN
3.
4.
BLACK
SHIELD
5.
NOTE: CUSTOMER MUST INSTALL
SUPPLIED FERRITE (P/N 222-028)
OVER THE END OF TEMPERATURE
RELAY
PIN
NO1.
NC
2.
3.
COMM
SHIELD
A/C POWER
SENSOR ON LOCAL AND REMOTE.
EARTH GROUND CONNECTION
5 1
1 4 1 2 3
J1
J11
2 1
J13
J2
J9
1 2 3
RS232
PIN
2.
I/O
TX1.
RX
RTN3.
ANALOG OUTPUTS
PIN
OUTA +1.
2.
OUTA -
3.
OUTB +
OUTB -4.
Note:
FERRITE
Figure 2-8: Wall-Mount Input/Output Terminal Blocks
Installation 2-5
October 2007
Analog Outputs Note: When the OptiSonde is being programmed, the analog outputs
provide 4–20 mA signals representing the designated
parameters.
• For 4–20mA output, connect to terminals labelled 4–20 (+) and
RTN (–).
Note: The maximum load allowed for current output is 500 Ohms.
Example: Assume a temperature output, scaled to range from 0°C
(Tlower) to 100°C (Tupper), with a measured actual temperature of
23°C (Tactual): The current output is calculated by:
Tactual Tlower–()
Iout
yielding an output current of 7.68 mA.
------------------------------------------------- Tupper Tlower–()
23 0–()
---------------------100 0–()
16()4+× 7.68mA=
20 4–()4+×=
(2-1)
(2-2)
Alarm Outputs The alarm output connects to the contacts of a 7-Amp, Form C
(SPDT) relay.
Make connections as follows:
• For normally open contacts, connect to NO and COMM.
• For normally closed contacts, connect to NC and COMM.
Any available parameter can be used to control an alarm relay by
programming the parameter name and its threshold values. An alarm
can also be programmed to monitor the state of the Control, PACER
Balance, or Service indicators. (See Chapter 4 for programming
instructions.)
Two threshold values are programmed for each parameter—an upper
and a lower value. These values designate an alarm band. How they
are used depends on the alarm type programmed. Details of the alarm
bands are shown on the following pages.
2-6 Installation
October 2007
Set Point Alarm For the Set Point alarm type, the alarm band provides hysteresis to
prevent frequent operation of the alarm relay when the parameter is
near the specified value. The relay is activated when the parameter
exceeds the upper limit, and deactivated when the parameter goes
below the lower limit.
Figure 2-9: Set Point Alarm
Inner Band Alarm For the Inner Band alarm type, the alarm relay activates whenever
the parameter value is between the lower and upper limits.
Figure 2-10: Inner Band Alarm
Outer Band Alarm For the Outer Band alarm, the alarm relay activates whenever the
parameter value is greater than the upper limit or less than the lower
limit.
Figure 2-11: Outer Band Alarm
Installation 2-7
October 2007
Serial Output The Serial Output connector is located on the rear panel of the
benchtop unit (see Figure 2-2 on page 2-2), and inside the wall-mount
unit (Figure 2-6 on page 2-4). The output provides RS-232C serial
communications between the unit and a terminal or a PC running in
terminal emulation mode.
The benchtop connector is a standard 9-pin D connector. For
connection to a serial device, the wallmount cable is wired as shown
in Figure 2-8 on page 2-5. The baud rate can be programmed using
the Comms menu (see page 4-10). The data format is 8 bits, 1 stop bit,
no parity.
2-8 Installation
October 2007
Sensor Information GE Sensing produces a variety of sensors compatible with the
OptiSonde, ranging from one to two stages of thermoelectric cooling.
A comparison chart listing specifications of each sensor appears in
Appendix D. The following sections provide information on
installing the following GE Sensing dew point sensors:
• Model 1111H — Single-stage sensor with 1” M-NDT
• Model 1111H-GE — Dew point single-stage sensor with flange
• Model 1211H — Two-stage sensor; for high pressure and temp.
• Model D-2 — Two-stage sensor
When selecting a location for installing a sensor, consider the
following criteria:
• Locate the sensor as close as is practical to the source of the gas to
be measured, to keep the sampling lines as short as possible. This
minimizes the system response time and reduces the error rate at
low frost points due to sample line outgassing.
Caution!
The OptiSonde electronics and sensors are for General
Purpose Locations only. They are not for use in hazardous
(classified) locations. Sample air/gas shall be non-
combustible only.
• Choose a sensor location that provides access to the dewpoint
sample cavity cover, to facilitate periodic mirror cleaning.
Caution!
Never place the sensor in a location where temperatures
rise above the maximum rated temperature for the device.
See Appendix D for complete sensor specifications.
Installation 2-9
October 2007
Sampling Lines Keep the length of sample tubing between the source and the sensor
short, for quick response and highest accuracy. All sampling line
compression fittings provided with the sensor are for ¼-inch diameter
tubing, unless otherwise specified at the time of order.The material
used for the inlet lines can have an important effect on the validity of
the readings. Do not use rubber hose or plastic tubing such as PVC or
Tygon, because of their hygroscopic nature.
When measuring frost points below –30°C, sample gas leaving the
sensor outlet should be vented through a coil approximately two feet
long, since backflow of ambient moisture into the sensor can take
place even under positive pressure. Use stainless steel tubing and
fittings, and ensure that all plumbing is completely free from leaks.
Stainless steel is the material of choice.The sampling system should
allow for periodic cleaning. It may be helpful to install a tee and
closing valve on the inlet side, to permit the sensor to be shut off
while the sampling lines are flushed. At very low humidities, even a
trace amount of contamination can alter measured frost point, so
cleanliness is particularly important.
Ensuring Heat Transfer Be sure the sensor has an adequate heat sink when operating in hot
environments. The sensor must never be allowed to reach a
temperature above its rated limit. It is not sufficient merely to ensure
that the sensor is in an environment whose temperature is below the
rated limit; a means must be supplied to remove heat from the sensor.
When the Model 1111H, 1211H or D-2 sensors are used at ambient
temperatures of 20° to 24°C, full rated depression can be achieved by
mounting the sensor on a smooth, thermally conductive surface (such
as metal), which tends to remain at the ambient temperature.
If possible, do not operate the sensor continuously at or near full
depression. Doing so may decrease the anticipated life of the
thermoelectric heat pump.
When measuring dew points at or above the ambient temperature, the
sensor must be heated to a temperature of at least 5 to 10°C above the
highest anticipated dew point (but not higher than the sensor
temperature rating). Some sensors can be mounted on a liquid heat
exchanger, or a temperature-controlled electric hot plate, or installed
in a heated enclosure. GE Sensing recommends closed-loop active
control of the elevated sensor body temperature.
The sensor base should be coated with zinc-oxide-filled silicone
thermal grease and securely anchored to the heat sink with suitable
fasteners. Allow ½ hour for the sensor to reach thermal equilibrium
after adjusting the temperature of the heat sink.
2-10 Installation
October 2007
Sample Lines for High Dew
Point Measurements
Sampling lines carrying gas to the sensor must be heated and
insulated when the dew point of the gas is above the sample line’s
ambient temperature. The simplest way to achieve this is to use heater
tape (either thermostatically controlled, or continuously operating,
and sized to provide the required temperature rise). At high
temperatures, use stainless steel tubing with adequate insulation to
avoid hot and cold sections in the line and to avoid water absorption/
desorption cycling as the heater is thermostatically controlled. GE
Sensing can provide custom heated systems. Please contact our
application engineers.
Filter Requirements If the gas to be monitored is free from particulates and hydrocarbon
liquids or vapor, filtering is not necessary . However, most sample gas
streams contain some particulates, and using a filter reduces the need
for frequent mirror cleaning. On the other hand, filtering tends to
slow the system’s response, particularly at low frost points.
The model BF12-SS filter may be used inline; GE Sensing’s
application engineers would be pleased to review your application
and recommend an appropriate sampling system.
A void using glass wool, cellulose, and othe r hygroscopic materials as
a filter medium.
Flow Rate It is important to have adequate flow through the sensor. Too little
flow can slow the response (particularly at very low frost points). Too
much flow can cause instability of the control system at high dew
points and can reduce the depression capability of the thermoelectric
cooler at very low dew points. Too much flow also accelerates the
3
rate of system contamination. A flow rate of 2 to 2.5 ft
min) is ideal for most applicatio ns.
/h (∼ 1 liter/
Installation 2-11
October 2007
Sensor Installation This section provides installation details for the GE Sensing line of
chilled-mirror humidity sensors.
Model 1111H Sensor The Model 1111H is an open-type sensor (see Figure 2-12 below )
with 45°C depression capability at 25°C @ 1 A TM. It can be threaded
into standard pipe fittings or mounted in a type 0111D pressure boss,
which encloses it and adapts it for ¼-inch compression fittings. When
installing the sensor in the pressure boss, remove the black aluminum
sensor cover. A second version, the 1111H-G E, extends 9 in. and
includes a duct-mounted flange and a removable PTFE filter.
For maximum thermal conductivity, the base of the Model 0111D
pressure boss should be coated with heat-conducting grease. When so
installed on a surface suitable for dissipating heat, the sensor will
achieve its maximum rated depression. See the Chilled Mirror Sensor
Comparison Chart in Appendix D.
Figure 2-12: Model 1111H Sensor for Duct Mounting
Model D-2 Sensor The Model D-2 is a general purpose, two-stage sensor with 65°C
(117°F) of depression capability at 25°C @ 1 ATM. It features wetted
parts of stainless steel and glass, for durability in demanding
industrial applications. The Model D-2 can be used as a benchtop
sensor, mounted to a heat sink, or mounted to a cooling fan for
maximum operating range. Advanced features include fieldreplaceable optics and cooler assemblies, and auxiliary visible light
optics with a viewing window for inspecting the mirror during
operation (see Figure 2-13 below).
For maximum thermal conductivity , the base of the Model D-2 sensor
should be coated with heat-conducting grease. When so installed on a
surface suitable for dissipating heat, the sensor will achieve its
maximum rated depression. See the Chilled Mirror Sensor
Comparison Chart in Appendix D.
Figure 2-13: Model D-2 Sensor
2-12 Installation
October 2007
Model 1211H Sensor The Model 1211H is a two-stage sensor with 65°C (117°F) of
depression capability at 25°C @ 1 ATM. It features wetted parts of
stainless steel and may be used at higher temperature and pressure
than the D2 sensor. The Model 1211H can be used as a benchtop
sensor, mounted to a heat sink. Features include a field-replaceable
mirror, optics and cooler assembly. See the Chilled Mirror Sensor
Comparison Chart in Appendix D.
Connecting the Sensors Dew point and temperature sensors provided by GE Sensing for the
OptiSonde monitor are pre-wired with connectors installed. Plug
these connectors into their corresponding sockets as shown in
Figure 2-2 on page 2-2 for the benchtop unit, or Figure 2-6 on page 24 for the wall-mount unit. The 1111H sensor can be mo un ted d irectly
to the wall-mount enclosure to facilitate room monitoring. Ensure that
the sensor or cable is fully inserted, and the ring coupler fully handtightened for reliable operation. Tighten dome nut to 22 in-lb (2.5
Nm) to assure a proper seal for IP65 rating.
Installation 2-13
Chapter 3
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