United Process Controls Probe Buddy User Manual

USER MANUAL

Probe Buddy

Smart O2 Probe Simulator & Tester

CONNECT WITH US

PROBE BUDDY – USER MANUAL Page 2 of 27

Revision #

Revision Date

Revision Description

007

August 16, 2018

Instrument Cables included.

006

May 23, 2018

Foil revision, process values, cable types, cal and factory mode

005

May 8, 2018

Updated process equations and factor menus

004

April 25, 2018

003

April 2, 2018

002

March 22, 2018

001

September 20, 2017

000

September 17, 2017

UPC_MAN013_R7

MANUAL #: 013

(C)

No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual, or otherwise, without prior written permission of 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.

TECHNICAL ASSISTANCE

For all questions or concerns regarding the operation of the PROBE BUDDY, please consult the last page of this manual for contact information.

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Table of Contents

1 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 ......................................................................................................... 7

Standby Mode .............................................................................................................. 8

Input Mode ................................................................................................................... 9

1.6.1 Using Input Mode ................................................................................................... 9

Output Mode ................................................................................................................. 9

1.7.1 Using Output Mode .............................................................................................. 10

Probe Test Mode ........................................................................................................ 11

1.8.1 Why Measure Sensor Impedance? ...................................................................... 11

Alarm Display ............................................................................................................. 12

2 SETUP MENU ................................................................................................................. 13

3 PROCESS FORMULAS ................................................................................................. 17

Carbon Formula.......................................................................................................... 17

Dew Point Formula ..................................................................................................... 17

Oxygen Formula ......................................................................................................... 18

4 CALIBRATION ............................................................................................................... 19

Calibration Displays and Keyboard Operation ............................................................ 20

Preparing for Input Calibration .................................................................................... 21

4.2.1 Calibration of Inputs ............................................................................................. 21

Preparing for Output Calibration ................................................................................. 22

4.3.1 Calibrating the Outputs Signals ............................................................................ 22

Calibration of Cold Junction ........................................................................................ 22

5 DIAGNOSTIC ALARMS ................................................................................................. 23

6 BATTERY REPLACEMENT ........................................................................................... 23

7 TECHNICAL DATA ......................................................................................................... 24

LCD Graphic Display .................................................................................................. 24

Analog Signals............................................................................................................ 24

General ....................................................................................................................... 25

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Standards Conformity ................................................................................................. 25

8 REFERENCES ................................................................................................................ 25

Available Cables: ........................................................................................................ 25

PROBE BUDDY – USER MANUAL Page 5 of 27 UPC_MAN013_R7

1 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.

The important features of the tester are:

• Operates as sensor test/meter or sensor signal simulator

• Accepts selectable TC and mV inputs from any oxygen sensor

• Outputs selectable TC and mV signals to simulate an oxygen sensor

• Performs a sensor impedance test when connected to the sensor

• Computes carbon, dewpoint or oxygen in input or output mode

• Low power LCD display for HMI

• Small hand-held package

• Easy access connections on the top panel

• Operates on standard 9V battery

LCD Graphic Display

The LCD display is a low power 132x32 Pixels graphic display, equivalent to 4x22 characters.

Signal Connectors

There is a sensor millivolt and sensor thermocouple connector located on the top of the PROBE BUDDY. The standard T/C connector is a B type standard mini-thermocouple plug with alligator clips. The millivolt connector is a standard banana plug with alligator clips. Optional cables are available that provide mating connectors for UPC probes – Carbonseer, Quicksilver, AccuCarb, AtmoProbe – and other sensors and installed cables. See the table in the reference section of this manual for a list of available cables.

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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.

1.3.1 Single Key Functions

TC / mV toggles between the TC and mV selection when configured for output mode.

It also serves to move the cursor from the TC to the mV values. Use the arrow keys to position the cursor and change the digit value.

IN / OUT selects the IN/OUT mode. Both the millivolt and T/C signals shift from input to output when this button is toggled. Output levels for either signal can be adjusted, if ramp mode is not active. When input mode is selected, the actual signal levels are

displayed and are not adjustable.

Setup allows access to the setup menu. Press and hold for 5 seconds to enter Setup mode.

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Enter / ON starts up the simulator and allows data entry in the setup mode. Press and hold the 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.

Left Arrow moves the digit cursor to the left in output mode or moves left through the main menu selection in setup mode.

Down Arrow deceases the selected digit value in output mode or moves down the selected setup menu.

Up Arrow increases the selected digit value in output mode or moves up in the selected setup menu.

Right Arrow moves the digit cursor to the right in output mode or moves right through the main menu selection in setup mode.

1.3.2 Dual Key Functions

Enter / ON + Right Arrow

Pressing the Enter and Right Arrow keys simultaneously starts or stops the sensor test.

Enter / ON + Left Arrow Pressing the Enter and Left Arrow keys simultaneously opens the Service mode on the PROBE BUDDY.

Normal Operation

The following figure shows the PROBE BUDDY display layout.

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1. SIGNAL DIRECTION ICON - Changes the signal direction of both the thermocouple and millivolt signal by pressing the IN/OUT key. Left arrow (pointing out) indicates output mode. Right arrow (pointing in) indicates input mode.

2. TEMPERATURE – Display of thermocouple signal is based on the thermocouple type and temperature scale (°C/°F) selected in the setup menu.

3. TEMPERATURE SCALE – Indicates the temperature scale

4. PROCESS VALUE – Selected process is displayed here based on the temperature and millivolt signals, either inputs or outputs. The scale will change according to the process.

5. RAMP – Indicates that the selected output signal is ramping from a selected start and stop range. The ramp function is enabled in the SETUP / OUTPUTS menu. One or both outputs will ramp if enabled. Changing values are displayed.

6. PROCESS – Indicates the selected process: DPT for dewpoint, %C for carbon, %O2 for oxygen, and PPM for %O2 values below 00.01% oxygen.

7. SENSOR MILLIVOLTS – Shows the measured or set sensor millivolt output.

8. DIGIT CURSOR – Cursor indicates the digit selected to change. The cursor shifts from temperature to millivolts when the TC/MV key is pressed. The arrow keys change the cursor position and digit value. The cursor is only available when the signal output mode is selected.

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. This setting

PROBE BUDDY – USER MANUAL Page 9 of 27

1600° F 1.12%

72.0 mV %O2

IMPEDANCE 1.20K RECOVERY 10 SEC

→

TC TYPE - K COLD JUNC 65

Enter

1600° F 1.12%

72.0 mV %O2

→

UPC_MAN013_R7

determines how long the unit will remain on, without any key being pressed, during the specified period of time. This feature is available to minimize power drain on the battery.

Input Mode

1.6.1 Using 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.

If you are using the cable set with alligator clips, there will be a cold junction error introduced to the temperature measurement, but the intention here is to confirm operation of the TC and confirm the process value.

Output Mode

The input function has been selected with the calculated oxygen display for the thermocouple and millivolt input signals. Pressing the Enter key cycles between the available displays

The output function has been selected with the calculated oxygen display for the selected thermocouple and millivolt outputs. Pressing the TC/mV key cycles between the TC/mV output values. The ◄ or ► keys move the cursor on the digits of the value selected.

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