SYNOPSIS

OXYGEN
TRANSMITTER
PROJECT DURATION: 03.08.2018 to 20.09.2018

DEVELOPED BY : BIBHAS MANDAL

MANUFACTURED BY: STEAM EQUIPMENTS PVT.LTD
TINY INDUSTRIAL ESTATE, KONDWA, PUNE - 411048.
1.

2. Working

3. Error: Reference source not founds

4. Error: Reference source not found & PCB design

5. Error: Reference source not found / BOM & Budget

6. Calibration

7. Future scope of improvements

8. Error: Reference source not found/ References

1. Overview

The requirements for Oxygen readings in hazardous locations is a daunting

task and requires special certified enclosure & electronics, sensors to face
the challenges in extreme harsh atmosphere & locations with good
reliability. The cost of imported quality transmitter is @Rs. 80000 and
indigenous products also cost @ Rs.50000.
Our target manufacturing price is below Rs.25000 SEPL make.
To overcome the need for dependency on imports for ATEX O2 transmitters
Gave rise to the need for the development for “MAKE IN INDIA” indigenous
oxygen transmitter suitable for the hazardous area and is feasible in price &
technology.
The Oxygen transmitter is an electrochemical fuel cell sensor using KE-25F3
Figaro sensor giving mV o/p signal according to the oxygen gas measured.
The oxygen sensor mV is amplified by Opamps and fed to A/D convertor in
turn driving a digital 3 ½ Digit LCD display, displaying the measured oxygen
reading in percentage.

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The transmitter is loop powered by DCS / PLC / 24 V DC supply and we get
4-20mA current readings corresponding to the Digital display readings.

2. Working

After connecting the transmitter in series with 24 V DC loop power systems

either thru DCS / PLC etc. the transmitter switches ON with the LCD display
showing some ambient / process readings as per the oxygen sensor mV
output. Normally the display would show 19-21% O2 in ambient clean air
and accordingly the 4-20mA readings in series to the transmitter
connection is also available.
Calibration is needed for the oxygen transmitter Display readings and the 4-
20mA readings and both should match with the actual percentage oxygen
sensed by the sensor.
The Zero & Span preset are also available for the Digital Display calibration
as well as the side port of the transmitter housing marked the Z & S for zero
& span respectively for the 4-20mA current calibration as per the
transmitter true readings.
No touch buttons and keypads are required for this transmitter to operate
as it’s purely an analog circuit coupled with a digital display, hence
microcontroller is not used and not required for this project. Reliability is
increased due to very low component count and double sided industrial
glass epoxy PCB.
Being loop powered transmitter no relay / alarms and LED indication is used
to keep the current consumption and thereby the voltage drop across the
loop power supply to minimum.
The oxygen sensor is housed in an aluminum / SS machined housing using
neoprene O-ring to protect the certification of the transmitter housing
tightened by 4 no’s Allen screws. The sensor housing also incorporates a
coalescing filter element to safeguard the oxygen sensor against heavy
moisture & particulate matter. The fine filter is preceded by a scrubber
canister which contains PURAFIL chemical useful for corrosive & acidic

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gases in trace quantity. The inlet and out let gases are connected by
standard ¼” NPT SS316 fittings.
The whole assembly can be mounted on a base plate as per the image or
the assembly can be mounted on a 2” to 4” pipe with suitable pipe clamp &
hardware.

3. Electronics.
The 24V loop power enters the transmitter thru the diode and then the
voltage regulator, the voltage regulator LM317T regulates the internal
voltage for the A/D convertor & LCD display driver and Opamps to +5V DC
max. The ICL7650 Opamps amplifies the incoming mV signal from the
Oxygen sensor and is its gain is basically controlled by the DIP switches
with incoming selectable resistors for the Opamps gain, the fine gain is
achieved by the mA Zero & Span trim pots connected in feedback line to
the Opamps circuitry. The gain in turn increases or decreases the required
4-20mA of the circuitry which corresponds to the oxygen readings.
The LCD DPM IC drives the mV signal and displays on LCD in 3 ½ digit.
IC 7106 or similar is used to drive the LCD display.
The whole electronics and the oxygen sensor is mounted in the flameproof
die cast aluminum enclosure certified by CMRI hence the whole assembly is
absolutely safe to use for the hazardous area.

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4. Schematics & PCB design

MAIN AMPLIFIER PCB

ZERO & SPAN PCB
 5. Part list & BOM for the transmitter with budget
1 OXYGEN TRANSMITTER 0-25%, 4-20MA LOOP POWERED    
SR.NO. BOM QTY @ COSTING MAKE
1 TRANSMITTER HOUSING FLP WITH PCB 1 9800 NISHKO
2 TRANSMITTER PCB SEPL DESIGN 0 NA NA
3 OXYGEN SENSOR KE-25F3 1 6700 TOSHNIWAL SENSING
4 PURAFIL CHEMICAL 1 200 CASH PURCHASE
5 CLASSIC FILTER ELEMENT 12-32-50C 1 1100 MICROSERVICE TOOL
6 SENSOR HOLDER IN SS316 1 2500 MICROSERVICE TOOL
7 SS316 TUBES 1/4" 1 200 SEPL
8 BULKHEAD UNION 1 650 SEPL
9 ELBOW FITTINGS 4 650 SEPL
10 ACRYLIC CANNISTER 4" LENGTH 1 500 SEPL
11 FLP CABLE GLANDS 1/2" 1 270 SEPL
12 SS316 MOUNTING PLATE 1 1500 SEPL
13 1/4" FERULES WITH FITINGS 4 1500 SEPL
14 HARDWARE SS316 8 40 CASH PURCHASE
15 OPTIONAL PIPE CLAMP 2" 1 300 CASH PURCHASE
16 ANALYSERS STICKERS & LABELS 1 250 LOCAL
17        
18        
19        
20        
21        
22        
23        
    Rs. 26160  
6. Calibration
a) The calibration should be carried out first using N2 as zero gas for @ 5
minutes at 1 LPM and the corresponding digital display must be
adjusted to get 0.1% as the Zero value. The 4-20mA Zero pot at the
side panel is also to be adjusted to 4mA during the zero calibration.
b) The (span gas) ambient clean instrument air from compressed air line
or cylinders may be used to feed the transmitter and flow kept for @5
minutes at 1 LPM, as the readings stabilize the Span pot of the Digital
display should be adjusted to get the 20.9% readings and Span pot at
side panel adjusted for 17.5mA for 20.9% O2, repeat the above steps if
calibration is not found satisfactory in the first attempt.
c) Use zero & span gas few times to check the transmitter response and
the repeatability of the instrument.

7. Future scopes & improvements.

a) We are presently using a readymade FLP transmitter from Nishko

instruments suitable for the mV range of the KE-25 oxygen sensor
range 0- 80mV. In future the PCB images as attached will be used and
redesigned if required and used to save manufacturing cost and time.
b) Microcontroller based transmitter with push button switches will
eliminate the need for the preset potentiometers for the display and
gain adjustment.
c) Menu and alerts will also be added as special features for easier
calibration and use.
8. Sources & references.
a) Nishko Instruments Pvt.Ltd transmitter
b) Figaro sensor KE-25F
c) ICL 7650 datasheet
d) LM317T datasheet