ORBITEC OXY- SMART: Your tool to monitor the quality of flushing gas: The ORBITEC OXY-SMART is a mobile and easy-to-use measuring device that can measure and determine residual oxygen concentration in flushing, welding and forming gases in the welding technique. It can be used with inert gases and forming gases, such as nitrogen, argon, helium and other rare gases. Forming gases are mixtures of nitrogen or argon and hydrogen, with a maximum hydrogen fraction of 10%. The device is equipped with a three-digit display that shows the measured oxygen concentration in ppm.
ORBITEC OXY- SMART: Your tool to monitor the quality of flushing gas: The ORBITEC OXY-SMART is a mobile and easy-to-use measuring device that can measure and determine residual oxygen concentration in flushing, welding and forming gases in the welding technique. It can be used with inert gases and forming gases, such as nitrogen, argon, helium and other rare gases. Forming gases are mixtures of nitrogen or argon and hydrogen, with a maximum hydrogen fraction of 10%. The device is equipped with a three-digit display that shows the measured oxygen concentration in ppm.
Instruction Manual OXY- SMART
1
OXY- SMART
ORBITEC
GmbH
Willi-Brehm-Straße 8
D-63500 Seligenstadt
Phone: +49 (0)6182 / 78693-0
Fax: +49 (0)6182 / 78693-10
E-Mail: info@orbitec-group.com
Internet: www.orbitec-group.com
Instruction Manual OXY- SMART
2
Contents
1. Preface ..................................................................... 3
2. Restrictions .............................................................. 4
3. General structure ..................................................... 5
3.1. Front view ................................................................................... 5
3.2. Top view ..................................................................................... 6
3.3. Lateral view ................................................................................ 6
3.4. Rear view .................................................................................... 7
4. Explanation of icons ................................................. 8
5. Commissioning - Operation ...................................... 9
6. Measuring gases containing H2 .............................. 13
7. Monitoring ranges - Programming functions .......... 14
8. Charging process .................................................... 15
9. Filter status ............................................................ 17
10. Technical data ........................................................ 18
11. Servicing and maintenance .................................... 19
Instruction Manual OXY- SMART
3
1. Preface
Correct formatting is imperatively required for quality assurance when welding
high-alloy, corrosion-resistant components.
Only at very low residual oxygen content during the welding process
it is possible to attain neat and corrosion-resistant welding seams with little colouring
on the inner surface of the tube.
An insufficient gas protection results in
annealing colouring or carburization in the
heat affected zone as well as a reduction
of the corrosion resistance of the welding
seam and thus it is unsuitable for any tube
installation.
To monitor the quality of the flushing gas
before the welding process, it is necessary
to use measuring devices to check the
residual oxygen content.
The welder or the operator can use the
measuring device Oxy-SMART to check
and document the residual oxygen
content. The ppm value to be entered in
the display can be freely selected. If not
otherwise imperatively prescribed, a value
of < 30 ppm is generally sufficient at the
beginning of the welding process. If the
measured value falls below the entered
value, the colour on the display changes
from red to green.
It is possible to start the welding process.
The mobile measuring device Oxy-SMART
serves to record the residual oxygen
content in flushing, welding and forming
gases in the welding technique.
Residual oxygen concentration can be
measured and determined in the following
gas mixtures: Inert gases and forming
gases. Inert gases are among others
nitrogen, argon, helium and other rare
gases. Forming gases are gas mixtures consisting of nitrogen or argon and
hydrogen. There are different gas mixtures with different H2 fractions, the maximum
fraction of hydrogen must not exceed 10 %.
The measuring device is not suitable to perform measurements of explosive gas
mixtures, in particular it is not suitable to measure pure hydrogen. There is a risk of
explosion!
Instruction Manual OXY- SMART
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2. Restrictions
The measuring device is not suitable to perform measurements of explosive
gas mixtures, in particular it is not suitable to measure pure hydrogen.
There is a risk of explosion!
! ! ! DURING THE CHARGING NOT MEASURE ! ! !
This leads to overheating and possibly
Destruction of lithium-ion batteries
!!! Do not aspirate liquids or vapours !!!
This results in the destruction of the sensor and of the internal measuring gas
pump
The measuring device is not suitable to monitor the ambient air
and must not be used to protect people
No measuring without filter – no warranty claim
Only use original filters made by ORBITEC
Caution when working in an environment with organic vapours such as e.g.
scorching of plastic materials
Such vapours might result in the sensor destruction
Never open the Oxy-SMART !!!
Have the battery only replaced by authorized specialised staff
of the company ORBITEC GmbH
Do not change or modify any devices.
Any changes or modifications render the
warranty claim null and void
Instruction Manual OXY- SMART
5
3. General structure
3.1. Front view
Filter
Measuring gas
hose
Display
Measuring gas
inlet
Keyboard
Instruction Manual OXY- SMART
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3.2. Top view
3.3. Lateral view
Charging
socket
Measuring gas
outlet
Measuring gas inlet
Hose connection
Lanyard eyelet
Wedge-shaped structure,
hence ergonomic,
well readable and operable
Instruction Manual OXY- SMART
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3.4. Rear view
Protective rubber
frame
Anti-skid rubber feet
Type plate
Ergonomically
shaped housing
Calibrates seals
Instruction Manual OXY- SMART
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4. Explanation of icons
999 ppm O2
Three-digit display
max. measuring range
Minus / Down
Menu navigation,
Reducing the
selected values
Pump
Switching the
measuring gas pump
on and off
ON/OFF
Switching the
measuring device on
and off
P
Programming
button for monitoring
range and setting
Plus / Up
Menu navigation,
Increasing the
selected values
H2
Changing the gas
type
Inert / H2
Battery
Battery charge
status indicator
Pump
when the pump is
activated
the turbine turns
Inert / H2 display
the currently selected
measuring gas is
displayed
Instruction Manual OXY- SMART
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5. Commissioning - Operation
Switching on the measuring device
By pressing the ON/OFF key, the Oxy-SMART is switched
on. The device heats up the sensor which has to be brought
to a preset temperature in order to allow a correct measuring
process. During this time it is not possible to perform any
measurements.
In the standby mode the cell is heated up to 50%.
Structure of the measuring equipment
Recommended structure:
Since most of purge gases are heavier than air, it is recommended to connect the
gas inlet at the lowest point of the system or the piping to expel the air and the
residual oxygen effectively.
Oxy-SMART
Weld joint
Gas outlet
Measuring
point
Gas inlet
Instruction Manual OXY- SMART
10
Never obstruct the gas outlet hole at the measuring point with the tube,
the flushing gas must always outflow freely:
The pump installed in the device must be allowed to suck in the flushing gas without
overpressure.
Instruction Manual OXY- SMART
11
After having installed the device, switch on the pump of the Oxy-SMART .
Then, the sensor is heated up up to 100%:
Measurement can be started as soon as the sensor is heated up:
Battery
charge status
Pump is
turning
Heating up
phase
Gas type
Preset gas
value of the
release 30ppm
factory setting
Measured value
999ppm O2
Instruction Manual OXY- SMART
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The measured value decreases:
By increasing the flushing time, the residual oxygen is suppressed and the measured
value is more and more reduced. After falling below the preset limit value, in this case
30ppm, the colour of the display changes from red to green.
Take the tube out of the gas outlet hole, switch off the pump.
The Oxy-SMART switches over to the standby mode, it is possible to start the
welding process.
Instruction Manual OXY- SMART
13
6. Measuring gases containing H2
In order to measure gases containing hydrogen, change the Oxy-SMART
setting by pressing the H2 button,
The following screen is displayed:
Then measuring can be performed exactly in the same way as for inert gases.
The exact hydrogen fraction is not important for the measuring process,
But the maximum fraction of hydrogen must not exceed 10%.
!!! IMPORTANT !!!
After having worked with gases containing hydrogen, residues of gas remain
in the surfaces of the ducting and in the filter material
over an extended period of time.
If after the operation with forming gas, inert gas is measured, such as e.g.
nitrogen or argon, the measuring display will reach 0 ppm more rapidly than
usual.
In such a case, the device should be flushed with air for about 30min in order
to achieve again reproducible and usable measuring values.
The measuring device is not suitable for use with explosive gas mixtures, in
particular it is not suitable to measure pure hydrogen.
There is a risk of explosion!
Shift the device
to gas
containing H2
Instruction Manual OXY- SMART
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7. Monitoring ranges - Programming functions
The Oxy-SMART has a programming menu which allows to consider different
monitoring limits and settings. Press the button P in order to open the menu.
The following screen is displayed:
Release – Limit value red/green
30ppm factory setting
Language – 0-German, 1-English
Standby – Pump is switched off, cell heating
is reduced to 50%, display illumination is
dimmed
Auto-Off – the Oxy is completely switched off
Info – Information to be viewed:
Year of construction, serial number, last
calibration, next calibration and operating
hour counter
Scroll the menu items with the navigation buttons ˄ ˅ and select with the button P.
Change the desired value with the navigation buttons ˄ ˅ and confirm with the P.
The menu item 01 Release can also be directly selected by pressing the navigation
buttons ˄ ˅. The following screen is displayed:
Change the limit value by pressing
the navigation buttons ˄ ˅.
After about 3 seconds the screen changes over to
the basic screen.
Instruction Manual OXY- SMART
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8. Charging process
The Oxy-SMART is equipped with powerful lithium ion batteries, allowing a service
time of 9h, a standby time of 30h and the batteries are recharged to 100% within 3h.
Only use the power supply unit included in the delivery for charging.
It is best suitable for worldwide use thanks to the different replaceable plugs:
Insert the plug of the power supply unit into the charging socket of the Oxy.
The batteries are charged, the charging process is indicated on the display:
The battery is charged up to 100% after about 3h charging time.
The battery is
charged
It is not possible
to overcharge it,
The device
switches off
automatically
Instruction Manual OXY- SMART
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! ! ! DURING THE CHARGING NOT MEASURE ! ! !
Simultaneous charging and measuring causes a high heat in the body.
The temperature of the housing is monitored and if the maximum temperature,
the following message appears:
This message indicates an invalid temperature the batteries.
Please switch off the unit and let it cool to room temperature.
Lithium-ion batteries should only be charged in
temperatures between 0 ° C and 50 ° C.
So This message also appears when the batteries are too cold
for charging – the Oxy-SMART let acclimate.
Please switch off the unit and warm to room temperature.
This message indicates a defect in the battery.
Please send the device in for review.
Batteries may only trained ORBITEC
Qualified personnel to be replaced.
Instruction Manual OXY- SMART
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9. Filter status
The sensor requires a minimum quantity of measuring gas in order to perform an
exact measurement. If this quantity is not reached, a higher or completely useless
measuring result is to be expected.
A used or obstructed filter may be the cause of this.
The measuring device can read the filter capacity (use - wear) and indicates the
result by means of an error message on the display:
In case of such a warning, please replace the filter and examine if the tube or the
hose kit are damaged or if foreign particles have been sucked in. In case of doubt,
replace the whole hose set incl. the tube. Please only use the filters prescribed by
ORBITEC GmbH.
Designation
Item No.
Illustration
Complete hose
kit
Item No.: 1.3.5016
Filter
Item No.: 1.3.5015
Cannula
Item No.: 1.3.5020
Spare hose 1m
Item No.: 1.3.5019
Øa-7mm Øi-4mm L-1000mm Mat.: PVC
Instruction Manual OXY- SMART
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10. Technical data
Measuring device (dimensions, weight)
Technical data
Measuring range 5 – 999 ppm O2
Operating temperature – 0 to 50°C
Sample gas temperature – max 50°C
Dimensions (L x W x H) 160 mm x 80 mm x 35 mm
Weight incl. hose kit 350 g
Supply voltage 12 V
Charging cable 100 – 240 V incl. different adapters for worldwide use
9 h operating time by lithium ion technology
30 h standby time
3 h charging time
Scope of delivery:
Measuring device for residual oxygen
Charging cable incl. different adapters
Hose kit, 1 m, incl. filter and tube
Calibration certificate
Plastic box with inlay
Instruction Manual OXY- SMART
19
11. Servicing and maintenance
The measuring device Oxy-SMART is equipped with a maintenance-free O² sensor.
In order to avoid measuring errors, the device should be calibrated by ORBITEC
GmbH once a year.
Only store the Oxy-SMART under dry conditions!
Do not use any aggressive cleaning agents!
Clean the housing with a dry cloth!
Liquids must not penetrate inside the housing e.g. through the charging socket
or the measuring gas outlet
The oxygen measuring device and the accessories were
manufactured and tested based on permanent quality
assurance according to DIN EN-ISO 9001.
Check accuracy and functioning of the measuring
equipment at regular intervals of 12 months. The device
is delivered including a calibration certificate with 12
months validity.
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ORBITEC OXY- SMART: Your tool to monitor the quality of flushing gas: The ORBITEC OXY-SMART is a mobile and easy-to-use measuring device that can measure and determine residual oxygen concentration in flushing, welding and forming gases in the welding technique. It can be used with inert gases and forming gases, such as nitrogen, argon, helium and other rare gases. Forming gases are mixtures of nitrogen or argon and hydrogen, with a maximum hydrogen fraction of 10%. The device is equipped with a three-digit display that shows the measured oxygen concentration in ppm.
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