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IOSI-02 signal converter

Building on the success of its predecessor, the IOSI-01, the IOSI-02 is a DIN-rail mounted programmable signal converter designed for Read-Ox sensors. It processes both the thermocouple mV signal and the oxygen cell mV signal (EMF), converting these raw inputs into calculated outputs such as temperature, log(pO₂) and oxygen concentration.

The IOSI-02 is equipped with three independent 4–20 mA analog output channels, a 4–20 mA analog input channel and a RS485 serial interface supporting Modbus ASCII or RTU protocols. These features allow for seamless integration into plant-wide data logging and control systems.

The IOSI-02 comes with an MSI installation package that includes two dedicated PC applications:

  • IOSI02config Connects via USB for device configuration and real-time data display. Tailored specifically for IOSI-02 setup and monitoring.
  • IOSI02modbus Designed for long-distance data logging (up to 1200 meters) over RS485. Includes specialized features for iron-ratio calibration (exclusive to the glass melt redox sensor).

 

Standard IOSI-02 analog output settings are available for various Read-Ox sensors, including:

 

The Read-Ox IOSI-02 signal converter has following key features:

  • High-impedance oxygen cell input (>1 GOhm) for accurate sensor readings, range -1.15V to +1.15V
  • Thermocouple support for types B, E, J, K, N, R, S, and T
  • Isolated 4–20 mA analog input, ensuring signal integrity
  • Three independent 4–20 mA analog outputs, loop-powered (12–30 V DC), galvanically isolated from each other, inputs, and power supply
  • Electrical isolation between input circuitry, digital interfaces, power supply, and analog outputs
  • Fully programmable output ranges for flexible integration
  • Wide power supply range: 8–24 V DC, with low power consumption (typically 1 VA)
  • USB-powered option for convenient setup and diagnostics
  • Plug-in terminal blocks for easy installation and maintenance
  • DIN rail mounting for secure and standardized deployment
  • Onboard in-situ sensor impedance test to monitor sensor condition over time
  • Inter-IOSI power distribution through DIN rail connector
  • Inter-IOSI master/slave communication via the DIN-rail connector enabling more analog outputs, analog inputs, or RS485 Modbus interfaces per sensor, and supporting combined measurements from multiple sensors for advanced calculation results.

IOSI02CONFIG

The IOSI-02 signal converter can be configured through the dedicated PC application IOSI02config, developed specifically for the IOSI-02. The IOSI-02 is connected directly to a PC via the USB port on its front panel, using driverless USB communication for quick and hassle-free setup. Users can select from standard calculation modes and 4–20 mA output ranges tailored to each Read-Ox sensor type. In addition, the system offers full flexibility, allowing end users to define custom calculation parameters and output scaling to meet specific operational requirements. The IOSI02config application also supports real-time data visualization and recording, with graphical display options for monitoring and analysis.

 

 

IOSI02modbus

The IOSI02modbus PC application is purpose-built for long-distance data logging via the RS485 serial interface of the IOSI-02, supporting communication over distances of up to 1200 meters. This capability is especially valuable in industrial environments where the IOSI-02 is typically housed in a cooled DIN rail enclosure near the furnace, while the PC is located remotely in a control room. Designed with the glass melt redox sensor in mind, IOSI02modbus offers advanced features such as real-time monitoring of the Iron-Ratio of finished glass product, using Time Delayed Calibration (TDC)

 

 

Sensor impedance test

The IOSI-02 signal converter features an onboard sensor impedance test, allowing users to assess the condition of the connected oxygen sensor. The internal resistance (impedance) serves as a diagnostic indicator:

› A high impedance may suggest the sensor is approaching the end of its operational life and should be considered for replacement.

› A very low impedance may indicate a damaged or broken oxygen cell.

› During probe installation, the measured impedance can also help verify whether the sensor tip has been properly immersed in the melt, a critical factor for accurate readings and sensor performance.

This test can be performed directly within the data logging window of both the IOSI02config and IOSI02modbus PC applications. Once initiated, the sensor’s impedance is automatically measured and displayed, providing immediate feedback for maintenance and installation validation.