4000 series (includes 4100, 4200 & 4900)

Transcription

1 4000 series (includes 4100, 4200 & 4900) Please record your analyser details below Part Number Serial Number Tag Number

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3 A B No. Value Unit Name I % OXYGEN 6 I % I vpm OXYGEN OXYGEN I vpm ALARM WARM AUTO UP CAL! MAINT OXYGEN FAILURE Figure A Figure B 4000 Series - Configuration and Operation 04000/003D/0 i

4 C FLUSH TIME FLUSH TIME FLUSH TIME FLUSH TIME HI SAMPLE LO T AUTO CAL! AUTO CAL! AUTO CAL! AUTO CAL! AUTO CAL! AUTO CAL! AUTO CAL! Figure C ii 4000 Series - Configuration and Operation 04000/003D/0

5 D CALIBRATE MANUAL CAL LOW CAL HIGH CAL PRESS* HISTORY MEASURE P OFFSET SPECIFY P OFFSET LOW HISTORY HIGH HISTORY P OFFSET HISTORY* CHK L & H CHECK LOW CHECK HIGH SET UP AUTO CAL SET ALARM ASSIGN SET UP AUTO CAL ONE CYCLE RELAYS CONFIG TXD CAL CONFIG TXD GROUP ma OUTPUT DISPLAY ma INPUT OUTPUTS ALARMS RELAYS ma OUTPUT DIAGNOSTICS ID UTILITY INST PARAMETERS CLOCK NEW PASS SUPERVISOR COMMS SCREEN OPERATOR SET COMMS PARMS SET COMMS MODE SELECT SCREEN [ EDIT KEY ] DEFINE SCREEN LNG ALARMS FAULTS Figure D TXD PARAMETERS DISPLAY ALARMS ALARM HISTORY FAILURE MAINTENANCE * FOR Pm OXYGEN PURITY MODULE ONLY * * FOR Gfx NO MODULE ONLY LABELS FACTORS LO & HI TOL DECI TIME CONSTANT DERIVE N0x* * DISPLAY FAILURES FAILURE HISTORY DISPLAY MAINT MAINT HISTORY 4000 Series - Configuration and Operation 04000/003D/0 iii

6 NOTES iv 4000 Series - Configuration and Operation 04000/003D/0

7 1 INTRODUCTION 1.1 Warnings, Cautions and Notes This publication includes WARNINGS, CAUTIONS and NOTES which provide information relating to the following: WARNINGS Hazards which could result in personal injury or death. CAUTIONS Hazards which could result in equipment or property damage. NOTES Alert the user to pertinent facts and conditions. 1.2 About this manual (Key to Figures) This manual covers software configuration and operation. Further copies of this manual may be ordered, reference part number 04000/003D. Addresses for technical assistance and spares are given on the rear cover. An installation manual is supplied with the analyser which includes the technical specification, routine maintenance and spares information, reference part number 04000/005D. A service manual is available for use by qualified personnel, reference part number 04000/002D. Modbus is a trademark of AEG-MODICON Series - Configuration and Operation 04000/003D/0 1

8 KEY TO FIGURES Figure A Analyser front view 1. Sample filter (optional) 2. Flowmeters (optional) 3. Display 4. Keypad 5. Display contrast adjustment 6. Sample needle valves (optional) Figure B Display 1. Titles 2. Module location (2 characters) 3. Measurement value (6 characters) 4. Engineering units (3 characters) 5. Measured name (6 characters) 6. Measurements 7. Alarm icon 8. Warm up icon 9. Autocalibration icon 10. Maintenance icon 11. Failure icon Figure C Typical autocalibration sequence (In this example calibration gas 1 is the 'zero' gas, calibration gas 2 is the 'span' gas.) 1. Autocalibration commences, calibration gas 1 is supplied to the analyser 2. Measuring calibration gas 1 3. Calibration gas 2 is supplied to the analyser 4. Measuring calibration gas 2 5. Calibration gas 1 re-applied to the analyser 6. Re-measuring calibration gas 1 7. Sample gas is supplied to the analyser to flush out sensor ("post flush") Figure D User interface menu map WARNING The user should note that 4000 series instruments contain no user serviceable parts inside. The instrument enclosure protects the user from electric shock and other hazards. All servicing should be referred to qualified personnel Series - Configuration and Operation 04000/003D/0

9 CONTENTS Page Section 1 INTRODUCTION 1.1 Warnings, Cautions and Notes About this manual (Key to Figures) Introduction to the user interface 4 Section 2 INITIAL CONFIGURATION 2.1 Power Up and Shutdown procedure General access to analyser functions Setting languages Setting passwords Setting time and date 8 Section 3 MAIN CONFIGURATION 3.1 Component name and unit definition Alarms Allocation of relays External analogue input configuration Analogue outputs Defining and selecting measurement display screen Response time Serial communications Calculation of total nitrogen oxides (NO x ) concentration 18 Section 4 CALIBRATION 4.1 Introduction to calibration Setting Low and High calibration tolerances Manual calibration and checking Calibration of paramagnetic pressure transducer Autocalibration and autocheck setup 25 Section 5 VIEWING CONFIGURATION AND HISTORY FILES 5.1 Displaying 'Current' alarms and faults Displaying alarm settings Displaying output configuration Displaying analyser histories Displaying analyser identity and diagnostics Series - Configuration and Operation 04000/003D/0 3

10 1.3 Introduction to the user interface The user interface consists of a keypad and a large LCD. During normal use the LCD will show either the default measurement display or a menu based screen editor display. The measurement display The measurement display is shown by default and can be user configured to show the measurements made by the analyser. The status of the instrument plus the occurrence of an alarm or fault is also displayed via icons at the bottom of the screen. The display line for each measurement consists of four fields: 1) The module location defines the identity of the transducer for each measurement. The letter "I" indicates an internal gas sensor module, the letter "E" an external transducer (user supplied) and the letter "D" indicates a derived measurement (as in the case of total nitrogen oxides - refer to section 3.9). The letter is followed by a number defining the gas sensor module location. 2) The measurement value field is a 6 character number showing the concentration measured. 3) The engineering units field is user defined with 3 characters showing the units of measurement. 4) The measurement name field is a 6 character field to show the name or TAG number. The keypad The display may be returned to measurement display at any time by pressing the 'MEASURE' key. If no key is pressed the analyser returns to the measurement display after one minute. This timeout is extended to 20 minutes during the calibration options. Press the 'MEASURE' key at any time to return to the default measurement display. Pressing the 'MENU' key activates the top level menu. It does not affect the continuous measurement activities of the analyser. Within menu displays, the user highlights the desired option using the arrow keys ( ) and then presses the 'ENTER' key to action the indicated menu selection or to confirm completion of text or numerical input. Pressing the 'QUIT' key aborts the current activity and returns to the previous menu level. The 'EDIT' key is a short-cut key to access the measurement display editing functions Series - Configuration and Operation 04000/003D/0

11 NOTE When inputting data, a key press will be ignored if the data entered is invalid. When entering numeric information or text, the left and right arrow keys are used to move between characters or digits and the up and down arrow keys are used to change each character or digit. Negative imaging (white text on black background) indicates the active word, character or digit position. If the Measure, Menu or Quit keys are used to terminate a data entry (rather than the Enter key) then the data entered is lost. The screen icons Autocalibration icon Alarm icon Warm Up icon Failure icon Maintenance icon is displayed when autocalibration is active. is displayed if any of the concentration alarm levels are reached. is normally displayed when the instrument is turned on. If a sensor fails to achieve its normal temperature operating conditions within a specified time, the icon will be turned off and a failure icon raised. is displayed if any serious fault condition occurs within the analyser. is displayed if a condition arises that requires operator attention Series - Configuration and Operation 04000/003D/0 5

12 The menu display To access the menu, the 'MENU' key should be pressed. The analyser will then present the top level menu, which in turn leads on to other menus. The overall menu structure is shown in Figure D. During any menu operation, the fundamental measurements are still being made by the analyser and all relevant outputs, alarms and diagnostics remain active. Data input When alphanumeric text data input is required, the up and down arrow keys allow scrolling and selection of any available item in the analyser's character set. Numeric data input may be set to: i) Any number in the range 0 to 9. ii) A minus sign (only as the first character) iii) A decimal point - the position of the decimal point may be changed from that offered as a default. Any position except the right most digit may be used. If an invalid data entry is made, the input will be ignored and the display return to the start of the relevant data entry screen. No warning message will be generated. Password protection Certain operations require the use of a password. There are two passwords, a supervisor password which gives access to SETUP and CALIBRATION and an operator password, giving access to CALIBRATION only. These are factory set to 4000, but may be changed if required; refer to section Series - Configuration and Operation 04000/003D/0

13 2 INITIAL CONFIGURATION 2.1 Power Up and Shutdown procedure When initially powered up, a message sequence will be displayed. This will start with the term: 'SYSTEM OK'and progress through a number of screens detailing the analyser, it's configuration and the software fitted, before displaying: 'MEASURING'. If the user does not wish to see the power up messages then these can be bypassed by pressing the measure key during the 'SYSTEM OK' message. The measurement display should now appear. The display "contrast" control may be adjusted if necessary using a small flat bladed screwdriver. See Figure A for location of the adjustment, accessed from the bottom of the front facia. The warming-up icon (see Figure B) may be displayed until all heated gas sensor modules are at their respective operating temperature. This may take up to 6 hours. The reading of certain gas sensor modules may be replaced by a row of stars ('******') during the warming-up period. Analyser may not have reached optimum performance after the warming up icon is extinguished, see Installation Manual for recommended warm up times. To shut down, disconnect the sample gas, flush through with a clean purge gas (e.g.: nitrogen), then remove power. 2.2 General access to analyser functions It is recommended that the user refers to the menu map (Figure D) and locates the function required. Then, using the keypad and display follow the route as mapped. It will often be necessary to enter the password, which is factory set to At display screen: ENTER PASSWORD 0000 The cursor will initially be on the digit furthest to the left. Use the up arrow to increment the first digit to 4. The display should now be showing Press ENTER 2.3 Setting language Go via SETUP/UTILITY to LNG - press ENTER ENGLISH / DEUTSCH Select required language and press 'ENTER' Series - Configuration and Operation 04000/003D/0 7

14 2.4 Setting passwords Go via SETUP/UTILITY to NEW PASS - press ENTER SUPERVISOR OPERATOR NEW OPERATOR (NEW SUPERVISOR) PASS = 0000 NEW PASS IS???? ACCEPT YES/NO SUPERVISOR OPERATOR 2.5 Setting time and date Select either supervisor or operator password then press 'ENTER'. Using the arrow keys, specify the new password. When the value shown is correct press 'ENTER'. Confirmation is required, select 'YES' or 'NO' then press 'ENTER'. To return to measurement display press 'MEASURE'. The time and date must be set correctly before setting up autocalibration and for history log entries to have the correct time and date stamp. The time and date are retained for at least two days while the analyser is switched off. Go via SETUP/UTILITY to CLOCK - press ENTER TIME = 12:54 DATE = 10/12/01 CHANGE DATE,TIME YES/NO SET CLOCK SET YEAR 0000 Current time/date is temporarily displayed, (no action is required). Select 'YES' or 'NO' then press 'ENTER'. Use the arrow keys to set, when the value shown is correct press 'ENTER'. SET MONTH 00 " SET DAY 00 " SET HOUR 00 " SET MINUTE 00 " SELECT FORMAT Select format then press 'ENTER'. DDMMYY/MMDDYY TIME = 12:57 DATE = 10/12/01 The new time/date is temporarily displayed (no action is required) Series - Configuration and Operation 04000/003D/0

15 3 MAIN CONFIGURATION 3.1 Component name and unit definition The name of each measurement may be changed (six characters in length max). The default character is ' ' which cannot be displayed but is used to indicate the maximum number of characters allowed. If fewer than the maximum number of characters is entered the first ' ' is taken to be the last character. All analyser measurements are based on percentage concentrations. In order to convert to vpm, for example, a 'scale factor' (of 10,000) is used. The user may 're-define' the measurement units by adjusting this scale factor. This factor will be applied to the displayed value, all outputs, alarm and calibration configurations. The measurement display units and component name are displayed, right justified, in fields of three and six characters, respectively. To left justify or centralise them the appropriate number of spaces can be added at either end of the string. Go via SETUP/UTILITY to LABELS - press ENTER I1 COMPONENT NAME I1 ENG UNIT (Factory set to '%' or 'vpm') I1 SCALE FACTOR (E.g.: for percent for vpm) Any combination of up to 6 characters may be used e.g. "Oxygen" or "AT-123". Use the arrow keys to change a character and when the name is correct press 'ENTER'. This entry only defines the label which follows the measurement value, it does not actually affect the measurement value (see below). Change characters as above. This entry may be used to rescale the factory calibration. This factor will be applied linearly to the displayed value, all outputs, alarm and calibration configurations. Change value as above Series - Configuration and Operation 04000/003D/0 9

16 3.2 Alarms The analyser has four concentration alarm settings for each measurement (referred to as AL1, AL2, AL3 and AL4). Each may be enabled or disabled, and the states of the following parameters need to be set up for every enabled alarm: i) FREEZE to prevent alarms during calibration or FOLLOW so that alarms may be activated by calibration gases. ii) HIGH concentration alarm or LOW concentration alarm. iii) The concentration LEVEL at which the alarm is to occur. iv) The HYSTERESIS (dead band) of the alarm, this may be used to avoid 'chatter' if the typical sample concentration is close to the alarm level. Go via SETUP to SET ALARM - press ENTER SELECT MEASURE I1 Oxygen % I1 Oxygen SELECT AL1/2/3/4 I1 Oxygen AL1 ENABLE/DISABLE I1 Oxygen AL1 FREEZE/FOLLOW I1 Oxygen AL1 HIGH/LOW ALARM I1 Oxygen AL1 LO LEVEL = % I1 Oxygen AL1 LO HYST =00.000% I1 Oxygen SELECT AL1/2/3/4 Select required measurement, (Oxygen % is shown as an example), press 'ENTER'. Select required alarm, press 'ENTER'. Select required state, press 'ENTER'. Select required state, press 'ENTER'. Select required state, press 'ENTER'. Set the value to the required alarm level, press 'ENTER' when correct. Set the value to the required hysteresis, press 'ENTER' when correct. Select other alarms as required and repeat above. When all alarms have been set for a gas sensor module use 'QUIT' to select another module Series - Configuration and Operation 04000/003D/0

17 3.3 Allocation of relays NOTE A high alarm will be signalled when the sample concentration rises above the alarm level. This will be cleared when the sample falls further below the alarm level than the value of hysteresis. A low alarm will be signalled when the sample concentration falls below the alarm level. This will be cleared when the sample rises further above the alarm level than the value of hysteresis. With the exception of dedicated external autocalibration relays, each relay may be set up to respond to any combination of the following: i) Failure of transducers I1 to I4, where fitted and of milliamp inputs E1 and E2. ii) Maintenance required for transducers I1 to I4, where fitted. iii) Calibration in Progress for transducers I1 to I4. iv) Any concentration alarms. v) Chassis Failure, Chassis Maintenance required. vi) Warming Up, for transducers I1 to I4, where applicable. Any existing relay allocation may be edited or cleared. When cleared the relays will remain non-functional. NOTE Optional relays supplied specifically for external autocalibration or any relay configured to control external valves will be used exclusively for that purpose. Attempts to change such configuration via the 'allocation of relays' function are inhibited and will result in the message "RELAY ASSIGNED TO AUTOCAL" Series - Configuration and Operation 04000/003D/0 11

18 The identity of each relay conforms to the standard 4000 series output numbering system, as listed in the installation manual, which also includes a list of default relay allocations. Go via SETUP/ASSIGN to RELAYS - press ENTER SELECT RELAY 1.3 ASSIGNED OR 1.3 UNASSIGNED RELAY ASSIGNMENT 1.3 EDIT/CLEAR OR 1.3 ASSIGN? Y/N 1.3 I1 Oxygen AL1 HI % Y/N or 1.3 CAL IN PROG YES/NO or 1.3 FAILURE YES/NO or 1.3 MAINTENANCE YES/NO or 1.3 CHASSIS MAINT or CHASSIS FAILURE YES/NO or 1.3 WARM UP YES/NO SELECT RELAY 1.3 ASSIGNED OR 1.3 UNASSIGNED Use the arrow keys to select the required relay then press 'ENTER'. Select 'EDIT' to edit allocation, or re-assign a cleared relay OR select 'CLEAR' to clear the relay then press 'ENTER'. The display will now show all available alarms and functions which may be selected to operate the relay (1.3 in this example). Select 'YES' and press 'ENTER' to allocate the item to the relay OR 'NO' and press 'ENTER' to move to the next item. For concentration alarms the alarm set point will be displayed, an H or L will also be displayed to show the HIGH or LOW status. Maintenance, Failure and Warm up assignments can be made for each transducer and the chassis. Use the arrow keys to select another relay then press 'ENTER' Series - Configuration and Operation 04000/003D/0

19 3.4 External analogue input configuration Two external, linear analogue inputs are provided on the instrument, identified as E1 and E2. The name and units for these variables are modified using the LABELS menu entry, in a similar manner to internal transducers (section 3.1). An additional 'ENABLED/DISABLED' command may be used to turn inputs on or off under the SETUP/ASSIGN menu. Input scaling (calibration) is set up via the MAN CAL menu, refer to section Analogue outputs The analyser can have up to eight analogue outputs depending on the number of options fitted. Each output has two ranges: R1 (the default range) and R2 (selected using the external contact). Maximum output span is limited to twice the full scale range of the transducer (except Zirconia sensors). Note: performance typically will begin to degrade above 120%FSD. As a guide, minimum output spans should be at least 100 times the transducer noise level, (refer to Installation manual, section 7). The parameters for an output may be edited or cleared. When cleared the output is nonfunctional. Each may be assigned to any one gas sensor, and following parameters must be set up for all outputs used: i) Gas sensor module to which analogue output is to be assigned. ii) Scale (Lower & Upper limits) of the analogue output, range 1. iii) Scale (Lower & Upper limits) of the analogue output, range 2. iv) 0 to 20mA or 4 to 20mA. In the case of a 4 to 20mA, the actual minimum current allowed in normal operation must also be specified. v) FREEZE the analogue output during calibration or allow it to FOLLOW calibration sample concentrations. vi) Set the output to JAM LOW or JAM HIGH in the event of a measurement failure condition. The output will be forced to zero or 20.5mA respectively - this only applies to 'Failures' (not Maintenance faults) Series - Configuration and Operation 04000/003D/0 13

20 NOTE If the 4-20mA output is used and a 'minimum current' of less than 4mA is specified (in iv above), 4mA still corresponds to the lower limit of the output range (set in ii or iii above). Go via SETUP/ASSIGN to ma OUTPUT - press ENTER SELECT ma OUTPUT 1.1 ASSIGNED OR 1.1 UNASSIGNED ma OUTPUT ASSIGN 1.1 EDIT OR 1.1 ASSIGN? Y/N SELECT MEASURE I1 Oxygen % 1.1 I1 Oxygen R1 L=000.00U= I1 Oxygen R1 0-20mA/4-20mA 1.1 I1 Oxygen R1 LOW LIMIT= 4.0mA 1.1 I1 Oxygen R1 FREEZE/FOLLOW 1.1 I1 Oxygen R1 JAM NONE/LOW/HIGH 1.1 I1 Oxygen R2 L=00.00 U= SELECT ma OUTPUT 1.1 ASSIGNED OR 1.1 UNASSIGNED Use the arrow keys to select the required output then press 'ENTER'. Select 'EDIT' to edit allocation, or re-assign a cleared relay OR select 'CLEAR' to clear the relay, then press 'ENTER'. Select the measurement to be output, then press 'ENTER' (I1 Oxygen used in this example). Set Lower and Upper limits for the output, the decimal point may be moved and negative values may be entered for the lower limit. When both values are correct press 'ENTER'. Select required state and press 'ENTER'. Adjust lower output current limit (range: 0, 3.6 to 4.0), if necessary, and press 'ENTER'. Select required state, press 'ENTER'. Select required state, press 'ENTER'. Repeat the above process for range R2. Use the arrow keys to select another output, then press 'ENTER' Series - Configuration and Operation 04000/003D/0

21 3.6 Defining and selecting measurement display screen By default, one factory measurement display screen is provided. If required, up to five different measurement display screens may be defined and displayed in succession. Each screen definition may show up to four measurements. Screen definitions can be scrolled manually (press MEASURE) or automatically (every 8s). Use the EDIT key to go to DEFINE SCREEN - press ENTER SELECT SCREEN NUMBER : 1 SELECT MEASURE 1 I1 O2 % MORE MEASURES? YES/NO SELECT ORDER 1ST SCREEN IS : 1 MORE SCREENS? YES/NO AUTOSCROLL? YES/NO Use the arrow keys to select the required screen to define then press 'ENTER'. Use the arrow keys to select the first required measurement then press 'ENTER'. Choose 'YES' to add more measurements to this screen definition, or 'NO' to finish or select another screen for definition. When all required screen definitions have been entered go to SELECT SCRN menu. Use the arrow keys to select the required 1st screen then press 'ENTER'. Select as required, press 'ENTER'. Select required state, press 'ENTER'. The number of decimal places displayed for each measurement may be selected. Go via SETUP/UTILITY to DECI - press ENTER SELECT MEASURE I1 O2 % I1 O2 % DECI PTS=0/1/2/3 Use the arrow keys to select the required sensor module, then press 'ENTER'. Select as required then press 'ENTER.' 4000 Series - Configuration and Operation 04000/003D/0 15

22 3.7 Response time The response time for each measurement may be increased by adding a user time constant in order to reduce noise. The displayed reading and analogue output are both affected. Normal setting for this additional constant is 0, maximum is 60 (selection is empirical). Go via SETUP/UTILITY to TIME CONSTANT - press ENTER SELECT MEASURE I1 Oxygen % I1 Oxygen % TIME CONST = Serial communications This section details the analyser configuration of the serial communications. For details of connection, continuous output interpretation and Modbus data mapping refer to the 4000 Series installation manual. A choice of RS232 and RS485 interfaces is available in all modes. SET COMMS MODE Use the arrow keys to select the required sensor module, then press 'ENTER', if only one module is fitted this section will be omitted. Set between 0 and 0200 then press 'ENTER'. Go via SETUP/UTILITY to SET COMMS MODE - press ENTER SELECT MODE Use arrow keys to select the required NONE communications mode, then press ENTER. or CONTINUOUS or MODBUS ASCII or MODBUS RTU FRAME FREQUENCY= 0000 S MODBUS ADDRESS = 247 Present only if CONTINUOUS mode is selected. Use the arrow keys to select the required frequency, (in seconds, maximum value of 9999S) then press ENTER. A zero value will disable serial data output. Present only if MODBUS ASCII or MODBUS RTU mode is selected. Use arrow keys to enter the required Modbus address (valid addresses are from 1 to 247) Series - Configuration and Operation 04000/003D/0

23 SET COMMS PARMS, Default Listing Parameter Default Interface RS232 or RS485 RS232 Stop bit - 1, 1.5 or 2 1 Number of data bits - 7 or 8 8 Parity - EVEN, ODD or NONE EVEN Baud rate ( characters per second ) , 4800, 2400 or Hardware handshaking (fixed) NONE For CONTINUOUS communications these parameters should be set as required by the receiving device. For Modbus communications they should be set as required by the Modbus master device. Go via SETUP/UTILITY to SET COMMS PARMS - press ENTER SELECT RS232/RS485 Select as required, then press 'ENTER'. SELECT STOP Select as required, then press 'ENTER'. BIT 1/1.5/2 SELECT DATA BITS 8/7 Select as required, then press 'ENTER'. SELECT PARITY EVEN/ODD/NONE SELECT BAUD RATE 9K6/4K8/2K4/19K2 232,1, 8, E, 9K6 ACCEPT? YES/NO Select as required, then press 'ENTER'. Select as required, then press 'ENTER'. Confirm 'YES' that the specified communications parameters are correct, or 'NO' to re-edit Series - Configuration and Operation 04000/003D/0 17

24 3.9 Calculation of total nitrogen oxides (NO x ) concentration For a 4000 analyser measuring nitric oxide (NO) the facility exists to calculate an estimate of the total nitrogen oxides (NO x ) level, based on the measured NO level. This estimate can be displayed and output as a separate measurement, identified on the display by a "D" prefix in the module location field. Units and calibration are fully dependent on the associated NO measurement. The total NO x estimate is derived according to the formula: [NOx] = a * [NO] + b * [NO] 2 In most simple combustion processes it is recognised that the NO concentration accounts for approximately 95% of the total NO x. In this case the total NO x content can be estimated using factors (a) of 100/95 ( = 1.053), and (b) of zero (0.00). Go via SETUP/UTILITY to DERIVE NOx - press ENTER I1 NOx LINEAR Set as required, then press 'ENTER'. COEF I1 NOx SQUARE Set as required, then press 'ENTER'. COEF Series - Configuration and Operation 04000/003D/0

25 4 CALIBRATION 4.1 Introduction to calibration Analyser calibration may checked or adjusted manually or automatically. These activities will result in an entry in the calibration history log, labelled as a "CHK" or a "CAL". In manual calibration (the term calibration includes 'checking') the operator is guided through the sequence by messages on the display and each gas sensor module must be calibrated separately. Autocalibration or autocheck are referred to together as "autocalibration". Progress may be monitored on the display (see Figure C) and the measurement of the sensor(s) being calibrated will flash. The autocalibration cycle can be initiated in four ways: by the internal timer by external contact closure by keypad entry by Modbus command Pressing any key during the cycle will allow the autocalibration to be stopped. If aborted, the final "post flush" sequence is run. This may also be aborted in the same way. Autocalibration may also be stopped by means of a Modbus command. NOTE Autocalibration cannot be configured to perform a HIGH calibration (21% oxygen "air point") with a zirconia oxygen gas sensor module. The instrument will only respond to autocalibration initiation from the internal timer, external input or Modbus command if no faults are indicated. Autocalibration can be initiated from the keypad when there is a fault condition. All of the following sections assume that calibration gases as recommended in the installation manual are available to the analyser! If the analyser is still warming-up and a manual calibration is attempted, a warning message will be given with an option to proceed. For optimum performance, all gas sensor modules should reach operating temperature before performing initial calibration. Autocalibration can be configured to calibrate all gas sensor modules independently, or in any simultaneous combination Series - Configuration and Operation 04000/003D/0 19

26 4.2 Setting Low and High calibration tolerances A limit may be placed on the amount by which a calibration may be changed. If exceeded during autocalibration it will be aborted and a fault indicated. If exceeded during manual calibration a warning will be given with an option to proceed. Go via SETUP/UTILITY to LO & HI TOL - press ENTER I1 Oxygen LO TOL 00.00% I1 Oxygen HI TOL 00.00% * It is recommended that the tolerance should not be greater than 10% of sensor FSD - the factory default settings. 4.3 Manual calibration and checking Set the required low cal tolerance* then press 'ENTER'. Set the required high cal tolerance* then press 'ENTER'. In most cases it is recommended that a LOW calibration is made before any HIGH calibrations, however, if both points are to be calibrated for a Zirconia sensor, the reverse is true. Notes: (apply to the calibration procedure on the next page) PRESS (pressure) calibrations are only applicable to Oxygen Purity sensors * If the module is warming-up a warning will be given with an option to proceed. ** If the calibration has changed by more than the tolerance a warning will be given with an option to proceed. *** If the calibration was not successful a temporary message will be displayed e.g. 'BAD [LOW/HIGH] CAL, CAL IGNORED'. This indicates that the output of the gas sensor module is very significantly outside of the expected range for the calibration gas entered. Check the value of the calibration gas. NOTE If autocalibration is configured, manual calibrations will activate the valve signalling, however, the relays must first be set up within autocalibration Series - Configuration and Operation 04000/003D/0

27 An oxygen sensor in module position 1 has been used in this example of calibration: Go via CALIBRATE to MANUAL CAL - press ENTER CALIBRATE I1 Oxygen % LOW/HIGH/PRESS( ) HISTORY/CHK L&H I1 LOW TARGET Oxygen 00.00% LT00.00 LC00.04 I1 Oxygen OK? Y/N LOW CAL IN PROGRESS CAL RESULT LT LC LOW/HIGH/PRESS HISTORY/CHK L&H I1 HIGH TARGET OXYGEN= 99.98% HT99.98 HC99.85 I1 Oxygen OK? Y/N HIGH CAL IN PROGRESS CAL RESULT HT99.98 HC99.98 Select required measurement, then press 'ENTER', if only one module is fitted this section will be omitted. Select 'LOW', then press 'ENTER'. (*) Set to the low calibration gas concentration, then press 'ENTER'. LT is the target concentration. LC is the current concentration. Introduce low cal gas, when 'LC' has stabilised it may be accepted (**) or rejected. Temporary message, no action required. The calibrated reading is displayed for 1 minute (***) - press QUIT to obtain next menu. The low point cal is now complete, select another function or press 'MEASURE' to go to measurement display - assume that a 'HIGH' calibration has been selected. Set to the high calibration gas concentration, then press 'ENTER'. HT is the target concentration. HC is the current concentration. Introduce high cal gas, when 'HC' has stabilised it may be accepted (**) or rejected. Temporary message, no action required. The calibrated reading is displayed for 1 minute (***) - press QUIT to obtain next menu Series - Configuration and Operation 04000/003D/0 21

28 Manual checks should use the same samples as for calibration adjustment. An oxygen sensor in module position 1 has been used in this example of checking calibration: Go via CALIBRATE to MAN CAL - press ENTER CALIBRATE I1 Oxygen % LOW/HIGH/PRESS HISTORY/CHK L&H CHECK LOW CHECK HIGH I1 Oxygen CHK L CONC = 0.5% OR Select required measurement, then press 'ENTER', if only one module is fitted this section will be omitted. Select CHK L&H and press 'ENTER'. Select 'LOW' or 'HIGH'. Introduce low cal gas; when the reading has stabilised, press 'MEASURE' to return to the measurement display and stamp the cal check result in the cal history buffer. I1 Oxygen CHK H CONC = 99.85% Introduce high cal gas; when the reading has stabilised press 'MEASURE' to return to the measurement display and stamp the calibration check results in the cal history buffer. NOTE It is not possible to quit from a calibration check without stamping the result in the calibration history buffer. No warnings are given regarding the validity of the calibration check Series - Configuration and Operation 04000/003D/0

29 4.4 Calibration of paramagnetic pressure transducer (Only applicable to oxygen purity gas module.) To perform this it is necessary to expose the pressure transducer to two different sample pressures whilst sampling the HIGH cal gas: i) analyser venting to atmospheric pressure ii) analyser venting to a slightly elevated pressure of 1.25psig / 8.6kPag above atmospheric pressure The minimum pressure elevation required for this procedure is 1psig / 6.9kPag, the maximum pressure elevation is 1.5psig / 10.3kPag. This may be performed by temporarily fitting a suitable needle valve on the analyser sample outlet for the paramagnetic purity module and adjusting it to restrict the outlet to achieve an increase in sample pressure in the sensor. The overall sample flow, however, should remain constant as far as possible during this procedure. WARNING Do not exceed the specified maximum sample inlet pressure (pressure driven option) or maximum inlet flow rate (flow driven option) during this procedure or transducer damage may result. NOTE This procedure must be preceded by a low calibration. For most accurate results the high calibration gas should be pure oxygen. Gases containing less than 15% oxygen must NOT be used for the calibration of the pressure transducer. This procedure must be immediately followed by a high calibration Series - Configuration and Operation 04000/003D/0 23

30 Go via CALIBRATE to MAN CAL - press ENTER CALIBRATE Select required measurement, then press 'ENTER'. I1 Oxygen % LOW/HIGH/PRESS HISTORY/CHK L&H LOW/HIGH/PRESS HISTORY/CHK L&H MEASURE P OFFSET SPECIFY P OFFSET O= P = LOW POINT OK Y/N APPLY PRESSURE I1 Oxygen O= P = HIGH POINT OK Y/N REMOVE PRESSURE I1 Oxygen P OFFSET psia I1 Oxygen 0.23 MEASURE POFFSET SPECIFY P OFFSET LOW/HIGH/PRESS HISTORY/CHK L&H Conduct a 'LOW' calibration as detailed in section 4.3. Select 'PRESS', then press 'ENTER. Select 'MEASURE P OFFSET' then press 'ENTER'(If a low calibration has not been performed a warning will be given). Introduce HIGH cal gas with no outlet restriction, and allow both readings of Oxygen and absolute Pressure (psia) to fully stabilise then note readings and sample flow rate (the pressure reading updates every 10s) press 'ENTER' to accept. Temporary message, with the HIGH gas still flowing increase the pressure in the sensor by partially closing the outlet needle valve - adjust the supply to maintain the noted flow rate. The pressure reading should be increased by 1.25psi when both (oxygen and pressure) readings have fully stabilised, press 'ENTER' to accept. If the pressure change is inadequate a warning will be given ('PRESS DIFF LOW') - with the option to restart. Temporary message. Remove the restriction from analyser vent by fully opening the needle valve again. Temporary display of resultant pressure offset figure. Press 'QUIT'. Conduct a 'HIGH' calibration as detailed in section 4.3 (then remove the needle valve) Series - Configuration and Operation 04000/003D/0

31 4.5 Autocalibration and autocheck setup With the use of up to four autocalibration Groups it is possible to configure fully independent calibration of any sensor configuration. The following parameters must be set up for either autocalibration or autocheck, hereafter referred to as "Autocalibration": The time and date must be correctly set before using autocalibration. Selection of 'LOW' or 'LOW & HIGH' autocalibration (remember that Zirconia sensors cannot have a high autocalibration). LOW and HIGH calibration gas concentrations. Autocalibration period (i.e. time between successive autocalibrations; minimum 1 hour, maximum 59 days + 24 hours). Date and time of start of cycle (first autocalibration). Flush time - this may be set, to suit the installation, to a value between 0.5 and 16 minutes so that each gas concentration stabilises before being read. After each flush time the gas will flow for an additional minute to allow the new 'calibrated' level to be viewed or recorded. Selection of autocalibration or autocheck. Calibration Gas Relays (if analyser relays are to be used). It is necessary to specify which calibration gas (1 or 2) is used for the LOW calibration of each sensor. Autocalibration groups An Autocalibration group (comprising one to four sensors) is a group of sensors that: Will be Autocalibrated together. Share the same relays controlling calibration gases and by inference the same calibration gases (but the definition of which cal gas is high or low for each sensor is independent of group). Require the same type of autocalibration; i.e: LOW & HIGH, check or cal. Require the same flush time. Groups are independent, but only one autocalibration can be in progress at any one time. A queuing mechanism is used to ensure autocalibrations are not missed, however, the queue is of finite length. The user is expected to avoid filling it by 'over' scheduling. Figure C shows the response of a typical sensor during autocalibration in which CAL 1 is used to set the sensor low (zero) and CAL 2 the high (span). Further explanation of the events occurring at each stage is given in the installation manual along with configuration details for users who use the serial output to control autocalibration valves Series - Configuration and Operation 04000/003D/0 25

32 If autocheck is selected, corrections are not calculated or applied, however the magnitude of the differences in reading are stored in the calibration history logs. NOTE If an out of calibration tolerance fault is generated during the autocalibration procedure then this may only be removed by performing a subsequent successful one cycle auto or manual calibration. A sensor warming up or failure flag prevents autocalibration for all sensors in a group. Go via CALIBRATION/AUTOCAL to SET UP AUTO CAL - press ENTER All sensor specific parameters will be set first: CONFIG TXD CAL Select 'CONFIG TXD CAL', then press 'ENTER'. CONFIG CAL GROUP SELECT MEASURE Select sensor to configure. The following should be set for all transducers. I1 O2 LOW=00.00% I1 O2 HIGH=100.00% I1 O2 LOW GAS IS 1/2? ASSIGN I1 to CAL GROUP 1 Set to the concentration of the low gas, then press 'ENTER'. Set to the concentration of the high gas, then press 'ENTER (this display will not appear if 'LOW' has been selected, ref next page). Select which gas (CAL1 or CAL2) is the low gas for this sensor, then press 'ENTER'. Select which Autocalibration group to assign transducer to, then press 'ENTER'. Once all parameters for all sensors to be calibrated have been set, it is necessary to assign each to a group: CONFIG TXD CAL Select 'CONFIG CAL GROUP', then press 'ENTER'. CONFIG CAL GROUP SELECT CAL GROUP Select the group to configure, if the group has no sensors allocated to it, it cannot be setup. Use CONFIG TXD CAL option to define a group Series - Configuration and Operation 04000/003D/0

33 CAL GROUP 1 ENABLE/DISABLE Set as required, then press 'ENTER' (When disabled, autocalibrations and remote autocalibrations will not occur). SELECT AUTOCAL Select as required, then press 'ENTER'. LOW / LOW & HIGH SELECT MODE Select as required, then press 'ENTER'. AUTO CAL/CHK SAMPLE/ CAL RELAY Set as required, then press 'ENTER'. 0.1 CURRENT CAL 1 /CAL 2 RELAY Set as required, then press 'ENTER'. 0.2 CURRENT SET FLUSH TIME Set as required, then press 'ENTER'. 0.5 Min ENTER PERIOD Set as required, then press 'ENTER'. DAYS 00 ENTER PERIOD Set as required, then press 'ENTER'. HOURS 00 TIME 12:07:16 Temporary display of current time and date. DATE 10/11/95 ENTER START TIME Set as required, then press 'ENTER'. YEAR 0000 ENTER START TIME As above. MONTH 00 ENTER START TIME As above. DAY 00 ENTER START TIME As above. HOUR 00 ENTER START TIME As above. MINUTE 00 TIME 12:00:00 Temporary display of start time and date. DATE 10/12/95 Repeat the above for all defined Calibration groups Series - Configuration and Operation 04000/003D/0 27

34 Initiating autocalibration or autocheck from the keypad Go via CALIBRATION/AUTOCAL to ONE CYCLE - press ENTER SELECT CAL GROUP Select the group to autocalibrate, then press 'ENTER'. Initiating autocalibration/autocheck by external contact closure An autocalibration may be initiated by closing an external switch (refer to installation manual for details). This initiates an autocalibration on all enabled groups in sequence. This input will be ignored if an autocalibration is already in progress. Initiating autocalibration/autocheck by Modbus communications An autocalibration on an individual group may be initiated remotely by a Modbus master (refer to installation manual for details). Disabling/enabling autocalibration and autocheck Choose ENABLE or DISABLE from the CONFIG CAL GROUP menu option, press ENTER, then press QUIT at the "SELECT AUTOCAL" prompt, see page 26. ALSO: To run a single timed autocalibration, at the designated start time: Set PERIOD DAYS = 00 and PERIOD HOURS = 00 Then, to re-enable timed autocalibration or autocheck: i) set PERIOD to a proper (non zero) time ii) reset the start time Note: the ONE CYCLE menu option is always enabled Series - Configuration and Operation 04000/003D/0

35 5 VIEWING CONFIGURATION AND HISTORY FILES 5.1 Displaying 'Current' alarms and faults Go via ALARMS to DISPLAY ALARMS - press ENTER I1 O2 AL HIGH 5.2 Displaying alarm settings The first alarm is displayed, if further alarms are present an arrow will be shown, use the arrow keys to access. Go via FAULTS/FAILURE to DISPLAY FAILURES - press ENTER I1 CELL TEMP LOW The first fault is displayed, if further faults are present an arrow will be shown, use the arrow keys to access. Go via FAULTS/MAINTENANCE to DISPLAY MAINT - press ENTER I1 LO CAL TOL FAIL The first fault is displayed, if further faults are present an arrow will be shown, use the arrow keys to access. Go via SETUP/DISPLAY to ALARMS - press ENTER SELECT MEASURE I1 Oxygen I1 Oxygen AL1 LO80.00% DISAB I1 Oxygen AL1 LO HYST 0.1% FOL...ETC... I1 Oxygen AL4 LO HYST 0.1% FOL Use arrow keys to select required measurement. Then press 'ENTER'. The configuration of each of the four alarms (AL1 to AL4) is shown on two screens making a total of eight screens to be viewed, use the up arrow to obtain the next screen. This is the last of the eight screens, press ' QUIT' to select another measurement Series - Configuration and Operation 04000/003D/0 29

36 5.3 Displaying output configuration Relays Go via SETUP/DISPLAY to RELAYS - press ENTER DISPLAY RELAY 1.3 ASSIGNED or 1.3 UNASSIGNED 1.3 I4 Oxygen AL4 LO % or HI % or FAILURE etc. ma Outputs Use arrow keys to select the required relay then press 'ENTER'. The first allocation to this relay will be displayed, if there are further allocations an arrow will be shown, use the arrow keys to access. Press 'QUIT' to select another relay. Go via SETUP/DISPLAY to ma OUTPUT - press ENTER DISPLAY ma OUTPUT 1.1 ASSIGNED or 1.1 UNASSIGNED 1.1 I1 Oxygen R1 L=99.000U= I1 Oxygen R1 4-20mA FREEZE 1.1 I1 Oxygen R2 L=99.000U= I1 Oxygen R2 0-20mA FOLLOW Use arrow keys to select the required output then press 'ENTER'. The information on each analogue output is shown on four screens, use the up arrow to obtain the next screen. This is the last of the four screens, press 'QUIT' to select another analogue output Series - Configuration and Operation 04000/003D/0

37 5.4 Displaying analyser histories The analyser retains history entries (up to 40 per 'section') for the following events: Alarms: an entry is made each time an alarm appears ('ON') or is cleared ('OFF'), in the following format: [gas sensor module site number] [measurement name][alarm no.] [alarm level] [alarm sense] e.g. I2 O2 AL LOW Go via ALARMS to ALARM HISTORY - press ENTER Oxygen AL2 ON 12:13:20 12/06 Use up arrow to view next screen, press 'MEASURE' to return to measurement display. Faults: an entry is made each time a fault appears or is cleared. There are two history files, one relating to FAILURES, the other to MAINTENANCE. Refer to menu map, go to FAULTS - press ENTER FAILURE MAINTENANCE DISPLAY FAILURES FAILURE HISTORY OR DISPLAY MAINT MAINT HISTORY SELECT OBJECT I1,I2,I3,I4,E1,E2, CHASSIS or ALL. I1 CELL TEMP LO 12:13:20 12/06 Select either option as appropriate, then press 'ENTER'. Select required history, then press 'ENTER'. Select object to view the log for, then press 'ENTER'. Use arrow keys to view further entries Series - Configuration and Operation 04000/003D/0 31

38 Calibration: an entry is made each time a calibration or calibration check is performed, in the following format: [gas sensor module site number] [measurement name] [type of calibration] [difference] [time and date] e.g. I3 Oxygen CML :54:20 24/07 Calibration types: C or V Calibration or calibration check (Validation). M or A Manual or Auto. L or H Low or High. MPO Measured Pressure transducer Offset * SPO Specified Pressure transducer Offset * Difference: Difference between measured and target concentration, (current measured value - target value of calibration sample, i.e. a positive number indicates a positive drift). * Applicable to paramagnetic oxygen purity modules only. Go via CALIBRATE/MANUAL CAL to HISTORY - press ENTER LOW/HIGH Select history to view, then press 'ENTER'. P OFFSET HISTORY I1OxygenCML0.213 Use arrow keys to view further entries. 01:15:20 28/ Series - Configuration and Operation 04000/003D/0

39 5.5 Displaying analyser identity and diagnostics Identity Go via SETUP/DISPLAY to ID - press ENTER 4000 SERIES Use up arrow to view next screen /CP0_xx MODEL4104C1 Use up arrow to view next screen. S NUM 1234 Press 'MEASURE' to return to measurement display. ORDER NUM TRANSDUCER I1 PARAMAGNETIC TRANSDUCER I2 ZIRCONIA etc The measurement signals from gas sensors may be displayed for diagnostic information, typical examples are shown below: Go via SETUP/DISPLAY to DIAGNOSTICS - press ENTER I2 CELL EMF Use up arrow to view next screen Volts I2 CELL TEMP Use up arrow to view next screen C I1 CO2 DIF SIG Use up arrow to view next screen Volts I1 CO2 GAS SIG Volts Use up arrow to view next screen or press 'MEASURE' to return to measurement display. For a more detailed assessment of the diagnostics information please refer to the 4000 Series Service manual part number C Series - Configuration and Operation 04000/003D/0 33

40 NOTES Series - Configuration and Operation 04000/003D/0