Novatech 1638 Manuale utente

Dew Point Analyser

Model 1638

August 2009

1638 Dew Point Analyser 1

CONTENTS

1SPECIFICATIONS..........................................................................................................................3

2DESCRIPTION..............................................................................................................................13

3INSTALLING & COMMISSIONING ..........................................................................................19

4OPERATOR FUNCTIONS ...........................................................................................................33

5SETTING UP THE TRANSMITTER ...........................................................................................39

6MAINTENANCE...........................................................................................................................57

APPENDICES

APPENDIX 1 PROBE OR SENSOR EMF TABLES.............................................................................62

APPENDIX 2 % OXYGEN SCALE TO LOGARITHMIC....................................................................65

APPENDIX 3 SAMPLE LOG PRINT OUT...........................................................................................66

APPENDIX 4 CIRCUIT SCHEMATICS................................................................................................67

APPENDIX 5 MODBUS™ REGISTER MAP AND APPLICATION NOTES.....................................76

Note: This manual includes software modifications up to Version 8.11, May, 2006

This manual is part of the product sold by Novatech Controls Pty. Ltd. ("Novatech Controls") and is provided to the

customer subject to Novatech Controls' conditions of sale, a copy of which is set out herein. Novatech Controls'

liability for the product including the contents of this manual is as set out in the conditions of sale.

All maintenance and service of the product should be carried out by Novatech Controls' authorised dealers.

This manual is intended only to assist the reader in the use of the products. This manual is provided in good faith but

Novatech Controls does not warrant or represent that the contents of this manual are correct or accurate. It is the

responsibility of the owner of the product to ensure users take care in familiarising themselves in the use, operation and

performance of the product.

The product, including this manual and products for use with it, are subject to continuous developments and

improvement by Novatech Controls. All information of a technical nature and particulars of the product and its use

(including the information in this manual) may be changed by Novatech Controls at any time without notice and

without incurring any obligation. A list of details of any amendments or revisions to this manual can be obtained upon

request from Novatech Controls. Novatech Controls welcome comments and suggestions relating to the product

including this manual.

Neither the whole nor any part of the information contained in, or the product described in, this manual may be adapted

or reproduced in any material form except with the prior written approval of Novatech Controls Pty. Ltd.

All correspondence should be addressed to:

Technical Enquires

Novatech Controls Pty Ltd

309 Reserve Road

Cheltenham Victoria 3192 Phone: Melbourne +61 3 9585 2833

Australia Fax: Melbourne +61 3 9585 2844

Website:

http://www.novatech.com.au/

August 2009

21638 Dew Point Analyser

USING THIS MANUAL

The Novatech 1638 Oxygen Transmitter has a variety of user-selectable functions.

They are simple to use because each selection is menu driven. For options you are not sure about; read the manual on

that particular item.

Please read the safety information below and the ‘Installation’ section before connecting power to the analyser.

CAUTION 1

The probe or sensor heater is supplied with mains voltage. This supply has electrical shock danger to maintenance

personnel. Always isolate the analyser before working with the probe or sensor.

The EARTH wire (green) from a heated probe or sensor must ALWAYS be connected to earth.

CAUTION 2

Combustion or atmosphere control systems can be dangerous. Burners must be mechanically set up so that in the worst

case of equipment failure, the system cannot generate explosive atmospheres. This danger is normally avoided with

flue gas trim systems by adjustment so that in the case of failure the appliance will not generate CO in excess of 400

ppm in the flue. The CO level in the flue should be measured with a separate CO instrument, normally an infrared or

cell type.

CAUTION 3

The oxygen sensor which is heated to over 700°C (1300°F) and is a source of ignition. Since raw fuel leaks can occur

during burner shutdown, the analyser has an interlocking relay that removes power from the probe or sensor heater

when the main fuel shut-off valve power is off. If this configuration does not suit or if it is possible for raw fuel to

come into contact with a hot oxygen probe or sensor then the Model 1638 analyser with a heated probe or sensor will

not be safe in your application.

An unheated probe can be utilised in such applications, however the oxygen readings are valid only above 650°C

(1200°F).

August 2009

1638 Dew Point Analyser 3

SPECIFICATIONS

Section

Number

1.1MODEL 1638 OXYGEN & DEW POINT ANALYSER.................................................................4

1.2SERIES 1230 OXYGEN PROBES & SENSORS............................................................................7

1.3PURGE & CALIBRATION CHECK ACCESSORIES..................................................................11

1.4FILTER PURGE PRESSURE SWITCH ........................................................................................11

1.1 MODEL 1638 OXYGEN & DEW POINT ANALYSER

DESCRIPTION

The Novatech model 1638 oxygen analyser / transmitter provides in-situ measurement for one or two oxygen probes in

annealing and other furnaces with protective atmospheres of hydrogen / nitrogen. The analyser provides local

indication of oxygen and dew point plus sixteen other selectable variables.

One or two oxygen sensing probes in one process can be controlled from one analyser to providing an average and/or

individual probe signals. Two linearised and isolated 4 to 20 mA output signals are provided for oxygen and for dew

point. Alarms are displayed at the analyser and relay contacts activate remote alarm devices. The analyser, which is

available for heated or unheated zirconia oxygen probes, provides automatic on-line gas calibration check of the probe

and filter purging. The electronics self-calibrates all inputs every minute.

The 1638 has a keyboard for selecting the output range, thermocouple type, etc., as well as maintenance and

commissioning functions. The instrument is microprocessor based and all adjustments are made using the keyboard.

•Used for product quality control to avoid blueing or browning of steel products during the annealing process

•Used for monitoring hydrogen / nitrogen protective atmospheres in applications such as lead holding furnaces

•Automatic selection of second probe on probe failure

•Simple to install

•Linear output of % oxygen and dew point for recording or control

•Built in safety features

•24 different alarm conditions that warn the operator of oxygen, dew point, probe or analyser problems

•Isolated RS 232-C printer/computer interface and an RS 485 MODBUS network interface

•Safety interlock relay for heated oxygen probes

REF

1638

Oxygen

nalyse

Com

uter and/or Printe

(Optional)

Reference Ai

Nitrogen

Flowmete

Calibration

Checking

Calibratio

Solenoid

Purge

Solenoid

Zirconia Oxygen Probe Recorder/

controller

larms

Cable

Oxygen Probe and Analyser System

August 2009

41638 Dew Point Analyser

August 2009

1638 Dew Point Analyser 5

SPECIFICATIONS

Inputs

•Zirconia oxygen probe, heated or unheated

•Furnace thermocouple, field selectable as type K or R

•Process purge complete / main flame established safety interlock (for heated probes)

•Purge pressure switch

•Remote alarm accept

Outputs

•Two linearised 4 to 20 mA DC outputs, max. load 1000Ω

•Common alarm relay

•Three other alarm relays with selectable functions

Computer

•RS 232-C or RS 485 for connection of a computer terminal or printer for diagnostics of the analyser, sensing

probe, or process. This connection is suitable for network connection to computers, DCSs or PLCs using

MODBUS protocol.

Range of Output 1

Field selectable from the following:

Output Zero Range Span Range

Dew point -60°C to +20°C -40°C to +40°C

-76°F to +84°F -56°F to +104°F

Linear oxygen 0 to 99 % 1 to 100 %

Oxygen, reducing range 1.0 -16 % oxygen 1.0-30 % oxygen

If 2 probes are used -

Linear oxygen, probe 1 0 to 99 % 1 to 100 %

Reducing oxygen output probe 1 1.0 -16 % oxygen 1.0-30 % oxygen

Dew point, probe 1 -60°C to +20°C -40°C to +40°C

-76°F to +84°F -56°F to +104°F

Linear O2, probe 1 & 2 averaged 0 to 99 % 1 to 100 %

Reducing O2, probe 1 & 2 averaged 1.0 -16 % oxygen 1.0-30 % oxygen

Dew point, probe 1 & 2 averaged -60°C to +20°C -40°C to +40°C

-76°F to +84°F -56°F to +104°F

Note:

The average dew point, linear O2and Reducing O2selections will automatically select to the operating probe if one

probe fails, or selects probe 1 if both probes fail.

Range of Output 2

Field selectable from the following:

Output Zero Range Span Range

Linear O20 to 99 % 1 to 100 %

Oxygen, reducing range 1.0 -16 % oxygen 1.0-30 % oxygen

Dew point -60°C to +20°C -40°C to +40°C

-76°F to +68°F -40°F to +104°F

Sensor EMF 0 to 1200 mV in 100 mV steps 100 to 1300 mV in 100 mV steps

Aux Temperature 0 to 1300°C in 100°C steps 100 to 1400°C in 100°C steps

If 2 probes are used -

Linear O2, probe 2 0 to 99 % 1 to 100 %

Oxygen, reducing range, probe 2 1.0 -16 % oxygen 1.0-30 % oxygen

Dew point, probe 2 -60°C to +20°C -40°C to +40°C

-76°F to +68°F -40°F to +104°F

Probe EMF 1 0 to 1200 mV in 100 mV steps 100 to 1300 mV in 100 mV steps

Probe EMF 2 0 to 1200 mV in 100 mV steps 100 to 1300 mV in 100 mV steps

August 2009

61638 Dew Point Analyser

Range of Indication, Upper Line

•Oxygen auto ranging from 10-30 to 100 %

•Dew point -60 °C to +40 °C, -76 °F to +104 °F

Indication Choice, Lower Line

Any or all of the following can be selected for lower line display:

•Dew point probe 1

•Dew point probe 2 **

•Dew point probe 1 and 2 averaged **

•Date - time

•Run Hours since last service

•Date of last service

•Oxygen probe 2 **

•Oxygen probe 1 and 2 averaged **

•Probe EMF 1

•Probe EMF 2 **

•Temperature probe 1

•Auxiliary Temperature *

•Temperature probe 2 **

•Impedance probe 1

•Impedance probe 2 **

•Ambient Temperature

•Ambient Relative Humidity

* If the analyser is enabled for 1 probe

** If the analyser is enabled for 2 probes

Accuracy

•±1% of actual measured oxygen value with a repeatability of ±0.5% of measured value.

Relay Contacts

•0.5A 24 VAC, 1A 36 VDC

Environmental Rating

•Operating Temperature: -25 to 55°C

•Relative Humidity: 5 to 95% (non-condensing)

•Vibration: 10 to 150Hz (2g peak)

Power Requirements

•240 or 110V, 50/60 Hz, 105 VA (heated probe)

•240 or 110V, 50/60 Hz, 5 VA (unheated probe)

Weight

•Analyser, 3.75 kg

Degree of Protection

•IP65 without reference air pump

•IP54 with reference air pump

Mounting

•Suitable for wall or surface mounting.

1.2 SERIES 1230 OXYGEN PROBES & SENSORS

DESCRIPTION

Novatech series 1230 oxygen probes and sensors employ state-of-the-art zirconia sensors and advanced materials,

which provide the following benefits:

•Improved control due to fast response time to typically less than four seconds

•Cost-efficient design provides improved reliability

•Longer-life probes with greater resistance to corrosion from sulphur and zinc contaminants in flue gas

•Low cost allows maintenance by replacement

•Reduced probe breakage due to greater resistance to thermal shock and mechanical damage during installation and

start-up

•Series 1230 probes are simple to install and maintain. All models provide direct measurement of oxygen level.

On-line automatic calibration check is available if required. Probes may be used with Novatech combustion

controllers and some analyser models from other manufacturers.

All Novatech oxygen probes are designed and manufactured to exacting standards of performance and reliability.

Series 1230 probes are the result of extensive research and development by Novatech, industry and government

agencies. Novatech Controls provides application and after sales support for oxygen probes, sensors and analysers,

worldwide.

Model 1231 Heated Oxygen Probe

Model 1232 Unheated Oxygen Probe

August 2009

1638 Dew Point Analyser 7

EXHAUST

1234 OXYGEN

SENSOR

NOVATECH

CONTROLS

CABLE GLAND

ID LABEL

EXHAUST 1/4" NPT FEMALE

GAS INLET 1/4" TUBE ELBOW

Model 1234 Oxygen Sensor

STANDARD PROBE ‘U’ LENGTHS

1231 1232

250 mm (10”) 500 mm (20”)

350 mm (14”) 750 mm (30”)

500 mm (20”) 1000 mm (40”)

750 mm (30”) 1500 mm (60”)

1000 mm (40”)

1500 mm (60”)

2000 mm (80”)

Ordering Information

1. Probe insertion length (from process end of mounting thread to probe sensing tip).

2. Mounting thread (process connection), BSP or NPT (for size of thread refer to specifications).

3. Lagging extension length, if required.

4. If model 1232 probe, state preferred thermocouple type (refer to specifications).

August 2009

81638 Dew Point Analyser

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