6000 InSitu Analyser System

Transcription

C O M T E C® 6000
O2 / COe* InSitu Analyser System
Installation & Operating
Manual
Version No. 05
Valid for Software Version 3.00.15
Revision Date: 08 November 2010
O2
CO
*
2,6 %
17 ppm
COe is the short hand for CO equivalent . For more information please contact ENOTEC.
O2/COe COMTEC 6000 InSitu
Analyser System
Version 05.300.15
Page 1 of 80
Analyser System
Version 05.300.15
Page 2 of 80
Table of Contents
1
General User Information
6
1.1
Preface
6
1.2
Warranty
7
1.3
Declaration of EC-Conformity
8
1.4
System Overview
9
1.5
Package List for a COMTEC® 6000 InSitu Analyser
System
10
1.6
Information on the CE-Certification
11
1.7
Notes on this Manual
11
1.8
Symbols used in this Manual
12
1.9
Intended Use
12
1.10
General Safety Instructions
13
1.11
Corrosion
13
1.12
Safety Hazards
13
COMTEC® 6000 Installation Information
14
Installation of the Electronic Unit and Electrical and
Pneumatic Cables
14
Requirements at the Mounting Place of the
Electronic Unit
14
Requirements for the Probe Signal Cable FEP0007/8
15
2.4
Requirements for the Pneumatic Cable FEP-0002
15
2.5
Installation of the Electronic Unit
16
2
2.1
2.2
2.3
2.5.1 Access to the terminals
16
2.5.2 Wiring Diagram of the Electronic Unit
17
2.5.3 Function of the relay contacts
18
®
2.5.4 Wiring Diagram of the COMTEC 6000 Analyser System
2.6
2.7
Preparation and Connection of the Pneumatic Cable
FEP-0002 at the Electronic Unit
19
20
2.6.1 Preparation of the Pneumatic Cable
20
2.6.2 Connection of the Pneumatic Cable
21
Installation of the probe with all electrical and
pneumatic connections
Analyser System
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22
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2.8
Requirements at the Mounting Place of the Probe
22
2.9
Mounting of the Mating Flange at the Duct
23
2.10
Adjustment of the Probe Filter Head
2.11
Mounting of the Probe Protection Tube at the
Mounting Flange
24
Connection of the Probe Signal Cable FEP-0007/8
and Pneumatic Cable FEP-0002 at the Measuring
Probe
25
2.12
2.13
3
V-Shield
23
2.12.1 Electrical Connections
25
2.12.2 Pneumatic Connections
26
Insulation of the Protection Tube outside the Duct
System Start Up and Calibration
26
27
Description of the Electronic Unit for COMTEC®
6000 InSitu Analyser Systems
27
3.2
General Description of the Function
27
3.3
General operating instructions
28
3.4
Start-up of the COMTEC® 6000 InSitu Analyser
System
29
3.5
COMTEC® 6000 Probe heating phase
29
3.6
Amounts and Adjusting of Test gas and Reference
air
30
3.1
3.6.1 Reference air
30
3.6.2 Test gas
31
3.7
Main Window
32
3.8
Values (Actual Value Menu)
33
3.9
Parameter Menu
35
3.10
3.9.1 Altering a Parameter by the Example of the O2 Measuring
Ranges
38
3.9.2 Altering a Parameter by the Example of a Limit Alarm Value
38
3.9.3 O2 Correction ‘wet’ or ‘dry’ value
40
Menu / Cal.
41
3.10.1 First Steps for Calibration
43
3.10.2 Two point System test + Calibration for O2 and COe
44
3.10.3 O2 Output Settings
47
3.10.4 COe Output Settings
48
3.10.5 Common … Settings
48
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3.10.6 COe … Measurement OFF
4
Service and Maintenance
4.1
51
Service and maintenance of the COMTEC® probes
51
4.1.1 Replacing filter element
51
4.1.2 Replacing filter head
52
4.1.3 Exchange of probe inner part
53
4.1.4 Exchange of ZrO2 sensor
54
4.1.5 Exchange of the COe sensor
55
4.2
Status messages/Error messages
57
4.3
Troubleshooting
61
4.4
5
4.3.1 Unsteady, widely varying Measuring Value (O2)
61
4.3.2 No COe-Measuring Value; Arrow instead of a value
61
4.3.3 No Measuring Value for O2; empty Bar Graph
61
4.3.4 O2 reads higher than expected, and COe reads lower than
expected
62
4.3.5 O2 Display remains at the End of the Measuring Range or is
higher than expected
62
Exchange Fuses and change of Voltage
63
Technical Datas and Drawings
64
5.1
Requirements of the Gas Supply
64
5.2
Probe
65
5.2.1 Dimensional drawing of probe KES600x
66
5.2.2 Protection tube flange
66
5.2.3 Adapter plate ADP-6000
67
5.2.4 Adapter plate ADP-6000-S01
67
5.2.5 Probe components
68
5.3
Electronic Technical Data & Dimensions
69
5.4
Gas plan SME-5 Instrument air (Version A)
71
5.5
Gas plan SME-5 Instrument air (Version 1)
72
5.6
Gas plan SME-5 with O2 Reference air pump
73
6
7
50
Electronic Assembly Overview
74
6.1
Mounting plates of Field housing
74
6.2
Mounting plates of 19”Rack
76
Table of figures
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78
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1
General User Information
1.1
Preface
Dear customer,
Thank you for selecting our COMTEC® 6000 as your InSitu Flue Gas Oxygen/Combustibles (COe*) measuring system.
ENOTEC has been producing its world famous OXITEC® Oxygen Analysers
for more than 30 years, and now our COMTEC® Oxygen/Combustibles
(COe) measuring system enhances our product line. ENOTEC are committed to total quality and performance and we have continuously enhanced our
products to integrate various additional features and functions. In this package, the electronic unit uses the very latest Microprocessor Technology,
making the SME5 electronic unit one of the most advanced and up-to-date
monitoring units permitting you to reduce your maintenance & fuel costs to
achieve an increased measuring accuracy with more operational reliability
due to new monitoring functions.
In our COMTEC® 6000 probes you will find the Zirconium Oxide measuring
sensor which is gas-tight sealed in place using a special process and technique developed by our company. This leads to a considerably increased
service life as compared to "glued or cemented" measuring sensor that has a
tendency to leak or crack during operation. The O2 sensor is a proven gastight design providing greater measuring accuracy, durability and longer
working life with the experience of more than 30,000 installations. For COe
measurement, we have integrated a high temperature MXP- sensor.
All ENOTEC instruments are thoroughly tested in the factory and are subject
to a strict ISO 9001 Quality Assurance procedure. Therefore, with the correct
installation, the operation of the COMTEC® 6000 InSitu Analyser System is
very easy to use and user friendly. It will provide you with many years of operation with perfect measuring results.
Please read this manual carefully and follow the instructions as directed. If
you have any questions, or you are unclear about any aspect of the installation or operation, our Service Department, regional sales offices or approved
distributors will be pleased to assist. The factory contact points are Tel: +49
2264-45780 or Fax: +49 2264 457831. You may also visit us at our website
http://www.enotec.de or http://www.enotec.com or contact us by
e-mail: info@enotec.de.
Marienheide, January 2010
Dipl.-Ing. Fred Gumprecht
Managing Director
ENOTEC GmbH
*
COe is the short hand for COequivalent
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1.2
Warranty
ENOTEC
2 YEAR
WARRANTY
ENOTEC warrants that the equipment manufactured and sold by it will, upon shipment, be free of defects in workmanship or material. Should any failure to conform to
this warranty become apparent during a period of two years after the date of shipment, ENOTEC shall upon prompt written notice from the purchaser, correct such
nonconformity by repair or replacement of the defective part or parts. The purchaser
is not entitled to claim any other legal remedies on the basis of this warranty. Please
refer to the complete ENOTEC warranty policy for details.
ENOTEC does not warrant equipment supplied by it against normal deterioration.
Corrosive gases and solid particles may cause damages and make a repair or a replacement necessary as a consequence of normal wear and tear during the warranty period. The COe sensor is such a product, with a guarantee limited to one
year.
All ENOTEC products and systems which do incorporate a heated sensor must be
operated under continuous conditions. If the heater power is switched off and
on regularly, more thermal stress for the probe heater, the probe thermocouple and
the ZrO2 cell will cause shorter life time. If it is not possible to operate the heated
equipment continuously for a longer period of time, please contact ENOTEC for
technical advice.
Note: When installing the equipment, the customer must ensure that all necessary
supply lines are connected and the operating temperature of the probe is reached.
Experience has shown that products installed but not put into operation may be
damaged by the process or by external influence. ENOTEC will not accept any responsibility for such damages.
ENOTEC does not warranty ENOTEC products and systems which have been combined with products or components from suppliers not approved by ENOTEC (e.g.
probe signal cable, probe flange gaskets).
When installing and commissioning ENOTEC products and systems, you have to
use proper tools. If there is any damage due to the use of wrong tools, ENOTEC will
not accept any responsibility for damages.
MANUFACTURER:
ENOTEC GmbH
Höher Birken 6
D-51709 Marienheide, Germany
TEL:
+49 (0) 2264 / 45780
FAX: +49 (0) 2264 / 457831
Email: info@enotec.de
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1.3
Declaration of EC-Conformity
ENOTEC GmbH
Höher Birken 6
51709 Marienheide/Rodt
Germany
CE Mark - Conformity
to EC Directive Electromagnetic Compatibility 2004/108/EG
®
We declare that the COMTEC 6000 InSitu Analyser System as detailed below due to its design and
construction as well as the type sold by us complies with the relevant basic safety and health requirements of the EC Directive. This declaration becomes invalid if the appliance is modified without our prior
consent.
Identifier:
Evaluation electronics Type:
Relevant
EC-directives:
®
COMTEC 6000 InSitu Analyser System
......................................................................................
SME 5
......................................................................................
EC Low-voltage Directive (73/23/EEC)
EC Directive Electromagnetic Compatibility (89/336/EEC)
EC Directive Product Liability (85/374/EEC)
Applied harmonised
generic standards:
Applied standards and
technical specification,
in particular:
EN 55011 Kl.A:2007
Emission
EN 61000-6-2:2005
Resistance to interference
EN 61000-3-2:2006
Current harmonics
EN 61000-3-3:1995 + A1,A2
Flicker
EN 61000-4-2:2001
EN 61000-4-3:2006
ESD
Irradiation E-field
EN 61000-4-4:2005
Burst
EN 61000-4-5:2001
Surge
EN 61000-4-6:2001
Inflow E-field
EN 61000-4-11:2005
Voltage dip
EN 61000-3-2
Current harmonics
EN 61000-3-3
Flicker
CISPR 16-1
Interference voltage Kl.A
CISPR 16-1
Radiation E-field Kl.B
Date / Manufacturer’s signature: 1st August 2008 signed Fred Gumprecht
.....................................................................................
Position:
Managing Director
.....................................................................................
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1.4
System Overview
8
O2 2,6 %
CO 23 ppm
1
a
b
c
d
e
2
3
4
6
7
5
Figure 1 System overview
System components
Electronic unit SME5
Probe signal cable FEP-0007/8
Pneumatic cable FEP-0002
O2/COe-Probe
Protection tube
Mating flange
Analyser System
Customer components
Processing room
Test gas 2
Instrument air/Reference air (with pump)
Power supply
Output signals (analog and digital)
Test gas 1 (only instrument version A and
version with pump)
Process gas
Version 05.300.15
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1.5
Package List for a COMTEC® 6000 InSitu
Analyser System
•
•
•
•
Probe with protection tube and gaskets
Probe Signal Cable (if ordered)
Probe Pneumatic Cable (if ordered)
Electronic unit with the product manual and parts kit:
Quantity Part No.
Description
6
0-L-000033
ferrite sleeves
1
0-F-000069
fuse 6.3 A semi time-lag (spare part)
1
0-F-000083
1
0-F-000084
1
0-F-000113
Fuse 1.0 A fast acting (spare part)
9
0-P-000092
support sleeves for Parker ¼’’ pneumatic connection to link the FEP-0002 at the probe terminal box
1
0-R-000055
clamp ring for Parker ¼’’ pneumatic connection to
link the FEP-0002 at the probe terminal box
(spare part)
1
0-R-000056
nut for Parker ¼’’ pneumatic connection to link the
FEP-0002 at the probe terminal box (spare part)
1
0-R-001960
Closure to cover the COe sensor guiding tube
inside the probe terminal box. Please use also a
gasket-set.
1
0-P-000992
Gasket set
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Version 05.300.15
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1.6
Information on the CE-Certification
After having completed and successfully passed EMC-tests, the complete
ENOTEC InSitu Analyser System - consisting of measuring probe, electronic
unit and probe signal cable - has a conformity certificate.
If parts of this system are operated with products not supplied or approved
by ENOTEC, the CE-conformity is no longer valid.
Likewise, all warranties are void if the system is operated in a configuration not authorized by ENOTEC!
Note
The enclosed ferrite sleeves must be placed over the terminal leads of the cable (see wiring chapter 2.5.2). The CEconformity is void if these ferrite sleeves are not fitted!
Note
The ground (Earth) connection must be installed thoroughly
using the correct cable of at least 1,5 mm² minimum. It is
very important that the equipotent bonding is installed correctly.
Please note that some electrical devices (e.g. frequency
converter etc.) close to the system can create considerable
electrical disturbance and instability. So for normal function
of the COMTEC® 6000 InSitu Analyser System it is important that these devices be installed away from the system
and in accordance with the manufacturer’s installation notes
and guidelines.
Please do not run the probe cable near power supply cables, or near motors and their cables, as frequency converters control them because this could cause interference effects. If possible, do not cross the cables because this could
interference effects. However, if this is unavoidable please
make sure that these cables are only crossed at right angles.
1.7
Notes on this Manual
This document describes the design, installation, commissioning, operation,
maintenance and trouble-shooting of the COMTEC® 6000 InSitu Analyser
System.
Only authorized, qualified personnel may work on this equipment. These
personnel must be familiar with all warnings, safety references and maintenance tasks in accordance with this instruction manual. The perfect and safe
use of this equipment presupposes appropriate transport, professional storage and installation as well as careful operation and maintenance.
Analyser System
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1.8
Symbols used in this Manual
Important information as well as safety instructions are emphasised by the
below-mentioned symbols. Please make sure that all safety advices and
warnings are observed at all times.
Note
Advises important information, which should be pointed out
particularly.
Important
Warns of the risk to damage parts or the complete system or
to reduce its function.
Warning
Warns of dangers, which results from inappropriate handling
and which can entail death, bodily harm and/or substantial
property damage.
Warning – Hot Surface
Warns of the danger from burns, which result from hot system parts.
1.9
Intended Use
Note
The COMTEC® 6000 InSitu Analyser System is a system for
measuring the oxygen concentration and the concentration
of COe* in flue gases. For reasons of safety and the possible occurrence of accidents, unauthorized conversions and
modifications of the system are prohibited.
Warning
The minimum concentration of O2 in flue gas should, under
normal process conditions, not be less than 0.5%. The system must not be used for the determination of the O2/COe
content of gases, whose lower explosion limit (LEL) can be
exceeded. There is danger of explosion, since the measuring cell temperature of the O2 measuring cell is
840 °C
(1544 °F).
*
COe is the short hand for COequivalent
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1.10 General Safety Instructions
The COMTEC® 6000 InSitu Analyser Systems may only be operated by authorized trained skilled persons. For reasons of immunity to interference, it
must be ensured that the connection between measuring probe and electronic unit is only made with the ENOTEC probe signal cable and pneumatic
tubing.
The O2/COe measuring probes supplied by us may only be used with
ENOTEC electronic units or with compatible electronic units approved by
ENOTEC.
Important
Under no circumstance may the measuring probe be directly
connected to the 230V main power, as this will immediately
destroy the probe heater element!
1.11 Corrosion
The probe may only be used in flue gases whose composition is uncritical
regarding the corrosive effect on the materials used. With increased risk of
corrosion, regular checks at suitably short intervals are necessary.
1.12 Safety Hazards
During operation, the temperature of the probe filter head and
of all parts exposed to flue gas is 150 °C – 500 °C (302 °F932 °F). Direct contact with the hot parts for dismantling or
maintenance will cause severe burns!
The probe may only be removed with heat-insulated gloves.
Before removing the probe, always switch off the supply voltage to the electronic system. After removal, store the probe
in a safe, protected place and wait until it has cooled downs
below 35 °C (95 °F).
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2
COMTEC® 6000 Installation Information
2.1
Installation of the Electronic Unit and
Electrical and Pneumatic Cables
Note
Only qualified and authorized personnel may work on this
instrument. These personnel must be familiar with all
warnings, safety instructions and maintenance work in
accordance with these operation instructions. The reliable
and safe operation of this equipment requires careful
transportation, professional storage, and installation and
commissioning, as well as careful operation and maintenance.
2.2
Electronic Unit
Keep the minimum distance to adjacent objects
Install in eye height
Avoid vibrations greater 2g
Keep the protection class
Ambient temperature with instrument air
Min.: -20 °C/Max.: +55 °C
Ambient temperature with pump
Min.: -20 °C/Max.: +50 °C
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2.3
Requirements for the Probe Signal Cable
FEP-0007/8
Keep the maximum
cable length
(max.50m)
Max. 50 m
Note the minimum bending
radius.
FEP-0007Rmin=252 mm
FEP-0008 Rmin=329 mm
during installation
during operation
+50 °C
Max.
-5 °C
Min.
+90 °C
Max.
Note the temperature limits
-40 °C
Min.
Cross the probe signal cable (FEP-0007/8) at right
angle to the power supply
cables
2.4
Requirements for the Pneumatic Cable
FEP-0002
Note the minimum bending
radius.
FEP-0002Rmin=138 mm
during installation
during operation
+50 °C
Max.
-5 °C
Min.
Analyser System
+90 °C
Max.
-40 °C
Min.
Version 05.300.15
Note the temperature limits
Page 15 of 80
2.5
Installation of the Electronic Unit
Note
You find dimensional drawings of the Electronic unit under
the chapter 5.3.
Drillings for the electronic unit
Use suitable screws
Electronic unit
Figure 2 Installation of the Electronic
unit
2.5.1 Access to the terminals
Loosen the Phillips
screws
M4 and remove
the terminal cover
Terminals for power
supply and the O2/COe
Probe
Figure 3 Access to the terminals
Terminals for analog
and digital signals
To connect the wires with
a small screwdriver, follow
step 1 to 3.
Figure 4 Instruction for the function of the terminals
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2.5.2 Wiring Diagram of the Electronic Unit
Figure 5 Wiring diagram of the electronic unit
Ferrite sleeves (Enclosure)
Power supply cable (provided by the
customer)
Analog output cable (provided by the
customer)
status signal cable (provided by the
customer)
Probe signal cable
FEP-0007/8
Internal Power supply (115/230V
1
AC, 50/60Hz,max 1A)
4
L
Phase
5
N
neutral wire
6
PE
grounding conductor
Power supply (115/230V AC,
50/60Hz)
1
L
phase
2
N
neutral wire
3
PE
grounding conductor
Shielding
Shield terminal
Power supply probe heater (115V)
8
L
black
9
N
blue
10
PE
green/yellow
O2-sensor signal
12
+
brown
13
brown/white
Thermocouple (O2)
14
+
green
15
white
Probe solenoid valve
23B
L
Supply for probe
23B
N
solenoid valve
(115VAC)
24A
L
grey
24B
N
grey/blue
COe sensor
32A
white 2
COe sensor in
32B
white 1
33A
red 4
COe heater out
33B
red 3
Analog outputs (active 4-20mA)
17A
+
O2
17B
O2
34A
34B
+
-
COe
COe
Relay contacts for status signals
18 A/B
Maintenance
19 A/B
20 A/B
System Error
Output A
COe Maint./O2 MR
21 A/B
O2 Limit Alarm 1
22 A/B
O2 Limit Alarm 2
Measuring Range O2 (12..24V DC)
25A
+
25B
Calibration release (12..24V DC))
27A
+
27B
-
1
The output voltage of this contacts(4…6)
has always the same voltage as on the power supply input on contacts (1…3)
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2.5.3 Function of the relay contacts
Relay contact
System error
Contact closed
No system error
Maintenance
System off or maintenance is active
System off, maintenance
or measuring range is
active
Output A
COe maintenance
or O2 measuring
range
O2 Limit Alarm 1
O2 Limit Alarm 2
Analyser System
No O2 Limit Alarm 1 active
No O2 Limit Alarm 2 active
Version 05.300.15
Contact open
System off, probe is
heated or system error is
active.
(Details of error messages see chapter 4.2)
No maintenance
No maintenance or no
measuring range is active
System off or O2 Limit
Alarm 1 active
System off or O2 Limit
Alarm 2 active
Page 18 of 80
2.5.4 Wiring Diagram of the COMTEC® 6000 Analyser System
Figure 6 Wiring and terminal connection diagram of COMTEC® 6000
Analyser System
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2.6
Preparation and Connection of the
Pneumatic Cable FEP-0002 at the
Electronic Unit
2.6.1
Preparation of the Pneumatic Cable
Figure 7 Mounting instructions for pneumatic tubes
Components for the pneumatic connections
Pneumatic tubing of the pneumatic
cable FEP-0002
Nut
Clamp ring
Support sleeve
Both, the pneumatic tubing for the reference air (blue) and the test gas
and
(green) have to be prepared with support sleeves , clamp rings
nuts.
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2.6.2 Connection of the Pneumatic Cable
2.6.2.1 Field housing
Cable glands
M20 (for power supply
cable)
M25 (for FEP-0007/8
probe signal cable)
M20 (Signal cable)
M20 (Signal cable)
Spare
Pneumatic connections (¼”)
Test gas 2 in
Figure 8 Connections of the COMTEC® 6000 Field housing
Test gas out
(green tubing of FEP-0002)
Instrument air in (system with Instrument air
version)
or
Reference air in (system with pump
version)
Reference air out
(blue tubing of FEP-0002)
Test gas 1 in (only instrument version A and version with pump)
2.6.2.2 19” Rack
1
3
2
4
5
Figure 9 Gas connections of the COMTEC® 6000 in 19’’ rack
Pneumatic connections (¼”)
Test gas 1 in (only instrument version A and version with pump)
Test gas out (green tubing of FEP-0002)
Instrument air in (system with Instrument air version)
or
Reference air in (system with pump version)
Reference air out (blue tubing of FEP-0002)
Test gas 2 in
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2.7
Installation of the probe with all electrical
and pneumatic connections
Note
Only qualified and authorized personnel should work with
this instrument. These personnel must be familiar with all
warnings, safety instructions and maintenance work in accordance with these operating instructions. The fault free
and safe operation of this equipment requires proper
transportation, professional storage, set up and installation,
as well as careful operation and maintenance.
2.8
Probe
Flue gas temperature, pressure and all other process conditions must be in
accordance with the specification. Leave enough space for insertion/removal
of the probe and protection tube (if supplied) and ensure access to the
measuring probe and/or connecting box.
Before cutting the hole in the flue gas duct, make sure that the inside of the
duct has enough space for probe installation, and that no soot is blown out
nearby, or any obstacles are in the way.
For probe lengths exceeding 2000 mm, a support must be mounted inside
the duct (every 2 m) to prevent the probe and mounting tube from flexing or
bending.
+80 °C
Max.
max. 500°C
-40 °C
Min.
Avoid vibrations greater 2g
The ambient temperature at the connection
box and the process temperature must not
be exceeded.
Keep the protections class of the connection
box.
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2.9
Mounting of the Mating Flange at the Duct
The flange has to be mounted with an angle of 1° to 3°
densed flue gas elements can flow back into the duct.
, so that the con-
1° - 3°
D
A
3
Schnitt A-A
A
1
2
Figure 10 Mounting of the mating flange at the duct
Pitch of the mating flange
The flange has to be welded gastight.
Mating flange (supplied by customer)
See dimensions in chapter 5.2.3 or 5.2.4
2.10
Adjustment of the Probe Filter Head
V-Shield
Note
Find out the flow direction of the process
gas at the installation place.
Figure 11 Adjustment of the measuring probe in the flue gas
Analyser System
Version 05.300.15
Unscrew the retaining
ring (clockwise) with
a hook wrench
Turn the filter head Vshield
into the right
position
with a pin
wrench Adjust the position of the shield against
the flow direction
Fix the retainer ring
after adjusting the
filter head
Page 23 of 80
2.11
Mounting of the Probe Protection Tube at
the Mounting Flange
Note
Use for the installation of the probe only new and undamaged gasket.
Tighten the nuts firmly, to guarantee the density of the
flange connection. Isolate the counter flange. Never
leave the probe longer time unheated in the running
process.
Figure 12 Mounting of the protection tube at the mounting flange
Adapter plate
Protection tube
Protection tube flange gasket
Connection box
O2/COe probe
Probe flange gasket
Probe flange
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2.12
Connection of the Probe Signal Cable FEP0007/8 and Pneumatic Cable FEP-0002 at
the Measuring Probe
2.12.1 Electrical Connections
Note
The Probe Signal Cable FEP-0007/8 has to be connected
to the terminal board in the probe terminal box. Please do
not fix the shield here.
(Same terminals as in chapter 2.5.4)
1 2 3 4 6 7 8
ws/br
wh/br
braun grün weiss schw. blau gr.ge.
brown green white black blue gr.ye.
- + + - L N
mV
Messzelle
cell
mV
Thermoelement
thermocouple
9 10 11 12 13 14
2
1
grau gr.-bl. ws/rt ws/rt
grey gr.-bl. wh/rd wh/rd
3
4
rot rot
red red
L N RS RH
115 V ~
Sondenheizung
probe heating
115 V ~
Magnetventil
solenoid valve
0,5V
15V
COe-Sensor
COe-sensor
COe-Sens. Heiz.
COe-sens. heat.
Figure 13 Electrical connections of the measuring probe
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2.12.2 Pneumatic Connections
Blue tubing (Ref. air)
Green tubing (Test gas)
Cable glands for probe
signal cable (FEP-0007/8)
1
2
3
Figure 14 Connection of the pneumatic tubes at the measuring probe
The two pneumatic tubes – blue and green have to be fixed at the probe
terminal box. Please follow the colour code: connect the green tubing with
the green ring and connect the blue tubing to the blue ring
Note
For mounting instructions of the pneumatic tube
see chapter 2.6.1
2.13 Insulation of the Protection Tube outside
the Duct
Note
If a cooling protection tube is used, the part of the protection
tube outside the duct wall must be insulated or heated if
necessary, to prevent flue gas temperature inside the probe
below the dew point.
Electrical heaters are available from ENOTEC as accessories. The bolts of the probe flange must remain accessible.
The probe protection tube has to be
insulated
outside the duct to
avoid temperatures
below the acid dew
point of the flue gas
inside the probe.
1
Figure 15 Insulation of a probe protection tube
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3
System Start Up and Calibration
3.1
3.2
Description of the Electronic Unit for
COMTEC® 6000 InSitu Analyser Systems
General Description of the Function
The SME 5 electronic unit is designed for connection to one O2/COe measuring probe. The mV signal of the measuring sensors are amplified and then
converted into a digital signal in the electronic unit (14 Bit converter). The µprocessor linearises and corrects the signal according to Nernst’s equation
of the O2 measuring sensor. The O2 value is then displayed as a percent
value and the mA output has an isolated 4 - 20 mA output.
The COe measurement is achieved as a mV measurement of the heated
COe sensor. The COe sensor temperature is controlled. The SME 5 microprocessor converts this voltage into a digital signal and displays ppm COe
and drives the 4-20 mA output.
As a standard, the electronic unit has two O2 measuring ranges and one
COe measuring range. These measuring ranges can be freely defined in
their initial and/or final value (within permissible system-related limits). The
second O2 measuring range can be switched remotely 3.9.1 on page 38).
The second O2 measuring range is signalled by a relay contact to the outside. The electronic unit is completely self-controlled. Any system errors occurring are displayed as clear text with an online help function for information.
The COMTEC® user Interface permits intuitive operation by means of a selfexplanatory menu structure.
Until the COMTEC® 6000 probe has reached its operating temperature, the
System Error contact is open and the display shows that the probe is heating
up. The progress of the heating phase is shown by a bar indicating the current probe temperature. During the heating phase, all system parameters, as
well as (actual) values in the corresponding menus, can be selected on demand from the keypad.
When the probe has reached its operating temperature and is stable within ±
0.1 °C, actual measurements are read, the System Error contact closes and
the standard actual value display appears on the screen. The system is now
ready for O2/COe measurement.
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3.3 General operating instructions
The electronic unit is operated by means of four soft keys and a numeric
keypad. The functions of the soft keys always adapt to the current menu
window. The numeric keypad serves only for entering numerical values.
The ENOTEC user interface is designed for intuitive usage of the electronic
unit. This means that as a rule there is no need to study the instruction manual during operation.
Figure 16 Front panel of the COMTEC® 6000 electronic unit after the COe sensor is enabled
By pressing the soft keys [menu/cal.], [values] or [parameter] the respective
menus can be obtained. In each of these menus various options can be selected from a list using the soft keys [] and []. If there are more than 4 options, this is indicated by an arrow on the right hand side of the menu list.
This arrow indicates that there are more options to follow. The option which
can currently be selected has a black background and light letters and one
can get access with the soft key [enter].
The main display provides the information about the actual O2 value in (Vol.)
% and the COe (CO and other combustible gases) value in ppm. You will
also get the information about the adjusted measuring range (on top of the
bar graph: left number: minimum level of the adjusted measuring range; right
number: maximum level of the adjusted measuring range.
If the COe value is out of range, this status will be indicated by an arrow (see
Figure.
Figure 17 COe value out of range
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3.4
Start-up of the COMTEC® 6000 InSitu
Analyser System
Important
Before the COMTEC® 6000 InSitu analyser system is powered
up make sure that the conditions comply with the following
points:
• Does the line voltage correspond with the voltage shown on
the type label of your COMTEC® 6000?
• Are all electrical connections made in accordance with the
instructions in this manual?
• Are all pneumatic connections made correctly and gastight
to prevent the probe from ingress of ambient air?
• Is the COMTEC® 6000 probe installed in a flue gas that
corresponds with the probe specification?
• Do the ambient conditions for the electronic correspond with
the specifications for the electronic unit?
3.5 COMTEC® 6000 Probe heating phase
After switching on the COMTEC® 6000 analyser system by fitting in the fuse
F1 for the power supply, the COMTEC® logo appears on the display for a
short time. During this time, all parameters relevant for a fault-free functioning and start-up are checked automatically.
If during this check any system errors are found, the electronic unit will show
them in clear text (press then the soft key [status]). You will find a detailed
error and warning description in chapter 4.2 on page 57 and the following.
When the O2 sensor temperature is stable within ± 1.0 °C/0.18 °F (this
should be the case after approx. 20 to 60 minutes), O2 and COe measurement is released and the main window appears on the display. If the maximum heating-up time (default setting: 60 minutes) is exceeded or if such an
excess is predictable due to the heat-up speed, then the heating is turned off
and the error message "heating system don’t work" appears.
During the O2 sensor heating phase, all actual values can be called up in the
corresponding actual value menu window with the soft key [values]. You can
also enter the menu/cal. and the parameter menu by pressing the corresponding soft keys. Please note that some functions will not be available during the heating phase (e.g. calibrations). If you try to start menu items like a
calibration, you will get following information: “Function is being delayed until
probe is heating up”.
Note
After switching on the COMTEC® 6000 InSitu analyser
system, you have to wait 2 hours before any other activities are possible.
After completion of the heating phase, the main window is shown in the display (see Figure 18).
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Figure 18 Display after heating up (main window)
Note
Before you can trust the values, calibration is required.
3.6
Amounts and Adjusting of Test gas and
Reference air
3.6.1
Reference air
It is possible to adjust the reference air flow rate with the help of a screwdriver. (see Figure 19 or Figure 20)
The flow rate of reference air can be read of in the values menu.
Starting from the main window: [Values] > “O2 … actual values” > [Enter] >
“O2 ref.-air flow rate”
Flow rate:
30 l/h - 40 l/h
+
Figure 19 Adjusting ref. air flow rate at field housing
+
-
Figure 20 Adjusting ref. air flow rate at 19”rack
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3.6.2
Test gas
Version A and with Pump (Two Test gas inputs)
The flow rate of the test gas will be shown on the display as in chapter 3.10.2
described. To adjust the flow rate you need a test gas bottle with pressure
reducer and a needle valve.
Flow rate:
Input pressure:
150 l/h - 180 l/h
max. 3 bar
Version 1 (One Test gas input)
It is possible to adjust the flow rate of test gas 1 with the help of a screwdriver. (see Figure 21 or Figure 22) To adjust the flow rate of test gas 2 you
need a test gas bottle with pressure reducer and a needle valve.
Flow rate:
Input pressure:
150 l/h - 180 l/h
max. 3 bar
+
-
Figure 21 Adjusting test gas 1 flow rate at field housing
+
Figure 22 Adjusting test gas 1 flow rate at field housing
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3.7
Main Window
In the main window the currently measured oxygen value and COe value is
displayed. A bar graph shows current value relating to the measuring range
of the output signals.
Figure 23 Display: main window (example) after calibration
This main window branches into four menus:
Main window
Status
menu/cal.
values
parameter
Menu
Description
Status resp. If the Measuring Range Switching is set to “local” and there is
MR1/2
no error or alarm, the measuring range can be selected with
this key. In this case the soft key is marked with "MR1/2". In the
case of an error or alarm this soft key is labelled with "status"
and with this soft key the errors and/or alarms can be called up.
Calls up the system menu, in which you have access to calibraMenu/Cal.
tion functions, system settings, system tests etc.
Values
Displays all actual values of the system.
Calls the parameter menu, in which several parameters are
Parameter
shown. These parameters can also be altered.
Table 1 Branching of the main window
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3.8 Values (Actual Value Menu)
Figure 24 Display: values menu
In the value menu the following current actual values of the electronic unit
can be called up:
Result of last system test
Result of last O2 calibration
Result of last COe calibration
O2 … Actual values
Actual Values
• O2 measured wet value [%]
• O2 calculated dry value [%]
• O2 mA output value [mA]
• O2 sensor raw value [mV]
• O2 sensor temperature [°C/°F]
• O2 heater power [%]
• O2 ref.-air flow rate [l/h]
COe … Actual values
• COe measured wet value [ppm]
• COe mA output value [mA]
• COe sensor voltage [mV]
• COe sensor temperature [°C/°F]
• COe heater voltage [mV]
• COe heater current [mA]
• COe heater resistance [Ω]
• COe heater power [mW]
• Version MXP-Board
Common … Actual values
• Cold junction temperature [°C/°F]
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Categories
Result of last
system test
Result of last
O2 calibration
Result of last
COe calibration
O2
Actual value
Unit
Comment
Shows the O2 and COe values determined by the last
system test. There is also shown the time passed by
since the last system test has been performed. Attention: A system reset deletes the indication of the time
passed by.
Shows the O2 value determined by the last O2 calibration. There is also shown the time passed by since the
last O2 calibration has been performed. Attention: A
system reset deletes the indication of the time passed
by.
Shows the COe value determined by the last COe
calibration. There is also shown the time passed by
since the last O2 calibration has been performed. Attention: A system reset deletes the indication of the
time passed by.
O2 measured wet
vol % This is the measured (wet) O2 value based on the senvalue
sor voltage in wet flue gas.
O2 calculated dry
vol % At flue gas moisture correction of > 0% this is the calvalue
culated (dry) value. This value is also displayed in the
main window and given out by the mA output.
O2 mA output value mA
The O2 value current output depends on the O2 range.
The O2 range can be changed in the parameter menu
O2 sensor raw value mV
Measured sensor voltage of the O2 Zirconium oxide
sensor
O2 sensor tempera- °C/°F Measured sensor temperature of the O2 Zirconium
ture
oxide sensor (Temperature unit can be changed to °F,
see chapter 3.10.5.1)
%
Heater power in % of the O2 sensor heater
O2 heater power
O2 ref.-air flow rate l/h
COe
Common
COe meas. wet
value
COe mA output
value
ppm
This value shows the measured flow rate of the reference gas (air: 20.95% O2) used for the Zirconium oxide
sensor. Required value: 5 – 60 l/h (typical 40l/h).
Indication of the measured COe value
mA
The COe value current output dependent on the COe
range.
The COe range can be changed in the parameter
menu
COe sensor voltage mV
This is the measured value of the COe sensor in dependence to the combustibles
COe sensor tem°C/°F Measured sensor temperature of the COe sensor
perature
(Temperature unit can be changed to °F, see chapter
3.10.5.1)
COe heater voltage mV
This is the heater voltage of the COe sensor
COe heater current mA
This is the heater current of the COe sensor
COe resistance
Ω
This is the controlled resistance value of the COe
heater. The COe sensor temperature depends on the
COe heater resistance
COe heater power mW This is the heater power of the COe sensor heater
Version MXP-Board
Shows the version of the MXP-Board
Cold Junction Tem- °C/°F Cold junction temperature of the thermocouple element
perature
(Temperature unit can be changed to °F)
Table 2 Values menu
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If instead of a value only underscores are shown, this means that presently no
valid value for this parameter is available.
3.9
Parameter Menu
Figure 25 Display: parameter menu
In the first parameter menu window you can select between four items as
shown.
After having selected between the four possible parameter items and after
having selected a parameter for the first time with the soft key [enter], a window appears requesting the entry of a code. If the maintenance code was
not yet changed after the installation, then one confirms the inquiry through
[enter] without any input of numbers. To change the system code or to reset
to the factory code “0000” see chapter 3.10.5.4 on page 50 (change and reset).
After having entered the valid system code, there appears a window where
the corresponding value can be altered.
Note
The system code is factory-set to 0000
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Following parameters can be altered in the parameter menu:
Test gas parameters
• O2 test gas 1 (bottle) [%]
• O2 test gas 2 (bottle) [%]
• CO test gas 2 (bottle) [ppm]
O2 sensor parameters and
measuring ranges
Parameter
• Sensor constant [mV]
• Sensor slope [mV/dec]
• Measuring range 1 from [% O2]
• Measuring range 1 to [% O2]
• Measuring range 2 from [% O2]
• Measuring range 2 to [% O2]
• Limit 1 alarm [O2 min]
• Limit 2 alarm [O2 min]
• Correction flue gas [vol% moisture]
COe sensor parameters and
measuring ranges
• Sensor Offset [mV]
• Sensor slope [mV/0,1%]
• Measuring range end [ppm CO
Global system parameters
• Probe type [KES/KEX 6 0 0 X]
• Probe cable length [m]
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Category
Test gas parameters
Parameter
O2 test gas 1
(bottle)
O2 test gas 2
(bottle)
CO test gas 2
(bottle)
O2 sensor
parameters
and measuring ranges
Sensor constant
COe sensor
parameters
and measuring ranges
Unit Values
%
20.950 %
Comment
O2 concentration of the test gas bottle 1
Default value: 20.950 %
%
2.1 %
O2 concentration of the test gas bottle 2
Default value: 2.1 %
ppm 1000 ppm
CO concentration of the test gas bottle
2
Default value: 1000ppm
mV -20mV to 10mV O2 sensor constant
Note: a successful O2 calibration will
overwrite this constant.
Sensor slope
mV +35mV to
/dec +55mV
Measuring
range 1 from
Measuring
range 1 to
Measuring
range 2 from
Measuring
range 2 to
Limit 1 alarm
%
0 % - 21 %
%
0 % - 25 %
%
0 % - 10 %
%
0 % - 25 % %
%
0 % - 25 % min
or max
Limit 2 alarm
%
0 % - 25 % min
or max
Corr. flue gas
(H2O correction)
%
0 % - 50 %
Sensor Offset
mV
0mV – 50mV
Sensor Beta
Sensor
Gamma
Measuring
range end
O2 sensor slope
Note: a successful O2 calibration will
overwrite this slope.
Start value of the O2 measuring range 1
(see chapter 3.9.1 ) Default value: 0%
End value of the O2 measuring range 1
Default value: 21 %
Start value of the O2 measuring range 2
Default value: 0%
End value of the O2 measuring range 2
Default value :10 %
Limit value 1 for O2 min (alarm is set
when the O2 concentration falls below
the limit value) or max (alarm is set
when the O2 concentration rises above
the limit value) alarm.
Limit value 2 for O2 min (alarm is set
when the O2 concentration falls below
the limit value) or max (alarm is set
when the O2 concentration rises above
the limit value) alarm
Moisture content in the flue gas for the
calculation of O2 value which would be
measured in dried process gas. Entry
will change shown value on the display
and mA output to a dry value.
Default setting: 00.0% (no calculation)
(see chapter 0)
COe Sensor offset.
Note: a successful COe calibration will
overwrite this offset.
COe Sensor Beta
Note: a successful COe calibration will
overwrite this point.
COe Sensor Gamma
ppm 100ppm 2000ppm
Measuring range of COe
Default value: 1000 ppm
Table 3 Parameter menu
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3.9.1
Altering a Parameter by the Example of the O2 Measuring Ranges
The electronic unit possess two freely adjustable O2 measuring ranges.
The measuring ranges of electronic unit can be determined freely. For
example one changes the “O2 Measuring Range 1” as follows:
To reach the menu option "O2 Measuring Range 1" please enter the parameter menu with [parameter] and select here the item “O2 sensor
params and meas.ranges”. Please press now the downward arrow until
the point "Meas.range 1 from" is reached. Then the point is to be accessed with [enter], and the system code has to be inputted and confirmed.
In the menu option "Meas.range 1 from" the initial value of the measuring
range can be indicated now.
Note
It should be noted that the initial value of the measuring range cannot be larger than the final value.
Likewise the final value cannot be selected smaller
than the initial value. Otherwise the electronic unit
does not permit the entered values.
After input of the initial value this value will be confirmed with [enter] and
the final value of the measuring range can be keyed in the menu option
"O2 meas. range 1 to". As soon as this value is also confirmed through
[enter], the electronic unit updates with the new measuring range.
Note
If you try to enter a value outside the permitted limits,
the corresponding limit value is selected.
3.9.2
Altering a Parameter by the Example of a Limit Alarm
Value
In this chapter the altering of a parameter will be explained using the example of value “limit 1 alarm”. For this purpose enter the parameter menu
with [parameter], select here the item “O2 sensor params and
meas.ranges” and select then with the downward arrow the item "Limit 1
alarm”. Then the point can be called up with [enter], and the system code
has to be inputted and confirmed.
Figure 26 Display: parameter input (example)
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In the window “Parameter Input – O2 System Params”, the parameter to
be altered is displayed in clear text with the current value. If special functions are assigned to this parameter (as like “min/max” as in this example), these are displayed, too.
The numeric value can be altered using the numeric keypad. To correct,
the cursor can be moved back with the [←] key. The sign can be selected
independently of the cursor position with the [±] key.
In this example, the secondary parameter “min/max” can be changed by
the corresponding soft keys.
Note
If you try to enter a value outside the permitted limits, the
corresponding limit value is selected.
The altered value has to be confirmed with the soft key [enter].
Note
When pressing the soft key [cancel], the altered value is
cancelled and the old value maintained.
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3.9.3 O2 Correction ‘wet’ or ‘dry’ value
By design principle the COMTEC® 6000 measures the wet values. To
calculate and show the values as dry values in the display and also on
the mA-output, you have to enter the amount of moisture in the flue gas.
For this enter the parameter menu with pressing the soft key [parameter].
Select the item “O2 sensor params and meas.ranges” with [enter] and
then downwards to the item “Corr. flue gas” with [enter]. Now an information text will appear:
“Important information:
Moisture correction flue gas
When a fixed value is entered (average vol.% water vapour
content of the flue gas) the InSitu measured ‘wet’ value (real
value) will be converted into a ‘dry’ value. The ‘dry’ value is always higher than the ‘wet’ value!
A ‘dry’ value is designated by the ‘dry’ label at the top of the bar
graph of the measured value in the main measurement display.”
Accept this information with [continue]. Enter now the amount of moisture
in the flue gas and accept the entry with [enter].
You will now see the measured O2 value in the main window with the remark ‘dry’.
Figure 27 Display: O2 value is shown as a dry value
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3.10 Menu / Cal.
When selecting the menu with the corresponding soft key [menu/cal.], first a
code enquiry appears, where the system code (factory-set to 0000) must be
entered and confirmed with [enter].
Note
The system code is factory-set to 0000.
After entering the system code, the menu appears.
Figure 28 Display: menu/cal.
In this menu, the following functions can be selected:
O2/CO System test/calibration
O2 Output settings
menu/cal
CODE
• Freezing of measured O2 value
• O2 measuring range switching
• O2 mA-output damping
COe Output settings
• Freezing of measured CO value
• COe measured value damping
Common Settings
•Change temperature unit °C/°F
• Automatic calibration
• Relay output assignments
• Change system code
• Service
• Software version
COe Measurement OFF or ON
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Category
Menu Point
Description / Remarks
O2/COe ...
System test / calibration
System test /cal.
with test air /gas
O2/ Output settings
Freezing of
measured O2
value
O2 measuring
range switching
O2 mA-output
damping
COe…
Output settings
Freezing of
measured COe
value
COe measured
value damping
Common
Settings
Change temperature unit
°C/°F
Automatic calibration
Relay output
assignments
Change system
code
Service
Performs a system test with test air and
test gas (two-point-calibration). After the
successful system test the new calibrated
values can be taken over as calibration
values.
"Freezes" the last measured value for O2
while calibration
See chapter 3.10.3.1 on page 47
Sets the operation mode to either "local" or
"remote"
Allows to alteration (change) to the damping time of the mA output for O2
Maximum value: 55 sec
"Freezes" the last measured value for COe
while calibration
See chapter 3.10.4.1 on page 48
Allows to alteration (change) to the damping time of the mA output for COe
Maximum value 30 sec
Select unit temperature: °C or °F
See chapter 3.10.5.1
COe …
Measurement OFF
(or ON)
Software version
Disable COe
measurement
Performs an automatic calibration
Possible assignments for Output A:
COe maintenance / O2 measuring range
Changes the code for the menu and the
parameter menu
Calls up the service menu (service code
required)
Shows the software version of the
®
COMTEC 6000 firmware
In this menu item the COe sensor can be
disabled (if enabled before) or the COe
sensor can be enabled (if disabled before).
See chapter 3.10.6 on page 50
Table 4 Menu / Calibration
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3.10.1 First Steps for Calibration
Important
Before you begin with the calibration make sure that the
conditions comply with the following points:
• You will need two test gas bottles for the system test and
calibration:
• Test gas 1 must contain 21% O2 in N2 and no combustibles like CO. Quality like synthetic air or instrument air
• Test gas 2 should contain 500 to 1000ppm CO and
2.1% O2 in N2.
Attention
Both test gases may require SO2 in ppm. Please contact
ENOTEC.
Are all pneumatic connections made correctly and gastight
to prevent the probe from ingress of ambient air? Please
make sure, that the tubing you use to connect the test gas
bottles to the electronic unit are adapted for this use (temperature-resistant, clean, undamaged).
Both test gas bottles have to be connected:
Connect the test gas 1 to test gas 1 connection and test gas 2 to test gas 2
connection. ( see chapter 2.6.2 )
The calibration starts from the main window.
Note
If the COMTEC® 6000 probe has only just heated up,
please wait at least 2 hours before you calibrate the O2
sensor and before commissioning the COe sensor.
Please wait at least 24 hours before you make the final
system test calibration.
Press the soft key [menu/cal.]. Before you enter this menu, you are asked
to put in the system code first.
Figure 29 Display: code input
Normally you have only to confirm the factory default code by pressing the
soft key [enter]. This does only work, if the system code has not been
changed. Otherwise put in the 4-digit system code using the keypad on the
right side of the display panel, and then press the soft key [enter].
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3.10.2 Two point System test + Calibration for O2 and COe
This menu item starts with a system test and after this system test you may
decide if you want to take the results to calibrate the system.
Note
At any time you can cancel the procedure with the button
[cancel].
Enter the menu by pressing the soft key
[menu/cal.] and select the
menu item “O2/COe system test/calibration” by
pressing [enter].
The following display
indicates that test gas 2
is being supplied to the
probe.
Press [continue].to reach
the next level, or wait for
a few seconds.
The flow rate must be
between |>…<|(150l/h –
180l/h.) To adjust the
flow rate see chapter 3.6)
Press [continue] to reach
a few seconds.
System test with test gas
2 starts automatically and
you can see all relevant
values on the display.
After the test with test
gas 2 has finished, the
following display indicates that test gas 1 is
being supplied to the
probe.
a few seconds.
Now you have to adjust
the test gas flow rate.
The flow rate must be
between |>…….<|
(150l/h – 180l/h.)
a few seconds.
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Also the system test with
test gas 1 starts automatically and you can
see all relevant values on
the display.
After the system test has
finished, you will get the
results of this system
test. You can also see all
presettings which were
relevant for this system
test. By using [] you
can see all information.
Now you can decide if
you want to take the values for a calibration. The
window with the results of
the last system test will
disappear after 60 seconds. Now the results will
be safe for 2 hours. During this time you can get
the results back (starting
from the main window):
[values] > Results of last
system test > [Enter].
Decide:
Press [no calibr.] to
cancel this procedure
Press [calibr.] to perform a calibration
Here you have to enter
the test gas bottle value
of test gas 1 for O2
(Take the values from the
test certificate of the bottle!)
Press [enter].to reach the
next level.
Enter the test gas bottle
value of test gas 2 for O2
next level.
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Enter the test gas bottle
value of test gas 2 for
COe
next level.
After entering the values
you will see, how the
measured values of O2
will be calibrated.
Press [calibr.] to calibrate
the O2 sensor or [no
calibr.] to cancel the procedure.
Now you see the calibration values of the COe
sensor.
Press [calibr.] to calibrate
the COe sensor or [no
calibr.] to cancel the procedure.
After the calibration you
get the results of the last
calibration of O2.
Press [continue] to get
the results of the COe
sensor or [return] to close
the procedure.
Here you see the results
of the last calibration of
the COe sensor.
Press [return] to close the
procedure.
Note
You will find the results of the last calibrations in the menu
item [values].
Before you perform a second system test (as a verification of
the calibration) you have to wait at least 1.5 hours. This time
is necessary to achieve reproducible results with each system test.
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3.10.3 O2 Output Settings
3.10.3.1 Freezing of Measured O2 Value
Start with the main window: [menu/cal.] “O2 … output settings” with [enter]
“Freezing of measured O2 value” with [enter] “Freezing of meas. O2
value … OFF” with [enter] and select the soft key [ON].
Under this menu item freezing of measuring O2 value memory can be
switched ON during calibration. With the freezing of measured O2 value on,
the last measured value before calibration is saved so that at the current
output the measuring value, which changes because of the calibration, has
no effect. The currently measured value is released again after an adjustable
delay, when the calibration is completed.
The default delay time is 3 minutes and can also be changed under this
menu item (“Return to flue gas in”) within the limits of 1 to 10 minutes.
3.10.3.2 O2 Measuring Range Switching
Start with the main window: [menu/cal.] “O2 … Output settings” with [enter] “O2 measuring range switching”.
Preloaded adjustment is “remote”. You can change the adjustment to “local”
by pressing []. Accept the change with [enter]. Return to the main window
with [cancel].
The electronic unit has two measuring ranges. The switching mode of the
ranges can be made manually from the instrument keypad, or by an external
remote 12-24 voltage input signal. This microprocessor parameter location is
used to determine which mode of range switching is required - local or remote.
The factory preset default in the electronic unit is "remote" range switching.
This means that in the case of an open digital input, the measuring range 1
is active. At the modus "local“, the measuring range can be changed in the
main menu with the soft key MR1/2 by hand.
Note
In case of errors and alarms, the soft key MR1/2 in the main
menu is occupied by status information. The status function
has the highest priority, therefore this means in case of errors
the measuring range cannot be changed manually (by hand).
3.10.3.3 Damping of O2 mA Output
Start with the main window: [menu/cal.] “O2 … output settings” with [enter]
“O2 mA-output damping” with [enter].
Preloaded adjustment is “00 sec”. Please enter the time in seconds by using
the numeric keypad and accept the entry with [enter]. By pressing [cancel]
you will come back to the main window.
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The mA-output can be damped if required. There are optional settings from 0
sec. (without damping) to a maximum of 55 sec. are available.
Damping is useful if the oxygen output signal of the electronic unit is spiky or
rough due to sudden process condition changes. A smooth or damped output can be obtained with the attenuation setting feature.
3.10.4 COe Output Settings
3.10.4.1 Freezing of measured COe Value
Start with the main window: [menu/cal.] “COe … output settings” with [enter] “Freezing of measured COe value” with [enter] “Freezing of
meas.COe value … OFF” with [enter] and select the soft key [ON].
Under this menu item a freezing of the measured COe value can be switched
ON during calibration. With the freezing of measuring COe value on, the last
measured value before calibration is saved so that at the current output the
measuring value, which changes because of the calibration, has no effect.
The currently measured value is released again after an adjustable delay,
when the calibration is completed. The default delay time is 20 minutes and
can also be changed under this menu item (“Memory hold time”) within the
limits of 1 to 180 minutes.
3.10.4.2 Damping of COe Measured Value
Start with the main window: [menu/cal.] “COe … output settings” with [enter] “COe measured value damping” with [enter].
Preloaded adjustment is “1 sec”. Please enter the time in seconds by using
the numeric keypad and accept the entry with [enter]. By pressing [return]
The measured value for COe can be damped if required. There are optional
settings from 1 sec. (without damping) to a maximum of 30 sec. are available.
Damping is useful if the measured value for COe is spiky or rough due to
sudden process condition changes. A smooth or damped value can be obtained with the attenuation setting feature.
3.10.5 Common … Settings
3.10.5.1 Change temperature unit °C/°F
Start with the main window: [menu/cal.] “Common … Settings” with [enter]
“Change temperature unit °C/°F” with [enter].
Select the unit by pressing []. By pressing [cancel] you will come to the
main window without any changing.
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3.10.5.2 Automatic calibration
“Automatic calibration” [enter].
COMTEC® 6000 offers the opportunity of automatically performing a calibration procedure at regular intervals. This procedure however requires the version with a fully automatic pneumatic unit. All settings required for an automatic calibration can be made in this menu.
These are:
Automatic Calibration ON/OFF
As a standard, ACAL is off. In this item, ACAL can be activated.
Release mode
1. Time+External release
2. External release
3. Time only
Interval time (e.g. 90 days)
Indication of the calibration cycle time in days. At a value of 0 days the
calibration starts immediately upon release, this is important for a manual
remote calibration.
Remaining time xx days and xx hours
The remaining time until the next calibration is indicated under this item.
Note
For automatic calibration it is essential to connect a probe
with solenoid valve and to ensure that the test gas “air” is
always available and under pressure (instrument air version) or a pneumatic unit with pumps must be installed.
Important
If the calibration time interval in the parameter menu is
set to zero seconds for example - to make a remote calibration - it is very important that the release signal has a
maximum time of 60 seconds. A release signal of more
then 60 seconds could restart the calibration a second
time.
Please note that there is no "real time" clock in the electronic unit. It does not
know time of day, month or year. Only a clock-pulse generator is used for
automatic calibration purposes.
3.10.5.3 Relay output assignments
“Relay output assignments” with [enter] “Output A assignment”.
By pressing [] you can change the relay assignment from “COe maintenance” to “O2 meas. range”. Accept the change with [enter]. By pressing
[cancel] you will come back to the main window.
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3.10.5.4 Change System Code
“Change system code” with [enter].
In this menu item, the system code can be changed. Please enter now the
old code with the numeric keypad. Accept your entry with [enter]. Enter now
the new code with the numeric keypad. Accept your entry with [enter]. Repeat the new code and accept with [enter]. Now you get the information, that
the new code is accepted and this information has to be confirmed with [ok].
Note
If the changed system code is lost, a reset of the whole system is needed. Please contact ENOTEC.
3.10.5.5 Service
“Service” with [enter].
This menu item is reserved for ENOTEC service personnel only. It is factorycoded.
3.10.5.6 Software Version
“Software version” with [enter].
You will get the information about the software version. By pressing [return]
This menu item provides information about the software status and the level.
3.10.6 COe … Measurement OFF
Start with the main window: [menu/cal.] “COe … Measurement OFF” with
[enter]. In this menu item the COe measurement can be disabled.
The menu item “COe … Measurement OFF” appears only if the COe measurement is enabled. Otherwise the menu item “COe … Measurement ON” is
shown instead.
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4
Service and Maintenance
4.1
Service and maintenance of the COMTEC®
probes
4.1.1 Replacing filter element
The probe may only be removed with heat-insulated gloves. Before removing the probe, always switch off the supply voltage of
the electronic system. After removal, store the probe in a safe,
protected place and wait until it has cooled down below 35 °C.
Procedure:
with a hook wrench and
a) Loosen the retaining ring at the filter head
screw off the filter head from the probe
with a pin wrench.
2
1
Figure 30 Removing of the filter head
If needed, a set of spanners for loosening the filter head can be ordered at
ENOTEC.
Part-No.: PST-0002 (for filter heads with retaining ring)
Both sets of spanners contain additionally an Allen key for the loosening of the
O2 sensor screws.
Probe may be hot!
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b) Clamp the filter head
into a vice.
c) Remove the old filter
completely. Also, clean
the grooves in the metal
fixing.
Figure 31 Dismantling of filter
2
3
1
+ H2O
1a
d) Insert the new filter
with cement as follows:
Mix cement
thoroughly and coat both the
grooves in the seat
and the filter around the
seat at the outside. Press
the filter into the seat by
turning it. Wipe the cement between filter and
seat and remove excess
material inside as well.
Figure 32 Insert the new filteri
Note
The cement dries at room temperature within 24 hours. Using
the cement supplied by ENOTEC, all types of ceramic filters
of the ENOTEC product range can be inserted and fixed.
4.1.2
Replacing filter head
The probe may only be removed with heat-insulated gloves.
Before removing the probe, always switch off the supply voltage of the electronic system. After removal, store the probe
in a safe, protected place and wait until it has cooled down
below 35 °C.
For the change of the filter head the retainer ring at the filter head is to be
loosened (have a look at Figure 30 on page 51). The filter head can be unscrewed and taken out now. The new filter head is now screwed on the
probe tube. Before the retainer ring is tightened again, the V-shield must be
aligned to the flue gas flow.
If needed, a set of spanners for loosening the filter head can be ordered at
ENOTEC.
Part-No.: PST-0002
The set contains additionally an allan key for the loosening of the O2 sensor
screws.
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4.1.3
Exchange of probe inner part
Take the probe out of the protection tube and wait until it has cooled down.
The probe may only be removed with heat-insulated
gloves. Before removing the probe, always switch off the
supply voltage of the electronic system. After removal,
store the probe in a safe, protected place and wait until it
has cooled down below 35 °C.
If necessary, clean the probe from dirt and dust etc., after it is cooled down.
4
2
1
3
6
5
Figure 33 Exchange of probe inner part
Disconnect all wires of the probe in the connection box , loosen the tubes
and , and the two screws.
Pull off the thin transparent reference air
pipe from the screwed entry connection in the housing wall.
Carefully pull out the probe inner part. (4 hole ceramic rod with signal measuring wire, thermocouple element and heater).
Push in carefully the new inner part into the probe, (The inner part is pressed
by the holding plate with spring pressure.) and connect all wires and pneumatic tubes.
Connect the wires as follows:
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Terminal
1
2
3
4
6
7
8
9
10
11
12
13
14
Colour
white/brown
orange
green
white
black
blue
green/yellow
grey
grey
white (no.1)
white (no.2)
red (no.3)
red (no.4)
Description
Signal wire, O2 sensor
signal wire, O2 sensor
thermocouple element 1
thermocouple element 1
heating element O2
heating element O2
ground/earth
solenoid valve
solenoid valve
COe-sensor measuring value
COe-sensor measuring value
COe-sensor heating element
COe-sensor heating element
Polarity
+
+
-
Unit
mV
mV
mV
mV
Table 5 Connection of the probe inner part
Install the probe and carry out an O2 calibration.
4.1.4
Exchange of ZrO2 sensor
Take the probe out of the protection tube and wait until it has cooled down.
Dismantle the probe inner part as in chapter 4.1.3 described.
Then unscrew the filter head and dismantle the test gas distributor with guide
tube , by loosening the two Allen® screws.
Now remove the 4 Allen® screws at the Measuring cell flange and remove the
measuring cell
of the probe tube.
Remove also carefully the old Measuring flange gasket
6
7
1
2
3
4
5
Figure 34 Mounting O2 sensor holder tube (for KES600x)
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No.
Description
Probe tube with flange
Measuring flange gasket
Measuring cell holder with flange
4 Allen® screws (M5x12)
Protection cap
2 Allen® screws (M5x12)
Test gas distributor with guide tube
ENOTEC – Part-No.:
Z02-6001
Z02-6011 (MLT)
0-R-002100
Clean the flange at the probe tube with fine sandpaper. Tighten the new O2
sensor with a new sealing and four new screws at the O2 sensor flange of
the probe tube. Insert the probe inner part and ensure, that the inner parts do
not clamp in the probe tube. Press the holding plate against the spring, so
that the inner parts are pressed against the O2 sensor with sufficient spring
loading.
Install the probe (see chapter 2.7) and carry out an O2 calibration (see chapter 3.10.1).
4.1.5 Exchange of the COe sensor
In addition, the outside of the probe is hot (300 °C).
Warning
Before changing the COe-sensor please switch off the
power supply by removing the external power supply fuse
or by removing the fuse F1 at the electronic unit!
1. Disable the COe-Sensor via the software:
[menu/cal.] (enter system code) “COe ... Measurement OFF” <yes>.
Switch off the power supply
3. Disconnect the COe sensor wires
at the terminal block no. 11-14.
(Instruction for the function of the
terminals see chapter 2.5.1)
Figure 35 Connection of the COe sensor
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4. Unscrew and remove
the cap nut.
5. Unfix
the
clamping
ring , the O-ring
and
the retainer ring .
4
2
3
6. Pull the COe-sensor out
of the probe. Attention:
Maybe hot
1
Figure 36 Pull out the COe sensor
7. Prepare the new COe
sensor as follow:
Take the clamping ring, the
O-ring, retainer ring and the
cap nut and cover them
over the COe sensor.
2
1
Note: Mind the position of
the bevel. Bevel must face
O-ring!
Figure 37 Prepare the new COe sensor
4. Insert the new COe-sensor into the probe.
5. Adjust the excess length of the
COe-sensor.
ca.1cm
Figure 38 Insert the new COe sensor
6. Tighten the cap nut. Please tighten the cap nut once more after the
system and the plant are in normal operation for two hours.
Note
Ensure a gas-tight connection using new sealing kit.
7. Connect the COe sensor wires at the terminal block no. 11-14.
8. Switch on the power supply.
9. Wait until the system is heated up to nominal temperature.
The system is to be enabled now, please follow the instructions in Chapter
3.10.6 COMTEC® 6000 Electronic Unit.
Note
After the exchange of the COe sensor the values COe Offset
etc. have to be entered into the parameter menu. You will find
these values on the test protocol of the sensor.
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4.2
Status messages/Error messages
Status Messages / Error Messages / Troubleshooting
Figure 39 Display: error messages
If errors or alarms occur during operation, these are displayed as clear text in
the status menu. All errors and alarms must be acknowledged and/or cleared
with the soft key [enter] in this menu display.
A help function for the status messages is available in this menu.
Note
If the electronic unit is put into operation without a probe connected, some system errors will occur. E.g. heating system
does not work, error sensor signal out of range, error wire
breakage thermo element. When the electronic unit is then
connected to a probe, these errors will be shown again, because the microprocessor stores the errors as they occur in a
permanent memory (EEPROM). After acknowledgement of
each of these errors, the system operates normally.
The following status messages are possible:
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Message
Possible reasons
Heating system
does not work
The probe could not heat to the nominal tempera- During start up
ture
Possible reasons: Reference air flow rate is too
high, blown fuses, insufficient power supply voltage, broken probe cable, broken heater wires,
heater resistance failure of the probe heater (must
be between 37.5 and 47.5 Ohms).
Warning
Make sure that the power is
switched off when doing this test!
As the result of a calibration check, the calculated During calibracell constant is outside the tolerance range pation
rameters of the microprocessor settings. Therefore
the electronic unit continues with the previous/former cell constant value. The microprocessor
tolerance range is factory set to: -50mV to +10mV.
O2 sensor constant out of tolerance
Occurrence
LED/Relay contact
LED “Error”
Relay”System
error” contact
open
LED”Error”
Relay”System
error” contact
open
O2 sensor slope As the result of a calibration check, the calculated
out of tolerance mV/Decade slope is outside the tolerance range.
The electronic unit therefore continues with the
previous/former slope value.
Tolerance: 35mV to 55mV per decade
Possible reasons: Test gas flow to low (⇒ Check
the test gas tubes, if needed exchange of the test
gas and reference gas tubes), solenoid valve not
open, incorrect test gas concentration.
During calibra- LED”Error”
tion
Relay”System
error” contact
open
COe Beta-Factor Wrong Testgas, or COe sensor error
out of range
Check the Testgas, repeat the calibration, and if
necessary change the COe sensor.(Contact
ENOTEC for help )
tion
Relay”System
error” contact
open
O2 sensor signal Test gas flow too high, Unstable test gas concen- During system LED”Error”
unstable
tration, unstable test gas pressure, wrong V-shield test
Relay”System
position, filter is broken or filter head is missing
error” contact
open
COe sensor
signal unstable
Test gas flow too high, Unstable test gas concen- During system LED”Error”
tration, unstable test gas pressure, wrong V-shield test
Relay”System
position, filter is broken or filter head is missing
error” contact
open
Test gas flow too Insufficient instrument air supply, blown fuses,
high/low
insufficient test gas supply, test gas tube blocked, tion
and “Maint.”
solenoid valve is not open or test gas bottle is not
open/empty
Timeout while
test gas supply
Unstable test gas concentration, unstable test gas During calibra- LED”ERROR”
pressure, wrong V-shield position, filter is broken tion
Relay”System
or filter head is missing
error”
contact
open
Autom. calibration cancelled
mV output value of the probe is unstable, cell con- During autostant or mV/Dec. slope outside of microprocessor matic calibratolerance/range (Note: the corresponding error is tion
shown on the electronic
unit display)
At any time
Reference air
Insufficient instrument air supply, Reference air
flow too high/low tube blocked, Dirt in the tubing and by this a possible damage of the needle valve
Tolerance: min 5l/h, max 60l/h, min. 1bar/14.5psi
Analyser System
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LED”Error”
Relay”System
error” contact
open
LED“Error”
Page 58 of 80
Message
Possible reasons
Occurrence
LED/Relay contact
Thermocouple
wire broken
Connection failure or broken probe cable
At any time
LED”Error”
Relay”System
error” contact
open
O2 sensor signal O2 cell signal wire not connected, bad connection, At any time
out of range
push the probe inner part assembly, broken probe
cable,
faulty thermocouple, large amount of combustibles
in the flue gas.
Tolerance: 45mV to +265mV
LED”Error”
Relay”System
error” contact
open
Temp. of electronic out of
spec.
The temperature of the electronic unit is outside
At any time
the allowed operating limits
Possible reasons: Ambient air temperature is too
high. The temperature of the electronic unit is
outside the allowed operating limits
Tolerance: -20 °C (-4 °F) to +70 °C (158 °F) within
its housing
LED”Error”
Relay”System
error” contact
open
Probe tempera- Flue gas temperature too high (see chapter 5.2),
At any time
ture too high
failure thermocouple, failure heater, wrong connec(O2 sensor only) tion at terminal box.
Tolerance: +20 °C / 68 °F of the preset probe temperature max. 890 °C
LED”Error”
Relay”System
error” contact
open
Probe tempera- Reference air flow too high, blown fuses, heater
At any time
ture too low
failure, broken probe cable, actual power supply
(O2 sensor only) voltage to the electronic unit (230V/115V ±10%).
Limit:-20 °C/68 °F of the preset probe temperature
LED”Error”
Relay”System
error” contact
open
Alarm limit 1
Oxygen limit 1 out of range
Alarm limit 2
Note: Not active, when measuring value memory is
active
Oxygen limit 2 out of range
At any time
LED”Alarm”
Relay”O2 limit
alarm 1” contact
open
At any time
Note: Not active, when measuring value memory is
active
O2 value freezing The measuring value memory (freezing) is still
At any time
active
active
LED”Alarm”
Relay”O2 limit
alarm 2” contact
open
LED”Maint.”
COe value freez- The measuring value memory (freezing) is still
ing active
active
At any time
LED”Maint.”
COe sensor
Blown fuse on the COe sensor board, unplugged
board communi- connection cable between display board and COe
cation error
sensor board, electronic failure of the COe sensor
board
At any time if
COe measurement is
enabled
LED”Error”
Relay”System
error” contact
open
Short circuit COe Resistance of the COe sensor heater is out of tolsensor heater
erance.
Please measure the insulation resistance. (see
wiring chapter 2.5.4)
At any time if
COe measurement is
enabled
LED”Error”
Relay”System
error” contact
open
Open circuit COe Resistance of the COe sensor heater is out of tolsensor heater
erance or wire breakage
Please measure the insulation resistance. (see
wiring chapter 2.5.4),
At any time if
COe measurement is
enabled
LED”Error”
Relay”System
error” contact
open
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Message
Possible reasons
Occurrence
LED/Relay contact
Open circuit COe Connection failure or wire breakage
sensor
At any time if
COe measurement is
enabled
LED”Error”
Relay”System
error” contact
open
Data memory
error COe sensor electronic
Electronic failure of the COe sensor board
At any time if
COe measurement is
enabled
LED”Error”
Relay”System
error” contact
open
ADC error COe
sensor heater
At any time if
COe measurement is
enabled
LED”Error”
Relay”System
error” contact
open
ADC error COe
sensor
At any time if
COe measurement is
enabled
LED”Error”
Relay”System
error” contact
open
Data fault
EEprom
A data error has occurred in the microprocessor
and the electronic unit continues with factory default values. Please contact ENOTEC.
During commissioning
LED”Error”
Relay”System
error” contact
open
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4.3
Troubleshooting
4.3.1 Unsteady, widely varying Measuring Value (O2)
Occurrence: At any time
Possible reasons
Intermittent contact caused by
wire breakage
Procedure
Check the O2 sensor temperature (set value
840 °C/1544 °F or 800 °C/1472 °F for Ex
systems)
Intermittent contact inside the Measure the mV value on the terminals of
probe - internal mV connection the power supply board
Broken filter element
Visual inspection by dismounting the probe
Wrong installed V-shild
Visual inspection by dismounting the probe
Probe has been installed with- Visual inspection by dismounting the probe
out filter head
Intermittent contact inside the Check the spring tension
probe – low spring tension for
the O2 signal contact wire internally
4.3.2 No COe-Measuring Value; Arrow instead of a value
Possible reasons
Procedure
The physical measuring range Perform a O2/COe system test
is exceeded
An error of the COe sensor
Check all electrical connections as well.
exists
4.3.3 No Measuring Value for O2; empty Bar Graph
Possible reasons
Procedure
O2 value out of the coverage of Perform a O2/COe system test
the electronic unit, for example
caused by a low O2 concentration in connection with a high
COe concentration
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4.3.4 O2 reads higher than expected, and COe reads lower
than expected
Possible reasons
Procedure
This may be due to a poor seal Tighten or replace the COe sensor coupling
of the COe sensor coupling
assembly.
located in the terminal box
housing. If the stainless steel
nut is not tight enough the Oring seal allows ambient air to
enter into the COe senor
mounting tube and that of
course influence the sensors
readings.
4.3.5 O2 Display remains at the End of the Measuring Range
or is higher than expected
Possible reasons
Leakages at the measuring
probe or at the O2 sensor
flange seal.
Solenoid valve does not close
because solid particles (metal
swarf or any other dust particles) are inside the solenoid
valve
Analyser System
Procedure
Check all flanges and screw connections for
tightness. Exchange O2 sensor or replace
O2 sensor flange seal. In case of a leakage
in the area of the zirconium oxide O2 sensor, the O2 sensor must be exchanged.
Check the test gas tubing inside the probe
terminal box. Is there any dust visible in the
opaque (white) test gas tube inside the
probe terminal box? It is possible, that the
instrument air used as test air is contaminated by dust or condensed solids out of the
flue gas have settled there. It is also possible, that metal swarf (test gas tubing made
out of copper or stainless steel) settles inside the solenoid valve during system test /
calibration.
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4.4
Exchange Fuses and change of Voltage
The electronic unit has five accessible fuses (see Figure 40):
Figure 40 Position of the fuses and the switcher between 230 V and 115 V operation (SW1)
Part
Current Kind of Fuse
Task
F3
1A
F4
1A
F5
1A
Protection of the electronic
unit
Protection of the electronic
unit
Protection of the solenoid
valve
SW1 switch
F1
6.3 A
F2
4A
fast-acting 5x20 mm glass tube
fuse
fast-acting 5x20 mm glass tube
fuse
semi time-lag 5x20 mm glass tube
fuse
115 V AC to 230 V AC
semi time-lag 5x20 mm glass tube Protection of the entire sysfuse
tem
semi time-lag 5x20 mm glass tube Protection of the probe
fuse
heater
Table 6 Fuses
Important
The fuses on the circuit board below the cover protect the
electronic unit and should only be replaced by service personnel, because otherwise damage to the electronic unit
cannot be excluded.
Analyser System
Version 05.300.15
Page 63 of 80
5
Technical Datas and Drawings
5.1
Requirements of the Gas Supply
Instrument air for reference air supply
Specification:
According to ISO 8573-1 class 2
(Particle size max. 1µm,
Particle density max. 1mg/m³,
Oil content max. 0,1mg/m³,
Pressure dew point max. -20 °C)
Input pressure:
2-10 bar
Input flow rate
continuously maximum 40 l/h (for reference air supply),
Test gas for calibration / system test
Input pressure:
max. 3 bar
Specification
test gas 1:
21% O2 in N2 (synthetic air)
Specification
test gas 2:
2.1 Vol.-% O2 and x ppm CO in N2 where 'x' must correspond to the selected maximum value of the COe
measuring range (accuracy +/- 2%). That is:
For a measuring range of 0 to 1000ppm please take test
gas with about 800ppm CO (± 50ppm) in 2.1 Vol.% O2
(± 0,1Vol.% O2) and N2.
For a measuring range of 0 to 500ppm please take test
gas with 400ppm CO (± 50ppm) in 2.1 Vol.% O2 (±
0,1Vol.% O2) and N2
Input flow rate
1,1 +/- 0,1 bar max. 180 l/h in the 2. step of calibration
and during the system test with test gas 2.
Note
The flow rate of the test gas bottle is set via the bottle pressure.
Analyser System
Version 05.300.15
Page 64 of 80
5.2
Probe
Flue gas temperature:
KES600x: up to 500 °C (932 °F)
up to 1400 °C (2552 °F) with cooling protection tube
Insertion length:
KES-6001:
KES-6002:
KES-6003:
KES-6004:
KES-6005:
Insertion length with cooling protection tube:
500/1000 mm (Other length contact
ENOTEC)
Measuring principle:
Zirconium oxide for O2
MXP for COe
Flue gas pressure:
-50 to +50 mbar (-0.725 to +0.725 PSIG)
Flow velocity:
0 to 50 m/s
Ambient temperature:
-40 °C to +80 °C (-40 °F to +176 °F)
Response time (O2):
0,5 s (flue gas flowing at > 10m/second)
T90 time (O2):
5 s (flue gas flowing at > 10m/second)
Probe material:
V4A (1.4571/316SS) 316L Stainless Steel
Type of protection:
IP65
Voltage supply:
via electronic unit
Dimension:
see dimension sheet
Probe mounting:
Horizontal – Preferred
Vertical Down – Possible
Important Note: Vertical mounted probes
will generally have slower response time
because of the lower gas exchange dynamic
Analyser System
Version 05.300.15
470 mm
930 mm
1850 mm
2770 mm (Contact ENOTEC)
3690 mm (Contact ENOTEC)
Page 65 of 80
O 84
5.2.1 Dimensional drawing of probe KES600x
172
120
C
Figure 41 Dimensional drawing of probe KES600x
Probe type
KES 6001
KES 6002
KES 6003
KES 6004
KES 6005
5.2.2
Protection tube flange
Abmessungen
Dimensions
Flanschtyp
type of flange
45°
D
b
d2 holes
k
A
(9,00)
12,5 190,5 19,0
(0,50) (7,50) (0,75)
8
ANSI 3" 300lbs
209,5
(8,25)
28,6 168,3 22,2
(1,13) (6,63) (0,87)
8
190,5
(7,50)
23,9 152,4 19,1
(0,94) (6,00) (0,75)
4
190,0
(7,48)
18,0 150,0 18,0
(0,71) (5,91) (0,71)
4
200,0
(7,87)
20,0 160,0 18,0
(0,79) (6,29) (0,71)
8
DIN2527 DN100/PN16 220,0
20,0 180,0 18,0
(0,79) (7,09) (0,71)
8
120,6 11,0
(4,75) (0,43)
8
186,0 11,0
(7,32) (0,43)
4
DIN2527 DN150/PN16 285,0
(11,22)
R
22,0 240,0 22,0
(0,87) (9,45) (0,87)
8
228,6
(9,00)
12,5 190,5 19,1
(0,50) (7,50) (0,75)
8
ANSI 4" 150lbs FF eq. 228,6
Order code:
Order code:
F
ANSI 3" 150lbs
Order code:
J
DIN2527 DN80/PN6
Order code:
K
DIN2527 DN80/PN16
Order code:
Order code:
L
M
Servomex 700 eq
Order code:
N
Servomex 790M eq
Order code:
P
(8,66)
155,0
(6,10)
220,0
(8,66)
Order code:
ANSI 4" 150lbs RF
Order code:
Length C (mm)
470
930
1850
2770
3690
T
All dimensions in mm (inch)
d2
k
D
90°
d2
k
D
Mat.: 1.4571
b
Figure 42 Dimensional drawing of the protection tube flanges for KES600X
Analyser System
Version 05.300.15
Page 66 of 80
Adapter plate ADP-6000
M 16
5.2.3
45
O 90
18
O 191
O 229
Figure 43 Dimensions of adapter plate ADP-6000
Adapter plate ADP-6000-S01
101,6
M16
5.2.4
O 95,6
45
250
O 191
O 229
Figure 44 Dimensions of adapter plate ADP-6000-S01
Analyser System
Version 05.300.15
Page 67 of 80
5.2.5
Probe components
6
7
5
3
8
4
4a
9a
2a
9
2
1
Figure 45 Probe components with working cycles
No.
ENOTEC – Part-No.:
ASK-0003
MSR-6001
FLD-1000
SIK-600x (x=1,2…5)
ZO2-6011
MZD-0005
0-R-002311
KES60000x0000(x=1,2…5)
KEF-200x
BAF-200x
SMF-200x
KES60000D000
KES600000x00(x=1,2…5)
(see table in chapter 5.2.1)
KES600000x00(x=A, B…)
(see table in chapter 5.2.2)
Depending on flange type
Analyser System
Version 05.300.15
Description
Connection box
Probe tube
Probe flange gasket
Probe inner part complete
O2 Measuring cell complete (MLT)
Metal-O-ring seal
Test gas distributor with insulation
tube
Filter head
Ceramic filter with cement
Basalt filter with cement
Sintered metal filter with cement
COe sensor
Protection tube
Protection tube flange
Protection tube flange gasket
Page 68 of 80
5.3
Electronic Technical Data & Dimensions
Dimensions:
see dimensional drawings for the different
housings
Main voltage
230 V / 50...60 Hz (± 10%)
115 V / 50...60 Hz (± 10%)
Power consumption
400 VA during start up, 100 - 200 VA running
Recommended fuse
10 A
Ambient temperature
Version with instrument air: -20 °C (-4 °F) to
+55 °C (+131 °F)
Version in 19” rack: 0 °C (+32 °F) to 60 °C
(+140 °F)
Other temperatures on request
Relay outputs, potential-free
24 V / 1 A
Max. relay output solenoid
valve
230V ~ 1A:
Analog input O2 sensor
Re > 9 MΩ
Ue: -45mV to +265mV for the active measuring range
Resolution of the digitizers in
the active measuring ranges
14 Bits + sign (O2), 10 Bits (COe)
Analog input thermocouple
Re: > 900 kΩ
Temperature compensation
located on the circuit board
Signal output 4...20 mA
max. load 500 Ω potential-free, active
Reaction time of the mA output with a change of 100mV on the O2 sensor
input <200 ms
Display
LC-Display, LED-lit 240 x 64 dots graphic
display
Measuring accuracy
±0.2% of actual measured value (O2)
Protection class
IP66 (electronic unit in field housing)
IP20 (electronic unit in 19” rack)
Analyser System
Version 05.300.15
Page 69 of 80
300
240
400
420
440
4X O 8,5
260
132 (3HE)
Figure 46 Dimensions of the electronic unit in field housing
308
482
Figure 47 Dimensions of the electronic unit in 19’’ rack
Analyser System
Version 05.300.15
Page 70 of 80
5.4
Gas plan SME-5 Instrument air (Version A)
1
3
2
1
4
2
3
2
5
3
1
6
7
8
9
10
11
12
13
14
Figure 48 Gas plan (instrument air version A)
Electronic unit
O2/COe Probe
Flow meter
3/2-way solenoid valve
(for test gas 2)
(for test gas 1)
Choke reference air
Pressure reducer
Analyser System
Version 05.300.15
Instrument air in
(2-10 bar, oil free, dry)
Test gas 1 in
(max. 3 bar)
Test gas 2 in
(max. 3 bar)
Test gas out green tubing
(150-180l/h)
Reference air out blue tubing (5-60l/h; optimal:30-40l/h))
Probe reference air in blue
tubing
Probe test gas in green tubing
Page 71 of 80
5.5
Gas plan SME-5 Instrument air (Version 1)
1
3
2
1
4
2
3
2
5
3
1
6
8
7
10
9
11
12
13
14
Figure 49 Gas plan (instrument air version 1)
Electronic unit
O2/COe Probe
Flow meter
(for test gas 2)
(for test gas 1)
Choke reference air
Pressure reducer
Analyser System
Version 05.300.15
Choke for Test gas 1
Instrument air in
(2-10 bar, oil free, dry)
Test gas 2 in
(max. 3 bar)
(150-180l/h)
Reference air out blue tubing (5-60l/h; optimal:30-40l/h))
tubing
Page 72 of 80
5.6
Gas plan SME-5 with O2 Reference air pump
1
3
2
1
4
2
3
2
6
5
3
1
7
8
10
9
11
12
13
14
Figure 50 Gas plan (with pump)
Electronic unit
O2/COe Probe
Flow meter
(for test gas 2)
(for test gas 1)
Reference air pump
Miniature filter
Analyser System
Version 05.300.15
Reference air in
Test gas 1 in
(max. 3 bar)
Test gas 2 in
(max. 3 bar)
(150-180l/h)
Reference air out blue tubing (30-40l/h))
tubing
Page 73 of 80
6
Electronic Assembly Overview
6.1
Mounting plates of Field housing
Mounting plate 1 (with instrument air,
Version A and Version 1)
1
ENOTECPart No.
Description
TRA-00017
Toroid transformer
2x115V;sec.115V/330VA
Solenoid valve for test gas
P01
P02
Internal flow meter for reference air and test gas SME5
Pressure regulator with two
chokes Version 1 (see
chapter 5.5)
Pressure regulator with one
chocke Version A (see
chapter 5.4)
PGM-0001
PGM-0002
2
DFM-00001
3
4
0-P-000780
0-P-001369
5
Figure 51 Mounting plate 1(instrument air)
Mounting plate 1 (with pump)
1
ENOTECPart No.
Description
TRA-00017
Toroid transformer
2x115V;sec.115V/330VA
P01
P02
Reference air pump
115V/50Hz; 30l/h
PGM-0001
2
PGM-0002
DFM-00001
3
PLU-0025
4
5
Figure 52 Mounting plate 1(with pump)
Analyser System
Version 05.300.15
Page 74 of 80
Mounting plate 2 (with instrument air)
1
ENOTECPart No.
Description
0-L-000100
0-L-000080
COe-Sensorboard
Power board
ENOTECPart No.
Description
0-L-000100
0-L-000080
0-P-000658
COe-Sensorboard
Power board
Miniature filter 0,3µm
2
Figure 53 Mounting plate 2(instrument air)
Mounting plate 2 (with pump)
1
2
3
Figure 54 Mounting plate 2 (with pump)
Analyser System
Version 05.300.15
Page 75 of 80
6.2
Mounting plates of 19”Rack
Mounting plate (with instrument
Version A and Version 1)
1
air,
ENOTECPart No.
Description
0-P-000780
Pressure regulator with two
chokes Version 1 (see
chapter 5.5)
Pressure regulator with one
chocke Version A (see
chapter 5.4)
Toroid transformer
2x115V;sec.115V/330VA
P01
Power board
COe-Sensorboard
P02
2
0-P-001369
3
4
5
6
TRA-00017
DFM-00001
PGM-0001
0-L-000080
0-L-000100
PGM-0002
7
Figure 55 Mounting plate (instrument air)
Mounting plate (with pump)
ENOTECPart No.
Description
PLF-0001
PLF-0002
TRA-00017
Test air / ref. air filter
Spare filter element
Toroid transformer
2x115V;sec.115V/330VA
Reference air pump
COe-Sensorboard
Power board
P01
P02
1
2
3
4
5
DFM-00001
PLU-0025
0-L-000100
0-L-000080
PGM-0001
PGM-0002
6
7
8
Figure 56 Mounting plate (with pump)
Analyser System
Version 05.300.15
Page 76 of 80
ENOTECPart No.
Description
0-L-000102
COMTEC 6000 front
panel with electr.
without RS232 interface option
Figure 57 Display and microprocessor unit)
Analyser System
Version 05.300.15
Page 77 of 80
7
Table of figures
Figure 1 System overview ..................................................................................................................................9
Figure 2 Installation of the Electronic unit.........................................................................................................16
Figure 3 Access to the terminals ......................................................................................................................16
Figure 4 Instruction for the function of the terminals ........................................................................................16
Figure 5 Wiring diagram of the electronic unit ..................................................................................................17
®
Figure 6 Wiring and terminal connection diagram of COMTEC 6000 ............................................................19
Figure 7 Mounting instructions for pneumatic tubes.........................................................................................20
®
Figure 8 Connections of the COMTEC 6000 Field housing............................................................................21
®
Figure 9 Gas connections of the COMTEC 6000 in 19’’ rack .........................................................................21
Figure 10 Mounting of the mating flange at the duct ........................................................................................23
Figure 11 Adjustment of the measuring probe in the flue gas..........................................................................23
Figure 12 Mounting of the protection tube at the mounting flange ...................................................................24
Figure 13 Electrical connections of the measuring probe ...............................................................................25
Figure 14 Connection of the pneumatic tubes at the measuring probe............................................................26
Figure 15 Insulation of a probe protection tube ................................................................................................26
®
Figure 16 Front panel of the COMTEC 6000 electronic unit after the COe sensor is enabled ......................28
Figure 17 COe value out of range ....................................................................................................................28
Figure 18 Display after heating up (main window) ...........................................................................................30
Figure 19 Adjusting ref. air flow rate at field housing .......................................................................................30
Figure 20 Adjusting ref. air flow rate at 19”rack................................................................................................30
Figure 21 Adjusting test gas 1 flow rate at field housing ..................................................................................31
Figure 22 Adjusting test gas 1 flow rate at field housing ..................................................................................31
Figure 23 Display: main window (example) after calibration ............................................................................32
Figure 24 Display: values menu .......................................................................................................................33
Figure 25 Display: parameter menu .................................................................................................................35
Figure 26 Display: parameter input (example) .................................................................................................38
Figure 27 Display: O2 value is shown as a dry value .......................................................................................40
Figure 28 Display: menu/cal. ............................................................................................................................41
Figure 29 Display: code input ...........................................................................................................................43
Figure 30 Removing of the filter head ..............................................................................................................51
Figure 31 Dismantling of filter ...........................................................................................................................52
Figure 32 Insert the new filteri ..........................................................................................................................52
Figure 33 Exchange of probe inner part ...........................................................................................................53
Figure 34 Mounting O2 sensor holder tube (for KES600x) ...............................................................................54
Figure 35 Connection of the COe sensor..........................................................................................................55
Figure 36 Pull out the COe sensor ...................................................................................................................56
Figure 37 Prepare the new COe sensor............................................................................................................56
Figure 38 Insert the new COe sensor ...............................................................................................................56
Figure 39 Display: error messages...................................................................................................................57
Figure 40 Position of the fuses and the switcher between 230 V and 115 V operation (SW1)........................63
Figure 41 Dimensional drawing of probe KES600x..........................................................................................66
Figure 42 Dimensional drawing of the protection tube flanges for KES600X ..................................................66
Figure 43 Dimensions of adapter plate ADP-6000 ...........................................................................................67
Figure 44 Dimensions of adapter plate ADP-6000-S01 ...................................................................................67
Figure 45 Probe components with working cycles ...........................................................................................68
Figure 46 Dimensions of the electronic unit in field housing ............................................................................70
Figure 47 Dimensions of the electronic unit in 19’’ rack ...................................................................................70
Figure 48 Gas plan (instrument air version A)..................................................................................................71
Figure 49 Gas plan (instrument air version 1) ..................................................................................................72
Figure 50 Gas plan (with pump) .......................................................................................................................73
Figure 51 Mounting plate 1(instrument air).......................................................................................................74
Figure 52 Mounting plate 1(with pump) ............................................................................................................74
Figure 53 Mounting plate 2(instrument air).......................................................................................................75
Figure 54 Mounting plate 2 (with pump) ...........................................................................................................75
Figure 55 Mounting plate (instrument air).........................................................................................................76
Figure 56 Mounting plate (with pump) ..............................................................................................................76
Figure 57 Display and microprocessor unit) .....................................................................................................77
Analyser System
Version 05.300.15
Page 78 of 80
Analyser System
Version 05.300.15
Page 79 of 80
Distribution & Service:
ENOTEC GmbH
Höher Birken 6
D-51709 Marienheide
Germany
Phone: +49 (0) 2264 / 4578-0
Fax:
+49 (0) 2264/ 4578-31
E-Mail:
info@enotec.de
Internet: www.enotec.com
ENOTEC National:
Sales Office North/East
Herr Dirk Jeworowski
Broistedt Str. 26
D - 21423 Winsen
Tel.: ++49 (0) 4171 6672 70
Fax: ++49 (0) 4171 7876 400
E-Mail: jeworowski@enotec.de
Sales Office West
Herr Thomas Bechstein
Zum Stollen 4
D – 51674 Wiehl
Tel.: ++49 (0) 2262 7527 97
Fax: ++49 (0) 2262 7528 01
E-Mail: bechstein@enotec.de
Sales Office Middle
Herr Dipl.-Ing. Dieter Rieß
Oderstraße 44
D - 64546 Mörfelden-Walldorf
Phone: ++49 (0) 6105 9462 38
Fax: ++49 (0) 6105 9462 85
E-Mail: riess@enotec.de
Sales Office South
Herr Dr. Claus Gumprecht
Gössmannsreuth 1
D - 95326 Kulmbach
Phone: ++49 (0) 9221 9050 20
Fax:
++49 (0) 9221 9050 41
E-Mail: sales@gumprecht.org
ENOTEC International:
ENOTEC UK Limited
PO BOX 9026
DUMFRIES
DG1 3YH
United Kingdom
ENOTEC Inc.
6206 Sandy Ridge Circle NW
North Canton
Ohio 44720
USA
Phone: +44 8442470102
Fax: +44 8442470302
E-Mail: enotec.uk@enotec.com
Phone: +1 330 498 0202
Fax: + 1 330 497 9802
E-Mail: enotec.inc@enotec.com
ENOTEC ASIA PTE. Ltd.
151, Pasir Panjang Distripark
Block 1
#02-19 Pasir Panjang Road
Singapore 118480
Your Distribution:
Phone: +65 6100 2188
Fax: +65 6399 2780
E-Mail: enotec.asia@enotec.com
Analyser System
Please contact:
ENOTEC GmbH
Phone: ++49 (0) 2264 / 4578-0
Fax:
++49 (0) 2264 / 4578-31
E-Mail: info@enotec.de
Version 05.300.15
Page 80 of 80

6000 InSitu Analyser System

Transcription

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