Manu101 H2Smart

H2SMARTTM
Intelligent Hydrogen Sampling System

User Manual
CONNECT WITH US
H2Smart™_rev020 – User Manual Page 2 of 42
Manu101r20
MANUAL #: 101
Revision # Revision Date Revision Description

020 March 27, 2020 Updated Process Connection in Specification table;
revised bottom view schematic to feature IN and OUT
connectors; added adapter to front and side views;
inserted Filter Plate Option section; expanded
Communications section to include Profibus Registers
019 September 18, 2019
THIS MANUAL IS SUPPLIED ELECTRONICALLY.
COPYRIGHT(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. (UPC-Marathon).
The information contained in this document is STRICTLY CONFIDENTIAL and

PROPRIETARY to UPC-Marathon, and shall not be: i) reproduced or disclosed in part or in
whole, ii) used for any design or manufacturing of heat treating and/or control equipment, or
any other purpose except for that which it is supplied under the terms of the Contract, unless
the express written authorization is obtained from UPC-Marathon.
Drawings and photographs included in the documentation are the property of UPC-Marathon,
and it is strictly forbidden to reproduce them, transmit them to a third party, or use them for
manufacturing and/or design of equipment. Sub-licensing of any technical information
contained in this Documentation is strictly forbidden under the terms of the Contract.
UPC-Marathon reserves the right to modify this document without prior notice.
DISCLAIMER:
The H2SMARTTM is to be used by the industrial operator under his/her direction. UPC-
Marathon is not responsible or liable for any product, process, damage or injury incurred while
using the H2SMARTTM. UPC-Marathon makes no representations or warranties with respect to
the contents hereof and specifically disclaims any implied warranties or merchantability or
fitness for any purpose.
WARRANTY:
UPC-Marathon warrants its goods as being free of defective materials and faulty workmanship.
Contact your local sales office for warranty information. If warranted goods are returned to
Copyright © UPC-Marathon All rights to copy, reproduce and transmit are reserved.
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UPC-Marathon during the period of coverage, UPC-Marathon will repair or replace without
charge those items it finds defective. The foregoing is Buyer's sole remedy and is in lieu of all
other warranties, expressed or implied, including those of merchantability and fitness for a
particular purpose. Specifications may change without notice. The information we supply is
believed to be accurate and reliable as of this printing. However, we assume no responsibility
for its use.
DISCLAIMER:
The H2SmartTM is to be used by the industrial operator under his/her direction. UPC-Marathon
is not responsible or liable for any product, process, damage or injury incurred while using the
H2SmartTM. UPC-Marathon makes no representations or warranties with respect to the
contents hereof and specifically disclaims any implied warranties or merchantability or fitness
for any purpose.
Declaration of incorporation according to EC Machinery Directive 2006/42 / EC, Annex II

B
Hereby we declare that the incomplete machine

H2SmartTM
Due to its design and construction, as well as in the design it places on the market, as far as
the scope of supply allows, it complies with the following basic requirements:
2014/30/EU Electromagnetic Compatibility Directive

Harmonized standards:
EN 61000-6-2:2008 Electromagnetic compatibility (EMC) - Part 6-2: Generic
standards - Immunity for industrial environments
EN 61000-6-4:2008+A1:2012 Electromagnetic compatibility (EMC) - Part 6-4: Generic
standards - Emission standard for industrial environments
EN 50581:2012 Technical documentation for the assessment of electrical
and electronic products with respect to the restriction of
hazardous substances
2006/95/EC Low-Voltage Directive

EN 61010-1:2011 Safety requirements of electrical equipment for
measurement, control and laboratory use. Part1: General
requirements
Compliant with 2002/95/EC RoHS Directive
Recycling: per 2002/96/EC W.E.E.E Directive
We declare that the special technical documentation in accordance with Annex VII, Part B has
been prepared for this incomplete machine and we undertake to transmit it to the supervisory
authorities in digital form on request.
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For the purpose of the Machinery Directive 2006/42/EC, the partly completed machinery may
not be put into service until it has been determined that the machine in which it is to be
installed complies with the provisions of this Directive, provided that this Directive applies to
this machinery.
We would like to point out that the following actions may affect the above attested conformity
and the characteristics of the product:
• Installation and operating errors or failure to observe the instructions in the operating
instructions supplied with the product.
• Replacement of parts or original accessories by unauthorized persons or replacement
with parts that are not approved by the manufacturer.
To ensure EMC compliance, the device must always be connected to protective earth. This
connection is made via the M12 connector.
AMS Conformity (North America)
This product conforms to SAE Aerospace Material Specifications AMS 2759/10 for nitriding
and 2759/12 for nitrocarburizing.
TECHNICAL ASSISTANCE
For all questions or concerns regarding the operation of the H2SmartTM, please consult the last
page of this manual for contact information.
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Table of Contents
1 INTRODUCTION ............................................................................................................... 7
2 SPECIFICATIONS ............................................................................................................ 7
Physical ........................................................................................................................ 7
Performance ................................................................................................................. 7
Operating ...................................................................................................................... 7
Recommended Calibration ........................................................................................... 8
3 INSTALLATION ................................................................................................................ 8
Overview ...................................................................................................................... 8
Physical Characteristics ............................................................................................. 10
Installations Steps ...................................................................................................... 12
3.3.1 Step 1 .................................................................................................................. 13
3.3.2 Step 2 .................................................................................................................. 13
3.3.3 Step 3 .................................................................................................................. 14
3.3.4 Step 4 .................................................................................................................. 15
4 ELECTRICAL INSTALLATION ...................................................................................... 17
Power and Electrical Connections .............................................................................. 17
Oxygen Probe Connector (Optional Feature – Connector and Add-on Card) ............ 19
5 OPERATING INSTRUCTIONS ....................................................................................... 20
6 PREVENTIVE CARE ...................................................................................................... 21
Sample gas pump....................................................................................................... 21
7 CONFIGURATION (INTEGRATED WEB SERVER) ...................................................... 22
Device Information...................................................................................................... 22
Technical Support....................................................................................................... 22
Upgrade ...................................................................................................................... 23
System Overview........................................................................................................ 23
Furnace Model State .................................................................................................. 24
Alarms Management .................................................................................................. 25
TCP I/P Configuration ................................................................................................. 26
Profibus Configuration ................................................................................................ 27
Analog Output Configuration ...................................................................................... 27
Digital IO Configuration .............................................................................................. 28
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Display Configuration ................................................................................................. 29

Real Time Clock Configuration ................................................................................... 29
Units Configuration ..................................................................................................... 30
O2 Sensor Configuration ............................................................................................. 30
Furnace Model Configuration ..................................................................................... 31
Backup ....................................................................................................................... 32
Firmware Update ........................................................................................................ 33
8 FILTER PLATE OPTION ................................................................................................ 33
9 COMMUNICATIONS....................................................................................................... 35
MODBUS TCP Registers ........................................................................................... 35
CANBUS Registers .................................................................................................... 38
PROFIBUS Registers ................................................................................................. 39
10 CUSTOMER SUPPORT ................................................................................................. 42
Table of Figures
Figure 1 - Bottom View ............................................................................................................ 10
Figure 2 - Front View ............................................................................................................... 11
Figure 3 - Side View ................................................................................................................ 12
Figure 4 - Step 1 ...................................................................................................................... 13
Figure 5 - Step 2 ...................................................................................................................... 14
Figure 6 - Step 3 ...................................................................................................................... 14
Figure 7 - Step 3 ...................................................................................................................... 15
Figure 8 - Step 4 ...................................................................................................................... 16
Figure 9 - Heat trace cable installation .................................................................................... 16
Figure 10 - Electrical Installation .............................................................................................. 17
Figure 11 - Probe Connector ................................................................................................... 20
Figure 12 - Filter Plate Option.................................................................................................. 34
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1 INTRODUCTION
The H2SmartTM is an integrated thermal conductivity sampling system designed to measure
the concentration of a gas sample in binary or quasi-binary mixtures. It is especially suitable to
measure hydrogen content or dissociation level with high accuracy in nitriding and
nitrocarburizing atmospheres and to calculate the parameters necessary for nitriding process
control. A unique measuring cell design and advanced electronics eliminate the need for a
reference gas cell, thus simplifying the installation.
It includes an integrated sampling pump with variable output and a flow monitoring circuit with
pump saturation warning and flow alarm. The pump provides a continuously controlled flow
despite possible sampling line obstructions or filter contaminations, thus assuring accurate
measurements and better process control.
The measuring block is maintained at a preset temperature with high accuracy to provide
stable measuring conditions and protect the system from moisture formation and cell
contamination during nitrocarburizing.
The system status and measured results are displayed on a large, easy to read
alphanumerical display.
2 SPECIFICATIONS
Physical
Width (including
170 mm / (6.7”)
mounting bracket):
Height: 190 mm / (7.5”)
Depth: 140 mm / (5.5”)
Weight: 4 kg / (8.8 lbs)
Process
1/4" Swagelok tubing connector, 6mm adaptor available
Connection:
Performance
Accuracy: +/- 0.5% of reading plus +/- 0.3% of full scale
Linearity: < 0.5% of full scale
Repeatability: < 0.5% of full scale
Zero drift: < 0.5% of full scale per month
Sampling flow: 0.5 lpm / (1 cfh) controlled
Response time: 95% in 30 sec @ 0.5 lpm / (1 cfh)
Operating
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24VDC, 2.5 Amps max. Use only well-regulated power

Power requirements:
supply
2 x analog, sourcing, individually isolated,
Outputs: 4 – 20 mA (R<500 Ohm)
4 x digital OUT, 24 VDC, 0.7 A max.
1 x analog, dedicated temperature sensor (optional)
Inputs:
2 x digital, 24 VDC
Working pressure: ambient +/- 70mbar (1PSI)
Ambient
< 57°C (<135°F)
Temperature:
Maximum Continuous Vacuum generated 350mbar - abs
(5 psi)
Sampling pump:
Maximum Continuous Pressure generated 1.4barg / (20
psig)
Recommended Calibration
Polynomial
12 months
calibration
3 INSTALLATION
Overview
The H2SmartTM unit is to be installed away from the furnace and the sample
gases are tapped from the exhaust lines. Ensure that the source and dump lines are at the
same pressure. Do not install spanning an oil/water bubbler or other pressure control valves.
CAUTION
The sampling gas temperature entering the H2SmartTM must be < 90°C (195F°). Usually this
condition is easily accomplished by selecting the proper length and heat dissipation condition
of the sampling supply line. Necessary heat dissipation for the sampling flow of 0.5 lpm (1 cfh)
and temperature difference 500°C (932°F) is less than 10 W (35 Btu/hr) and depend on the
sampling gas composition.
CAUTION
Handle with care, do not drop. The sensor is susceptible to shock, and it is a static sensitive
device, use proper handling procedures
CAUTION
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Installations with dirty exhausts (powder residues, injections, Malcomizing, masking, furnaces
with oil seals) require a supplementary pre-filter. We suggest a 5µm (or as required for your
particular condition) with a surface area of not less than 200 cm2 (30 in2).
For ferritic nitrocarburizing, we suggest that this pre-filter is also heat traced.
End user must ensure that gases entering the unit are free of contaminants such as water, oil
or other.
Always purge the chamber when possible. Consider to “sample” when the furnace is purging
to limit the precipitate in the chamber.
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Physical Characteristics
BOTTOM VIEW
1 2 3 4
9
Process
Gas Flow
Process OUT
Gas Flow 8
IN
Figure 1 - Bottom View
1 Power 6 Optional Communications

2 Oxygen Probe (EMK + TC) 7 Analog Out
3 Taux (temp sensor) 8 IN Connector, 1/4" Swagelok tubing
4 Digital I/O 9 OUT Connector, 1/4" Swagelok tubing
5 Ethernet
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FRONT VIEW
Figure 2 - Front View
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SIDE VIEW
Figure 3 - Side View
Installations Steps
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3.3.1 Step 1
Two support brackets and four screws are used to secure the H2SmartTM unit. Attach unit to a
panel wall using four #10 (M5) screws
Figure 4 - Step 1
3.3.2 Step 2
Pre-measure and bend the tubing accordingly.
Pre-swage Swagelok ferrules to the tubing’s using Swagelok Pre-swaging tool or spare
Swagelok fitting
CAUTION
Do not swage the tubing in the H2SmartTM connectors!
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Attach tubing to Exhaust
Figure 5 - Step 2
3.3.3 Step 3
Connect 1/4” tubing to Swagelok connector using a 9/16” wrench or metric equivalent - do not
over tighten
* Follow Swagelok instruction to assemble piping with tube fitting.
Figure 6 - Step 3
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Assembly Instructions
a. Insert tubing into the Swagelok tube

fitting
b. Make sure that tubing rests firmly on
the shoulder of the tube fitting body
and that the nut is finger-tight
c. Scribe the nut at 6 o’clock position
d. While holding fitting body steady,
tighten the nut 1 1/4 turns to the 9
o’clock position
Figure 7 - Step 3
Reassembly Instructions
a. Insert tubing with pre-swaged ferrules into fitting body until the front ferrule seats.
b. Rotate the nut with a wrench to the previously pulled-up position. At this point, a
significant increase in resistance will be encountered.
c. Tighten slightly with the wrench. Note: don’t use the gap inspection gauge with
reassembled fittings.
3.3.4 Step 4
Heat tracing the sample gas tubes for Ferritic Nitrocarburizing furnace
In order to avoid clogging of the sample gas tubes by ammonium carbonate and condensation,
the sample tubing / piping should be kept at temperatures within the range of 85 – 90oC (185 -
195°F) by external heat tracing. For this purpose, typically, a heat trace cable is run close to
the tube bundle, tightly pressed against the tubes by appropriate cable ties. The whole
assembly is then wrapped in thermal insulation material.
Use pipe insulation whenever you run heat tracing!
Try to run the in and out tubing side by side such that the heat tracing sensor and the cable all
fit nicely in one tightly packed bundle. This will ease the installation of the insulation and
maximize efficiency.
Mount the optional heat tracing temperature sensor to the tube bundle inside the thermal
insulation, at a distance of 30 - 60 cm / (1 - 2 ft) from the H2SmartTM connectors.
Use an appropriate solid-state relay controlled by the heat tracing control output to switch
power to the heat tracing cable.
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Due to the high probability of “dirty gas”, sharp bends in the piping
should be avoided. Try to keep the piping as smooth and as straight
as possible as this will aid in the heat tracing / insulation later. Avoid
unnecessary loops, fittings or traps in piping.
See the wiring diagram section for more information.

The H2SmartTM will regulate the heat tracing temperature to 203°F
(95°C) as long as it is powered up without further user action.
Important consideration
• Digital I/O’s and H2SmartTM main power shall be powered from the
same source
Figure 8 - Step 4 • Arrange the heat tracing cables and the temperature sensor as
shown
• 15 W/foot (45 W/meter) is good for typical installations with average insulation
• Heating cable has to be placed up to the inlets plate of the H2SmartTM
• Cable has to heat both (inlet and outlet) connectors
• Thermal insulation shall be in contact with inlets plate and be properly sealed
• No gap shall exist between inlets plate and the insulation
• Temperature sensor has to be attached to the tubing only, it should not touch the
heating cable
Note: Heat tracing insulation not shown

Figure 9 - Heat trace cable installation
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4 ELECTRICAL INSTALLATION
Connect the system to a well-regulated 24VDC power supply capable of supplying 2.5A
minimum (3A typical).
Connect power cable to 24 V power supply
Figure 10 - Electrical Installation
CAUTION
The H2SmartTM will be permanently damaged if connected to 115 or 230VAC
Within the specified limits, the value of the supply voltage will not influence the accuracy, but a
power supply with bad stability may increase measurement noise of the system. Use a well-
regulated power supply and do not operate other heavy loads from the same supply.
The specified power consumption is only true during start-up, after operating temperature is
reached, the power consumption will decrease to 20% - 40% of the specified value, depending
on ambient temperature.
Power and Electrical Connections

Power 24 VDC - M12-5 connector
Pin Description Cable*
1 +24 VDC BRN
2 NOT USED WHT
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Power 24 VDC - M12-5 connector

3 COM BLU
4 NOT USED BLK
5 GND YEL/GRN
Digital I/O – DB15 Male connector

1 DI1 + 1
2 DI1 - 2
3 DI2 + -
4 DI2 - 2
5 DO 3 4
6 DO 2 5
7 DO 1 6
8, 15 24 V COM 2
9, 10, 11 NOT USED -
12 DO 4 -
13, 14 +24 VDC 3
NC Green/Yellow
Analog Out - DB9 Female

Pin Description Cable *
1 AO1 + Brown
2 AO1 - White
3 AO2 + Yellow
4 AO2 - Green
6, 7, 8, 9 NOT USED -
5 GND Shield
Taux (Heat Trace Sensor) – DB9 Male

Pin Description
7 SENSOR SIGNAL
8 SENSOR VCC
3 GND
1, 2, 4, 5, 6, NOT USED
9
*
Color designation of the cables supplied by UPC-Marathon
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Opt. Communication – DB9 PROFIBUS

Pin Description
1 SHIELD
2 NC
3 RX/TX+
4 RTS
5 BUS GND
6 BUS VCC
7 NC
8 RX/TX-
9 NC
Opt. Communication – DB9 MODBUS RTU

Pin Description
1 SHIELD
2 NC
3 RX/TX+
4 NC
5 BUS GND
6 BUS VCC
7 NC
8 RX/TX-
9 NC
Opt. Communication – DB9 CANBUS

Pin Description
1 NC
2 CAN L
3 BUS GND
4 NC
5 SHIELD
6 BUS GND
7 CAN H
8 NC
9 BUS VCC
Ethernet - RJ-45 STD connector
Oxygen Probe Connector (Optional Feature – Connector and Add-on Card)
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The optional oxygen probe card with high impedance input comes with a user-friendly DB9
connector where you can terminate the mV and TC signal from the oxygen probe using only a
precision screwdriver. Move the slider to the right to release, left to grip (as shown in the
drawing below).
Connector
Figure 11 - Probe Connector
PIN O2 Probe db9 connector
RED Probe mV (+)

BLK Probe mV (-)
GRN Probe TC (+)
WHT Probe TC (-)
Note that the H2SmartTM Oxygen Probe card’s thermocouple input can be configured as type K
or S. It is crucial to use the webserver to select the appropriate setting.
5 OPERATING INSTRUCTIONS
Connect the system to a well-regulated 24VDC power supply capable of supplying 2.5A. Once
power is applied, the system heats up the measuring cell to operational temperatures. Flow
measurement is disabled, and the sampling pump is off during heat up to avoid contamination
of the system with condensation. Depending on ambient temperature, heat up takes about 30
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minutes. Full accuracy is reached after 1h. It is always recommended to keep the system
powered up and use the "Sampling enable" digital input or digital communication to activate or
deactivate the sampling flow.
When the operating temperature is reached, the "Sampling enable" digital input or digital
communication command must be active to start sample gas pump, enable sampling flow
control and gas composition measurement.
Display
The display shows the following information, depending on the system status:
Display shows: Status

Process Variable i.e. % diss., %H2 Sampling enabled; value is displayed
O2 Probe mV + Temperature, KN, If enabled, the mV and temperature is displayed
Alarms (in order of priority)
Ticker Information such as IP address, FW version and up time.
Wrench symbol Maintenance is due. See webserver.
KN and KC Calculation
The KN and KC calculations run internally in the unit based on the furnace volume, the inlet gas
flows, and the reading from the H2SmartTM sensor. To ensure a correct furnace atmosphere
calculation, the process flows into the furnace must be updated whenever they are changed.
The updates must be made at all times during the recipe, even during non-nitriding stages.
These changes can be made via the communication adaptor (MODBUS, ProfiBus or
CANBus). The communication data register assignments can be found in this manual. The
furnace atmosphere is continually updated based on the flow rates and the stored furnace
volume.
Valid KN and KC calculated values require the furnace to be at nitriding temperature, as well as
the H2SmartTM sampling enabled. When the sampling is disabled, the KN and KC calculations
are disabled and will return a 0.00 value. If sampling is enabled under non nitriding conditions,
the KN and KC calculations will not return valid KN and KC values.
6 PREVENTIVE CARE
All maintenance and preventive care must be carried out by trained personal only in
compliance with the applicable safety standards.
Sample gas pump

The life time of the sample gas pump is dependent on the
Maintenance period
composition of the gas.
Action Send the unit in for service in case of a pump failure.
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WARNING
Prevent liquids such as water or oil from entering the sampling line.
WARNING
Never use sharp objects (wire, screwdriver, etc.) to check or unblock the H2SmartTM
sampling Swagelok connectors and internal lines. Never use compressed air to clean
the H2SmartTM.
This may create a health hazard and permanent instrument damage.
7 CONFIGURATION (INTEGRATED WEB SERVER)

Using a web browser, navigate to the IP address of the H2Smart. Many parameters can be
set / adjusted such as IP address, alarm details, and other user accessible variables. The
default access is: u: admin / pw: ammonia
Device Information
Technical Support
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Upgrade
System Overview
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Furnace Model State
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Alarms Management
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TCP I/P Configuration
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Profibus Configuration
Analog Output Configuration
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Digital IO Configuration
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Display Configuration
Real Time Clock Configuration
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Units Configuration
O2 Sensor Configuration
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Furnace Model Configuration
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Backup
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Firmware Update
8 FILTER PLATE OPTION
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Process
Gas Flow
IN
Process
Gas Flow
OUT
Figure 12 - Filter Plate Option
Plate dimensions: 500mm w x 750mm h
Process connections: ¾ “ NPT Female
Junction Box Electrical connections:
Pin Description
1 24VDC + Supply
2 0VDC Supply
3 CAN L
4 CAN H
5 CAN GND
6 Sampling Enable Input (24VDC)
7 Flow Alarm Output (24VDC)
8 Pump Saturation Alarm Output (24VDC)
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Pin Description
9 Oxygen Probe mV +
10 Oxygen Probe mV -
11 Heat Tracing 230/120 VAC L
12 Heat Tracing 230/120 VAC N
13 Heat Tracing Output (230/120VAC Pulsed)
9 COMMUNICATIONS
MODBUS TCP Registers
Input Low/High
Data Type Details
Register Word
999 test register Ushort always 1234 readout
1000 Hi reserved
Bit0: Sampling enabled (pump on)
Bit1: Block ready
Bit2: Enable sampling request on digital input
System State UINT
1001 Lo Bit3: Enable sampling request from web application
Bit4: Enable sampling request on Profibus
Bit5: Enable sampling request on Modbus
Bit6: Enable sampling request on CAN
1002 Hi reserved
Bit0: 24V power supply failure
Bit1: 3V3 power supply failure
Bit2: -VFL power supply failure
Bit3: +VFL power supply failure
Hardware Alarms UINT
1003 Lo Bit4: -15V power supply failure
Bit5: +15V power supply failure
Bit7: Real time clock malfunction
Bit8: Storage device malfunction
1004 Hi reserved
Bit0: Could not initialize non-volatile configuration service
Bit1: Could not initialize system supervision service
Bit2: Could not initialize filesystem
Bit3: Could not initialize ethernet service
Bit4: Could not initialize IO service
Bit5: Could not initialize HTTP server
Bit6: Could not initialize Modbus server
System Alarms UINT Bit7: No filesystem detected
1005 Lo
Bit8: Could not initialize display service
Bit9: Could not initialize measurement block service
Bit10: Could not initialize O2 card service
Bit11: Could not initialize Profibus server
Bit12: Could not initialize CAN server
*Bit13: Could not initialize furnace model service
Bit30: Could not update device's firmware
Bit31: Empty EEPROM detected
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Input Low/High
Data Type Details
Register Word
1006 Hi reserved
Bit0: Flow off limits
Bit1: Pump saturation
Bit2: Temperature sensor open circuit detected
IO Alarms UINT Bit3: Block heater failure
1007 Lo
Bit4: Analog output 1 open circuit detected
Bit6: Thermocouple open circuit detected
Bit7: O2 probe impedance test failure
1008 Hi
H2 / Dissociation [%] Float
1009 Lo
1010 Hi
Block temperature [°C] Float
1011 Lo
1012 Hi
Thermocouple temperature [°C] Float
1013 Lo
Only if O2 card is present
1014 Hi
O2 probe emf [mV] Float
1015 Lo
1016 Hi
KN Float **
1017 Lo
1018 Hi
Ko Float ** Only if O2 card is present
1019 Lo
1020 Serial Number Ushort
1021 Hi
Total Working Hours UINT
1022 Lo
1023 Hours to next service Ushort
1024 Hi
Heat tracing temperature [°C] Float
1025 Lo
1026 Hi
Flow rate [l/m] Float
1027 Lo
1028 - 1029 - RESERVED
1030 Hi
FMO: CO content [%] Float *
1031 Lo
1032 Hi
FMO: CO2 content [%] Float *
1033 Lo
1034 Hi
FMO: CH4 content [%] Float *
1035 Lo
1036 Hi
FMO: H2 content [%] Float *
1037 Lo
1038 Hi
FMO: H2O content [%] Float *
1039 Lo
1040 Hi
FMO: NH3 content [%] Float *
1041 Lo
1042 Hi
FMO: N2 content [%] Float *
1043 Lo
1044 Hi
FMO: O2 content [%] Float *
1045 Lo
1046 Hi
FMO: Dissociation [%] Float *
1047 Lo
1048 FMO: KN Float Hi *
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Input Low/High
Data Type Details
Register Word
1049 Lo
1050 Hi
FMO: AC Float *
1051 Lo
1052 Hi
FMO: KO Float *
1053 Lo
1054 Hi
FMO: KC Float *
1055 Lo
1056 Hi
FMO: LogpO2 Float *
1057 Lo
1058 Furnace model simplified calculation Byte * 0 = not active, 1 = active
FMO = Furnace Model Output

* = Furnace Model option needed
** = Nitriding Potential option needed
Holding Low/High
Data Type Details
Register Word
1000 Enable sampling request Byte 1 = activate
1001 - 1029 Reserved
1030 Hi
Actual gas1 inlet flow [m3/h] Float
1031 Lo
1032 Hi
1033 Lo
1034 Hi
1035 Lo
1036 Hi
1037 Lo
1038 Hi
Actual gas5 inlet flow [m3/h] Float * Modbus input for furnace model
1039 Lo
1040 Hi
1041 Lo
1042 Hi
1043 Lo
1044 Hi
1045 Lo
1046 Hi
Furnace temperature [°C] Float
1047 Lo
1048 Reinitialize furnace model calculations Byte * 1 = activate
1049 Force simplified model calculations Byte * 1 = activate, 0 = deactivate
Supported error codes
Error code Fault Description

2 illegal data address Modbus register is not supported
3 illegal data value Data requested to be stored in holding register is out of range
4 slave device failure Undefined error occurred
6 slave busy Device is busy proceeding request
FMO = Furnace Model Output

* = Furnace Model option needed
** = Nitriding Potential option needed
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Holding Low/High
Data Type Details
Register Word
1000 Enable sampling request Byte 1 = activate
1001 - 1029 Reserved
1030 Hi
1031 Lo
1032 Hi
1033 Lo
1034 Hi
1035 Lo
1036 Hi
1037 Lo
1038 Hi
Actual gas5 inlet flow [m3/h] Float * Modbus input for furnace model
1039 Lo
1040 Hi
1041 Lo
1042 Hi
1043 Lo
1044 Hi
1045 Lo
1046 Hi
Furnace temperature [°C] Float
1047 Lo
1048 Reinitialize furnace model calculations Byte * 1 = activate
1049 Force simplified model calculations Byte * 1 = activate, 0 = deactivate
Supported error codes

Error code Fault Description
2 illegal data address Modbus register is not supported
3 illegal data value Data requested to be stored in holding register is out of range
4 slave device failure Undefined error occurred
6 slave busy Device is busy proceeding request
CANBUS Registers
Input Low/High
Data Type Details
Register Word
0 Hi reserved
Bit0: Pump Saturation
Bit1: Pump Alarm
reserved
System State UINT
Lo reserved
reserved
reserved
reserved
6 Hi reserved
Bit0: Pump Status
reserved
System State UINT reserved
Lo
reserved
reserved
reserved
Manu101r20
Input Low/High
Data Type Details
Register Word
reserved
8 Hi
Probe Temperature Float Probe Temperature in degrees C
9 Lo
12 Hi
Probe mV (EMK) Float Probe EMK in MV
13 Lo
24 Hi
H2 / Dissociation [%] INT X 0.01
25 Lo
26 Hi
Block temperature [°C] UINT X 0.01
27 Lo
1002 Hardware Alarms UINT Hi reserved
Output Low/High
Data Type Details
Register Word
0 Hi reserved
Bit0: Pump Enable
reserved
reserved
System State UINT
Lo reserved
reserved
reserved
reserved
PROFIBUS Registers
Input License
Data Type Comments
Register required
Bit0: Sampling enabled (pump on)
0 System state Uint Standard
Bit1: Block ready
Bit2: Enable sampling request on digital input
Bit3: Enable sampling request from web application
Bit4: Enable sampling request on Profibus
Bit5: Enable sampling request on Modbus
Bit6: Enable sampling request on CAN
4 Hardware alarms Uint
Bit1: 3V3 power supply failure
Bit2: -VFL power supply failure
Bit3: +VFL power supply failure
Standard Bit4: -15V power supply failure
Bit5: +15V power supply failure
Bit7: Real time clock malfunction
Bit8: Storage device malfunction
Bit0: Could not initialize non-volatile configuration service
8 System alarms Uint
Bit1: Could not initialize system supervision service
Bit2: Could not initialize filesystem
Standard Bit3: Could not initialize ethernet service
Bit4: Could not initialize IO service
Bit5: Could not initialize HTTP server
Bit6: Could not initialize Modbus server
Manu101r20
Input License
Data Type Comments
Register required
Bit7: No filesystem detected
Bit8: Could not initialize display service
Bit9: Could not initialize measurement block service
Bit10: Could not initialize O2 card service
Bit11: Could not initialize Profibus server
Bit12: Could not initialize CAN server
Furnace
model Bit13: Could not initialize furnace model service
Bit30: Could not update device's firmware
Standard
Bit31: Empty EEPROM detected
Bit0: Flow off limits
12 IO alarms Uint
Bit1: Pump saturation
Bit2: Temperature sensor open circuit detected
Bit3: Block heater failure
Standard Bit4: Analog output 1 open circuit detected
Bit6: Thermocouple open circuit detected
Bit7: O2 probe impedance test failure
Bit8: Block temperature too high
16 H2/Dissociation [%] Float Standard
20 Block temperature [°C] Float Standard
24 Thermocouple temperature [°C] Float Standard
Only if o2 card is present
28 O2 probe emf [mV] Float Standard
Nitriding
32 Kn Float
potential
Nitriding
36 Ko Float Only if o2 card is present
potential
40 Serial number Ushort Standard

42 Total working hours Uint Standard
46 Hours to next service Ushort Standard
48 Heat tracing temperature [°C] Float Standard
52 Flow rate [l/m] Float Standard
56 Reserved Reserved
Furnace
60 Furnace model output: CO content Float
model
Furnace
64 Furnace model output: CO2 content Float
model
Furnace
68 Furnace model output: CH4 content Float
model
Furnace
72 Furnace model output: H2 content Float
model
Furnace
76 Furnace model output: H2O content Float
model
Furnace
80 Furnace model output: NH3 content Float
model
Furnace
84 Furnace model output: N2 content Float
model
Manu101r20
Input License
Data Type Comments
Register required
Furnace
88 Furnace model output: O2 content Float
model
Furnace
92 Furnace model output: Dissociation Float
model
Furnace
96 Furnace model output: Kn Float
model
Furnace
100 Furnace model output: Ac Float
model
Furnace
104 Furnace model output: Ko Float
model
Furnace
108 Furnace model output: Kc Float
model
Furnace
112 Furnace model output: LogpO2 Float
model
Furnace
0 = not active, 1 = active
116 Furnace model simplified calculations Byte model
Output License
Data Type Comments
Register required
0 Enable sampling request Byte Standard 1 = activate
1 Reserved Reserved
Furnace
20 Actual gas1 inlet flow [m3/h] Float
model
Furnace
model
Furnace
model
Furnace
model
Furnace
36 Actual gas5 inlet flow [m3/h] Float Profibus input for furnace model
model
Furnace
model
Furnace
model
Furnace
model
Furnace
52 Furnace temperature [°C] Float
model
Reinitialize furnace model Furnace
1 = activate
56 calculations Byte model
Furnace
Force simplified model calculations 1 = activate, 0 = deactivate
57 Byte model
Manu101r20
10 CUSTOMER SUPPORT
Americas Asia Europe

[email protected] [email protected] [email protected]
USA: +1 414 462 8200 Shanghai: +86 21 3463 0376 France: +33 3 81 48 37 37
Canada: +1 514 335-7191 Beijing: +86 10 8217 6427 Germany: +49 7161 94888-0
Poland: +48 32 296 66 00
Reach us at www.upc-marathon.com
UPC-Marathon brings together leading brands

to the heat-treating industry including
Atmosphere Engineering, Furnace Control,
Marathon Monitors and Process-Electronic, and
Waukee Engineering. We provide prime control
solutions through our worldwide sales and
services network with easy-to-access local
support.

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H2SMARTTM

Intelligent Hydrogen Sampling System

Revision # Revision Date Revision Description

THIS MANUAL IS SUPPLIED ELECTRONICALLY.

No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval

The information contained in this document is STRICTLY CONFIDENTIAL and

Declaration of incorporation according to EC Machinery Directive 2006/42 / EC, Annex II

Hereby we declare that the incomplete machine

2014/30/EU Electromagnetic Compatibility Directive

2006/95/EC Low-Voltage Directive

AMS Conformity (North America)

Display Configuration ................................................................................................. 29

24VDC, 2.5 Amps max. Use only well-regulated power

Figure 1 - Bottom View

1 Power 6 Optional Communications

Figure 2 - Front View

Figure 3 - Side View

Pre-measure and bend the tubing accordingly.

Attach tubing to Exhaust

* Follow Swagelok instruction to assemble piping with tube fitting.

a. Insert tubing into the Swagelok tube

Use pipe insulation whenever you run heat tracing!

See the wiring diagram section for more information.

Note: Heat tracing insulation not shown

Connect power cable to 24 V power supply

Figure 10 - Electrical Installation

Power and Electrical Connections

Power 24 VDC - M12-5 connector

Digital I/O – DB15 Male connector

Analog Out - DB9 Female

Taux (Heat Trace Sensor) – DB9 Male

Opt. Communication – DB9 PROFIBUS

Opt. Communication – DB9 MODBUS RTU

Opt. Communication – DB9 CANBUS

Ethernet - RJ-45 STD connector

Oxygen Probe Connector (Optional Feature – Connector and Add-on Card)

Figure 11 - Probe Connector

PIN O2 Probe db9 connector

RED Probe mV (+)

Display shows: Status

Sample gas pump

7 CONFIGURATION (INTEGRATED WEB SERVER)

Furnace Model State

TCP I/P Configuration

Analog Output Configuration

Real Time Clock Configuration

Furnace Model Configuration

8 FILTER PLATE OPTION

Figure 12 - Filter Plate Option

Plate dimensions: 500mm w x 750mm h

Process connections: ¾ “ NPT Female

Junction Box Electrical connections:

1028 - 1029 - RESERVED

FMO = Furnace Model Output

Supported error codes

Error code Fault Description

FMO = Furnace Model Output

Supported error codes

40 Serial number Ushort Standard