Connect the Electrical Leads Safety Precautions 16 Connection Diagram 17 Connect the Signal Leads 18 Connect the Power Supply Leads 19

Transcription

1 EasyLine O2 Oxygen Analyzer Operator s Manual 42/ EN

2 Contents Page Foreword 4 Guidelines for Installation and Operation 5 General Safety Precautions 6 Safety Precautions for Handling Electronic Measurement Devices 7 Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Preparation for Installation Unpack the Gas Analyzer 8 Items Delivered 8 Identification Plate 9 Analyzer Data Sheet 9 Installation Site Requirements 10 Check Sample Gas Path Seal Integrity 10 Install the Gas Analyzer Install the Gas Analyzer 11 Dimensional Diagram 12 Connect the Gas Lines Connection Diagram 13 Gas Inlet and Outlet Conditions 14 Connect the Gas Lines 15 Connect the Electrical Leads Safety Precautions 16 Connection Diagram 17 Connect the Signal Leads 18 Connect the Power Supply Leads 19 Start the Gas Analyzer Check the Installation 20 Purge the Sample Gas Path 20 Start the Gas Analyzer 21 Operate the Gas Analyzer Readout and Controls 22 Menu 24 2 EasyLine O2 Operator s Manual 42/ EN

3 Contents Chapter 7 Chapter 8 Chapter 9 Chapter 10 Chapter 11 Appendix Page Set Parameters Fundamentals 25 Component Parameters 26 Limit Parameters 28 Modbus Parameters 29 Factory and User Settings 30 Calibrate the Gas Analyzer Test Gases 31 Calibrate Sample Component 32 Perform Calibration Reset 34 Pressure Correction 35 Drift Reading 36 Maintenance Check Gas Path Seal Integrity 37 Status Messages, Troubleshooting Blinking Screen 39 Status Messages 40 Faults 42 Call for Service 43 Take the Gas Analyzer Out of Service and Pack it Take the Gas Analyzer Out of Service 44 Pack the Gas Analyzer 45 Gas Analyzer Structure 46 Specifications 47 Complete Analysis Apparatus 51 Index 52 42/ EN EasyLine O2 Operator s Manual 3

4 Foreword Content of this operator s manual Text type styles Symbols used in the manual Additional information on the Internet This operator's manual contains all the information you will need to safely and efficiently install, start-up, operate and maintain the EasyLine O2 gas analyzer. This operator's manual contains information on all the modules in the gas analyzer. Your gas analyzer as delivered may differ from the version described in this manual. 1, 2, 3,... identifies reference numbers in figures. 'LVSOD\ identifies a display on the screen. 'LVSOD\ identifies a blinking display on the screen. Ö identifies function keys Enter Back F identifies specific information on operation of the gas analyzer as well as on the use of this manual. identifies safety information to be heeded during gas analyzer operation in order to avoid risks to the operator. Additional information on ABB Analytical products and services is available on the Internet at Additional information If the information in this operator's manual does not cover a particular situation, ABB Service is prepared to supply additional information as needed. Contact your local ABB service representative or ABB Automation Service, Telephone: , Telefax: , callcenter.automation@de.abb.com This operator's manual is protected by copyright. The right is reserved to pursue civil or criminal penalties if this publication is translated, reproduced (electronic, mechanical, photocopying, recording, etc.), stored in information retrieval systems or networks or transmitted in any form without the permission of the copyright holder. 4 EasyLine O2 Operator s Manual 42/ EN

5 Guidelines for Installation and Operation The following basic steps should be followed when installing and operating the EasyLine O2 gas analyzer. Step Action See page Follow safety precautions 6, 7 1 Unpack the gas analyzer 8 2 Check gas path seal integrity 10 3 Install the gas analyzer 11 4 Connect the gas lines 15 5 Connect the signal leads 18 6 Connect the power supply 19 7 Check the installation 20 8 Purge the gas path 20 9 Start the gas analyzer Set the parameters Calibrate the gas analyzer 31 42/ EN EasyLine O2 Operator s Manual 5

6 General Safety Precautions Proper operation The device is designed for continuous measurement of concentrations of specific components in gases or vapor. The device is not to be used to measure combustible gas/air or gas/oxygen mixtures. Requirements for safe operation In order to operate in a safe and efficient manner, the device should be properly handled and stored, correctly installed and set-up, properly operated and carefully maintained. Personnel qualifications Only persons familiar with the installation, set-up, operation and maintenance of comparable equipment and certified as being capable of such work should work on the device. Special information and precautions These include The content of this operator's manual. The safety information affixed to the device. The applicable safety precautions for installing and operating electrical devices The applicable safety precautions for working with gases, acids, condensates, etc. National regulations The regulations, standards and guidelines cited in this operator's manual are applicable in the Federal Republic of Germany. The appropriate national regulations should be followed when the device is used in other countries. Device safety and safe operation The gas analyzer is designed and tested in accordance with EN Part 1/IEC , "Safety Provisions for Electrical Measuring, Control, Regulation and Laboratory Instruments" and has been shipped ready for safe operation. To maintain this condition and to assure safe operation, read and follow the safety information identified with the symbol in this manual. Failure to do so can put persons at risk and can damage the device as well as other systems and instruments. 6 EasyLine O2 Operator s Manual 42/ EN

7 Safety Precautions for Handling Electronic Measurement Devices Protective lead connection Risks of a disconnected protective lead Risks involved in opening the covers Risks involved in working with an open device Fuses When safe operation can no longer be assured The protective lead should be attached to the protective lead connector before any other connection is made. The device can be hazardous if the protective lead is interrupted inside or outside the unit or if the protective lead is disconnected. Current-bearing components can be exposed when covers or parts are removed, even if this can be done without tools. Current can be present at some connection points. The device must be disconnected from all power sources before being opened for any work. All work on a device that is open and connected to power should only be performed by trained personnel who are familiar with the risks involved. Never use patched fuses. Do not short-circuit the fuse holder contacts. If it can be assumed that safe operation is no longer possible, the unit should be taken out of service and protected against inadvertent use. The possibility of safe operation is excluded: if the device is visibly damaged if the device no longer operates after prolonged storage under adverse conditions after severe transport stresses 42/ EN EasyLine O2 Operator s Manual 7

8 Chapter 1 Preparation for Installation Unpack the Gas Analyzer Unpacking Step Action 1 Remove the gas analyzer and the protective packaging from the shipping box. 2 Remove the protective packaging and place the gas analyzer in a clean location. 3 Remove the adhesive packaging residue from the gas analyzer. F If there is shipping damage that points to improper handling, file a damage claim with the shipper (railway, mail or freight carrier) within seven days. Make sure the enclosed accessories are not lost (see the "Items Delivered" section). Keep the shipping box and packaging material for future shipping needs. Items Delivered Items delivered Quantity Description 1 EasyLine O2 gas analyzer 1 Power cord 1 6-pin female multipoint connector for analog outputs 1 12-pin female multipoint connector for digital outputs 4 Adhesive pads for mounting the device on a table 1 Fine filter (Part No ) 2 Operator's manuals (English and German) 1 CD-ROM with software and documentation 1 Analyzer data sheet (inside the device) 1 Thermal link (inside the device) 1 Thermal link replacement instructions (inside the device) 8 EasyLine O2 Operator s Manual 42/ EN

9 Identification Plate Figure 1 Identification Plate (Example) ABB Made in Germany EasyLine O2 F.-No Serial number Mains VAC, Hz, Power supply voltage, 90 VA frequency, consumption Output 4 20 ma, max. 750 Ω Output current, load Sample Components O Vol% Sample component and measuring range Pressure Sensor no/yes Pressure sensor installed Analyzer Data Sheet Contents of the analyzer data sheet The analyzer data sheet contains the following information: Order number (A-No.) Part number (P-No.) Serial number (F-No.) Production date Power supply (voltage, frequency, consumption) Software version Sample components and measuring ranges Serial numbers of installed components Where is the analyzer data sheet located? The analyzer data sheet is in a sleeve affixed to the back of the Sensor CPU board attachment plate (see Figure 7 on page 46) 42/ EN EasyLine O2 Operator s Manual 9

10 Installation Site Requirements Short gas paths The gas analyzer should be installed as close as possible to the sampling site. Locate the gas preparation and calibration modules as close as possible to the gas analyzer. (See "Complete Analysis Apparatus", page 51.) Adequate air circulation Provide for adequate natural air circulation around the gas analyzer. Avoid heat buildup. The entire surface of the housing is used to dissipate heat. Environmental conditions Air pressure hpa Ambient temperature In operation: +5 to +50 C Storage and shipping: 25 to +65 C Relative humidity max. 75 % Vibration The installation site must be free of vibrations. Check Sample Gas Path Seal Integrity Why should seal integrity be checked? Sample gas path seal integrity is verified at the factory. Since the gas analyzer can be adversely affected during shipping, we recommend checking it at the installation site. Seal integrity checking is described on page EasyLine O2 Operator s Manual 42/ EN

11 Chapter 2 Install the Gas Analyzer Install the Gas Analyzer Installation type The gas analyzer is intended for tabletop operation. Tabletop operation Attach the adhesive pads supplied with the unit to the bottom of the housing. Rack mounting The four M5 tapped holes on the bottom of the housing can be used for rack mounting (see Figure 2 on page 12). 42/ EN EasyLine O2 Operator s Manual 11

12 Dimensional Diagram Figure 2 Dimensional diagram (dimensions in mm) 12 EasyLine O2 Operator s Manual 42/ EN

13 Chapter 3 Connect the Gas Lines Connection Diagram Figure 3 Gas connections on rear of gas analyzer Sample gas inlet Sample gas outlet The gas connections are threaded fittings for DN 4/6 tubing. 42/ EN EasyLine O2 Operator s Manual 13

14 Gas Inlet and Outlet Conditions Gas inlet conditions Temperature +5 to +50 C Pressure p e 2 to 100 hpa (maximum 1000 hpa) Flow 20 to 60 l/h Pressure drop < 2 hpa at 60 l/h N 2 Definition p e = p abs p amb where p e = excess pressure, p abs = absolute pressure, p amb = atmospheric pressure Sample gas dew point The sample gas dew point should be at least 5 C below the lowest ambient temperature throughout the sample gas path. Otherwise a sample gas cooler or condensate trap is required. Corrosive gases Consultation with ABB Analytical is required if the sample gas contains Cl 2, HCl, HF, NH 3 or other corrosive components. Combustible gases When measuring combustible gases the sample gas path seal integrity should be checked regularly (see page 37). Gas outlet conditions The outlet pressure should be equal to atmospheric pressure. 14 EasyLine O2 Operator s Manual 42/ EN

15 Connect the Gas Lines Connect the gas lines Step Action 1 Square cut the tubing. 2 Slide the knurled nut and clamping ring over the end of the tubing as shown in the drawing. 3 Slide the tubing end up to the stop on the bushing. 4 Attach the knurled nut and tighten it by hand. Install a fine filter Install a fine filter ahead of the sample gas inlet. A fine filter (Part No ) is supplied with the gas analyzer. When installing the fine filter note the direction of flow indicated by the arrow on the housing. Install a flow meter Install a flow meter or monitor with a needle valve ahead of the sample gas inlet in order to adjust (20 to 60 l/h) and monitor the sample gas flow. Provide for gas system flushing Install a shutoff valve in the gas inlet line (this is definitely recommended for pressurized gases) and provide a means of flushing the gas line system via the sampling port with an inert gas, e.g. nitrogen. Evacuate exhaust gases F F Exhaust gases should be routed to the atmosphere or to an exhaust pipe directly or via the shortest possible large-diameter line. Do not route exhaust gases via flow reducers or shutoff valves. Process corrosive, toxic or combustible exhaust gases in an appropriate manner. Start the sample gas supply only when the gas analyzer has reached room temperature and after the warm-up phase has ended (see page 21). Otherwise the sample gas can condense in a cold analyzer. Note the gas inlet conditions (see page 14). 42/ EN EasyLine O2 Operator s Manual 15

16 Chapter 4 Connect the Electrical Leads Safety Precautions CAUTION! Follow all applicable national safety regulations for the preparation and operation of electrical devices as well as the following safety precautions. The protective lead should be attached to the protective lead connector before any other connection is made. The protective lead connection is assured when the power cable supplied is used. The gas analyzer can be hazardous if the protective lead is interrupted inside or outside the gas analyzer or if the protective lead is disconnected. Current-bearing components can be exposed when covers or parts are removed, even if this can be done without tools. Current can be present at some connection points. Never use patched fuses. Do not short-circuit the fuse holder contacts. Install a circuit breaker near the gas analyzer in order to completely isolate the unit from the power supply. Mark the breaker so that its relationship to the protected device is clear. 16 EasyLine O2 Operator s Manual 42/ EN

17 Connection Diagram Figure 4 Electrical connections on rear of gas analyzer DO/-X RS232/-X2 AO/-X4 RS485/-X3 DO/-X1 RS232/-X2 RS485/-X3 AO/-X4 Digital outputs Pins 1 3 Overall status signal Pins 4 6 Alarm signal 1 Pins 7 9 Alarm signal 2 floating double-throw contacts, max. contact load rating 30 VDC/1 A Relays are shown in the unpowered state. The unpowered state is the failure mode ("fail safe"). RS-485 and RS-232 interfaces for transferring measured values and status signals to host systems, e.g. to Windows applications via a DDE server. Modbus slave protocol in RTU (remote terminal unit) mode. It can use either the RS-485 or RS-232 interface. Configuration of the Modbus connection is described on page 29. Analog output Pins 1, 2 Sample component 4 to 20 ma, galvanically separated from ground, freely connectable to ground, max. gain vs. local protective ground potential 50 V, max. working resistance 750 Ω. The output signal cannot be less than 0 ma. 42/ EN EasyLine O2 Operator s Manual 17

18 Connect the Signal Leads Material required The wire type required depends on the length of the leads and the planned current load. The maximum conductor section is 1.5 mm 2, or 16 AWG. The matching plugs (female connectors) for the analog and digital output terminal strips are part of the normally supplied accessories. Analog outputs At the factory two jumpers are inserted in the matching plugs (female connectors) for the analog outputs. If no signal leads are installed, these jumpers close the output current circuit and prevent the display of status message 30 "Open Circuit in Analog Output" (see page 41). Modbus The maximum line length is 1200 meters for RS-485 and 15 meters for RS-232. Configuration of the Modbus connection is described on page 29. For detailed Modbus information see the "EasyLine Modbus and M-DDE Server" technical information sheet (Publication No. 30/ EN). Connect the signal leads Step Action 1 Connect the leads to the matching plugs (female connectors) according to the connection diagram (see page 17). 2 Connect the matching plugs to the terminal strips. 18 EasyLine O2 Operator s Manual 42/ EN

19 Connect the Power Supply Leads Power supply Input voltage Power consumption Connector 85 to 250 VAC, 47 to 63 Hz Max. 90 VA 3-prong grounded instrument plug per IEC 320/C14 Material required The gas analyzer is supplied with a 2-meter long power cord fitted with a 3-prong grounded plug. If this power cord is not used, the wiring material required will depend on the length of the leads and the planned current load. Connect the power supply leads Step Action 1 Make sure the power supply leads have an adequately dimensioned protective device (breaker). 2 Install a breaker in the power supply line or a switched receptacle near the gas analyzer to make sure the analyzer can be completely isolated from the power source. Mark the breaker so that its relationship to the protected device is clear. 3 Connect the power cord supplied to the gas analyzer power supply connection. 4 Connect the other end of the power cord to the power source. The gas analyzer starts operation. F Start the sample gas supply only when the gas analyzer has reached room temperature and after the warm-up phase has ended (see page 21). Otherwise the sample gas can condense in a cold analyzer. Note the gas inlet conditions (see page 14). 42/ EN EasyLine O2 Operator s Manual 19

20 Chapter 5 Start the Gas Analyzer Check the Installation Check the installation Step Action 1 Are all gas lines correctly connected? (see page 15) 2 Are all signal and interface leads correctly routed and connected? (see page 18) 3 Are all devices needed for gas preparation, calibration and exhaust processing correctly connected and ready for use? Purge the Sample Gas Path Prestart purge For the measurement of combustible gases the sample gas path must be purged before the gas analyzer is started. This should prevent the ignition of any explosive gas/air mixtures in the gas paths when the power supply is turned on. Purge gas Inert gas, e.g. nitrogen Purge gas flow max. 60 l/h Purge time approx. 40 sec. 20 EasyLine O2 Operator s Manual 42/ EN

21 Start the Gas Analyzer Start the gas analyzer Step Action 1 Activate the gas analyzer power supply with the externally mounted circuit breaker. (DV\/LQH2 29RO 2 The screen initially displays the gas analyzer name and the software version. 3 After a brief time the screen switches displaying measured values. Part of the screen will blink to indicate an error condition that is normal during the warm-up phase (see page 39). 4 Check the parameters and adjust as needed (see page 25). 5 After the warm-up phase ( 1 hour) the gas analyzer is ready to operate. 6 Calibrate the gas analyzer (see page 31). 7 Start the sample gas flow (20 to 60 l/h). F All screen displays shown in this manual are examples. As a rule, actual displays on the device will differ. 42/ EN EasyLine O2 Operator s Manual 21

22 Chapter 6 Operate the Gas Analyzer Readout and Controls Figure 5 Screen and keys Screen The lighted LCD screen consists of two lines of 20 characters each. Display in measuring mode (Examples) 29RO 26SDQ In measuring mode the screen displays: The sample component name The measured value in digits The physical unit for the measured value Press the -key to display the measured value as a percentage of the measuring range (span). F All screen displays shown in this manual are examples. As a rule, actual displays on the device will differ. Continued on next page 22 EasyLine O2 Operator s Manual 42/ EN

23 Readout and Controls, continued Number of places after the decimal point The number of places after the decimal point depends on the size of the measuring span (in physical units): Span < < < Places Fault displays Part of the screen blinks in measuring mode to indicate that the gas analyzer has experienced a fault. See "Status Messages, Troubleshooting" on page 39 for details on faults, causes and corrective actions. Keys The gas analyzer is operated using two arrow keys, the Enter key and the Back key. The Ö and keys are used to select a menu item change a value The Enter key is used to activate a menu item accept an edited value activate a function The Back key is used to Return to the first item in a menu or to a previous menu cancel the editing of a value Time-out If the operator does not use a key during a period longer than one minute during calibration or parameter setup, the gas analyzer will automatically revert to displaying measured values (time-out). The time-out function is deactivated if the user changes the value of a parameter or activates calibration. 42/ EN EasyLine O2 Operator s Manual 23

24 Menu Menu The EasyLine O2 menu structure is summarized below. The menu text appears only in English. Menu structure (Overview) 0HDVXUHGYDOXHGLVSOD\ &DOLEUDWH &DOLEUDWHFRPSRQHQW =HURFDOLEUDWLRQ 6SDQFDOLEUDWLRQ &DOLEUDWLRQUHVHW 3UHVVXUHDGMXVWPHQW 6HWWLQJSDUDPHWHUV 3DUDPHWHUVFRPSRQHQW =HURVHWSRLQW 6SDQVHWSRLQW )LOWHU 0HDVXULQJUDQJH 3DUDPHWHUVOLPLW /LPLW /LPLW /LPLWK\VWHUHVLV /LPLWK\VWHUHVLV 3DUDPHWHUVPRGEXV 0RGEXVEDXGUDWH 0RGEXVDGGUHVV 0RGEXVW\SH,QIRUPDWLRQ 'ULIW 'HOWDGULIW 6RIWZDUHYHUVLRQ (UURUOLVW 24 EasyLine O2 Operator s Manual 42/ EN

25 Chapter 7 Set Parameters Fundamentals General procedure The normal procedure for setting parameters is: 1. Press Enter to access the menu. 2. Select the Parameters menu item with the Ö or key. 3. Activate the Parameters menu item with the Enter key. 4. Change the parameters with the Ö or key. 5. Confirm the change with the Enter key or cancel the change with the Back key. 6. Use the Back key to return to the previous menu. Only parameters that blink in the display can be edited. The following example should clarify the details of this general description. Step Action Key Display Key 29RO 1 Access the menu. Enter &DOLEUDWH 2 Select the "Setting Ö 6HWWLQJSDUDPHWHUV Enter parameters" menu. 3 Select the submenu. Ö 3DUDPHWHUVFRPSRQHQW Enter 2 4 Select the parameter to be Ö =HURVHWSRLQW Enter changed. 9RO2 5 Edit the parameter value and Ö =HURVHWSRLQW Enter confirm the change. 9RO2 6 Return to the previous menu. =HURVHWSRLQW Back 9RO2 7 Return to the previous menu. 3DUDPHWHUVFRPSRQHQW Back 2 8 Return to the measured value display. 6HWWLQJSDUDPHWHUV Back 29RO 42/ EN EasyLine O2 Operator s Manual 25

26 Component Parameters Zero set point =HURVHWSRLQW 9RO2 =HURVHWSRLQW 9RO2 Test gas concentration set point for zero calibration Value range: Reference measuring range 1) start minus 25% of span to reference measuring range end Span set point 6SDQVHWSRLQW 9RO2 6SDQVHWSRLQW 9RO2 Test gas concentration set point for span calibration Value range: Reference measuring range 1) start to measuring range end plus 30 % of span Step interval The set point adjustment step interval is 0.2% of the span of the range in use. Set points for suppressed measuring range The zero and span set point values should be as close as possible to the limits of the suppressed measuring range. Filter (T90 time) )LOWHU VHFVHF )LOWHU VHFVHF )LOWHU VHFVHF )LOWHU VHFVHF Non-linear filter with two low pass time constants and switching threshold Time constant for constant measured value. Value range: 0 to 60 sec. Time constant for measured value changes. Value range 0 to 60 sec. Switching threshold as % of span of reference measuring range 1). On exceeding this value the time constant for measured value changes is effective. Value range: 0 to 9.99 % Recommendation The ratio of the time constant for constant measurement values to the time constant for measurement value changes should be 5:1. 1) For an explanation of the term "Reference Measuring Range" see page 27. Continued on next page 26 EasyLine O2 Operator s Manual 42/ EN

27 Component Parameters, continued Measuring range 0HDVXULQJUDQJH 9RO 0HDVXULQJUDQJH 9RO 0HDVXULQJUDQJH 9RO Measuring range Measuring range start Value range: Within the reference measuring range Measuring range end Value range: Within the reference measuring range Step interval The measuring range adjustment step interval is 0.5 Vol.-%. F Calibration of the measuring range should be verified after changing measuring range limits. Reference Measuring Range The gas analyzer has a physical measuring range ("reference measuring range"). The limits of this range are 0 Vol.-% O 2 and 100 Vol.-% O 2. Measuring Range Notes One measuring range can be selected within the limits of the reference measuring range. It is factory-set and calibrated to 0-25 Vol.-% O 2. The smallest measuring range is 0 to 2 Vol.-% O 2 ; the largest is 0 to 100 Vol.-% O 2. Measuring ranges within ignition limits should not be attempted. Measuring Ranges with Suppressed Zero-Point If the gas analyzer is ordered with a suppressed measuring range, a pressure sensor is installed at the factory (see Page 35). The suppressed measuring range is factory-set and calibrated to Vol.-% O 2. It can be adjusted within the limits of the reference measuring range; the smallest span is 2 Vol.-% O 2. The zero and span set point values should be as close as possible to the limits of the suppressed measuring range. 42/ EN EasyLine O2 Operator s Manual 27

28 Limit Parameters Limit Parameters Two limits can be set. Switching hysteresis can be set for each of the limits. Limit /LPLW2 2))9RO /LPLW2 2))9RO /LPLW2 2))9RO /LPLW2 2))9RO Limit of the sample component displayed Activation. Value range: ON or OFF Direction of effect. Value range: </> = Alarm on under/overflow of limit Limit. Value range: Within the reference measuring range Step interval The limit adjustment step interval is 0.1% of the span of the reference measuring range. Switching hysteresis /LPLWK\VWHUHVLV 9RO /LPLWK\VWHUHVLV 9RO Switching hysteresis Extent of switching hysteresis. Value range: Within the reference measuring range Step interval The hysteresis adjustment step interval is 0.01% of the span of the reference measuring range. 28 EasyLine O2 Operator s Manual 42/ EN

29 Modbus Parameters Modbus parameters Modbus parameters are set prior to connecting the gas analyzer to a PC or process control system via a Modbus link. Baud rate 0RGEXVEDXGUDWH 0RGEXVEDXGUDWH Baud rate Value range: 9600 or Address 0RGEXVDGGUHVV 0RGEXVDGGUHVV Address Value range: 1 to 255 Interface type 0RGEXVW\SH 56 0RGEXVW\SH 56 Interface type Value range: RS232 or RS485 F For detailed Modbus information see the "EasyLine Modbus and M-DDE Server" technical information sheet (Publication No. 30/ EN). 42/ EN EasyLine O2 Operator s Manual 29

30 Factory and User Settings Factory and user settings The following table lists the parameter settings made at the factory. The operator can enter any on-site or application-specific parameter changes in the column at the right. Parameter Factory Setting User Setting 3DUDPHWHUVFRPSRQHQW =HURVHWSRLQW 0 Vol% or 98 Vol% 6SDQVHWSRLQW 25 Vol% or 100 Vol% )LOWHU 3 sec 0 sec 0.1 % 0HDVXULQJUDQJH 0 to 25 / 98 to 100 Vol% 3DUDPHWHUVOLPLW /LPLW OFF < 0 /LPLW OFF < 0 /LPLWK\VWHUHVLV 0 /LPLWK\VWHUHVLV 0 3DUDPHWHUV0RGEXV 0RGEXVEDXGUDWH RGEXVDGGUHVV 1 0RGEXVW\SH RS EasyLine O2 Operator s Manual 42/ EN

31 Chapter 8 Calibrate the Gas Analyzer Test Gases Test gases Zero calibration Nitrogen (N 2 ) Span calibration Test gas with concentration in the selected measurement range Measuring ranges with Zero-point and end-point should only suppressed zero-point be calibrated with test gases with concentrations in the selected measuring range. Test gas dew point The test gas dew point must be nearly identical to the sample gas dew point. Test gas supply Test gases should be connected to the sample gas inlet (e.g. using a multiple-path valve). 42/ EN EasyLine O2 Operator s Manual 31

32 Calibrate Sample Component Wait until end of warm-up phase The gas analyzer should only be calibrated after the end of the warm-up phase (that takes 1 hour). F To optimize accuracy, perform a zero calibration prior to calibrating the span value. Current output The signal at the analog output (current output) tracks measured during calibration value changes during calibration. Limits during calibration If limits are activated, they are also active during calibration. Status signal During calibration, the status signal Maintenance Mode is during calibration output on "overall status" digital output and via Modbus. Calibration via Modbus For information about calibration via Modbus see the "EasyLine Modbus and M-DDE Server" technical information sheet (Publication No. 30/ EN). Continued on next page 32 EasyLine O2 Operator s Manual 42/ EN

33 Calibrate Sample Component, continued Step Action Key Display Key 1 Select the Calibrate menu. Enter &DOLEUDWH Enter 2 Select the sample component. Ö &DOLEUDWHFRPSRQHQW Enter 2 3 Select Zero calibration. Ö =HURFDOLEUDWLRQ Enter 2 4 Check the zero set point and Ö =HURVHWSRLQW Enter adjust as needed. 9RO2 5 Turn on the zero gas supply. &RQQHFW]HURJDV Enter 6 Start calibration if the measured 0HDVYDOXHVWDEOH" value reading is stable. 9RO2 7 Calibration in progress. :DLWFDOLVUXQQLQJ Enter 8 Accept calibration or 0HDVYDOXHRN" Enter 9RO2 reject calibration. Back 9 Select Span calibration. Ö 6SDQFDOLEUDWLRQ Enter 2 10 Check the span set point and Ö 6SDQVHWSRLQW Enter adjust as needed. 9RO2 11 Turn on the span gas supply. &RQQHFWVSDQJDV Enter 12 Start calibration if the measured value reading is stable. 0HDVYDOXHVWDEOH" 9RO2 13 Calibration in progress. :DLWFDOLVUXQQLQJ 14 Accept calibration or 0HDVYDOXHRN" 9RO2 reject calibration. Enter Enter Back This display shows that an error occurred during calibration and that calibration was unsuccessful. $PSOLILFDWLRQHUURU 9RO2 In this case, press Enter to return to the start of zero or span calibration, check the test gas concentration, correct as needed and repeat the calibration process. 42/ EN EasyLine O2 Operator s Manual 33

34 Perform Calibration Reset When should a calibration reset be performed? Perform a calibration reset when the gas analyzer can no longer be calibrated with normal means. A possible cause of this is calibration with the wrong test gases. What does the calibration reset do? A calibration reset returns the gas analyzer's calibration to factory default values. Additionally, the offset drift and amplification drift are electronically returned to initial calibration values (see page 36). Step Action Key Display Key 1 Select the Calibrate menu. Enter &DOLEUDWH Enter 2 Select the sample component. Ö &DOLEUDWHFRPSRQHQW 2 3 Select Calibration reset. Ö &DOLEUDWLRQUHVHW 2 4 Start the calibration reset. &DOLEUDWLRQUHVHW 6WDUWFDOUHVHW 5 Calibration reset is in progress. :DLWFDOLVUXQQLQJ Enter Enter Enter 6 Calibration reset has ended. &DOLEUDWLRQUHVHW 2 7 Press the Back key to return to displaying measured values. 34 EasyLine O2 Operator s Manual 42/ EN

35 Pressure Correction Air pressure effect Pressure Correction Integrated Pressure Sensor for Suppressed Measuring Ranges A change in atmospheric pressure by a certain amount will affect measured value readings. The gas analyzer is calibrated at the factory for an air pressure of 1013 hpa. If the air pressure at the operating site differs from 1013 hpa, the actual pressure can be corrected by manually entering a value (Calibration instructions, steps 1-3). If the gas analyzer is ordered with a suppressed measuring range, a pressure sensor is installed at the factory. The effects of air pressure changes on the measurement value are minimized by automatic internal pressure correction. Pressure Sensor Calibration F F F If the indication of the internal pressure sensor differs from the current air pressure, the pressure sensor can be calibrated. If the gas analyzer is ordered with a suppressed measuring range with a 20 Vol.-% O 2 span, pressure sensor calibration should be performed using the test and calibration software, not on the device directly. The pressure sensor is connected to the sample gas outlet line via a tee. To prevent the sample gas pressure from causing a false pressure reading, the sample gas flow should be stopped when calibrating the pressure sensor. After calibrating the pressure sensor the zero and span points must be checked and recalibrated as needed. Step Action Key Display Key 1 Select the Calibrate menu. Enter &DOLEUDWH Enter 2 Select Pressure adjustment. Ö 3UHVVXUHDGMXVWPHQW Enter 3 Set the pressure set point. Ö 3UHVVXUHVHWSRLQW K3D 4 Start adjustment if the measured 0HDVYDOXHVWDEOH" value reading is stable. K3D 5 Adjustment in progress. :DLWFDOLVUXQQLQJ 6 Accept the measured value. 0HDVYDOXHRN" K3D 7 Press the Back key to return to displaying measured values. Enter Enter Enter 42/ EN EasyLine O2 Operator s Manual 35

36 Drift Reading Drift 'ULIW2 RIIVDPSO Offset and amplification drift values are determined cumulative and based on the last initial calibration performed. Delta drift 'HOWDGULIW2 RIIVDPSO Offset and amplification delta drift values are determined based on the last and next-to-last calibration performed via the Modbus. F Drifts are displayed as a percentage of the user-set measuring range. 36 EasyLine O2 Operator s Manual 42/ EN

37 Chapter 9 Maintenance Check Gas Path Seal Integrity When should seal integrity be checked? Gas path seal integrity should be checked periodically. It should be checked regularly when measuring combustible gases. It should always be checked after a gas path has been opened inside the gas analyzer. Material required Quantity Description 1 Pressure gauge 1 Tubing, approx. 1 meter in length 1 Tee with shutoff valve Air or nitrogen CAUTION! If the seal integrity test is to be carried out with air and there is the possibility of a combustible gas being present in the gas path or if a combustible gas is to be introduced later, the gas path should first be purged with nitrogen. Otherwise the seal integrity test can be performed with nitrogen. Check gas path seal integrity (see Figure 6) Step Action 1 Seal off the sample gas outlet. 2 Use tubing to connect a tee fitted with a shutoff valve to the sample gas inlet. 3 Connect the free end of the tee to the pressure gauge. 4 Blow air or nitrogen through the shutoff valve until the gas path is pressurized to a p e of approx. 50 hpa (= 50 mbar). F Max. excess pressure p = 150 hpa (= 150 mbar). e 5 Close the shutoff valve. The pressure should not change measurably in 3 minutes. A sharper pressure drop is a sign of a leak in the gas path. Continued on next page 42/ EN EasyLine O2 Operator s Manual 37

38 Check Gas Path Seal Integrity, continued Figure 6 Seal integrity testing 50 hpa Air or Nitrogen 38 EasyLine O2 Operator s Manual 42/ EN

39 Chapter 10 Status Messages, Troubleshooting Blinking Screen Blinking screen Blinking of part of the screen in measuring mode indicates that the gas analyzer or process system has experienced a fault. Measured value exceeds/ is below measuring range limits 29RO The measured value reading blinks if the measured value of a sample component is more than 100% below the range limits or more than 130% above these limits. Maintenance request 29RO The sample component name display blinks if a Maintenance request condition has occurred. The gas analyzer is in a state that will soon require user intervention. The measurement value is valid. Failure 29RO The sample component name and measured value displays blink if a failure condition has occurred. The gas analyzer is in a state that immediately requires user intervention. The measurement value is invalid. Error list (Example) (UURUOLVW2 (UURUOLVW2 QRHUURUV In the event of faults, the status message numbers are displayed in the(uuru/lvwmenu item for each sample component (see page 40). To select the menu item, press the -key twice. This display indicates there are no errors present. 42/ EN EasyLine O2 Operator s Manual 39

40 Status Messages No. Status Problem Reaction / Solution 1 M F No new measured values from analog/digital converter. 2 M F Measured value exceeds the analog/digital converter value range. 3 M Offset drift exceeds half the permissible range. 4 M F Offset drift exceeds permissible range. Call for service. Check the plug connections in the gas analyzer. Call for service. Observe the drift value. If the drift value is under the value shown in the Specifications (see page 47), the sample value is correct. If drift exceeds this value, call for service. Call for service. Perform initial calibration (only possible with Optima TCT). Note: Permissible offset drift range: 150 % of measuring range. Drift reading see page M Amplification drift exceeds half the permissible range. 6 M F Amplification drift exceeds permissible range. Observe the drift value. If the drift value is under the value shown in the Specifications (see page 47), the sample value is correct. If drift exceeds this value, call for service. Call for service. Perform initial calibration (only possible with Optima TCT). Note: Permissible amplification drift range: 50% of sensitivity. Drift reading see page M Delta offset drift exceeds permissible range. 8 M Delta amplification drift exceeds permissible range. Note: Delta drift reading see page M F An error occurred during calculation of the measured value. 10 Measured value more than 100% below measuring range limits. 11 Measured value more than 130 % above measuring range limits. Only generated during calibration via Modbus. Check calibration plausibility. Switch power supply off and on again. Call for service. Continued on next page 40 EasyLine O2 Operator s Manual 42/ EN

41 Status Messages, continued No. Status Problem Reaction / Solution 12 M Temperature compensation measured value exceeds the analog/digital converter value range. 13 M Pressure compensation measured value exceeds the analog/digital converter value range. 14 M Temperature controller measured value exceeds the analog/digital converter value range. 15 M Temperature above or below upper and/or lower limit M Temperature above or below upper and/or lower limit M F IIC bus Display fault 22 M F IIC bus I/O fault Check the plug connections in the gas analyzer. Call for service. Check the plug connections in the gas analyzer. Check the sample gas pressure. Call for service. Check the plug connections in the gas analyzer. Call for service. Status messages during the warmup phase. If the status message appears after warm-up: Check if the permissible ambient temperature range is being maintained (see page 10). Check the connecting leads and plug connections. Check the line seating in the insulated jackets. Check the thermal link and replace as necessary. Switch power supply off and on again. Call for service. 30 M Broken analog output line. Check the analog output lines. No. Number of status message displayed in error list Status M Maintenance Request: Status is displayed on the screen and output via Modbus F Failure: Status is displayed on the screen and output on "overall status" digital output and via Modbus. F Maintenance Mode: Status is output during calibration on "overall status" digital output and via Modbus. 42/ EN EasyLine O2 Operator s Manual 41

42 Faults Flow Fault Cause Gas lines or filter dirty, plugged or leaking Corrective Action Disconnect the gas analyzer from the gas preparation system. Blow out the gas lines with compressed air or clear them mechanically. Change the filter elements and packings. Check gas line seal integrity. Gas analyzer gas paths crimped or leaking Disconnect the gas analyzer from the gas preparation system. Check the gas analyzer gas lines for crimping or loose connections. Check the integrity of the gas analyzer gas paths (see page 37 for instructions). Outlet pressure not equal to atmospheric pressure The outlet pressure should be equal to atmospheric pressure. Exhaust gases should be routed to the atmosphere or to an exhaust pipe directly or via the shortest possible large-diameter line. Do not route exhaust gases via flow reducers or shutoff valves. Unstable measured value reading Cause Vibration Corrective Action Take measures to reduce vibration. Increase the time constant (see page 26). Gas path leakage Check the integrity of the gas analyzer gas paths (see page 37 for instructions). 42 EasyLine O2 Operator s Manual 42/ EN

43 Call for Service Who to contact for further help? Contact your local ABB service representative or ABB Service, Telephone: , Telefax: , Before you call for service... Before calling for service because of a problem or status message, determine whether there actually is an error and whether the gas analyzer is actually operating out of specifications (see page 47). When you call for service... F When calling for service because of a problem or status message have the following information available: The gas analyzer serial number (F-No.) Found on the identification plate affixed to the back of the analyzer and on the analyzer data sheet. The gas analyzer Software Version Found in the,qirupdwlrqmenu item. An exact description of the problem or status as well as the status message number. This information will enable service personnel to help you quickly. When arranging for service due to a problem or status message, always have the analyzer data sheet available as it contains valuable information that can help to identify the problem. When returning the gas analyzer for service... If the gas analyzer is returned to the Service Department, e.g. for repair, please indicate which gases have been supplied to the gas analyzer. This information is needed so that service personnel can take any safety precautions required for harmful gases. 42/ EN EasyLine O2 Operator s Manual 43

44 Chapter 11 Take the Gas Analyzer Out of Service and Pack it Take the Gas Analyzer Out of Service Take the gas analyzer out of service Step Action Temporary Shutdown: 1 Turn off the sample gas supply. 2 Purge gas lines and the gas analyzer gas paths with dry fresh air or nitrogen for at least 5 minutes. 3 Turn off the gas analyzer power supply. Additional Steps for Long-Term Shutdown: 4 Remove the gas lines from the gas analyzer ports. Tightly seal the gas ports. 5 Remove the electrical lines from the gas analyzer connections. Ambient temperature Ambient temperature for storage and shipping: 25 to +65 C 44 EasyLine O2 Operator s Manual 42/ EN

45 Pack the Gas Analyzer Packing Step Action 1 Tightly seal the gas ports. 2 If the original packaging is not available, cover the gas analyzer with bubble paper or corrugated cardboard. 3 Place the gas analyzer in an adequately sized box lined with cushioning material (foam or similar substance). F The cushioning material's thickness should be adequate for the gas analyzer's weight and method of shipment. 4 Mark the box as "Fragile Material". Additional steps for overseas shipping Step Action 1 Add a drying agent (e.g. silica gel) and wrap the gas analyzer airtight in an additional 0.2-mm thick polyethylene sheet. F The amount of drying agent used should be adequate for the package volume and the planned shipping time (at least 3 months). 2 Also wrap the box in a layer of protective waterproof wrapping. Ambient temperature Ambient temperature for storage and shipping: 25 to +65 C F If the gas analyzer is returned to the Service Department, e.g. for repair, be sure to indicate which gases have been supplied to the gas analyzer. This information is needed so that service personnel can take any safety precautions required for harmful gases. 42/ EN EasyLine O2 Operator s Manual 45

46 Appendix Gas Analyzer Structure Figure 7 EasyLine O2 top view Power supply 2 Sensor-CPU board 3 O 2 detector 4 Pressure sensor 46 EasyLine O2 Operator s Manual 42/ EN

47 Specifications Measuring principle Smallest measuring range Note Stability Paramagnetic behavior of oxygen Magnetomechanical oxygen analyzer with short T 90 time 0 to 2 Vol.-% O 2 The following measurement data are based on N 2 as the associated gas. For other gas mixtures, the data shown can only be assumed to be attainable if the composition of the mixtures is known and if ABB Analytical has validated the suitability of the gas analyzer for the measuring task. The following data apply on condition that all influence effects such as flow, temperature and air pressure are constant. Linearity deviation 0.5 % of span Repeatability 0.5 % of span Zero drift 0.03 Vol.-% O 2 per week Following prolonged transport and storage time the drift can be higher during the first weeks of operation. Sensitivity drift Output signal variations Detection limit 0.1 Vol.-% O 2 per week or 1 % of measurement value per week (not cumulative), whichever is smaller. ±0.5 % of smallest measurement range span at 2 σ and electronic T90 time (static/dynamic) = 3/0 sec 0.5 % of span Influence effects Flow effect Associated gas effect Flow rate in the l/h range: 0.1 Vol.-% O 2 The effect of associated gases as a shift of the zero-point expressed in Vol.-% O 2 can be estimated using the approximate values in the following table: Continued on next page 42/ EN EasyLine O2 Operator s Manual 47

48 Specifications, continued Associated Gas Concentration 100 Vol.-% Zero-Point Shift Hydrogen H Vol.-% O 2 Argon Ar 0.26 Vol.-% O 2 Helium He Vol.-% O 2 Neon Ne Vol.-% O 2 Nitrogen N 2 ±0.00 Vol.-% O 2 Nitrogen Oxide NO Vol.-% O 2 Nitrogen Dioxide NO Vol.-% O 2 Nitrous Oxide N 2 O 0.20 Vol.-% O 2 Carbon Monoxide CO 0.01 Vol.-% O 2 Carbon Dioxide CO Vol.-% O 2 Ethane C 2 H Vol.-% O 2 Ethylene C 2 H Vol.-% O 2 Methane CH Vol.-% O 2 Propane C 3 H Vol.-% O 2 Propylene C 3 H Vol.-% O 2 Temperature effect Air pressure effect Ambient temperature in the range +5 to +50 C: At zero-point: 0.02 Vol.-% O 2 per 10 C On sensitivity: 0.2 % of measured value per 10 C At zero-point: No effect On sensitivity with no pressure correction: 1 % of measured value per 1 % air pressure change. The air pressure at the installation site can be adjusted manually in the analyzer. On sensitivity with automatic pressure correction using integrated pressure sensor (for measurement ranges with suppressed zero point): 0.01 % of measurement value per 1 % pressure change or Vol.-% O 2 per 1 % pressure change, whichever is greater Pressure Sensor Working Range: p abs = hpa Continued on next page 48 EasyLine O2 Operator s Manual 42/ EN

49 Specifications, continued Power supply effect Voltage and frequency in permissible range: 0.2 % of span Position effect Zero-point shift 0.05 Vol.-% O 2 per 1 deviation from horizontal location. Position has no effect on the hard-mounted unit. Dynamic Warm-Up Time 1 hour response T 90 Time T 90 5 s at a sample gas flow of 60 l/h and electronic T90 time (static/ dynamic) = 3/0 sec, gas change from N 2 to air Materials in contact with the sample medium Analyzer (Sample Chamber) Gas lines and connectors Stainless steel , glass, platinum, rhodium, epoxy resin FPM (Viton), PP Housing Electrical safety Design Housing protection type Housing material 1/2 19-inch housing for table use IP 20 per IEC 529 Base support: Sheet aluminum, Cover: Sheet steel Housing color Black (RAL 9005) Dimensions See dimensional drawing on page 12 Weight approx. 8 kg Tested per EN / EC Protection class I Overvoltage category Power supply: II Signal inputs and outputs: II Pollution rating 2 Safe isolation Power supply galvanically isolated from other circuits by means of reinforced or double insulation. Functional low voltage (PELV) on lowvoltage side Continued on next page 42/ EN EasyLine O2 Operator s Manual 49

50 Specifications, continued Electromagnetic Noise immunity Tested per EN compatibility RF suppression Class B per EN Mechanical stress In its original packaging, the gas analyzer will withstand normal shipping conditions, e.g. as found in rail transport. 50 EasyLine O2 Operator s Manual 42/ EN

51 Complete Analysis Apparatus Analysis apparatus An analysis apparatus generally consists of two groups of devices: System components take the sample gas from the process, prepare it and supply it to the analysis arrangement. The gas analyzer measures concentrations of sample gas components and converts them to an electrical signal. Sample gas properties The sample gas taken from the process can in most cases be processed by the gas analyzer with no further preparation. Excessively high dust content, temperature and dew point, as well as excess or insufficient pressure and, finally, the presence of interference components in the sample gas can adversely affect gas analyzer operation and cause erroneous measurement results. System components System components such as the sampling probe, sample gas line, sample gas cooler, pumps and filters work to assure that sample gas inlet conditions satisfy the requirements of the associated gas analyzer and provide reliable results regardless of process considerations and local conditions. 42/ EN EasyLine O2 Operator s Manual 51

52 Index Page Address (Modbus) 29 Analyzer data sheet 9 Baud rate (Modbus) 29 Calibration 31 Calibration reset 34 Drift reading 36 Sample component calibration 32 Set points 26 Test gases 31 Via Modbus 32 Complete analysis apparatus 51 Connecting Gas lines 15 Power supply leads 19 Signal leads 18 Connection diagram Electrical connections 17 Gas connections 13 Decimal places 23 Dimensional diagram 12 Display 22 Measuring mode 22 Drift 36 Electrical connections 17 Error list 39 Faults 42 Filter (T90 time) 26 Fine filter installation 15 Flow meter installation 15 Gas connections 13 Gas inlet conditions 14 Gas line connection 15 Hysteresis (Limit) 28 Identification plate 9 Installation 11 Installation site 10 Interface type (Modbus) 29 Items delivered 8 Keys 23 Limit 28 Lowpass 26 Measuring range limits 27 Menu 24 Modbus Connecting 18 Parameters 29 Page Operation Keys 23 Screen 22 Packing 45 Parameters Component parameters 26 Limit parameters 28 Modbus parameters 29 Setting 25 Power supply Connect 19 Specifications 19 Pressure correction 35 Purge (Startup) 20 Reference Measuring Range 27 Safety precautions 6, 7 Screen 22 Blinking 39 Seal integrity check Before operation 10 Maintenance 37 Set points (Calibration) 26 Signal lead connection 18 Specifications 47 Dimensional diagram 12 Electrical connections 17 Environmental conditions 10 Gas connections 13 Gas inlet conditions 14 Power supply 19 Startup 21 Prestart purge 20 Status messages 40 Step interval Limits 28 Measuring range 27 Set points 26 Structure 46 Switching hysteresis (Limit) 28 T90 time 26 Taking out of service 44 Test gases 31 Time-out EasyLine O2 Operator s Manual 42/ EN

53

54 Subject to technical changes Printed in the Fed. Rep. of Germany 42/ EN 10.01

55 EasyLine O2 Thermal Link Replacement (744547) Replacement thermal link The replacement thermal link (part number ) is located in the pocket affixed to the back of the Sensor CPU board mounting plate. EasyLine O2 Top view Thermal link location Replace the thermal link Step Action 1 Turn off the sample gas supply to the gas analyzer. Turn off the gas analyzer power supply. 2 Remove the three screws on the back of the gas analyzer and slide the base support from the cover. 3 Remove the three power supply mounting screws 1 on the bottom of the base support and remove the power supply. 4 Remove the sample gas line from the inside of the sample gas outlet 2. Make sure not to lose the knurled nut and sealing ring. Do not loosen the tubing on the pressure sensor! This can break the pressure sensor connection port. 5 Loosen the thermal link connection wiring 3. Disconnect plug 4. 6 Remove two screws 5 and slide the circuit board 6 to the side. 7 Remove screw 7 and pivot the support to the side. 8 Remove the defective thermal link 8 from the opening in the sample chamber housing. 9 Insert the new thermal link 8 in the sample chamber housing opening. 10 Swing the support back into place and secure it with screw Fasten circuit board 6 to the sample chamber housing with two screws 5. Reconnect plug Fasten the thermal link connection wiring Secure the sample gas line to the inside of the sample gas outlet Fasten power supply 1 to the base support with the three screws. 15 Slide the base support into the cover and secure with the three screws. F Make sure the springs are not bent in the process. 16 Check the integrity of the sample gas path (see the EasyLine O2 Operator s Manual for instructions). 17 Activate the gas analyzer power supply and start the sample gas supply. Subject to technical changes Printed in the Fed. Rep. of Germany 42/27-12 Z1 XA 03.01