SICK ZIRKOR302 E Oxygen Analyzer with Ejector Installation Commissioning and Operation Maintenance Manual

USER INSTRUCTIONS ZIRKOR302 E Oxygen Analyzer with Ejector Installation Commissioning and Operation Maintenance Table of Contents Docu No.  1 General.......................................................................................................... 4 1.1 1.2 1.3 Purpose of This Document....................................................................................................... 4 Operating Personnel ................................................................................................................ 4 Other Documents ..................................................................................................................... 4 2 Basic Safety Information ............................................................................. 5 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 Obligations and Liability ........................................................................................................... 5 Safety Symbols ........................................................................................................................ 6 Intended Use ............................................................................................................................ 6 Incorrect Usage ........................................................................................................................ 7 Informal Safety Measures ........................................................................................................ 7 Danger from Electrical Power .................................................................................................. 8 Hazardous Areas...................................................................................................................... 8 Removal from Service .............................................................................................................. 8 Alterations to the Construction of Devices ............................................................................... 8 3 General Description ..................................................................................... 9 3.1 3.2 3.3 3.4 3.5 3.6 Theoretical Fundamentals, Measuring Principle...................................................................... 9 General View.......................................................................................................................... 18 Probe ChapterView ................................................................................................................ 24 Gas Extraction Device (GED) ................................................................................................ 25 Protective Pipe with Aluminum Core...................................................................................... 27 Conformity .............................................................................................................................. 27 4 Installation .................................................................................................. 28 4.1 4.2 4.3 4.4 4.5 4.6 4.7 Prerequisites .......................................................................................................................... 28 Counterflange Assembly (Optional Accessory) ..................................................................... 29 Installing the Gas Extraction Device (GED) and the Protective Pipe for the GED ................ 30 Electrical and Pneumatic Connections................................................................................... 31 System Settings in Accordance with System Composition (Reduced to Case Studies) ....... 34 Installing the Gas Extraction Device and Pre-Filter Heater (Optional)................................... 35 Installing the Protective Pipe for High-Dust Applications ....................................................... 44 5 Operation and Display Controls ............................................................... 46 5.1 5.2 5.3 5.4 5.5 5.6 Multi-Function Key.................................................................................................................. 46 LED Display............................................................................................................................ 47 Monitor Output / DIP Switch................................................................................................... 48 Remote Display Software....................................................................................................... 48 Display/Control Unit................................................................................................................ 49 Parameter Groups.................................................................................................................. 55 6 Operation .................................................................................................... 56 6.1 6.2 6.3 6.4 Activating Measurement Mode............................................................................................... 56 Operating and Status Messages............................................................................................ 58 Practical Notes ....................................................................................................................... 59 Removal from Service ............................................................................................................ 61 7 Warnings and Faults.................................................................................. 62 7.1 7.2 7.3 7.4 7.5 Fault History ........................................................................................................................... 62 Display via Rows of LEDs on the Processor Board ............................................................... 62 Indication via Display and Operation Unit / Remote Display Software .................................. 64 Faults...................................................................................................................................... 65 Warnings ................................................................................................................................ 67 2 Table of Contents 8 Service and Maintenance........................................................................... 69 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 Recommendations for practical application............................................................................ 69 Checking and Calibrating the Probe....................................................................................... 70 Check with Test Gas .............................................................................................................. 71 Software Update to 5V006 with Flash-Update-Software V1.2 ............................................... 73 Removing the GED and Checking Penetrability .................................................................... 76 Removing the Probe Body...................................................................................................... 78 Checking the Measuring Cell Heaters.................................................................................... 79 Replacing the Measuring Cell and Measuring Cell Heater .................................................... 79 Cleaning and Replacing the Ejector (incl. Heater) ................................................................. 81 Checking the PT 100 Temperature Sensor............................................................................ 82 Replacing the Measuring Chamber........................................................................................ 83 Replacement of the pressure sensors.................................................................................... 87 Replacement of the analog output card ................................................................................. 88 Replacement of the base electronic ....................................................................................... 88 9 Disposal....................................................................................................... 89 10 Optional Accessories ................................................................................. 90 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 10.13 10.14 LSB-Module with 4 Analog Outputs Voltage, alternatively Current........................................ 90 LSB-Module with 4 Analog Inputs .......................................................................................... 93 LSB-Moduel with 4 Digital Outputs......................................................................................... 95 LSB-Module with 4 Digital Inputs ......................................................................................... 100 Internal Connection of LSB Modules (Max. 2 Modules)....................................................... 105 External Connection of LSB-Module .................................................................................... 107 Activating of LSB-Modules ................................................................................................... 108 Compressed Air Unit to Supply the LAMBDA TRANSMITTER E ........................................ 110 Gas Extraction Kit with Heater for Gas Extraction Device ................................................... 112 Gas Extraction Kit with Gas Extraction Device and Filter Heater......................................... 112 Protective Pipe for High-Dust Applications........................................................................... 113 Ceramic Gas Extraction Device ........................................................................................... 114 Counterflange ....................................................................................................................... 114 Optional Second RS422 Interface, Type K6029318 ............................................................ 115 11 Spare Parts and Consumables................................................................ 121 11.1 11.2 Consumables:....................................................................................................................... 121 Spare Parts:.......................................................................................................................... 122 12 Appendix ................................................................................................... 125 12.1 12.2 12.3 12.4 12.5 12.6 Technical Specifications ....................................................................................................... 125 Connection Diagram............................................................................................................. 128 Dimensions........................................................................................................................... 129 Base Electronics................................................................................................................... 130 Plug-in Jumpers.................................................................................................................... 132 Probe Record Pass (Front)................................................................................................... 135 3 General - Purpose of This Document 1 General 1.1 Purpose of This Document These operating instructions provide operators with information about: • Operation • Safety instructions • Maintenance • Troubleshooting Although other documents (e.g. Product Information) may provide additional information, they must not be regarded as a substitute for these operating instructions. 1.2 Operating Personnel For certain activities (electrical installation, for example), specialist knowledge is required. Such activities must only be carried out by suitably qualified personnel. Those responsible for personal safety must make sure that: • All work on the device components is carried out by qualified personnel only. • They always have access to the operating instructions supplied with the device as well as the associated order documentation when carrying out work and observe this documentation to avoid hazards and damage. Faults must be analyzed by qualified personnel. Measures must be taken to prevent consequential damage, personal injury, and damage to the system. Qualified personnel These persons must be qualified by virtue of their expertise (training, education, experience) or understanding of the relevant standards, specifications, accident prevention regulations, and properties of the system. It is crucial that these persons be able to identify and avoid potential hazards in good time. Technical experts are those persons defined in DIN VDE 0105, IEC 364, or directly equivalent standards, such as DIN 0832. User groups Two user groups have been defined for the LAMBDA TRANSMITTER E: • Manufactorer’s service technicians and trained customer personnel: Qualified technicians/engineers who have an in-depth knowledge of the device. • 1.3 Operators, in-house installation engineers: Technicians for instrumentation and control technology, electrical engineering and electronics, who have a basic knowledge of the device. Other Documents For accessories and special applications, consult the documentation supplied. 4 Basic Safety Information - Obligations and Liability 2 Basic Safety Information These operating instructions contain the most important information regarding the safe operation of the LAMBDA TRANSMITTER E . Always read them before starting work. Warnings must be observed at all times. 2.1 Obligations and Liability Observe notes in these operating instructions Before you can operate the device safely and properly, you must be familiar with the basic safety precautions and regulations. These operating instructions (in particular the safety precautions) must be observed by everyone who uses the LAMBDA TRANSMITTER E and connected components. In addition, the general and local accident prevention rules and regulations must be observed. Hazards when using the O2 The LAMBDA TRANSMITTER E is constructed in accordance with the current state ANALYZER of the art and recognized safety regulations. Measures must nonetheless be taken to prevent injury to the operator or a third person and to prevent the LAMBDA TRANSMITTER E or other objects from being damaged. The LAMBDA TRANSMITTER E must only be used: For its intended purpose When it is in good working order. Faults that could compromise safety must be rectified immediately. Warranty and liability Our "General Terms of Sale and Delivery" always apply. These are available to the operator as soon as a contract has been concluded. Warranty and liability claims for personal injury or material damage shall be excluded if they are attributable to one or more of the following causes: • The LAMBDA TRANSMITTER E and connected components have not been used for their intended purpose. • The LAMBDA TRANSMITTER E and connected components have been installed, commissioned, operated, or serviced incorrectly. • The LAMBDA TRANSMITTER E and connected components have been operated with safety and protective equipment that is either defective, incorrectly installed, or not in working order. • The information in the operating instructions regarding the operation, maintenance, and installation of the LAMBDA TRANSMITTER E and connected components has not been observed. • Unauthorized alterations to the construction of the LAMBDA TRANSMITTER E and connected components have been made. • Components subject to servicing have not been checked properly. • Repairs have been carried out incorrectly. • The ingress of foreign bodies or an act of God has resulted in catastrophic damage. 5 Basic Safety Information - Safety Symbols 2.2 Safety Symbols The following designations and symbols for hazards, warnings, and information are used in these operating instructions: DANGER Indicates potential danger for personnel, particularly due to electrical equipment. WARNING Indicates potential danger for personnel due to incorrect handling of system components. IMPORTANT! Indicates a risk of damage to system components and potential functional impairments. NOTE Highlights information on the features of the system or system components and provides additional tips. The operator must observe the legal accident prevention guidelines at all times and take all the appropriate measures to prevent personal injury and material damage. 2.3 Intended Use The LAMBDA TRANSMITTER E continuous measuring system measures the O2 concentration in non-combustible gases in the hyperstoichiometric range. Prerequisite All planning, mounting, installation, commissioning, maintenance, and repair work must be carried out by adequately trained personnel only and checked by experts. You must make sure that: • The system is used in accordance with the technical data and specifications regarding usage, assembly, connection, ambient, and operating conditions (see the order documentation, user information, rating plates, and so on) and the documentation supplied. • Users act in accordance with the local, system-specific conditions and with due consideration paid to operational hazards and specifications. • All of the measures required to maintain the device (e.g. for transportation and storage, as well as maintenance and inspection requirements) are provided. Correct Handling Intended use also includes: • Observing all the information in the operating instructions. • Carrying out all inspection and maintenance work. 6 Basic Safety Information - Incorrect Usage 2.4 Incorrect Usage It is forbidden to use the device in any other way than described above. Incorrect usage can be hazardous. If the measuring system is to be used in any other application in which its proper functioning cannot be ensured, consult the manufacturer beforehand. 2.5 Informal Safety Measures The LAMBDA TRANSMITTER E must only be operated when all the safety equipment is in good working order. The operator must take all the appropriate measures to prevent personal injury and material damage. You must make sure that: • The system is used in accordance with the technical data and specifications regarding usage, ambient, and operating conditions (see the order documentation, user information, rating plates, and so on) and the documentation supplied. • Users act in accordance with the local, system-specific conditions and with due consideration paid to operational hazards and specifications. • All of the measures required to maintain the device (e.g. for transportation and storage, as well as maintenance and inspection requirements) are provided. If the system is used or handled incorrectly, this can pose a risk to health or cause material damage. To prevent damage, observe the safety precautions at all times. If the LAMBDA TRANSMITTER E is used as a sensor in conjunction with a control system, the operator must ensure that a failure or malfunction cannot lead to operating conditions that cause damage or lead to other hazardous operating conditions. To prevent malfunctions, which can cause personal injury or damage to the system either directly or indirectly, the operator must ensure that: • The maintenance personnel can be alerted immediately and at any time. • The maintenance personnel is qualified to respond to malfunctions on the LAMBDA TRANSMITTER E and associated system malfunctions correctly. • The defective equipment can be switched off immediately if necessary. • Switching off equipment does not indirectly cause further malfunctions. The LAMBDA TRANSMITTER E is a high-quality electronic measuring system. It must be handled with care when it is removed from service, transported, and stored. 7 Basic Safety Information - Danger from Electrical Power 2.6 Danger from Electrical Power DANGER The LAMBDA TRANSMITTER E system components are designed for use in industrial power installations. When working on power connections or on live components, make sure that the power supply is switched off. Before reconnecting the power supply, install any shock protection devices that may have been removed. The relevant safety regulations must be observed at all times. 2.7 Hazardous Areas The LAMBDA TRANSMITTER E is installed directly in the gas-carrying duct above the counterflange. When the LAMBDA TRANSMITTER E is removed, corrosive and/or hot gases can – depending on the device and, in particular, if the duct is pressurized – escape from the duct. This gas can cause serious injury if appropriate protection measures are not taken. WARNING If the duct is pressurized and corrosive gases and/or temperatures in excess of 200°C (390°F) are present in the gas duct, gas can escape from the duct when the LAMBDA TRANSMITTER E is removed. For this reason, you must observe the following: • Switch the system off before you open it. If this is not possible, wear protective clothing and a mask. • Attach warning signs in the vicinity of the mounting location. • Close the opening immediately. Cover flange plates (dummy flanges) are available as accessories. WARNING The flange and the tube of the LAMBDA TRANSMITTER E is very hot. Cooling down before removing or wear protective gloves. 2.8 Removal from Service IMPORTANT! The LAMBDA TRANSMITTER E must not be switched off once it has been installed nor when the plant is shut down. Residual gases can cause corrosion and damage system components. If the device is stored outdoors, it must be protected from the elements. It must always be stored in a dry place and, if possible, in its original packaging. When decommissioning the device, protect the cable ends and connectors against corrosion. Corroded connectors can cause the device to malfunction. Whenever possible, transport the device in its original packaging. 2.9 Alterations to the Construction of Devices No alterations must be made to the construction of or equipment fitted to the LAMBDA TRANSMITTER E without the prior approval of the manufacturer. 8 General Description - Theoretical Fundamentals, Measuring Principle 3 General Description 3.1 Theoretical Fundamentals, Measuring Principle The O2 measuring cell essentially comprises a zirconium dioxide solid electrolyte tube, which is sealed at one end. The internal and external surface is coated with layers of precious metal as electrodes. The crystal lattice of the zirconium dioxide solid electrolyte, which is doped with yttrium oxide or other rare earth oxides, contains oxygen vacancies to enable oxygen ion conductivity that increases exponentially with the temperature. The solid-electrolyte cell, which can be heated by means of an internal electric heater, is surrounded by a quartz or ceramic cladding tube. A sample gas flow (500 ml/h; 0.13 gal/h) passes through the cladding tube by means of a flowcontrol capillary and an Ejectorextraction system. Probe section Ejector pump Electronics section Differential pressure N Automatic calibration device Transformer ZrO2 electrolyte pipe Pt electrodes Flow-control capillary Calibration gas Diff. pressure sensor Ejectorair outlet Differential press. V GED (MEV) Processor card Absolute pressure sensor Base Electronic Connection terminals Absolute pressure Fig. 3-1: Measuring principle of the LAMBDA TRANSMITTER E Calibration with compressed air (0… 2 hPa/ 0… 29 psi) Compressed air for Ejector (0… 2 hPa/ M 0… 29 psi) H M MEV LSB bus Analog 230/115 V output AC; 0/4…20 mA; 50/60 Hz 0…10 V Electric sensor heater Measuring gas (flue gas) Gas extraction device (GED) Changes in the sample gas flow (e.g. as a result of pressure variations upstream or downstream of the capillary) are recorded by means of a differential pressure measurement and corrected by the microprocessor. To determine the oxygen concentration in the sample gas, a DC voltage of between 0.4 and 1.0 V is applied to the electrodes in the cell (at an operating temperature of >800 °C/1,470 °F); the oxygen ions flowing through the solid electrolytes are measured using a milliammeter. All the oxygen in the sample gas ionizes under the influence of the direct-current voltage at the negative outer electrode. 9 General Description - Theoretical Fundamentals, Measuring Principle The negative oxygen ion flow is transported to the positive internal electrode and is discharged to form molecular oxygen. A linear correlation exists between the ionic current, which is measured as the probe current signal, and both the oxygen concentration and sample gas quantity that passes through the cell in each time unit. Calibrating this in line with a gas with a known oxygen concentration (preferably air with 20.96 vol. % O2) enables the sample gas flow rate to be determined. Variations in the sample gas flow rate are compensated by means of the differential pressure compensation. ZrO2 electrolyte tube Pt electrodes I [mA] 850 °C 1,560 °F 1,470 °F 800 °C 600 A (Iair) 400 Test gas (21% O2) d=0.5 l/h (0,13 gal/hr) d=0.42 l/h (0,11 gal/hr) 200 Fig. 3-2: Structure and function of the LAMBDA TRANSMITTER E oxygen probe 0 8 16 24 32 O2 [vol %] I H M Current as function of oxygen Electric sensor heater Measuring gas A d Calibration value (Iair ≈ 21 vol. % O2) Test/sample gas quantity This characteristic shows that it is not necessary to know the proportionality factor or the measuring gas quantity in order to measure the oxygen. It is sufficient to assign the oxygen concentration (O2 = 21%) to the probe current measured with air I (air) and then draw a straight line to the zero-point (I = 0; (O2) = 0) through the calibration point derived in this way. In practice, this means that the probe can be easily aligned and adjusted by assigning ~ 21 Vol. % O2 to the measured air value (20.96). If the cell is structured appropriately and a suitable voltage is applied, the linear characteristic of the probe depends solely on the sample gas quantity, which governs the gradient of the straight lines (see diagram). 10 General Description - Theoretical Fundamentals, Measuring Principle The temperature of the solid electrolytes and the electrodes is not explicitly incorporated in the probe signal, although it does determine the internal resistance of the probe or its limit current and, in turn, the measurable oxygen concentration range. The probe temperature does not need to be measured or regulated, but it must be ensured that it does not undershoot a defined critical value, which depends on the required measurement range. To measure oxygen concentrations of up to 21 vol. % (atmospheric oxygen) the minimum probe temperature is 800°C (1,470 °F), for example. The static probe characteristic I = f (O2) in the diagram shows that the measurement accuracy is generally stable, regardless of the probe temperature and oxygen concentration. Using a current-proportional probe voltage and by compensating pressure and temperature effects on the flow-control capillary, a measurement accuracy of more than ± 0.2 vol.% oxygen in flue gases of all common fuels can be achieved, even when measured values are not compensated. Probe (measuring cell) ageing is compensated by measuring the internal cell resistance and, in turn, adjusting (increasing) the temperature of the measuring cell over a broad range, and therefore does not affect the measurement accuracy. Long-term experience of operating the device under difficult conditions (e.g. incineration of industrial waste, waste incineration, bio/sewage gas, etc.) has shown that the measuring principle is extremely resistant to contamination provided that the LAMBDA TRANSMITTER E is used properly. Cross-sensitivity with non-combustible gas components (e.g. H2O, N2, CO2, NOX, SO2, etc.) is not an issue. When oxygen is present, combustible gas components are burnt off on the platinum-coated surface of the sensor, which is approx. 800 °C (1,470 °F),. Example: 2CO + O2 = 2CO2 This means that with 1 vol. % CO in the measuring gas, 0.5 vol. % oxygen too little is displayed. For this reason, this measuring principle is not suitable for measuring oxygen in combustible gases. NOTE The amperometric measuring principle of the Lambda transmitter yields an almost linear sensor characteristic. This characteristic passes through zero and its gradient is determined by an Calibration point. When the measurement is taken in ambient air with an oxygen concentration of ψcal = 20.96 vol. %, this point is normally derived by determining the probe current Ical [mA]. . With respect to the measured probe current I, the ideal oxygen concentration (ψO2) of any measuring gas is governed by the following formula: Gl. (1) ψ02,ideal = ψcal x I / Ical Depending on physical and design aspects, the LAMBDA TRANSMITTER E probe current depends not only on the oxygen content of the measuring gas, but also on the gas temperature (T), the differential pressure (∆p), the absolute pressure upstream of the flow-control capillary, the average molecular weight (Mm), and a function of the mean isentropic exponents (F(∆)) of the measuring gas in relation to the Calibration conditions (index "cal"): ψO2 =ψ02,ideal x pcal / p x (T/Tcal)1/2 x (Mm/Mm,cal)1/2 x F(ψ)cal / F(ψ) Gl. (2) To compensate these fault effects, the GM 302 oxygen analyzer features the following measured value corrections: • Temperature compensation • Pressure compensation • Flow Rate Compensation See also chapter 3.1.5 11 General Description - Theoretical Fundamentals, Measuring Principle 3.1.1 Housing Versions The LAMBDA TRANSMITTER E is supplied with one of two types of housing: • Sheet-steel housing • Cast-aluminum housing The two types of housing have a different internal structure but identical function. 3.1.2 General Functional Description The LAMBDA TRANSMITTER E is a versatile, microprocessor-based O2 measuring device for taking direct measurements of the O2 concentration of non-combustible gases in the hyperstoichiometric range (λ >1). The measuring method is based on the tried-and-tested ZrO2 current measuring principle. The measured values are output via an analog output with 0/4 to 20 mA or 0 to 10 V. The device can be operated via a display/control unit, a PC in conjunction with the remote display software, or via a remote display connected to the LAMBDA TRANSMITTER E via the LSB bus. 3.1.3 Advantages of the LAMBDA TRANSMITTER E Measuring Principle • Quasi-linear measurement signal with fixed zero-point • Calibration with ambient air (no special measuring gases required) • High measuring accuracy (better than 0.2 vol.% O2 in the range 0 to 21 vol.% O2) • Automatic probe checks and Calibration using compressed air • No mechanical pumps • Sensor element outside of the flue gas system (stack), no ignition source in the flue gas duct (TUEV confirmed) • Test gas temperature of max. 950 °C (1,740 °F) with metal extraction and up to 1,600 °C (2,900 °F) with ceramic gas extraction device • No gas preparation required, measurement directly in the humid flue gas • A small measuring gas quantity (approx. 0.5 l/h; 0.13 gal/hr) means that the measuring gas temperature does not affect the measurement accuracy. The sensor system itself is located outside the flue gas system. • Rapid response time of the entire system (T90) < 20 seconds with standard extraction (insertion depth: 500 mm/ 19.7 in) • No reference gas required • No temperature control required in the measuring cell • Simple operation • IP 66 (protection class) for ambient temp. of –20 °C to +55 °C (–4 to +130 °F) • The ZrO2 sensor, heater, and all gas-carrying components can be easily replaced by the end customer. • Electrical contacting outside the flue gas • Wide range of applications • The measuring gas-side components are identical to those in the previous system. • Maintenance free 12 General Description - Theoretical Fundamentals, Measuring Principle 3.1.4 Influence of Air Humidity on the Calibration Value of 20.96 vol.% O2 The calibration procedure of the LAMBDA TRANSMITTER E takes place by using compressed air. In order to consider the relative humidity of the compressed air used for the calibration procedure a calibration offset (parameter 297) has to be set. The setting of the calibration offset parameter (P297)at works: –0.1 vol% of O2. The influence of the rel. humidity of air in relation to the air temperature is shown in the following diagram. 0,00 -0,10 10 % relative humidity -0,20 Calibration offset in vol.% O 2 (P297) 20 % -0,30 30 % -0,40 40 % -0,50 50 % -0,60 60 % -0,70 70 % -0,80 80 % -0,90 90 % -1,00 100 % -1,10 0 5 10 15 20 25 30 35 40 45 50 Temperature [°C] Influence of air humidity on the O2 calibration value of 20.96 vol.% 13 55 60 General Description - Theoretical Fundamentals, Measuring Principle 3.1.5 Flow Rate Compensation The flow rate through the capillary depends on the average molecular weight/gas constants of the gas to be measured. With "normal" flue gases from oil, gas, and coal firing, the effect on the measurement accuracy is insignificant. The measurement error is within the specified measurement accuracy of ± 0.2 vol. % O2) The following diagram shows the fault effect for different fuels. This arises from the correlation between the sample gas flow rate and the average molecular weight/gas constants of the flue gas. The diagram shows the typical ratio of CO2 to H2O in the flue gas (calibration with dry air). Fig. 3-3: Fault effect for different fuels NOTE Fuel-specific flow rate compensation is deactivated by default. It can be activated via parameter 836. Fuel-specific flow rate compensation Fuel-specific compensation is set via parameter group 835 - 899. Correction of measured values Measured values are corrected via parameters 1280 to 1283. This is recommended in the following cases: • High level of humidity (H2O) and low CO2 content (e.g. downstream of wet scrubber) • High CO2 content and low H2O content 14 General Description - Theoretical Fundamentals, Measuring Principle 3.1.6 Cold-Start Delay The LAMBDA TRANSMITTER E features an intelligent cold-start delay function, which prevents flue gas from passing through a cold probe. The optimum time for switching on the measuring gas pump is governed by the temperature of the zirconium dioxide measuring cell, which is determined by measuring the internal cell resistance during the warm-up phase. The cold-start delay is always activated after the power has been switched off. This can be interrupted at any time, provided that the measured temperature in the area of the capillary exceeds 260°C: • Via the multi-function key • Via the remote display software • Via the display/control unit • Via the remote control unit (in preparation) During the cold-start delay, the system outputs either a substitute value or the "current measured value". Factory setting: non substitute value. Set via parameters 361 and 362. Start - Solenoid valve "calibration" OPEN - Air flows into measuring gas sampling tube. - Time-delayed ejector pump switch-on Wait 8 - 30 min (depending on measured internal resistance) Measure internal probe resistance Ri < 2 OHM no yes O2 value after 30 min: 21% ± 1%? no yes Solenoid valve "calibration" CLOSE Wait for 60 sec. Fig. 3-4: Intelligent cold-start delay Calibrate Mesure 15 General Description - Theoretical Fundamentals, Measuring Principle 3.1.7 Cold start Ri-table (Parameter 1984..1999) During the cold start the internal resistance (Ri) is measured, in order to recognize the heating condition of the probe. The determinde values are put in the cold start Ritable. On the base of these values a diagnostic of the cold start process is possible, otherwise they have no function. With an restart the values are deleted and again filled by the following cold start. Not used values are setted to „0“. 3.1.8 Ri-table (last Ri-value Parameter 1800...1898) Last measured Ri-value and Ri-table belongs together. The internal resistance and the heating power in the course of probe aging are stored. In the first entry of this history (last measured Ri-value), the internal resistance determined with the last aging compensation is put down in each case as well as the heating power and the time (operation hours). In the remaining parameters entries are put down, as soon as the heating power was changed by the aging compensation. After exchange of the sensor (Par. 104) this history will be deleted. 3.1.9 Aging compensation The aging of the sensor is compensated by increasing of the heating power. The internal resistance of the ZrO2-sensor is measured and if necessary an aging compensation (increasing the heating power) is accomplished. This takes place after the 1. calibration after coldstart and then approx. 1x per week (every 10000 minutes). The measured internal resistance of the sensor (Ri) is registered into the table in Par.1805...1898. Thus the aging of the sensor can be supervised. CAUTION! After exchange of the sensor the heating power must be reset on the basic value. Set Parameter 104 on „Release“ and acknowledge with „Enter“. If the instruction is implemented, the parameter 104 jumps back to "0". 3.1.10 Calibration history (Parameter 1570...1791) In the calibration history with each accomplishing automatic calibration a data set is stored. The data records are sorted, the last calibration is always put down in cal. history 1. If by the automatic calibration new data records are added, older data records are overwritten, simply the oldest data records are however not deleted, separate always temporally at closest placing overwritten, so that always a complete overview of the entire is presented. The parameters put down in the respective data record are self-describing. they correspond to the actual values of the parameters 74, 76, 54, 53, 51, 57, 18 and 5 available at the end of the calibration. By means of Par. 119 the calibration history can be deleted. 16 General Description - Theoretical Fundamentals, Measuring Principle 3.1.11 Calibration drift history (Parameter 3600...3679) In this history is stored the change of the O2-value of the last 40 automatic calibrations, together with the time (operation hours), so that e.g. the probe drift with a cyclic calibration every 24 hours for the last 40 days is available. This history is sorted, the newest entry always stands at the beginning. Examples for text + parameter in the display: **Calibration Drift History** Operating Hours Par. 3600: 7430 h Calibration modified about Par. 3601: -0,07 % Operating Hours Par. 3602: 7454 h Calibration modified about Par. 3603: +0,03 % e.c. up to Par. 3679 Not used values are setted to „0“. The values can be read out via the display or via the Remote-Display-Software. The parameters can also be queried via a Profibus-interface, which is connected to LSB. The output of the datas via CANopen-protocol is not be possible. 17 General Description - General View 3.2 General View 1 2 Fig. 3-5: LAMBDA TRANSMITTER E 1 Electronics section 2 Probe section Fig. Obligations and Liability 3-6: LAMBDA TRANSMITTER E mounted on the flue gas duct (side view) Connection dimensions, connection values 18 General Description - General View 3.2.1 LAMBDA TRANSMITTER E in Sheet-Steel Housing Display/control unit (optional) 0 Lock for opening the electronics section Additional operating/fault mode display via LED row, multi-function key, maintenance switch RS422/CAN/LSB communication LEDs Processor card LEDs for fuse monitoring RS232 PC interface for connecting the remote display software Fig. 3-7: Front view of electronics section DANGER Before opening the internal door (entry electronic section) disconnect line voltage !! 19 General Description - General View Probe and electronics transformer Proportional valves 1 and 2 (for air calibration below, For ejector above) Probe chapter(connection side) Solenoid valve 1 – air calibration Solenoid valve 2 – housing cooling Condensate tanks for differential and absolute pressure measurements LSB module (optional) Connection terminals (analog output) Compressed-air input – air calibration Compressed-air input – Ejectorpump Fig. 3-8: Internal view of electronics section 20 General Description - General View 5 Fig. 3-9: Connection side 8 5 7 1 6 2 3 4 1 Compressed air inlet for Ejectorpump 2 Cooling outlet 3 Compressed air inlet for air Calibration/cooling 4 Cooling inlet 5 Free cable connection (e.g. for analog output, LSB module, RS422 interface) 6 7-pin LSB/CAN female connection to gas extraction device and filter heater 2 3 1 7 4 6 5 7 7-pin LSB/CAN male connection to other devices with a LSB/CAN terminal 2 1 3 7 6 4 5 8 Power connection Fig. 3-10: Suitable cable connection 21 1 - NC 2 - CAN-GND 3 - CAN low 4 - CAN high 5 - GND from EVU 6 - +24V from EVU 7 - PE General Description - General View 3.2.2 LAMBDA TRANSMITTER E in Cast-Aluminum Housing RS 232 PC interface for connecting remote display software Operating and fault mode display (LED row) Multi-function key Processor card Locks for opening the electronics chapterLEDs for fuse monitoring Fig. 3-11: Front view of electronics section LEDs for fuse monitoring DANGER Before opening the internal door (entry electronic section) disconnect line voltage !! Probe and electronics transformer Proportional valve 1 (air calibration) Proportional valve 2 (ejector pump) Probe section Solenoid valve 1 (air calibration) Solenoid valve 2 (housing cooling) Analog output card Power connection Compressed air input for air calibration/housing cooling Compressed air input for Ejector (probe) Fig. 3-12: Internal view of electronics section System connector for power pack and gas extraction device heater 22 General Description - General View 7 Fig. 3-13: Connection side 8 6 5 4 3 2 1 1 Compressed air inlet for Ejectorpump 2 Cooling inlet 3 Compressed air inlet for air Calibration/cooling 4 Cooling outlet 5 Free cable connections (e.g. for analog output, LSB module, RS422 interface) 6 7-pin LSB/CAN female connection to gas extraction device and filter heater 2 3 1 7 4 6 5 2 7 7-pin LSB/CAN male connection to other devices with a LSB/CAN terminal 1 3 1 - NC 2 - CAN-GND 3 - CAN low 4 - CAN high 5 - GND from EVU 6 - +24V from EVU 7 - PE 7 6 4 5 EVU ... evaluation unit (option) 8 Power connection Fig. 3-14: Suitable cable connection 23 General Description - Probe ChapterView 3.3 Probe ChapterView Ejector Differential pressure connections Fig. 3-15: Probe chapter (side view) Measuring gas outlet O2 measuring cell (inside) PT100 temperature sensor Air calibration Ejector Differential pressure connections Air calibration connection PT100 temperature sensor Fig. 3-16: Probe chapter (connection side) 24 General Description - Gas Extraction Device (GED) 3.4 3.4.1 Gas Extraction Device (GED) View of Gas Extraction Device 2 1 3 Fig. 3-17: Detailed view of gas extraction device 1 2 3.4.2 Gas extraction device Sampling filter 3 Sintered metal pre-filter Test Gas Temperatures Up to 700 °C (1,290 °F) Up to 950 °C (1,740 °F) From 950 °C to 1,400 °C (1,740 °F) to (2,550 °F) Standard Capillary tube: Extraction attachment: Sintered metal filter: Protective pipe: Pre-filter: Material: Material: Material: Material: Material: 2.4851 (Alloy 601) 1.4762 Hastelloy X 1.4571 up to 700 °C (1,290 °F) Hastelloy X Inconell 600 Capillary tube: Extraction attachment: Sintered metal filter: Protective pipe: Pre-filter: Material: Material: Material: Material: Material: 2.4851 (Alloy 601) 1.4762 Hastelloy X Inconell 600 Hastelloy X Ceramic Ceramic gas extraction device Capillary tube: Material Protective pipe: Material Pre-filter: Material Filter mesh: 50 µm Up to 1,600 °C (2,910 °F) Available on request Below 180 °C (355 °F) Please note: Al2O3 Al2O3 Al2O3 The temperature across the entire length of the gas extraction device (capillary), including the sintered metal pre-filter, must be above the dew point (water/acid dew point). This means: Highly sulfurous fuels (heavy-grade oil, coal): above 180 °C (355 °F) Gas: above 80 °C (175 °F) Light fuel oil: above 120 °C (250 °F) If this cannot be ensured, the gas extraction device and, if necessary, the sintered metal pre-filter must be heated (see chapter4.5). 25 General Description - Gas Extraction Device (GED) IMPORTANT! In double-wall stacks, a heater for the gas extraction device is required. With flue gases that are 100% saturated (exhaust vapors), a sintered metal pre-filter must also be used. Meas. gas Fig. 3-18: Installation planning aid, max. temperatures Max. permissible temperature with standard GED protective pipe Acid dew point 180°C (355°F) Water dew point 100°C (210°F) Heater required for gas extraction device Heater required for gas extraction device and filter Dimension X in mm Fig. 3-19: Using a gas extraction device and filter heater 3.4.3 Insertion Depth Worth Knowing: • Max: 3 m (9.9 ft) • Recommended: only as long as required (1/4 – 1/3 of the duct cross-section) The "core flow measurement", which is often required, is often not necessary. "Strands" are, in practice, very rare. Experience has shown that they occur under the following conditions: • When gases of different temperatures collide (usually re-circulated air and flue gas). • With gas velocities less than 1m/s (3.2 Ft/sec) (separation). 26 General Description - Protective Pipe with Aluminum Core If genuine "strands" occur, however, it is extremely difficult to find an extraction location above the insertion depth of the measuring gas sampler that is suitable for all operating conditions. IMPORTANT! With horizontal installation, it is recommended that the protective pipe for the gas extraction device be supported as of the following gas extraction device lengths. Standard: above 1,000 mm (39.4 in) Ceramic protective pipe: above 1,000 mm (39.4 in) Protective pipe with heater for gas extraction device: above 1,000 mm (39.4 in) With additional filter heater: from 1,000 mm (39.4 in) The protective pipe support is supplied for the appropriate insertion depth. If the measuring point is subject to vibrations, support should be provided for the protective pipe for the gas extraction device with shorter gas extraction device lengths. 3.5 Protective Pipe with Aluminum Core The protective pipe with an aluminum core ( standard ex immersion depth >500mm) distributes the heat of the measuring gas equally across the entire length of the gas extraction device. An electrical heater is not usually needed. Protective pipe with aluminum core without heater: Type 6 57 R 3441…R 3444. IMPORTANT! With horizontal installation, it is recommended that the protective pipe for the gas extraction device be supported with lengths of > 1000 mm (3.9 in). The protective pipe support is supplied for the appropriate insertion depth. If the measuring point is subject to vibrations, support should be provided for the protective pipe with shorter gas extraction device lengths. Protective pipe support type 657R3520 3.6 Conformity LAMBDA TRANSMITTER E • Complies with the currently applicable VDE (Verein Deutscher Elektroingenieure) regulations. • Fulfills the requirements of the Federal German Pollution Control Act (13th and 17th Implementing Ordinances) and the German Clean Air Act (TA-Luft). Proof No.1: 205 155 98 N2-EP GM302 Proof No.2: 936 / 21203535 / B • Complies with the "minimum requirements for emissions-related measuring devices" of the federal environment office in accordance with the guidelines for the performance testing, installation, calibration, and maintenance of systems for continuous emissions measurements. 27 Installation - Prerequisites 4 Installation 4.1 Prerequisites Before installation, the following points must be taken into account: Measuring location The measuring location must be easily accessible. The weight of the LAMBDA TRANSMITTER E is about 30kg. Measuring gas temperature Condensation must not be allowed to form at the water/acid dew point in the gas extraction device. The temperature along the entire length of the gas extraction device must, therefore, be above the dew point. Guide values for temperature: • Light hydrocarbons (e.g. natural gas, propane, butane, hydrogen, etc.) > 80 °C (176 °F) • Light fuel oil > 120 °C (248 °F) • > 180 °C (355 °F) Fuels (e.g. fuel oil S, coal, pyrolysis gases, etc.) in which high levels of SO2, HCL, or corrosive substances are likely to form. IMPORTANT! If the temperature anywhere on the gas extraction device is below the dew point, a heater is required for the gas extraction device (see chapter 3.4.2, Fig 3.18/19). In double-wall stacks, a heater for the gas extraction device is required. With flue gases that are 100% saturated (exhaust vapors), a sintered metal pre-filter must also be used. NOTE Corrosion on the gas extraction device indicates that the temperature is below the dew point. If the gas extraction device is blocked, this is a sure sign that the temperature has fallen below the dew point. The desired temperature control value should never be set higher than required. The greater the heat output, the shorter the service life of the heater. Type of gas extraction device Usage limits for the gas extraction device material: • Standard stainless steel (material 1.4571): Up to 700 °C (1,290 °F) • Inconell: Up to 950 °C (1,740 °F) • Ceramic: Up to 1,400 °C (2,552 °F) • Versions up to 1,600 °C (2,910 °F) on request Dust content When a high dust content or abrasive flue gas constituents are present, an extra protective pipe (for high-dust applications) must be used for the gas extraction device. See chapter 10.11. Length of gas extraction device The length of the gas extraction device (GED) should always be kept to a minimum. The probe should be attached as close as possible to the measuring point (duct). 28 Installation - Counterflange Assembly (Optional Accessory) 4.2 Counterflange Assembly (Optional Accessory) 1. Plan the mounting position. It can be mounted in any position between –20° of the vertical axis to the horizontral axis. Connection side below. Fig. 4-1: Mounting position 2. Flame-cut a hole with a diameter of 125 mm (5 in) in the flue gas duct. WARNING When you create the apertures, parts that fall into the duct may cause damage. For this reason, a wire must be used to secure parts that are to be cut away. Appropriate measures must be taken to protect against hot, explosive, or poisonous flue gases that may escape. 3. Align the counterflange (see diagram) and weld it securely to the measuring point. The two threaded holes (M8) must face up/down. Isolation waterproof and thermic 125mm M8 Fig. 4-2: Align the counterflange with the measuring point and weld on. 4. Seal the aperture with a dummy flange 5. The neck must be isolated waterproof and thermic. CAUTION! If the neck is not be isolated, maybe you will be get dep point falling. This can falsify the measured value. 29 Installation - Installing the Gas Extraction Device (GED) and the Protective Pipe for the GED 4.3 Installing the Gas Extraction Device (GED) and the Protective Pipe for the GED Fig. 4-3: Installing the gas extraction device and protective pipe for the gas extraction device (work steps specified) a b c Gas extraction device . Absolute pressure capillary Baffle plate d e f Sintered metal pre-filter Securing mechanism for protective pipe Protective pipe IMPORTANT! All glands and threads must be treated with anti-seize paste (type 650 R 1090). 1. 2. 3. 4. Remove the protective cap from the measuring gas inlet. Mount the gas extraction device (a) and carefully secure (max. 6 Nm.). Screw in the absolute pressure capillary (b) by hand. Install the protective pipe (f) with the sintered metal filter (d) on the probe installation fitting. 5. Align the baffle plate (c) in such a way that it protects the filter (d) against contamination. The filter should be located in the "wake region". Direction of measuring gas flow Tighten the nut on the pre-filter. IMPORTANT! The sintered metal filter is very fragile. Once installed, Calibration cannot be carried out without the filter. 6. Attach the aperture securing mechanism (e) for the protective pipe (f) for the GED. 30 Installation - Electrical and Pneumatic Connections 4.4 Electrical and Pneumatic Connections CAUTION! Observe the line voltage !!! Factory default is AC230V. For changing over to AC115V see chapter 12.4.1 IMPORTANT! The LAMBDA TRANSMITTER E must only be operated when the ambient temperature is between -20 °C and +55 °C (-4 °F and 130 °F). Lambda-Transmitter Luftabgleich PV1 PV2 Gehäusekühlung 300L/h zum Ejektor Drossel Grundstellung geschlossen Grundstellung offen MV1 Schlauchanschluß 6x1mm Abgleich/Kühlung MV2 Schlauchanschluß 6x1mm Ejektor Drucklufteinheit Druckregler Ejektor (auf 2bar einstellen) Druckregler Vordruck (auf 4bar einstellen) Schlauchanschluß DN10mm Drucklufteingang Druckregler Abgleichluft/ Gehäusekühlung (auf 2bar einstellen) Fig. 4-4: Pneumatic connection Schlauchanschluß 8x1mm Automatischer Kondensatablass Fig. 4-5: Connections at the sheetsteel housing Fig. 4-6: Connections at the castaluminum housing 31 Installation - Electrical and Pneumatic Connections Fig. 4-7: Compressed air unit Fig. 4-8: Compressor unit Prescribed hose cross-sections Distance of 6 x 1 mm (0.04 in) to 2 m (6.6 ft) between the pressure control valve and the LAMBDA TRANSMITTER E, 10 x 1 mm between the compressor unit and LAMBDA TRANSMITTER E. A reducer to 6 x 1 mm is supplied. If distances are larger, the cross-sections must be adjusted accordingly. Alternatively, PA or PTFE hose may be used depending on the system-specific conditions. PUN hose - 6 x 1 mm (0.04 in), type 657 P 0547 IMPORTANT! Two separate pressure control valves must always be provided for the Ejectorpump and calibration. The two proportional valve control loops would otherwise affect each other, which could critically impair automatic calibration and, in turn, the function and measurement accuracy too. NOTE If the device is installed in a location that is difficult to access, it is recommended that the probe chapterbe installed separately from the electronics chapter(see chapter8.6 “Removing the Probe Body"). NOTE When installing the LAMBDA TRANSMITTER E on the counterflange at temperatures above 200 °C (392 °F), a second seal (type 657 R 3542) is recommended for heat 32 Installation - Electrical and Pneumatic Connections isolation. 33 Installation - System Settings in Accordance with System Composition (Reduced to Case Studies) 4.5 System Settings in Accordance with System Composition (Reduced to Case Studies) System Composition System Settings in the Transmitter on power supply unit for GED heater Case MEV heater Filter heater RS422 -GM31 conne ction EVU 31 LSB module(s) Optional 2nd RS422 (10.12) Par 121 Par 3895 Par 402 DIP switch SW1 (4.6.5) 1 0 0 0 0 0 no no heater LSB default ON 2 0 0 0 0 1 no no heater LSB default ON 3 0 0 0 1 0 no no heater CAN default OFF 4 0 0 1 0 0 no no heater LSB default ON 5 1 0 0 0 0 no MEV heater LSB default ON 6 1 0 0 0 1 no MEV heater LSB default ON 7 1 0 0 1 0 no MEV heater CAN default OFF 8 1 0 1 0 0 yes MEV heater LSB default ON 9 1 1 0 0 0 no MEV/filter heater LSB default ON 10 1 1 0 0 1 no MEV/filter heater LSB default ON 11 1 1 0 1 0 no MEV/filter heater CAN default OFF 12 1 1 1 0 0 yes MEV/filter heater LSB default ON • The variants with ONLY a filter heater have been omitted (inapplicable). • RS422 on board: can be switched between RS422 and CAN/LSB (using the jumper setting, see chapter12.5.1). Used with the gas extraction device/filter heater ('LSB') OR for LSB modules ('LSB') OR for the RS422 GM31 connection ('RS422'). • Second optional RS232 interface: if the RS422 GM31 connection is used and the first RS422 interface is assigned to the gas extraction device/filter heater ('LSB’) OR LSB modules ('LSB'). • Evaluation unit and the RS422 GM31 connection are mutually exclusive. • Evaluation unit requires the CAN bus. • LSB modules require the LSB bus. • Evaluation unit and LSB modules are mutually exclusive. • Parameter 121: no heater/gas extraction device heater/gas extraction device/filter heater • Parameter 3895: when operated with Evaluation unit on CAN/when operated WITHOUT Evaluation unit on LSB • Parameter 402: default temperature for gas extraction device heater: can remain at default setting (250 °C/482 °F)) • Parameter 058: "Measured temperature value from gas extraction device heater": measured value only. Not variable. 34 Installation - Installing the Gas Extraction Device and Pre-Filter Heater (Optional) 4.6 Installing the Gas Extraction Device and Pre-Filter Heater (Optional) f h i j (2x) k (2x) g e l m n d c b Fig. 4-9: Components of the gas extraction device and prefilter heater Connection cable length: 2 m (extension connecters not supplied, see 4.6.8) a a Gas extraction device with sampling filter b Absolute pressure capillary c Protective pipe with heater for gas extraction device d Heater for filter attachment e Threaded connector ends through which the connection cables are fed f Connection flange for gas extraction device heater (incl. 2 M8 x 35 securing bolts) g DN80PN6 flange seal Type 657R3542 4 5 h Securing mechanism for protective pipe (incl. 2 splints) i CU seal for protective pipe j Cutting ring (2x) k Screw caps (2x) l Baffle plate with filter attachment 20µm m Protective pipe support n Cable box for gas extraction device and pre-filter heater (power pack), incl. feeder and 5m LSB/CAN-line for connection to LT-E 7 10 9 13 6 Fig. 4-10: Installing the gas extraction device and pre-filter heater 1 11 12 14 35 8 Installation - Installing the Gas Extraction Device and Pre-Filter Heater (Optional) IMPORTANT! All glands and threads must be treated with anti-seize paste (type 650 R 1090). 36 Installation - Installing the Gas Extraction Device and Pre-Filter Heater (Optional) 1. Attach the connection flange (f) on the LAMBDA TRANSMITTER E . Use the M8 x 35 screws provided. Place flange seal DN80 (type 657 R 3540) (g) between the flanges. 2. Mount the gas extraction device (a) on the probe and secure (max. 6 Nm.). 3. Attach the absolute pressure capillary (b). 4. Push the screw caps (k) and the cutting ring (j) over the connection cable for the heater for the gas extraction device. 5. Route the connection cables with the screw cap and cutting ring through the threaded connector end (c) on the flange (affix the insulating hose at the end with insulating tape). 6. Insert the CU seal (i) in the probe. Mount the protective pipe with the heater (c) for the gas extraction device on the probe and secure. The filter should be located in the "wake region". 7. Tighten the second screw cap (k) on the connection flange (f). 8. Align the baffle plate with the filter attachment (l) in such a way that it protects the filter against the flow in the duct (see chapter4.3). 9. Tighten the nut on the pre-filter. IMPORTANT! The sintered metal filter is very fragile. Once installed, Calibration cannot be carried out without the filter. 10. Install the aperture securing mechanism for the protective pipe (h) and secure using the two splints provided. 11. Push the screw caps (k) and the cutting ring (j) over the connection cable for the pre-filter heater (d). 12. Route the connection cable for the pre-filter heater (d) through the second threaded connector end (e) on the connection flange (f). 13. Place the pre-filter heater (d) on the filter attachment (l). 14. Tighten the second screw cap (k) on the connection flange (f). 15. If the insertion depth is greater than 1,000 mm (39.4 in), the support (m) supplied in the set must also be attached. 16. Install the LAMBDA TRANSMITTER E on the counterflange using the flange seal (657 R 3542). See “Installing the LAMBDA TRANSMITTER E ”. 17. Establish the electrical connections for the gas extraction device and pre-filter heater on the power pack (type 657 R 3160). 18. Connect the power pack (chapter4.6) and LAMBDA TRANSMITTER E using a 7pin connector. 19. When the LAMBDA TRANSMITTER E and the power pack are switched on, the gas extraction device and pre-filter heater are recognized automatically. IMPORTANT! The heater must be in contact with the filter to ensure good heat transmission. 37 Installation - Installing the Gas Extraction Device and Pre-Filter Heater (Optional) 4.6.1 Power Pack for the Gas Extraction Device and Pre-Filter Heater CAUTION! Observe the line voltage !!! Factory default is AC230V. For changing over to AC115V see chapter 4.6.4 A separate power pack is required to electrically heat the gas extraction device and the sintered metal pre-filter. Note: this is supplied in the "gas extraction kit with heater for gas extraction device" and "gas extraction kit with gas extraction device and filter heater". Version: Wall-mounted housing IP 65 Features: Configurable heat output using LAMBDA TRANSMITTER E Interface: LSB or CANopen for data connection to LAMBDA TRANSMITTER E DIP switch (see chapter4.6.5) Connection for gas extraction device and pre-filter heater with PT100 Fig. 4-11: Power pack for electrically heating the gas extraction device and sintered metal pre-filter Electrical connection with PT100 measuring element 38 Installation - Installing the Gas Extraction Device and Pre-Filter Heater (Optional) 4.6.2 Power Pack Connections 4-pinpower connection: 230 V AC/ 50-60 Hz, or 115 V AC / 50-60 Hz (disconnect transformer, replac F1, see 4.6.3) 7-pin LSB/CAN connection to LAMBDA TRANSMITTER E . 7-pin LSB/CAN connection to other devices with a LSB/CAN terminal Power consumption: gas extraction device only: max. 400 VA, gas extraction device and prefilter: max. 500 VA Fig. 4-12: Connection side M20 cable bushing passages for pre-filter heater. M20 cable bushing passages for gas extraction device heater with PT100. Fig. 4-13: Suitable cable connection 39 Installation - Installing the Gas Extraction Device and Pre-Filter Heater (Optional) 4.6.3 Electronics Board of the Power Pack F1 Æ Main fuse line voltage F2 Æ Fuse print trafo F3 Æ Fuse heating X1 Æ Trafo connector primary winding, if line voltage = AC230V X2 Æ Bypass connector, if line voltage = AC230V or Trafo connector primary winding, if line voltage = AC115V X11 Æ Electrically connection for line voltage X12 Æ Electrically connection for line voltage SYSTEM BUS X13 Æ 11/12 Electrically connection GED-heating X13 Æ 13/14 Electrically connection prefilter-heating X14 Æ Electrically connection PT100 measuring element for the GED-heating X15 Æ Trafo connector secondary winding AC42V DIP Æ Micro switches SW1...SW12 BR1 Æ Position 1-2 Æ Normaly operation mode Position 2-3 Æ Mode for software update BR2 Æ Position 1-2 Æ 120R termination resistor SYSTEM BUS disable Position 2-3 Æ 120R termination resistor SYSTEM BUS enable 4.6.4 Switching over the line voltage from AC230V to AC115V (if required) 1.) Changing main fuse F1 New value 6,3A slow-blow 2.) Remove bypass connector X2 3.) Switch over trafo connector from X1 to X2 40 Installation - Installing the Gas Extraction Device and Pre-Filter Heater (Optional) 4.6.5 Function of the LEDs on the Power Pack Board: Interface LEDs 2 and 4 green = receive, yellow = send. When operating normally, the gas extraction device heater sends a short data packet every two seconds, (i.e. the yellow LED flashes briefly every two seconds); the green LED flickers irregularly as it shows all bus activity. Three green LEDs are located between the PT100 terminal and the heater terminals. From left to right: LED 5 (green, on the left): shows operating voltage, permanently lit. LED 1 (green, center): shows whether the gas extraction device heater is switched on or off. LED 3 (green, on the right): shows whether the filter heater is switched on or off. If a defect is detected on one or both heaters (normally a defective heater or fuse), the corresponding LED flashes very rapidly (approx. every 0.2 sec instead of every second). A current of approx. 0.6 A must be flowing through the filter heater and 1.3 A through the gas extraction device heater to trigger monitoring. 4.6.6 Assignment of DIP-switches on the board of the power pack SW 1 OFF CAN SW 1 ON LSB (software version 4V24a or more recent) SW2 (only relevant for standalone versions) SW 2 OFF Gas extraction device + filter heater SW 2 ON Gas extraction device heater only SW9 to SW12 determine the default required temperature of the GED-heater, if communication is not taking place (standalone). Otherwise, the temperature set in P402, is used for controlling. SW9 SW10 SW11 SW12 Required temperature 0 0 0 0 200 °C (392 °F) 0 0 0 1 100 °C (212 °F) 0 0 1 0 120 °C (248 °F) 0 0 1 1 140 °C (284 °F) 0 1 0 0 160 °C (320 °F) 0 1 0 1 180 °C (356 °F) 0 1 1 0 190 °C (374 °F) 0 1 1 1 200 °C (392 °F) 1 0 0 0 210 °C (410 °F) 1 0 0 1 220 °C (428 °F) 1 0 1 0 230 °C (446 °F) 1 0 1 1 240 °C (464 °F) 1 1 0 0 260 °C (500 °F) 1 1 0 1 280 °C (536 °F) 1 1 1 0 300 °C (572 °F) 1 1 1 1 OFF 41 Installation - Installing the Gas Extraction Device and Pre-Filter Heater (Optional) 4.6.7 Electrical Connection to LAMBDA TRANSMITTER E 2 5 6 4 1 3 7 Line voltage via 4p.-plug connector Elec. connection GED und pre filter heater cable length 2m LSB / CAN via 7p.plug connector cable length 5m 4.6.8 GED Heater – 2x2,5mm2, white PT100 – 2x0,25mm”, wh/rd Fliter 3x0,5mm2 Grey/black/green-yellow 1 LAMBDA TRANSMITTER E 2 Connection flange for GED heater 3 Counterflange 4 Support of the protective pipe 5 Protective pipe for GED heater 6 Heater for pre filter 7 Power pack Setting the LAMBDA TRANSMITTER E and the Power Pack (See also Chapter 4.5) Check DIP switch 1 on the power pack electronics board and the parameter setting in LAMBDA TRANSMITTER E . Set DIP switch 1 on the power pack electronics board: • To “ON” during operation without an evaluation unit (LSB operation) • To “OFF” during operation with an evaluation unit (CANopen operation) Set the parameters (service level) in LAMBDA TRANSMITTER E as follows: • Parameter 121: “gas extraction device heater“ or “gas extraction device and prefilter heater” • Parameter 402: “required gas extraction device temperature 250 °C (482 °F)” • Parameter 3895 when operating without evaluation unit set to: “LSB” • Parameter 3895 when operating with evaluation unit set to: “CANopen” Reading parameter (measured value): • Parameter 058: gas extraction device temperature “xx °C” NOTE If control via CANopen or LSB fails, the temperature setting for DIP switches SW9 to SW12 are still used (chapter 4.6.5). 42 Installation - Installing the Gas Extraction Device and Pre-Filter Heater (Optional) 4.6.9 Cable Connectors for Extending Gas Extraction Device and Pre-Filter Heater 2-pole (for pre filter heater): Lenght 100mm External diameter 24mm Conductor 2,5 sqmm Diameter cond. min 5mm, max 12,5mm, Item no. 657R3167 5-pole (for GED heater with Pt100): Lenght 150mm External diameter 35mm Conductor 2,5 sqmm Diameter cond. min 10mm, max 19mm, Item no. 657R3168 Type of protection IP67 Range of temperature -20°C...+66°C 4.6.10 Dimension Drawing of the Power Pack 43 Installation - Installing the Protective Pipe for High-Dust Applications 4.7 Installing the Protective Pipe for High-Dust Applications e Fig. 4-14: Components of the model for high-dust applications h g a c d b f f M8 x 25 hexagon socket screws with spring washer for securing the adapter flange to the counterflange g Flange seal for adapter flange h Seal set a Counterflange b Flange seal for counterflange c Protective pipe for gas extraction device for high-dust applications d Adapter flange for heater for MEVprotective pipe e Grub screw 2 1 3 4 5 c f a b d g f 6 8 h3 h3 h1 h1 h2 h2 h1 h1 Fig. 4-15: Installing the model for high-dust applications IMPORTANT! All glands and threads must be treated with anti-seize paste (type 650 R 1090). 44 Installation - Installing the Protective Pipe for High-Dust Applications 1. Push the flange seal (b) over the threaded rods of the counterflange. The counterflange must already be welded onto the flue gas duct. 2. Screw the protective pipe for high-dust applications (c) into the adapter flange (d). 3. Align the protective pipe for high-dust applications (c) with the flow direction of the flue gas and secure it using the grub screw (e). 4. Push the adapter flange (d) with the protective pipe for high-dust applications (c) over the threaded rods of the counterflange and secure it using the two M8 x 25 hexagon-socket screws with the spring washer (f). 5. Place the flange seal for the adapter flange (g) between the threaded rods of the counterflange (a). 6. Attach the seal set (h) to the probe unit on the LAMBDA TRANSMITTER E . Make sure that you do this in the correct order: • h1: Pressure disk • h2: Graphite seal for high-dust applications • h1: Pressure disk • h3: Disk springs 7. Remove the baffle plate from the filter attachment. 8. Install the gas extraction device and the protective pipe for the gas extraction device. See chapter 4.3 “Installing the Gas Extraction Device and the Protective Pipe GED on the LAMBDA TRANSMITTER E ”. 9. Install the LAMBDA TRANSMITTER E on the adapter flange. See chapter 4.2 “Installing the LAMBDA TRANSMITTER E ”. NOTE: A protective pipe support cannot be installed when a protective pipe for high-dust applications is used. 45 Operation and Display Controls - Multi-Function Key 5 Operation and Display Controls 5.1 Multi-Function Key All the basic functions can be executed by means of the multi-function key and maintenance switch. Fig. 5-1: Operation and display unit on the processor board 3 Maintenance switch S1 3a = "ON" position, 3b = "OFF" position 4 LED row: LED 1 to 12 1 DIP switch 2 Multi-function key T2 Function: Key T2 operation: Toggle the displayed warning/fault Briefly Reset the displayed warning/fault 3 sec* Quick start of measuring gas pump; interruption of cold start 3 sec/6 sec** * Some warnings/faults cannot be reset if the fault is still present or the routine is still running. ** If more than one warning/fault is present, the key must be pressed for 6 seconds. The mode „Maintenance“ can be activated via , maintenance switch S1, the display or via the Remote-Display-Software. The mode „Maintenance“ will also be enabled, if a higher release level via a password is activated (can be set in Par.974, default = “factory“). 46 Operation and Display Controls - LED Display 5.2 LED Display Legende: LED LED 1 ist aus blinkt leuchtet Maintenance Normal operation Maintenance mode active LED 2 — LED 3 — LED 4 Heater monitoring Heater control active Heater with fixed voltage LED 5 Operation mode display Calibration Measurement LED 6 Operation display Operation LED 12 Warning/fault display No warning/fault At least 1 fault is present At least 1 warning is present 47 Operation and Display Controls - Monitor Output / DIP Switch 5.3 Monitor Output / DIP Switch The following measured values can be queried via terminals 31 and 32: • Measured O2 value 5.4 • Probe voltage • Probe current Measurement Conversion Measured O2 value 0 - 2.5 V 0 - 25% O2 Probe voltage Probe current DIP switch SW2 SW1 -> off off 0 - 1.4 V 0 - 1,400 mV -> off on 0 - 1 V -> 0 - 1,000 mA on off Remote Display Software • For operation of the LAMBDA TRANSMITTER E via RS232 interface • To backup and restore the data set • Instructions are provided in the software. 48 Operation and Display Controls - Display/Control Unit 5.5 Display/Control Unit Cursor Enter key Menu keys Brightness and contrast Limit values Contrast + : + Contrast - : + Brightness + : + Brightness - : + Li 4 The limit value is exceeded Li 4 The limit value is undershot NOTE The limit values (Li 1 to Li 4) are only displayed if the limit value monitoring function has been activated. Menu keys 5.5.1 meas: Measurement cal : Calibration par: Parameter setup diag: Diagnostic “Meas” Menu Functions meas meas 49 Operation and Display Controls - Display/Control Unit 5.5.2 “Cal” Menu Functions cal ENTER ENTER see chapter 8.2 ENTER ENTER see chapter 8.3 50 Operation and Display Controls - Display/Control Unit 5.5.3 “Par” Menu Functions exit psw Return to previous menu Password entry *0 * * * *0 * exit Return to previous menu clear Reset to “”Released customer level” ---- 00 1 2 ...9 A B ... ++++ 00 Z Y ...A 9 8 ... Confirm password 51 Operation and Display Controls - Display/Control Unit view Display al l paramet ers. Th ese are divided into grou ps These groups contain other parameters exit s/l Return to previo us men u Change the scope of inf orma tio n *kw*_30_____[ 12 ; 42 ]_____ Value range for Change of parameter Default value (base value in EPROM) ÒReleased customer levelÓand parameter type: b = operation, k = customer, s = service, f = production ,w = write , r = read group- Scroll back to previo us group of paramet er group+ Scroll forward to next grou p of paramet er 52 Operation and Display Controls - Display/Control Unit change Parameter change Increase value Reduce value 2.2 2.2 30 30 30 Return to previous menu without change esc dflt OK exit s/l Parameter cannot be changed Parameter cannot be changed Value flashes: Mode of change is active Confirm default value Confirm change Back to previous menu view s/l group- Scroll back to previous group of parameter group+ Scroll forward to next group of parameter 53 Operation and Display Controls - Display/Control Unit 5.5.4 “Diag” Menu Functions Warnings and faults Confir mation o f error Note: Not all alarms/faults can be confirmed. Carry out troubleshooting diag1 + P+V exit Return to prev ious menu exit exit maint remote hist Reset limit value alarml Prerequisite: Reset mode ÒmanualÓor ÒacknowledgeÓ is selected Back to prev ious menu Switch on /o f f maintenance mode Maintenance switch S1 must be set on ÒoffÓ Establish connec tion with other LT dev ices via LSB Display o f fault/alarm history exit Back to prev ious menu Switch to entries made recently Switch to older entries Via „Trigger“ in par.118 the fault history can be deleted. 54 Operation and Display Controls - Parameter Groups 5.6 Parameter Groups Groups Test data Operating data Counters and times Commands Hardware options Probe glide voltage Probe heating Ejector heating Regular cold start Internal cold start Zero/Span values Probe check up Probe Calibration Ageing compensation Pump heating Cabinet cooling O2 test data configuration Monitor output Differential pressure adjustment Heater for gas extraction device Differential pressure sensor Pressure compensation Pressure measurement Temperature compensation Differential pressure compensation Modbus RS232 Condensate pump Automatic drift compensation Analog output 1…4 Analog input 1…4 Test data configuration Fuel configuration Limits Limit configuration Display Software version Digital outputs relais 1…7 Solenoid valves Pump diagnostics Flue gas controller Digital inputs 1…8 Service times Parameters 1 - 17 40 - 61 70 - 76 100 - 118 120 - 125 130 - 142 150 - 160 165 - 166 200 - 208 220 - 233 240 - 242 250 - 253 270 - 297 300 - 318 350 - 351 354 - 358 360 - 362 380 - 383 386 - 396 400 - 409 410 - 416 420 - 439 440 - 442 450 - 470 473 - 477 480 - 483 490 - 492 500 - 504 530 - 569 570 - 609 700 - 823 835 - 899 910 - 917 930 - 967 970 - 972 985 - 990 1030 - 1099 1100 - 1145 1153 - 1155 1160 - 1168 1170 - 1245 1260 - 1261 Groups PID controller Configuration of PID controller State of PID controller Constant values Password / serial number Parameter CRC16 Calibration history 1…16 Table RI Table of cold start RI Curve 1 Curve 2 Curve 3 Curve 4 Curve 5 Curve 6 Curve 7 Curve 8 Curve 9 Curve 10 Curve 11 Curve 12 Calibration drift history Temperature statistics LSB bus Parameter statistics Parameter fault Parameter commands 55 Parameters 1350 - 1357 1361 - 1372 1380 - 1391 1450 1472 - 1488 1490 - 1493 1580 - 1791 1800 - 1898 1984 - 1999 2000 - 2039 2050 - 2089 2100 - 2115 2150 - 2165 2200 - 2215 2250 - 2265 2300 - 2315 2350 - 2365 2400 - 2415 2450 - 2465 2500 - 2515 2550 - 2565 3600 - 3679 3750 - 3770 3800 - 3895 4900 - 4904 4910 - 4974 4980 - 4987 Operation - Activating Measurement Mode 6 Operation 6.1 Activating Measurement Mode CAUTION! Observe the line voltage !!! Factory default is AC230V. For changing over to AC115V see chapter 12.4.1 Switch on the LAMBDA TRANSMITTER E . NOTE If the factory settings have not been changed, the measurement is checked automatically and adjusted if necessary (cyclical calibration) after the "cold start", again after two hours, and then every 24 hours. Manual intervention is not normally necessary. The point at which the cyclical calibration should start can be set in par. 061. If the cold start is interrupted, the calibration must be triggered manually and should be repeated after 2 hours of operation. Each calibration will be listed in a history (par. 1570…1791). The history can be deleted via par.119. See also chapter 3.1.10. Typical values during initial commissioning after calibration with compressured air (20.96 vol. % O2): • Probe current (uncompensated): 500 ± 50 mA • Differential pressure via the capillary: 20 - 30 mbar (0.3 – 0.43 psi) • Temperature of capillary: 300 - 500 °C (572 – 932 °F) • Pressure increase during Calibration (read via parameter 50): 1 - 5 mbar (0.015 – 0.07 psi) • Heat output of measuring cell (read via parameter 54): 75 Watt Internal resistance (RI) of ZrO2 measuring cell (read via parameter 53): < 1Ω • For warranty reasons, the enclosed Probe Record Card (chapter 12.6) must be maintained during commissioning and kept with the LAMBDA TRANSMITTER E . IMPORTANT! The cold start cannot be interrupted until the temperature on the capillary is > 260 °C (500 °F). 56 Operation - Activating Measurement Mode 6.1.1 Output of the „Zero/Span“ values The output of the “Zero/Span” values can be activated via parameter 240 “ON/OFF” Output via: • Analoge output 1, terminals 42 / 43. • Digital output 4 at the LSB-Module (optionally) Function The output of the „Zero/Span“ values, effects after ending of each complete calibration. It doesn’t make any difference if the calibration is released manually, via digital input or via the internal timer. First will be issued the Zero value for 15 sec., afterwards the Span value. Additional to the output of the „Zero/Span“ values, closes the contact of output 4 at the optionally LSB digital output module. Additionally, the values can be issueded before calibration. For this purpose P241 must be set to “ON”. NOTE If calibration is released via the internal timer, it makes first a check-up. If the actual O2 value on air is inside the range of 21% O2 +/-0,2% (P 250), it will be carried out no calibration, by reason of reduction of the routine. Also will be issuded no Zero/Span values. If the Zero/Span values will be required via a digital input, will be always be carried out the value of the last complete calibration. Will be set P 250 (Check-up tolerance) to „0“, will be always carried out a complete calibration. Parameter • P 240: „Zero/Span output after calibration“ „ON“ (default OFF) Output of the „Zero/Span“ values • P 241: „Additional output check value to Zero/Span output" „ON“ (default OFF) Additional output of the „Zero/Span“ values before calibration • P 242: 1...60sec. (default 15 sec. for each value) Output timer of the Zero- and Span values • P 1052: Must be set to „not measure“. • P 1061: „Zero/Span“ Relay output 4 activated, for signal „Zero/Span output“ via LSB modul (optionally) • P 1201: „Zero/Span output“ Recall of the „Zero/Span“ values via digital input 4 from the LSB input module (optionally). 57 Operation - Operating and Status Messages 6.2 Operating and Status Messages 6.2.1 List of operating statuses: Operating notes State notes Description Cold start Once the device has been switched on, it remains in the "cold start" status until the probe is operational. Mesure The device is in "measure" mode and supplies a valid measured O2 value (provided that no fault is present). Calibration auto The normal automatic adjustment is accomplished Check up Air or measuring gas is fed to the probe and the measured value is output as standard. In this mode, an EPA check can be carried out externally, for example. Note that the measured value is only valid if no fault is present. 1. calibration The standard automatic adjustment or the first calibration before aging compensation is carried out. agingcompensation. The internal resistance of the ZrO2 measuring cell is measured and, if necessary, ageing compensation is carried out. (every 10000 min., the measured Ri is registered into the table in par.1805...1898). 2. calibration An optional second automatic calibration is carried out after aging compensation. Wait for measure Whenever the device is switched to or from measurement mode, the device remains in the "wait for measurement" status for a short period (a few minutes) to ensure that the measuring cell is filled with the gas to be measured once measurement mode has been activated. Manual calibration The device is in "manual calibration " mode. Air is fed to the probe and the calibration value can be changed manually via the remote control unit. Maintenance In addition to the above-mentioned operating statuses, the device is in "maintenance" mode. Maintenance mode can be activated via the maintenance switch, the display, or via the remote display software. Maintenance mode is also automatically activated when a higher release level is activated by means of a password. (can be set in par.974, default=“factory“). Warning One or more warnings lines up Fault One or more faults lines up 58 Operation - Practical Notes 6.3 Practical Notes 6.3.1 Smoothing for 'Jumping' Display Values The display can be smoothed if values 'jump'. Smoothing is specified by: parameter 360 for measured O2 value (“operational” release level). NOTE • A high degree of smoothing causes the measurement signal to slow down. • Condensate in the gas extraction device can cause measured values to fluctuate. Water droplets form at the capillary tube. If a water droplet enters the probe, it evaporates. When this occurs, the display falls towards 0 vol. % O2. When conditions are stable (measuring gas temperature), this occurs at almost regular intervals. Fig. 6-1: 'Jumping' display values 6.3.2 Measurement in Flue Gases with a High Water Content (Downstream of Wet Scrubber) Flow rate compensation is recommended in highly unbalanced flue gases with a high moisture and low CO2 content (see chapter3.1.5 "Flow Rate Compensation"). Parameter group 1280 to 1283 – "customer" or "service" release level. 6.3.3 Measurement in Humid and Highly Contaminated Flue Gas • The gas extraction tube (capillary tube) must be kept above the water/acid dew point along its entire length. Min. temperature: 180 °C (356 °F). • If the measuring gas temperature is lower, the gas extraction device must be heated. 59 Operation - Practical Notes 6.3.4 Wet/Dry Measurement, Deviations, Conversion Table NOTE The LAMBDA TRANSMITTER E carries out measurements directly in the humid flue gases (wet measurement). When extractive devices are used, flue gases are removed and prepared. “Dry measurements” are normally used here, since the humidity has been extracted from the flue gas. As a result, O2 measurement values vary (see diagrams below). O2% Natural gas (CH4) 0.8 0.7 0.6 Oil (CH2)x 0.5 0.4 O2 % (dry) = O (wet) + 0.3 0.2 Fig. 6-2: Theoretical max. deviations of the O2 concentration in wet and dry measurement. Fuel: natural gas or oil 0.1 % O2 0 1 2 3 4 6 5 (wet) % O2 (dry) Gas Oil 12 10 8 6 O 2(dry) = K x O2 (wet) 4 Fig. 6-3: Calibration plot for the concentration values of O2 (dry) and O2 (wet) 2 % O2 0 2 O2 concentration range Conversion table for concentration values of O2 (dry) and O2 (wet) 4 6 8 Constant C gas/Ch4 10 12 (wet) Constant C oil/(CH2)x 0 – 6 % O2 1.18 1.115 6 -12 % O2 1.12 1.08 0 -12 % O2 1.15 1.10 60 O2 Operation - Removal from Service 6.4 Removal from Service 6.4.1 Brief Service Interruption If the system is out of service for a short period, you are advised to allow measurement to continue. 6.4.2 Long Service Interruption If the system is out of service for longer than 10 weeks or if measurement is deactivated, you are advised to remove the Lambda transmitter. This prevents the flow-control capillary from corroding and becoming blocked. NOTE Once removed and disconnected from the power supply, the LAMBDA TRANSMITTER E can be stored for an unlimited period. The zirconium dioxide measuring element is only subject to wear during operation (when it is at the operating temperature). 61 Warnings and Faults - Fault History 7 Warnings and Faults 7.1 Fault History The fault history can only be called up via Display and Operation unit or via the remote display software, refer to 7.3 Faults. 7.2 Display via Rows of LEDs on the Processor Board 7.2.1 Calling Up and Resetting Faults and Warnings (See Also Chapter 5.1) 7.2.2 • Display the next fault/warning: Press multi-function key T1 once. • Reset a fault: Press multi-function key T1 for 3 sec/fault. Faults via LED codes Legend: LED 7 8 is off 9 10 11 12 flashes lights up Fault No fault Cell damaged Flow throughput to low, probe current < 200 mA (1) Difference pressure too low Defective probe heater Probe broken wire Wrong current input of solenoid valves Proportional valve ejector I probe too high Dynamic is missing Dirty pre-filter Error analog output Error parameters Delta-p cal. too low Proportional-valve cal. Delta-p ejector too high (1) Check parameter 51: the probe current from the last calibration is stored here. 62 Warnings and Faults - Display via Rows of LEDs on the Processor Board 7.2.3 Warnings via LED codes Legend: LED 7 is off 8 9 10 11 12 flashes lights up Warning No warning Defective heating control Dirty pre-filter Flow throughput too low, probe current < 260 mA (1) O2 cell aged – replace Delta-p low Defective MEV*-heating Defective pre-filter heating Cal. gas flow throughput too low, increase! P (abs) too high/ too low Probe temperature too high / too low Defective ejector heating Delta-p ejector high Defective MEV* temperature-measuring Not used Probe current limitation Line voltage too high/ too low Pressure compressed air too low No constant probe current while calibration Not used Not used Not used Not used Not used Not used Not used Dynamic is missing Dynamic test activated Cell exchanged? If yes activate P. 104 Housing temperature too high Cal. not possible, delta-p too low Offset differential pressure too high *GED = Gas Extraction Device (MEV = German abbrev.) (1) Check parameter 51: the probe current from the last calibration is stored here. 63 Warnings and Faults - Indication via Display and Operation Unit / Remote Display Software 7.3 Indication via Display and Operation Unit / Remote Display Software Warnings and faults Confir mation o f error Note: Not all alarms/faults can be confirmed. Carry out troubleshooting diag1 + P+V exit Return to prev ious menu exit exit maint remote hist Reset limit value alarml Prerequisite: Reset mode ÒmanualÓor ÒacknowledgeÓ is selected Back to prev ious menu Switch on /o f f maintenance mode Maintenance switch S1 must be set on ÒoffÓ Establish connec tion with other LT dev ices via LSB Display o f fault/alarm history exit Back to prev ious menu Switch to entries made recently Switch to older entries NOTE Triggering the parameter 118 deletes the fault history again. 64 Warnings and Faults - Faults 7.4 Faults Faults Possible cause Solution Section Cell damaged • Measuring cell severely aged • Replace measuring cell 8.8 Flow throughput too low, probe current < 200mA • Pre-pressure for ejector < 2 bar (29 psi) • Check pre-pressure 4.4 • Extraction attachment contaminated • Clean/replace 8.5 • Capillary blocked • Clean/replace 8.9 • Ejector or proportional valve defective/blocked • Clean/replace 8.5.1 • Pre-pressure for ejector < 2 bar (29 psi) • Check pre-pressure 4.4 • Leaks in hose/hose connect. • Check/replace • Ejector proportional valve defective/blocked • Clean/replace 8.9 • Loose throttle screw on capillary • Check and, if necessary, secure/replace 8.5.1 • Difference pressure sensor out • of the socket or sensor defectiv Check/replace 8.12 • Capillary (GED) flow too high • Check/replace 8.5 • Fuse F16, F17 • Check fuses 12.4 • Heater defective • Check/replace 8.7/8.8 • Fuse F208 defective • Replace fuse 12.4 • CO peak > 10,000 ppm • Supply cable breakage • Check connection cable 8.8 • Measuring cell defective • Replace measuring cell 8.8 • Base electronics defective • Replace base electronics 12.4 • Solenoid coil defective • Check Ri appr.35 Ω/ replace • Fuse F11 • Check/replace • Proportional valve defective • Replace Difference pressure too low Defective probe heater Probe broken wire Wrong current input of solenoid valves Proportional-valve ejector 65 12.4 Warnings and Faults - Faults • Gas extract. device not secure • Secure gas extraction device 8.5 • Measuring chamber broken • Replace measuring chamber 8.11 • ZrO2 measuring cell broken • Replace measuring cell 8.8 • Throttle screw loose • Check and, if necessary, secure throttle screw 8.5.1 • Capillary (GED) flow too high • Check/replace • Short-circuit between pin 94 and 97 on probe plug • Check plug assignments • Difference pressure sensor out • of the socket or sensor defectiv Check/replace Dirty pre-filter • Deposits on filter Clean/replace filter 8.5.3 Error analog output • Analog output module defective • Replace 8.13 • Unassigned outputs are activated. • Parameters 540, 550, and 560 must be switched off 5.5.3 Error parameters • The stored parameters are incorrect The device may be using default settings • Consult manufacturer Delta-p cal. too low • Calibration unit (P valve, S valve) defective • Check/replace 3.2 • No pre-filter (broken off) • Check/replace 8.5.3 • Pre-pressure compressed air for calibration: 2 bar (29 psi) • Check • Difference pressure sensor out • of the socket or sensor defectiv Check/replace Proportional valve defective • Replace • Remove the gas extraction device, loosen the throttle screw and clean both items 8.5. • Replace base electronics 8.14 I-probe too high Proportional-valve calibration • Will be relesed, when difference pressure by capillary is to high Delta-p ejector too high • • 7.4.1 • Capillary or gas extraction device has closed or become blocked 8.5 12.4 8.12 8.12 Electronics for Ejectoractivation defective Internal Electronics Fault Legend: LED is off 7 8 9 10 11 12 12 11 10 9 8 7 flashes lights up Electronics fault (rapid flashing) If an internal fault occurs, you must consult the manufacturer. For the address of the manufacturer, see "General Notes". 66 Warnings and Faults - Warnings 7.5 Warnings Warnings Possible cause Solution Section Defective heating control • • Fuse F16 Electronics defective • • Replace fuse Replace base electronics 12.4 8.14 Dirty pre-filter • Deposits on filter • Clean/replace filter 8.5.3 Flow throughput too low, probe current < 260 mA • • Clean/replace 8.5.2 • Replace 3.2 • Extraction attachment contaminated Ejectoror proportional valve defective/blocked Capillary blocked • Clean/replace 8.5.1 O2 cell aged –> replace • O2 measuring cell worn out • Replace measuring cell 8.8 Delta-p ejector low • • Check • • Clean/replace Check/replace • • Check/replace Check and, if necessary, secure/replace Check/replace • Pre-pressure for ejector < 2 bar (29 psi) Extraction device blocked Ejector or proportional valve defective/blocked Leaks in hose/hose connection Loose throttle screw on capillary Difference pressure sensor out of the socket or sensor defectiv Heater incorrectly connected • Heater burnt out or short-circuit • • Heater incorrectly connected • Heater burnt out or short-circuit • • Calibration unit (P valve, M valve) defective No pre-filter (broken off) • • • • • • Defective MEV (GED)-heating Defective pre-filter heating Cal. Gas flow throughput too low, increase ! Check electrical connections and fuse Measure internal heater resistance, replace 4.6 • Check/replace 3.3 • Check/replace 8.5.3 Absolut pressure out of the socket or sensor defektive Incorrect setting (factory setting: max. permissible pressure: 1100 mbar (16 psi) min. permissible pressure: 700 mbar (10.2 psi) • Check/replace 8.12 • Correct setting Consult manufacturer • • Temperature exceeds limit value of 550 °C (1,022 °F) PT100 temperature sensor defective Wire breakage in PT100 temperature sensor Electronics defective • Probe must be moved back to prevent damage Check and, if necessary, replace PT100 sensor Check connections (plug), cable Replace base electronics • • • Fuse F10 Cable incorrectly connected Heater burnt out • • • Check/replace Check Check/replace • Probe temperature too high/too low • • • Defective ejector heating 8.12 4.6 • 67 • 8.5.1 Check electrical connections and fuse Measure internal heater resistance, replace • P (abs) too high/too low • 8.9 • • • 8.10.1 12.4 8.14 12.4 8.9 Warnings and Faults - Warnings Delta-p ejector high • Capillary or gas extraction device has closed • • Electronics for ejectorcontrol defective Ejector or prop-valve defective • Remove the gas extraction device, loosen the throttle screw and clean both items Replace base electronics • Replace PT100 defective, cable incorrectly connected Heater electronics defective • • Check/replace gas extraction 4.6 device heater Check/replace The flow rate through the capillary may be too high Measuring chamber broken Base electronics defective Difference pressure sensor out of the socket or sensor defectiv • Check 8.5.1 • • • Check/replace Check/replace Check/replace 8.11 8.14 8.12 Incorrect power supply Electrical connection incorrect Mains plugs on motherboard not secure • • • Check the power supply Check electrical connection Ensure that mains plugs are secure 12.4 • Defective MEV-temperature measuring (for gas extraction device) • Probe current limitation • • • • • Line voltage too high/too low • • • 8.5.1 8.14 12.4 Pressure compressed air too low • • • • Supply cable may be blocked Calibration unit defective No pre-filter (broken off) Pre-pressure too low • • • • Check/clean Check/replace Check/replace Check that pressure is 2 bar (29 psi) No constnat probe current while calibration • High pressure fluctuations at measuring point Sintered pre-filter broken off Leak in gas supply Measuring chamber broken • • • • Check pressure increase and 5.5.3 increase smoothing, par. 360 8.5.3 Replace sintered pre-filter Check seals, glands 8.5.10 Check/replace • • • 3.2 3.2 8.2.3 4.4 Probe exchanged ? • Has the measuring cell been replaced? • If so, activate parameter 104. 5.5.3 Internal device temperature too high • The internal temperature is greater than 75 °C (167 °F). • • Check the solenoid valve Check air calibration prepressure: 2 bar (29 psi) Switch-on temperature adjusted in par. 354 (default = 40 °C/104 °F) If electronics temperature is implausible (par. 055), adjust it in par. 3769 3.2 4.4 Check/replace 8.12 • • Offset differential pressure too high • Difference pressure sensor out • of the socket or sensor defectiv 68 Service and Maintenance - Recommendations for practical application 8 Service and Maintenance The LAMBDA TRANSMITTER E is virtually maintenance free. Required maintenance work is displayed via the display/control unit: • Clean the flow-control capillary / replace the entire gas extraction device. • Clean the extraction attachment at the tip of the gas extraction device / replace the filter. • Clean/replace the filter attachment if the warning "pre-filter contaminated" is displayed. WARNING The flange and the tube of the LAMBDA TRANSMITTER E is very hot. Cooling down before removing or wear protective gloves. 8.1 Recommendations for practical application 8.1.1 Operations in maintenance interval of 4 weeks (compendium from TÜV inspection report) The operations in maintenance interval is limited to the visual check of the measuring device. Due to the automatic functional test and readjusting in an interval of 24 hours or more briefly, can be done in principle without a regular task of test gas. The examination and the calibration, if necessary, take place with ambient air. See also chapter 8.2. In individual cases the correctness of the calibration can be examined by the task of test gases on zero and reference point. Due to the measurement principle becomes the examination of the zero point no nitrogen, but a test gas with <2 Vol.-% O2. In all other respects the instructions of the manufacturer are to be considered. 8.1.2 Functional test and calibration (compendium from TÜV inspection report) For the execution of the functional test and/or before the calibration after guideline DIN EN 14181 the following procedure is suggested: • Visual check of the complete measuring device • Control of the tightness by task of zero and test gas for the calibration inlet of the probe. • Examine the linearity with zero and test gas • Examine the zero point and reference point drift in the maintenance interval (Control of the long-run drift after a basic calibration) • Determine the dead and response time • Examine the data flow (analog, status signals) to the evaluation system. Further details to the functional test and calibration are in the guideline DIN EN 14181 (September 2004), and/or VDI 3950 to take sheet 1 (July 1994). 69 Service and Maintenance - Checking and Calibrating the Probe 8.2 Checking and Calibrating the Probe NOTE The calibration procedure takes place by using compressed air (constant prepressure 2 bar-29psi). In order to consider the relative humidity of the air used for the calibration procedure a calibration offset (parameter 297) has to be set. The setting of the calibration offset parameter (P297)at works: –0.1 vol% of O2. That means: It is calibrated not on 21% O2, but on 20,9% O2. With extreme site conditions (the tropics, desert, etc.) the calibration offset is to be adjusted. See chapter 3.1.4. The probe is checked and/or calibrated automatically in 1 to 10,000 hour cycles. Parameter 270 ("customer" release level). Factory setting is 24 hours. Parameter 61: Reverse counter for cyclic calibration in minutes, can be set manually, in order to set the time for start of the cyclic calibration. Manual adjustment can be activated as follows: • Display/control unit (optional) • Via the PC in conjunction with the remote display software • Via the remote control unit (optional) NOTE The calibration is protected with a password. Which release level is to be used , can be set in par.260: OFF Æ No password is necessary CUSTOMER Æ Customer’s password is necessary (factory setting) SERVICE Æ Service password is necessary MAINTENANCE Æ Maintenance mode is necessary CUSTOMER + MAINTENANCE Æ Customer’s pw + Maintenance mode is necessary SERVICE + MAINTENANCE Æ Service password + Maintenance mode is necessary A counter can be activated to ensure that calibration is only carried out on every 12th calibration command (parameter 272). This is recommended if other measuring devices that require more frequent calibration are operated via the control unit. During calibration, the following output values can be selected (parameters 282 and 283): • Current measured value • Substitute value • Last measured value NOTE A check routine is carried out before cyclic and automatic calibration. If the actual O2 value deviates only slightly from the expected setpoint, no calibration is carried out. The tolerance can be set via parameter 250 ("customer" release level). The factory setting is +/- 0.3 vol. % O2. If calibration is triggered manually, it is always carried out. When the check begins, the displayed measured values are not plausible. 70 Service and Maintenance - Check with Test Gas Once calibration has been triggered, air is blown through the protective pipe to the sampling point. The gas quantity is controlled automatically by means of the proportional valve in such a way that the pre-filter is pressurized at between 2 and 5 mbar. This prevents flue gases from reaching the sampling point in the protective pipe, thereby ensuring that only calibration gas is present at the measuring gas sampling point. The pressure in the filter is measured by means of an absolute pressure sensor and the measured value is compensated within defined limits (± 50 mbar/0.73 psi). If the filter becomes contaminated, the gas flow is reduced via the proportional valve. If the flow rate is too low while the pressure is increasing quickly, the warning "dirty prefilter" is output. Due to its size, the filter is relatively resistant to contamination. If only a small part of the surface remains clean, this is sufficient for the measuring gas quantity of approx. 0.5 l/h (0.017 qft/hr) required for the measurement. Each calibration will be listed in a history (par.1570…1791). The .calibration history can be deleted via parameter 119. (See also chapter 3.1.10) 8.3 Check with Test Gas NOTE Pre-pressure 2 bar - 29psi ! The measuring gases used must not contain any combustible gas constituents (e.g. carbon monoxide (CO)). Combustible gas constituents are oxidized (incinerated) on the platinum electrode of the zirconium dioxide measuring cell, which is approx. 800 °C (1,472 °F), and reduce the oxygen to be measured. 8.3.1 Procedure A manual check can be triggered as follows: • Display/control unit (optional) • Via the PC in conjunction with the remote display software • Via the remote control unit (optional) NOTE The calibration is protected with a password. Which release level is to be used , can be set in par.260: OFF Æ No password is necessary CUSTOMER Æ Customer’s password is necessary (factory setting) SERVICE Æ Service password is necessary MAINTENANCE Æ Maintenance mode is necessary CUSTOMER + MAINTENANCE Æ Customer’s pw + Maintenance mode is necessary SERVICE + MAINTENANCE Æ Service password + Maintenance mode is necessary NOTE The “manual calibration” is limited to 15 minutes. Once this time has elapsed, the device switches back automatically to measuring mode. 71 Service and Maintenance - Check with Test Gas 1. Connect test gas with a constant pre-pressure from 2 bar – 29 psi at the calibaration gas inlet. 2. Open the calibration menu with the key “cal”, enter your password, and start the calibration with the order “Start manual calibration” Æ ENTER 3. Manual probe calibraton Æ „change value by arrow-keys“ (if necessary). 4. End of calibration Æ press OK Æ „End of calibration, back to mesure“ Æ ENTER 5. After end of calibration,disconnect the test gas and connect the compressed air again (constant pre-pressure 2 bar). 72 Service and Maintenance - Software Update to 5V006 with Flash-Update-Software V1.2 8.4 Software Update to 5V006 with Flash-Update-Software V1.2 • Switch OFF LAMBDA TRANSMITTER E. • Set plug-in jumper BR10 in LAMBDA TRANSMITTER E on processor board into position „P“ (enables programming mode). • Connect PC at RS232-interface from LAMBDA TRANSMITTER E. • Switch ON LAMBDA TRANSMITTER E (no display). • Start LT Flash-Update-Software (LTFlashUpdate V1.2.exe). • Select COM-Port and „CONNECT“ to LAMBDA TRANSMITTER E. 73 Service and Maintenance - Software Update to 5V006 with Flash-Update-Software V1.2 • Datas are reading out and a backup file will be created. • Continue with „NEXT“. • Select directory for bachup file and save it. • Continue with „NEXT“. • Select dirctory with update file and open it. The file for update must be named so that it begins with "update”. 74 Service and Maintenance - Software Update to 5V006 with Flash-Update-Software V1.2 • Update will be transmit in LAMBDA TRANSMITTER E. • After succesfully programming end with „END“. • Switch OFF LAMBDA TRANSMITTER E. • Reset plug-in jumper BR10 in LAMBDA TRANSMITTER E on processor board into position „N“. • Switch ON LAMBDA TRANSMITTER E. • Check the software version via „PAR“-key on the display (5V006) • The software update is now at the end. In these version 1.2 of the Flash-Update-Software the following parameters are taken over from the old device: P.48 PW probe heating P.51 Value of calibration P.57 Flow rate P.70 bis 81 All counters and times P.121 MEV / pre filter heating ON/OFF P.358 Cabinet cooling power on time P.386 Nomial value of differential pressure P.392 bis 395 Limits for differential pressure P.400 bis 409 Setting of MEV heating P.411 Offset differential pressure sensor P.970 up to 973 Setting display, language and contrast P.1480 up to 1483 Serial number P.1500 up to 1564 Measuring place name, probe number, etc P.1570 up to 1799 History of calibration P.1800 up to 1899 History of Ri P.3600 up to 3679 History of dirft P.3750 up to 3769 Temperature statistics P.3800 up to 3899 Setting LSB P.30030 up to 30064 Internal parameters of time 75 Service and Maintenance - Removing the GED and Checking Penetrability 8.5 Removing the GED and Checking Penetrability Fig. 8-1: Removing the gas extraction device (work steps specified) e Securing mechanism for protective pipe f Protective pipe for gas extraction device, with sintered metal pre-filter b a Absolute pressure capillary Gas extraction device (GED). 1. Remove the locking element (e) for the protective pipe (f) by removing the lower safety splint. 2. Unscrew the protective pipe (f) and carefully push forwards to remove. 3. Unscrew in the absolute pressure capillary (b) by hand. 4. Unscrew the gas extraction device (a) and carefully push forwards to remove. IMPORTANT! The tip of the gas extraction device, which projects into the probe, is very hot! 5. Check the penetrability of the gas extraction device. Place one side into a tumbler and blow compressed air through it. If the gas extraction device is blocked, it must be replaced. The capillary can also be unblocked by heating it to a very high temperature and by using a wire. See the description below. If this procedure does not work, the gas extraction device must be replaced. See chapter 11 for order numbers. 6. To install the device, carry out the above steps in reverse order. 76 Service and Maintenance - Removing the GED and Checking Penetrability 8.5.1 Unblocking the Capillary by Heating to a Very High Temperature: 1 2 3 Fig. 8-2: Unblocking the capillary by heating to a very high temperature (Ø < 0.03 in2) < 0,8 mm 1. 2. 3. 4. 5. 6. 8.5.2 4 2 Remove the throttle screw at the end of the capillary (probe side). Unscrew the extraction attachment (measuring gas side). Heat the capillary tube using a welding torch. Thread the wire through the capillary tube. Install the gas extraction device. Check the flow rate. If the flow rate is too high, the entire gas extraction device must be replaced. Cleaning the Extraction Attachment with Sintered Metal Filter Fig. 8-3: Removing the extraction attachment 1. Remove the extraction attachment. If the sintered metal filter cannot be removed, it must be drilled out and replaced. Replacement filters are available in packs of 10 (order no. type 6 55 R 2803, extraction attachment (complete) order no. type 655R0028). 2. Clean the extraction attachment and sintered metal filter. 3. Install the extraction attachment. 8.5.3 "Dirty pre-filter" The penetrability of the pre-filter is checked by monitoring the pressure increase during calibration. If the pressure in the filter increases by more than the threshold value (parameter 276, factory setting 50 mbar), an warning is output. When the warning "sintered metal pre-filter contaminated" is present, the probe must be removed and the pre-filter cleaned or replaced. NOTE The differential pressure before and during calibration is displayed. The pressure increase during the last calibration can be read via parameter 50. 77 Service and Maintenance - Removing the Probe Body 8.6 Removing the Probe Body To remove the probe body, the following tools are required: • 0.5 x 3.5 screwdriver • Size 13 combination wrench • Combination pliers Fig. 8-4: Probe chapter(connection side), LAMBDA TRANSMITTER E connection to probe body Thermal cover plate Blue connectors 4 x M8, width across flats 13 1. Unplug the mains plug and leave the LAMBDA TRANSMITTER E to cool down for 30 mins. 2. Open the housing and the mounting plate with the display/control unit. 3. Remove connectors X15 and X16 from the motherboard. 4. Remove the wires from the connector. 5. Remove all three hoses from the probe body. To do so, press down the blue connectors. Both hoses on the extraction device must be loosened at the glands and removed. 6. Remove the thermal cover plate by pulling the pins. Combination pliers can be used here. 7. Separate the LAMBDA TRANSMITTER E from the probe body at the neck of the housing and carefully remove. To do so, remove the 4 nuts (M8 / width across flats 13). The probe body has now been separated. The measuring cell, temperature sensor, and extraction device can be replaced (see the following section). 8. To install, carry out the above steps in reverse order. 9. Reset the heater control to the base value. 10. To do so, set parameter 104 to "Trigger" and acknowledge with "Enter". Once the command has been executed, parameter 104 returns to "0". NOTE When the probe body is being installed, the flat gasket on the housing (order no. type 657R3541) must be replaced. Seals are provided with the replacement sets. 78 Service and Maintenance - Checking the Measuring Cell Heaters 8.7 Checking the Measuring Cell Heaters 1. Check fuses F16 and F17 (see chapter12.4). If the fuses are OK, continue to step 2. 2. Unplug the connector. 3. Measure the resistance between pins 92 and 93 on connector X16 (see "Technical Specifications"). The resistance must be between 8 Ω and 11 Ω. 8.8 • If the resistance is towards ∞, the heater is defective and must be replaced (order no. type 657R3203). • If the resistance is within the permissible range, the electronics are defective and the base electronics must be replaced. Replacing the Measuring Cell and Measuring Cell Heater Required tools: 1.5 and 2.5 hexagon-socket spanners 2.5 hexagon-socket spanner Fig. 8-5: Sensor unit 1 3 Fig. 8-6: Measuring cell with heater 1 2 3 Teflon seals Sensor contact Sensor 2 1 4 5 4 5 79 Heater Metal sleeve Service and Maintenance - Replacing the Measuring Cell and Measuring Cell Heater NOTE Be extremely careful when replacing the measuring cell or the measuring cell heater because both components are ceramic and are, therefore, EXTREMELY FRAGILE! 80 Service and Maintenance - Cleaning and Replacing the Ejector (incl. Heater) 1. Remove the probe body (see chapter8.6). 2. Remove the sensor unit with sensor and heater. To do so, remove the 6 hexagonsocket screws (2.5 hexagon-socket spanner) on the sensor flange. 3. Carefully remove the sensor unit. 4. Remove the sensor contact (1.5 hexagon-socket spanner). 5. Carefully remove the sensor by pushing it forwards. 6. Remove and replace the sensor contact. 7. To install, carry out the above steps in reverse order. NOTE When installing the sensor unit in the probe body, do not forget the two Teflon seals (see picture). During installation, make sure that the sensor does not come into direct contact with the metal sleeve. 8. Reset the heater control to the base value. To do so, set parameter 104 to "Trigger" and acknowledge with "Enter". Once the command has been executed, parameter 104 returns to "0". Order no. for measuring cell replacement set: type 655 R 3201 8.9 Cleaning and Replacing the Ejector (incl. Heater) Eductor Aluminum seal, additional aluminum seal inside Fig. 8-7: Probe chapter(connection side) Required tools: Size 14 spanner 1. Remove the probe body (see above). 2. Remove the ejector and heater using the size 14 spanner. 3. To install, carry out the above steps in reverse order. During installation, do not forget the aluminum seals. Ejector (complete) order no: type 657 R 3202 NOTE Blocked gas paths in the ejector can be unblocked with boiling water. 81 Service and Maintenance - Checking the PT 100 Temperature Sensor 8.10 Checking the PT 100 Temperature Sensor R [W] 300 280 260R / 438°C 260 240R / 380°C 240 220R / 323°C 220 200R / 266°C 200 180R / 211°C 180 160 140R / 104°C 130R / 78°C 120R / 52°C 110R / 26°C 140 120 Fig. 8-8: PT100 table 100 0 10 20 30 40 50 60 70 80 90 100 150 200 250 1. Remove connector X15 (see chapter12.4). 2. Measure the resistance between pi 300 350 400 450 T [°C] 1. s 24 and 26 on connector X15. At room temperature, this should be approx. 110 Ω(see graph). If this is not the case, the PT100 is defective and must be replacnd must be replacnd must be replaced. 8.10.1 Replacing the PT100 Temperature Sensor PT100 temperature sensor Fig. 8-9: Probe chapter(connection side) Required tools: Size 8 spanner Remove the probe body (see chapter8.6). Remove the PT100 temperature sensor using the size 8 spanner. To install, carry out the above steps in reverse order. Order no. for replacement temperature sensor: type 657 R 3205 82 Service and Maintenance - Replacing the Measuring Chamber 8.11 Replacing the Measuring Chamber a b c e d l f g h j n i k m Fig. 8-10: Components of the probe section a b c d e f g Protective pipe intake Metal O-ring Test gas adapter Graphite seal for measuring chamber Absolute pressure intake pipe Disk springs Aluminum filler ring h i j k l m n Measuring chamber Aluminum filler ring Insulation seal Upper flange with sensor intake PT100 temperature sensor Hose connections Measuring cell and heater Required tools: • Screwdriver: 0.5 x 3.5 • Spanners (5.5 mm, 8 mm, 10 mm, 13 mm, 14 mm, 24 mm) • Combination pliers • Hexagon socket spanners (1.5 mm, 3 mm, 4 mm) 83 Service and Maintenance - Replacing the Measuring Chamber 8.11.1 Removing the Measuring Chamber 6 7 7 a 8 9 b c 4mm e 10 11 12 Fig. 8-11: Removing the measuring chamber (work steps specified) (part 1) l 13 h j 13 14 h f g Fig. 8-12: Removing the measuring chamber (work steps specified) (part 2) d 84 Service and Maintenance - Replacing the Measuring Chamber 1. Remove the protective pipe for the gas extraction device, the gas extraction device, and the absolute pressure capillary. 2. Remove the probe body (see chapter8.6). 3. For the remainder of the removal procedure, clamp the probe body in the vice. 4. Remove the measuring cell and heater (see chapter 8.8). 5. Remove the PT100 temperature sensor (see chapter 8.10). 6. Remove the 6 hexagon-socket-screws of the protective pipe intake (a). 7. Remove the protective pipe intake (a) and the metal O-ring (b). 8. Loosen the absolute pressure intake pipe (e) using the spanner and turn to the side. 9. Loosen the screw cap for the measuring gas adapter (c) using a spanner and remove the measuring gas adapter (c). 10. Remove both hose connections (l). 11. Remove the 6 hexagon-socket screws on the upper flange (j) by rotating them 90° (diagonally opposite sequence). 12. Remove the upper flange (j) with insulation seal and aluminum filler ring (i). 13. Use a blunt object to push the measuring chamber (h) out of the probe body. 14. Remove the graphite seal on the inside (d) of the measuring chamber. Order no. for measuring-chamber repair kit: type 657R3206 85 Service and Maintenance - Replacing the Measuring Chamber 8.11.2 Installing the Measuring Chamber 1 2 h f g d 3 4 5 6 l h j 7 8 9 b c 9 10 a 4mm Fig. 8-13: Installing the measuring chamber (work steps specified) e 86 Service and Maintenance - Replacement of the pressure sensors 1. Insert the new graphite seal (d) in the probe body. 2. Insert the disk springs (f) in the probe body with the curved side facing the measuring chamber flange. 3. Insert the new measuring chamber with the new aluminum filler ring (g). 4. Place the upper flange (j) with insulation seal and aluminum filler ring (i) on the measuring chamber. 5. Secure the 6 hexagon-socket screws on the upper flange (j) by rotating them 90° (in diagonally opposite sequence). 6. Install both hose connections (l). 7. Insert the measuring gas adapter (c) and secure the screw caps (17 Nm). Tighten with a different spanner. The flat side of the measuring gas adapter (c) must face the absolute pressure intake pipe. 8. Align the absolute pressure intake pipe (e) and secure with a spanner. 9. Insert a new metal O-ring (b) and insert the protective pipe intake (a). 10. Secure the 6 hexagon-socket screws on the protective pipe intake (a) by rotating them 90° (in diagonally opposite sequence). 11. Install the PT100 temperature sensor (see chapter8.10). 12. Install the measuring cell and heater (see chapter8.8). 13. Install the probe body (see chapter8.6). 14. Install the protective pipe for the gas extraction device, the gas extraction device, and the absolute pressure capillary. 8.12 Replacement of the pressure sensors Absolut pressure sensor Differential pressure sensor Holding plate Hose clip The pressure sensors are placed on the base electronic of the LAMBDA TRANSMITTER E. They are plug-in types and by a holding plate secured. • Remove holding plate. • Remove hose connection, may be the hose clips must be cut. • Remove pressure sensors. • With the plug-on of the pressure sensors, attend to the correct seat in the socket. • Plug-on hose connection (maybe use new hose clips). Hose clips are in the small accessories kit of the LAMBDA TRANSMITTER E (see spare parts) • Attach the holding plate. 87 Service and Maintenance - Replacement of the analog output card 8.13 Replacement of the analog output card analog output card retaining screw The analog output card is placed on base electronic. It is plug-in type and by a retaining screw secured.. • Remove retaining screw • Remove analog output card • Plug-on the new card an secure • See also chapter 12.5.2 8.14 Replacement of the base electronic Pressure sensors Analog output card Mounting of the processor card • • • • • • • Remove both pressure sensors (do not remove the hoses) Remove analog output card Unscrew the mounting of the processor card and remove processor card out of the 96-pole socket. Be careful. Remove all plug-in connectors Unscrew the 7 fastening bolts of the base elctronic (use a pin type socket wrench size 5,5) Exchange base electronic To install, carry out the above steps in reverse order. 88 Disposal - Replacement of the base electronic 9 Disposal The LAMBDA TRANSMITTER E was designed to minimize the impact on the environment. The individual modules can be easily separated and sent for recycling. 89 Optional Accessories - LSB-Module with 4 Analog Outputs Voltage, alternatively Current 10 Optional Accessories 10.1 LSB-Module with 4 Analog Outputs Voltage, alternatively Current 10.1.1 Functional Description • Module voltage: 4 analog outputs 0 - 10 V DC • Modul current: 4 analog outputs 0 - 20 mA • Jumper plugs enable rapid wiring of several modules • Can be used without programming The LSB-modules are output modules with a wide range of applications. They are controlled by LSB (setting P3895) (see section 4.5). These modules cannot be controlled by CAN. The module is triggered by a variable address (1 - 99) and the status of outputs is transferred to the data bits. If an analog output module with the same address is used in the system, the voltage/current measured there will be reproduced at the corresponding output. The 4 analog output values (1 to 4: P530 to P569) are output to the analog output module (activate using P3820). The address to be set is shown in parameter 3820. If voltage modules are used, 10 V is equal to 20 mA. NOTE Make sure that the address you set is not the same as that for another LSB module address! Setting the address in steps of 10 in steps of 1 10.1.2 Setting the Parameters for analog output module (with Software Version 4V24 or More Recent) Activation of analog output module P3820 P3895 on LSB Analog output 1 Analog output 2 Analog output 3 Analog output 4 P530-P539 P540-P549 P550-P559 P560-P569 90 Optional Accessories - LSB-Module with 4 Analog Outputs Voltage, alternatively Current 10.1.3 Parameter 530 / 540 / 550 / 560 Here, enter the measured value that is to be output at the analog output. The following settings are possible for each output: • Off • Measured O2 value • Configurable measured value 1 - 6 • Probe temperature • Probe absolute pressure • Probe current • Probe voltage • Internal O2 value 10.1.4 Parameter 531 / 541 / 551 / 561 Here, set the measurement range for each analog output. The following settings are possible: • 0-20 mA / 0-10 V • 4-20 mA • 4-20 mA / error 0 mA • 4-20 mA / error + maintenance 0 mA 10.1.5 Parameter 532 / 542 / 552 / 562 Here, set the start of the measurement range for each analog output. • E.g. “0” for 0% O2 10.1.6 Parameter 533 / 543 / 553 / 563 Here, set the end of the measurement range for each analog output. • E.g. “210” for 21% O2 10.1.7 Parameter 534 / 544 / 554 / 564 • Output value for each analog output in “mA” 91 Optional Accessories - LSB-Module with 4 Analog Outputs Voltage, alternatively Current 10.1.8 Technical Specifications Output Module • • • • • • • • • • • • Rated voltage UN Current consumption Power consumption Operating voltage range Operating temp. range Storage temp. range Suppressor circuit Function display Operation display Article number voltage module Article number current module Article number of external power pack 24 V DC 50 mA 1.2 W 0.8 - 1.1 x UN 0 °C to +55 °C (-4 °F to 130 °F) -25 °C to +70 °C (-13 °F to 158 °F) Polarity reversal protection for operating voltage Green LED for BUS activity and supply voltage Red LED for BUS error messages 663R4025S (with connection cable) Output current (10 V DC) (Analog output) Output voltage Measurement error/tolerance 5 mA Response time (from receiving to sending) Recovery time 15 ms (msec) Output current Accuracy Load Response time (from receiving to sending) Recovery time 0-20 mA 1% max. 300 Ohm 15 ms (msec) Connection cross-chapterof device terminals Connection cross-chapterof screwable plug-in terminals (BUS, power supply) Weight Housing dimensions (W x H x D) • 2.5 mm² (0.038 in2) • 1.5 mm² (0.023 in2) • • 95 g (0.2 lb) 35 x 68 x 60 mm (1.4 x 2.7 x 2.4 in) 663R4029S (with connection cable) 663R4024 Analog Outputs (Voltage) • • • • • 0 - 10 V DC U = {(N/32) x 9.9165 mV ±20 mV} ±1.1% U = output voltage in V N = numerical value (BUS) 550 ms (msec) Analog Outputs (Current) • • • • • 550 ms (msec) Housing • • • • 92 Optional Accessories - LSB-Module with 4 Analog Inputs 10.2 LSB-Module with 4 Analog Inputs 10.2.1 Functional Description • 4 analog inputs • Jumper plugs enable rapid wiring of several modules • Can be used without programming The LSB-modules are analog input modules with a wide range of applications. They are controlled by LSB (setting P3895) for installation on a DIN rail (see section 4.5). These modules cannot be controlled by CAN. The module is triggered by a variable address (1 - 99) and the status of inputs is transferred to the data bits. If the input status changes, a message is immediately sent to the LSB. Inputs can be switched from voltage input to temperature measurement input. The following settings can be made for every input using a DIP switch: • 0 - 10 V DC, Ni1000 (-50 to +150 °C/-58 to 300 °F) • Pt1000 (-50 to +150 °C/-58 to 300 °F) • Pt1000 (0 to +400 °C/-4 to 752 °F) Temperature sensors that can be used: Pt1000, Ni1000. To use the analog input module configured using P3821, “LSB input1” to “LSB input4” must be set as the desired analog input in P572 (582, 592, 602). This enables asynchronous balanced mode with integrated analog inputs and LSB inputs, which is necessary with the LAMBDA TRANSMITTER E , since input 4 is assigned entirely to temperature measurement. If the module or LSB fails, the analog values will fall to 0 after approximately 3 seconds. The address to be set is stored in parameter 3821. NOTE Make sure that the address you set is not the same as another LSB module address! The conversion factor is always 20 mA<->10 V. Setting the address in steps of 10 in steps of 1 NOTE for current input: 0 - 3 mA Æ 0 - 1.5V, 3 - 4 mA Æ 1.5 - 2 V, 4 - 20 mA Æ 2 - 10 V 10.2.2 Setting the Parameters for analog input module (with Software Version 4V24 or More Recent) Activation of analog input module Analog input 1 Analog input 2 Analog input 3 Analog input 4 P3821 P3895 on LSB P572 P582 P592 P602 93 Optional Accessories - LSB-Module with 4 Analog Inputs 10.2.3 Technical Specifications Input Module • • • • • • • • • • • • Rated voltage UN Current consumption Power consumption Operating voltage range Operating temp. range Storage temp. range Suppressor circuit Function display Operation display Input/BUS test voltage Article number Article number of external power pack 24 V DC 50 mA 1.2 W 0.8 - 1.1 x UN 0 °C to +55 °C (-4 °F to 130 °F) -25 °C to +70 °C (-13 °F to 158 °F) Polarity reversal protection for operating voltage Green LED for BUS activity and supply voltage Red LED for BUS error messages no disconnection 663R4026S (with connection cable) 663R4024 • Connectable temperature sensor Temperature meas. range Resolution Tolerance Additional meas. Range Resolution Tolerance Voltage measurement range Resolution Tolerance Input resistance Response time (from receiving to sending) Analog value updates Recovery time • Analog Inputs • • • • • • • • • • • • • • Pt1000, Ni1000 -50 °C to +150 °C (-50 to 300 °F) -50 °C to +150 °C 10 bit (appr. 0.2 °C) -50 °C to +150 °C approx. ±0.2 °C Pt1000 0 °C to +400 °C (32 to 750 °F) 0 °C to +400 °C 10 bit (approx 0.5 °C) 0 °C to +400 °C approx. ±0.5 °C 0 - 10 V DC 10 bit (10 mV/bit) Approx. ±20 mV 200 kΩ 15 ms (msec) • • at least every 3 s 550 ms (msec) • Housing: IP50, terminals: IP20 • Environment class 3k3 • 2.5 mm² (0.038 in2) • 1.5 mm² (0.023 in2) • • 95 g (0.2 lb) 35 x 68 x 60 mm (1.4 x 2.7 x 2.4 in) • • Housing • • • • • • Degree of protection (EN 60529) Range of relative humidity acc. to IEC60721-3-3 Connection cross-chapterof device terminals Connection cross-chapterof screwable plug-in terminals (BUS, power supply) Weight Housing dimensions (W x H x D) 94 Optional Accessories - LSB-Moduel with 4 Digital Outputs 10.3 LSB-Moduel with 4 Digital Outputs 10.3.1 Functional Description • 4 relay outputs of 250 V, 6 A • Jumper plugs enable rapid wiring of several modules • Manual emergency operation level • Can be used without programming The LSB-modules are digital output modules with a wide range of applications. They are controlled by LSB (setting P3895) for installation on a DIN rail (see section 4.5). These modules cannot be controlled by CAN. The module is triggered by a variable address (1 - 99) and the databits are informed whether data is required or commands are to be carried out. The 7 relay outputs can be output to 2 LSB relay modules, output 1 to 4 on the module set in P3822, and output 5 to 7 on the modules selected in P3823. You can find the address to be set in parameter 3822 and P3823. NOTE Make sure that the address you set is not the same as another LSB module address! Setting the address in steps of 10 in steps of 1 Manual emergency operation level Position “1” Æ output contact always closed Position “A” Æ output contact switched via LSB bus Position “0” Æ output contact always open 95 Optional Accessories - LSB-Moduel with 4 Digital Outputs 10.3.2 Setting the Parameters for digtal output module (with Software Version 4V24 or More Recent) Activation of digital output module 1 Relay output 1 Relay output 2 Relay output 3 Relay output 4 P3822 P3895 on LSB P1030-P1039 P1040-P1049 P1050-P1059 P1060-P1069 Activation of digital output module 2 Relay output 5 Relay output 6 Relay output 7 P3823 P3895 on LSB P1070-P1079 P1080-P1089 P1090-P1099 10.3.3 Parameters for Digital Outputs Up to 7 digital outputs can be configured freely on the LAMBDA TRANSMITTER E . The same parameters are available for the configuration of each digital output. These are: • Off position • Four functions (ORed) that trigger a switching operation • Display of the current relay position Factory assignment of digital outputs: • Output 1: general fault • Output 2: general warning and/or maintenance • Output 3: calibration • Output 4: limit value 1 • Output 5: not configured • Output 6: not configured • Output 7: not configured Parameter 1030 / 1040 / 1050 / 1060 Set the idle setting here. This setting is used when none of the four functions triggers a switching operation. The “diagnostics mode” setting allows the idle setting to be changed by means of the “position” parameter. • Low (open-circuit current principle) • High (closed-circuit current principle) • Diagnostics mode 96 Optional Accessories - LSB-Moduel with 4 Digital Outputs Parameters 1031-1034 / 1041-1044 / 1051-1054 / 1061-1064 The four functions are more or less identical and an operating status can act as a switching criterion. If a “limit value” (Li 1-4) is selected as a switching criterion, the output will switch when the limit value output is set. If “calibration” is selected as a switching criterion, for example, the output is not set to the off position during calibration. Each function (A, B, C, D) can have all of the operating statuses as switching criteria, although limit values Li1-4 or measuring gases are only allocated to individual functions. “Limit value 1” and “measuring gas 1” can only be allocated to “function A”; similarly “limit value 2” and “measuring gas 2” can only be assigned to “function B” etc. However, the OR operation used for the four functions allows all combinations to be varied. The following operating statuses can be selected as switching criteria: Warning, fault, calibration, check, cold start, measurement, maintenance, values 1 – 4, measuring gas 1 - 2 limit Parameter 1039 / 1049 / 1059 / 1069 This parameter displays the current switching state. If the parameter is changed in diagnostics mode, the output can be switched manually. 97 Optional Accessories - LSB-Moduel with 4 Digital Outputs 10.3.4 Limit Value Monitoring (Li) Exceeding/Undershooting the Limit Value Display See section 5.5 Parameter 930 / 940 / 950 / 960 Selection of the variable to be monitored for limit value 1 (2, 3, 4) 0 = off, 1 = measured O2 value, 2-7 = configurable measurement value 1-7, 8 = temperature probe, 9 = absolute pressure probe, 10 = probe current, 11= probe voltage Parameter 931/932 / 941/942 / 951/952 / 961/962 Form for maximum comparison value for Li 1 (2, 3, 4) 0 = off, 1 = constant value, 2-13 = calculated analog value 1-12 Form for minimum comparison value for Li 1 (2, 3, 4) 0 = off, 1 = constant value, 2-13 = calculated analog value 1-12 Parameter 933 / 943 / 953 / 963 Constant for maximum comparison value for Li 1 (2, 3, 4) (only when 931, 941, 951, 961= constant value) Parameter 934 / 944 / 954 / 964 Constant for minimum comparison value for Li 1 (2, 3, 4) (only when 932, 942, 952, 961= constant value) Parameter 935 / 945 / 955 / 965 Reset mode for limit value 1 (2, 3, 4) 0 = automatic, 1 = manual, 2 = acknowledge Parameter 936 / 946 / 956 / 966 Trigger delay for limit value 1 (2, 3, 4) 98 Optional Accessories - LSB-Moduel with 4 Digital Outputs 10.3.5 Technical Specifications Output Module • • • • • • • • • • • • • • • • Rated voltage UN Current consumption Power consumption Operating voltage range Response time (from receiving to relay switching) Release time (from receiving to relay switching) Recovery time Operating temperature range Storage temperature range Suppressor circuit Relay status display Function display Operation display Special features Article number Article number of external power pack • • • • • 24 V DC 100 mA 2.4 W 0.8 - 1.1 x UN 15 ms (msec) • 15 ms (msec) • • • • • • • • • • 200 ms (msec) 0 °C to +55 °C (-4 °F to 130 °F) -25 °C to +70 °C (-13 °F to 158 °F) Polarity reversal protection for operating voltage LED Green LED for BUS activity and supply voltage Red LED for BUS error messages Manual operation level with confirmation via BUS 663R4027S (with connection cable) 663R4024 Digital Outputs • • • • • • • • • • • • • • Output contact/material Switching voltage Max. making/breaking current Continuous current Protection of contacts Mechanical durability Contact life Permissible number of operations (cycles) per hour Insulation in accordance with VDE 0110 Rated voltage Overvoltage category Contamination level Coil/contact test voltage Contact/contact test voltage 4 NO contacts / AgNI • max. 250 V • 12 A / 4 s at 10 % on period • 6 A/relay, but max. 12 A/module • 6A 1x107 operating cycles 1x105 operating cycles • 360 at nominal load Degree of protection (EN60529) Connection cross-chapterof device terminals Connection cross-chapterof screwable plug-in terminals (BUS, power supply) Weight Housing dimensions (W x Hx D) • • Housing: IP50, terminals: IP20 2.5 mm² (0.038 in2) • 1.5 mm² (0.023 in2) • • 95 g (0.2 lb) 35 x 68 x 60 mm (1.4 x 2.7 x 2.4 in) C 250 V II 2 • 4,000 V AC 50 Hz 1 min • 1,000 V AC 50 Hz 1 min Housing • • • • • 99 Optional Accessories - LSB-Module with 4 Digital Inputs 10.4 LSB-Module with 4 Digital Inputs IMPORTANT! The module 663R4228 can not be used, without re-wiring, as a spare part for the module 663R4028. Pin assignment of the module 663R4028 (deliverable till December 2007) 24V DC 0V Ub GND 24V DC 1+ input 1 Supply voltage 12+ input 2 2- CAN-BUS Interface (LSB) CAN+ CAN - 3+ input 3 34+ input 4 4- Pin assignment of the module 663R4228 (deliverable from January 2008) 24V AC/DC 0V + - SpannungsVersorgung 24V AC/DC 1+ 2- input 2 Supply voltage H L 1- input 1 2+ CAN-BUS Interface (LSB) 3- input 3 3+ 44+ 100 Optional Accessories - LSB-Module with 4 Digital Inputs 10.4.1 Functional Description 663R4028/663R4228 • 4x 24 V DC digital inputs Inputs are made as 24 V DC voltage inputs with electrically isolation (663R4028) / without electrically isolation (663R4228). • Jumper plugs enable rapid wiring of several modules • Manual emergency operation level • Can be used without programming The LSB modules are input modules with a wide range of applications. They are controlled by LSB (setting P3895) for installation on a DIN rail (see section 4.5). These modules cannot be controlled by CAN. The module is triggered by a variable address (1 - 99) and the status of inputs is transferred to the data bits. If the input status changes, a message is immediately sent to the BUS. Digital inputs can be specified via 2 LSB modules: the module set in P3824 specifies inputs 1 to 4, the module set in P3825 specifies 5 to 8. If communication fails or a module is missing, the input signals change to 0 and timeout occurs after 3 seconds. The address to be set is stored in parameter 3824 and P3825. NOTE Make sure that the address you set is not the same as another LSB module address! Setting the address in steps of 10 in steps of 1 Digital Input Module Manual emergency operation level Position “1” Æ input always on HIGH Position “A” Æ input switched extraneously via contact Position “0” Æ input always on LOW 101 Optional Accessories - LSB-Module with 4 Digital Inputs 10.4.2 Setting the Parameters for digital input module (with Software Version 4V24 or More Recent) Activation of digital input module 1 Digital input 1 Digital input 2 Digital input 3 Digital input 4 P3824 P3895 on LSB P1170-P1175 P1180-P1185 P1190-P1195 P1200-P1205 Activation of digital input module 2 Digital input 5 Digital input 6 Digital input 7 Digital input 8 P3825 P3895 on LSB P1210-P1215 P1220-P1225 P1230-P1235 P1240-P1245 10.4.3 Parameters for Digital Inputs Eight digital inputs can be configured for the LAMBDA TRANSMITTER E . All 8 digital inputs are identical in structure and function. They are configured using the parameters listed below. Factory assignment of digital inputs: • Input 1 – pump on • Input 2 – triggers calibration • Input 3 – triggers check • Input 4 – triggers cyclical calibration • Input 5 – resets faults • Input 6 – fuel 2 • Input 7 – fuel 3 • Input 8 – fuel 4 Idle Level Parameters 1170/1180/1190/1200/1210/1220/1230/1240 Here you can set the idle setting for digital inputs. If the setting deviates from the one that is set, the actions specified in the functions (A,B,C,D) will be carried out If set here, the parameter can be used to trigger the functions (A,B,C,D) for the corresponding digital input. • Low (open-circuit current principle), i.e. the corresponding digital input is only set when a voltage of +24 V is flowing. • High (closed-circuit current principle), i.e. the corresponding digital input is only set when the voltage is 0 V or the input is open. • Diagnostics mode, i.e. the input status can be changed manually (see 10.4.3.3). 102 Optional Accessories - LSB-Module with 4 Digital Inputs Function A, B, C, D; Parameters 1171 – 1174 / 1181 – 1184 / 1191 – 1194 / 1201 – 1204 / 1221 – 1224 / 1231 – 1234 / 1241 - 1244 1211 – 1214 / The four functions are the same in structure; however, limit values LV 1 - 4 and fuels are only assigned to individual functions (A, B, C, D). Limit value 1 and fuel 1 can only be reset in function A; similarly limit value 2 and measuring gas 2 can only be reset in function B and so on. The following actions are possible: • None • Pump on Activates the measuring gas pump. • Calibration Triggers automatic calibration. • Check Triggers an automatic check. • Cycl. calibration An internal counter counts up, automatically triggering calibration when it reaches a certain value (parameter 272). The counter is then reset to zero. • Fault reset Acknowledges faults present. • Warning reset Acknowledges warnings present. • Li 1-4 reset Function A resets limit value 1, functions B, C, D reset limit values 2, 3, 4. • Fuel 1 Function A only selects fuel 1, function B, C, D select fuels 2, 3, 4. • No cal. If there is a signal at this input, the device cannot carry out calibration. If calibration is still ongoing, it is stopped immediately. • PID controller ON/OFF Switches off PID controller. Status Parameter 1175 / 1185 / 1195 / 1205 / 1215 / 1225 / 1235 / 245 This parameter displays the digital input status. The two possible statuses are “set” (the set functions will be triggered) and “not set”. The digital input status can be set manually with this parameter, as long as the “idle level” parameter is set to “Diagnostics mode”. 103 Optional Accessories - LSB-Module with 4 Digital Inputs 10.4.4 Technical Specifications Input Module • • • • • • • • • • Rated voltage UN Current consumption Power consumption Operating voltage range Operating temp. range Storage temp. range Suppressor circuit Function display Operation display Special features • • • • • • • • • • • • Input/BUS test voltage Article number • • • Article number of external power pack • 24 V/DC 50 mA 1.2 W 0.8 - 1.1 x UN 0 °C to +55 °C (-4 °F to 130 °F) -25 °C to +70 °C (-13 °F to 158 °F) Polarity reversal protection for operating voltage Green LED for BUS activity and supply voltage Red LED for BUS error messages Manual operation level with confirmation via BUS 2,500 V/AC 50 Hz 1 min 663R4028S (till December 2007) 663R4228S (from January 2008) with connecting cable 663R4024 Input voltage (control input) Input current (24 V DC) (control input) High-signal detection Low-signal detection Response time (from receiving to sending) Recovery time • • 30 V/DC 6 mA • • • >7 V/DC <3 V/DC 15 ms (msec) • 550 ms (msec) Degree of protection (EN60529) Range of relative humidity acc. to IEC60721-3-3 Connection cross-chapterof device terminals Connection cross-chapterof screwable plug-in terminals (BUS, power supply) Weight Housing dimensions (W x H x D) • Housing - IP50, terminals - IP20 • Environment class 3k3 • 2.5 mm² (0.038 in2) • 1.5 mm² (0.023 in2) • • 95 g (0.2 lb) 35 x 68 x 60 mm (1.4 x 2.7 x 2.4 in) Digital inputs • • • • • • Housing • • • • • • 104 Optional Accessories - Internal Connection of LSB Modules (Max. 2 Modules) 10.5 Internal Connection of LSB Modules (Max. 2 Modules) NOTE LSB modules can only be installed internally and connected in sheet-steel housing. They cannot be installed internally in cast-aluminum housing. Ader + / - Ader Nr. 72 / 73 Fig. 10-1: LSB module in LAMBDA TRANSMITTER E in sheetsteel housing Plug-in jumpers X12 plug Terminal 72/73 X206 plug Pin 3- / 9+ LSB module 1. Attach the LSB module (without the terminating resistor) onto the mounting rail. If more than one module is to be installed, connect these using the jumper plugs provided. 2. Secure the cable from the LSB module using cable ties. 3. Connect the wires numbered 72 and 73 with the X12 plug to numbers 72 and 73. 4. Connect wires labeled + / - to the X206 plug (pin 3 = - , pin 9 = +) for the power supply. 5. Set the parameters in LAMBDA TRANSMITTER E (see chapter4.5, 10.1 – 10.4) 6. Check the plug-in jumpers on the LAMBDA TRANSMITTER E base electronic 105 Optional Accessories - Internal Connection of LSB Modules (Max. 2 Modules) (see chapter12.5.1). 106 Optional Accessories - External Connection of LSB-Module 10.6 External Connection of LSB-Module NOTE: Any external LSB module must also have an external power supply. Modules can be connected in rows without any clearance. Once there are 15 modules in a row, a new external connection to the power supply must be made. More than 15 modules would overload the jumper plugs and cause them to burn out. If an external power supply is used, ensure that sufficient protection is available since there are no mains fuses. Install the LSB module in the required position. If more than one module is to be installed, connect these using the jumper plugs provided. Attach the 120 ohm LSB terminating resistor to the last module. Connect the LSB module to the external power supply (24 V DC) and the LSB. Order-Nr. Ext. power supply: 663 R 4024 NOTE: The maximum cable length between the LAMBDA TRANSMITTER E and the LSB module is 500 m. The module is connected to the LSB using the 7-pin connector on the housing. See also chapter3.4. 7-pin LSB/CAN connection to the gas extraction device and filter heater 7-pin LSB/CAN connection to other devices with a LSB/CAN terminal Set the parameters in LAMBDA TRANSMITTER E (see chapter4.5, 10.1 – 10.4) Check the plug-in jumpers on the LAMBDA TRANSMITTER E motherboard (see chapter12.5.1). Recommendations for lengths and cross-sectional areas of LSB cables are listed below: 0 - 40m 1 x 2 x 0,22 mm2 (0.4 x 0.8 0.01 in2), stranded in pairs, shielding, 120 Ω 40 - 300 m 1 x 2 x 0,34 mm2 (0.4 x 0.8 0.01 in2), stranded in pairs, shielding, 120 Ω 300 - 500 m 120 Ω 1 x 2 x 0,5 mm2 (0.4 x 0.8 0.02 in2), stranded in pairs, shielding, 107 Optional Accessories - Activating of LSB-Modules 10.7 Activating of LSB-Modules Examination at the LSB module • Make sure, that CAN low and CAN high, also the 24V-supply voltage ars correctly connected. • Make sure, that at the freely connection side between CAN low and CAN high a 120R-termination resistor is connected. • Set the LSB address at the module (up 10er, down 1er), which is specified in parameter 3820...3825 in LAMBDA TRANSMITTER E. No address may be assigned doubly. • With digital modules the switches of the hand control level must be set to „A“ . Examination of the parameters in LAMBDA TRANSMITTER E (see chapter 10.1...10.4) • One or more parameter 3820...3825 (depending from numbers of modules) must be activted P3820 – Activated a LSB module with 4 analog outputs P530...539 configured analog output 1 P540...549 configured analog output 2 P550...559 configured analog output 3 P560...569 configured analog output 4 • P3821 – Activated a LSB module with 4 analog inputs P570...579 configured analog input 1 P580...589 configured analog input 2 P590...599 configured analog input 3 P600...609 configured analog input 4 • P3822 – Activated a LSB module with digital outputs 1...4 P1030...1039 configured relay output 1 P1040...1049 configured relay output 2 P1050...1059 configured relay output 3 P1060...1069 configured relay output 4 • P3823 – Activated a LSB module with digital outputs 5...7 P1070...1079 configured relay output 5 P1080...1089 configured relay output 6 P1090...1099 configured relay output 7 • P3824 – Activated a LSB module with digital inputs 1...4 P1170...1175 configured digital input 1 P1180...1185 configured digital input 2 P1190...1195 configured digital input 3 P1200...1205 configured digital input 4 • P3825 – Activated a LSB module with digital inputs 5...8 P1210...1215 configured digital input 5 P1220...1225 configured digital input 6 P1230...1235 configured digital input 7 P1240...1245 configured digital input 8 • Parameter 3895 in LAMBDA TRANSMITTER E must be set to „LSB“. 108 Optional Accessories - Activating of LSB-Modules Setting of the plug-in jumpers in LAMBDA TRANSMITTER E (see chapter 12.5) • The jumpers BR10..14 (selection CAN/RS422) on the base electronic must be set to „CAN“. • The jumper BR15 (termination resistor ON/OFF) on the base electronic must be set to „R“ (ON). • The jumpers BR12 and BR13 (selection CAN/RS422) on the processor card must be set to „C“ (CAN). Setting of the plug-in jumpers in connection with a opionally power pack for GED and pre-filter heater (see chapter 12.5) • The jumpers BR10..14 (selection CAN/RS422) on the base electronic must be set to „CAN“. • The jumper BR15 (termination resistor ON/OFF) on the base electronic must be set to „CAN“ (OFF). • The jumpers BR12 and BR13 (selection CAN/RS422) on the processor card must be set to „C“ (CAN). • The jumper JP2 (termination resistor ON/OFF) on the power pack electronic board must be set to “2-3“ (ON). see chapter 4.6.3 • The DIP switch 1 on the power pack electronic board must be set to „ON“ (LSB operation) After power on the following condition must be present • Red LED at LSB module is OFF • Green LED at LSB module is blinking • CAN Rx/Tx-LEDs am LT10P are jittering If not, the following problem solutions • No LED at LSB module is flashing - No 24V supply voltage • Green LED at LSB module steady light, red LED is blinking - LSB module without address - No or wrong parameter 3820...3825 is activated • Green and red LED at LSB module steady light - Wrong addresse at LSB module is setted - Parameter 3895 set to „CAN“, must be set to „LSB“ - Jumpers BR10...14 on base electronic in position „RS422“ 109 Optional Accessories - Compressed Air Unit to Supply the LAMBDA TRANSMITTER E 10.8 Compressed Air Unit to Supply the LAMBDA TRANSMITTER E 10.8.1 Compressed Air Unit on Mounting Plate Fig. 10-2: dimensions in mm 1 Pre-pressure regulator (set to 4 bar/58 psi) 2 Ejectorpressure regulator (set to 2 bar/29 psi) 3 Pressure regulator for Calibration air/housing cooling (set to 2 bar/29 psi) 4 Hose connection for compressed air input, nominal diameter 10 mm (0.4 in). Recommended pre-pressure: 4 - 6 bar (58 - 87 psi) 5 Ejectorhose connection 4/6 mm (0.16/0.24 in) 6 Hose connection for Calibration air/housing cooling 4/6 mm (0.16/0.24 in) 7 Hose connection for automatic condensate drain 6/8mm (0.24/0.31 in) 8 Two fixing holes for alternative flange mounting 9 Four attachments for wall mounting Weight: 5.7 kg (12.6 lb) Type: 657R3005 for LAMBDA TRANSMITTER E in cast-aluminum housing Type: 657R4015 for LAMBDA TRANSMITTER E in sheet-steel housing 110 Optional Accessories - Compressed Air Unit to Supply the LAMBDA TRANSMITTER E 10.8.2 Compressed Air Unit in Housing Heated to Temperatures < 0 °C (< 32 °F) Fig. 10-3: Compressed air unit in housing of LAMBDA TRANSMITTER E 1 Pre-pressure regulator (set to 4 bar/58 psi) 2 Ejectorpressure regulator (set to 2 bar/29 psi) 3 Pressure regulator for Calibration air/housing cooling (set to 2 bar/29 psi) 4 Hose connection for compressed air input, nominal diameter 10mm. Recommended pre-pressure: 4 - 6 bar (58 - 87 psi) 5 Ejectorhose connection 4/6 mm (0.16/0.24 in) 6 Hose connection for Calibration air/housing cooling 4/6 mm (0.16/0.24 in) In points 4, 5 and 6, feed the hose through the cable connection and secure it to the hose connection. 7 Hose connection for automatic condensate drain 6/8mm 10 Fuse terminal (T2 fuse, 5 A) 11 Housing heater, 320 W 230 V Weight: 11 kg (24.2 lb) Type: 657R3006 Dimensions (W x H x D): 300 x 400 x 150 mm (12 x 15.7 x 6 in) Fig. 10-4: Dimensions 111 Optional Accessories - Gas Extraction Kit with Heater for Gas Extraction Device 10.9 Gas Extraction Kit with Heater for Gas Extraction Device The gas extraction device heater must be used in the following cases: • Test gas temperatures below the water/acid dew point • Penetration of brick stacks with very thick walls where there is a risk of the temperature in the capillary falling below the dew point. Fig. 10-5: Protective pipe for gas extraction device with heater and protective pipe support on the LAMBDA TRANSMITTER E Type (order no.) Connection cable length Material 800 mm (31.5 in) 6 57 R 3051 2 m (6.6 ft) 1.4571 1,000 mm (39.4 in) 6 57 R 3052 2 m (6.6 ft) 1.4571 1,400 mm (55.1 in) 6 57 R 3053A 2 m (6.6 ft) 1.4571 1,800 mm (70,9 in) 6 57 R 3054A 2 m (6.6 ft) 1.4571 Insertion depth Type corrosion-resistant-steel (REA) on request Additional protective pipe fpr Type REA-steel on request 1.4539 Polyester Cable connectors for extending the gas extraction device and filter heater type 6 57 R 3168 10.10 Gas Extraction Kit with Gas Extraction Device and Filter Heater The heater for the sintered metal filter attachment must be used when measuring gas temperatures fall below the dew point. Fig. 10-6: Heater for sintered metal filter attachment Insertion depth Type (order no.) Connection cable length 800 mm (31.5 in) 6 57 R 3061 2 m (6.6 ft) 1,000 mm (39.4 in) 6 57 R 3062A 2 m (6.6 ft) 1,400 mm (55.1 in) 6 57 R 3063A 2 m (6.6 ft) 1,800 mm (70,9 in) 6 57 R 3064A 2 m (6.6 ft) Cable connectors for extending the GED and filter heater (type 6 57 R 3168) 112 Optional Accessories - Protective Pipe for High-Dust Applications 10.11 Protective Pipe for High-Dust Applications Fig. 10-7: Protective pipe for highdust applications 1 2 3 4 5 No. Component Type (order no.) 1 Connection flange for protective pipe for high-dust applications 657R3511/R3512 2 Counterflange 657R3506/R3507 3 Pressure disks with disk springs and graphite seal 657P3531/R3532/R3530 4 Protective pipe for high-dust applications (standard 1.4571) 657 R 3560 (500mm) 657 R 3561 (800mm) 657 R 3562 (1000mm) 657 R 3563 (1400mm) 657 R 3564 (1800mm) External diameter 60mm Internal diameter 55mm 5 Gas extraction kit (standard 1.4571) 657 R 3010 (500mm) 657 R 3011 (800mm) 657 R 3012 (1000mm) 657 R 3013 (1400mm) 657 R 3014 (1800mm) Pressure disks with disk springs and graphite seals are supplied with the counterflange. For installation instructions, see chapter 4.7. 113 Optional Accessories - Ceramic Gas Extraction Device 10.12 Ceramic Gas Extraction Device For measuring gas temperatures of between 950 °C (1,740 °F) and 1,400 °C (2,552 °F), a ceramic gas extraction device must be used in conjunction with a ceramic protective pipe. Fig. 10-8: Ceramic gas extraction device with ceramic protective pipe 1 2 3 4 5 6 7 8 Gas extraction tube Ceramic filter (filter mesh: 50 µm) Ceramic protective pipe with filter Protective pipe to prevent heat transfer Cladding/insulation Boiler wall Insulation Flange Insertion depth Type (order no.) 500 mm (19.7 in) 6 57 R 3030 800 mm (31.5 in) 6 57 R 3031 1,000 mm (39.4 in) 6 57 R 3032 1,400 mm (55.1 in) 6 57 R 3033A 1,800 mm (70,9 in) 6 57 R 3034A 10.13 Counterflange M8 75 15 65 M16 1 125 4 151.5 165 190 Fig. 10-9: Counterflange Type Material 657 R 3506 Steel (cataphoretically painted) 657 R 3507 Stainless steel 1.4571 (V4A) 114 Optional Accessories - Optional Second RS422 Interface, Type K6029318 10.14 Optional Second RS422 Interface, Type K6029318 An RS422 module, a connection cable, an adapter board and a holding plate must be used for this option. Two holding plates are always supplied to cover both housing types (sheet steel and cast aluminum). See also chapter 4.5. 4 3 5 1 Fig. 10-10: Components of the 2nd RS422 interface 2 1 2 3 RS422 module Adapter board Bracket for LAMBDA TRANSMITTER E in sheetsteel housing 4 5 Bracket for LAMBDA TRANSMITTER E in cast-aluminum housing Connection cable The second RS422 interface is required if a GM31 analyzer is to be connected and the CAN or LSB interface is already assigned to an Evaluation unit or gas extraction device and filter heater, or an LSB module. If the CAN or LSB interface is not assigned, the RS422 interface provided (X12 on board) can be used. It must first be set via plug-in jumpers, however (see chapter 12.5.1). 115 Optional Accessories - Optional Second RS422 Interface, Type K6029318 10.14.1 Installing the Second RS422 Interface in Sheet-Steel Housing a Fig. 10-11: Installing the Second RS422 Interface in SheetSteel Housin Fig. 10-12: Installing the adapter board on the processor board Fig. 10-13: Connecting and laying the connection cable 116 Optional Accessories - Optional Second RS422 Interface, Type K6029318 117 Optional Accessories - Optional Second RS422 Interface, Type K6029318 IMPORTANT! Never connect the RS422 module when it is energized. It may be destroyed!! Switch off the power supply to the LAMBDA TRANSMITTER E . Open the LAMBDA TRANSMITTER E housing and front plate. Secure the holding plate (3), with the RS422 module (1) attached, to the cable connection (a). See Fig. 10-10. Plug the connection cable (5) into the RS422 module and route it under the front plate to the front side of the LAMBDA TRANSMITTER E . Then close the front plate. Remove the Perspex disk protecting the processor board. To do this, you must loosen three 3 screws. Remove the jumpers (x 9) from the processor board (b). See Fig. 10-11. Unscrew the three plastic screws (c) from the spacer on the processor board. Plug the adaptor board (2) into the processor board (d) (e). Screw the adaptor board (2) back together with the spacer (f). Snap off and remove the small lugs on the jumpers (g). Connect the RS422-module connection cable (5) to the adapter board (2)(h). See Fig. 10-12. The ribbon cable can be trimmed as needed since this will also be used in the LAMBDA TRANSMITTER E in cast-aluminum housing. Affix the cable run (i) and secure the connection cable to it. Screw the Perspex disk back on to the processor board (j). Close the LAMBDA TRANSMITTER E housing and reconnect the power supply. 118 Optional Accessories - Optional Second RS422 Interface, Type K6029318 10.14.2 Installing the Second RS422 Interface in Cast-Aluminum Housing a Fig. 10-14: Securing the RS422 modules on the side of the cast housing c b d f e Fig. 10-15: Installing the adapter board on the processor board g Fig. 10-16: Connecting and laying the connection cable 119 Optional Accessories - Optional Second RS422 Interface, Type K6029318 IMPORTANT! Never connect the RS422 module when it is energized. It may be destroyed!! 1. Switch off the power supply to the LAMBDA TRANSMITTER E . 2. Open the LAMBDA TRANSMITTER E housing. 3. Attach the RS422 module on the side wall of the housing using double-sided adhesive tape (a). See Fig. 10-14. 4. Plug the connection cable (5) into the RS422 module and route it over the front plate to the front side of the LAMBDA TRANSMITTER E . Then close the front plate. See Fig. 10-14. 5. Remove the jumpers (x 9) from the processor board (b). See Fig. 10-14. 6. Unscrew the three plastic screws (c) from the spacer bolts on the processor board. 7. Plug the adaptor board (2) in to the processor board (d) (e). 8. Screw the adaptor board (2) back together with the plastic screws (f). 9. Connect the RS422-module connection cable (5) to the adapter board (2)(g). See Fig. 10-15; 10-16 10. Close the LAMBDA TRANSMITTER E housing and reconnect the power supply. 11. The second RS422 interface is now ready for operation. No further settings need to be made. 120 Spare Parts and Consumables - Consumables: 11 Spare Parts and Consumables NOTE * Recommendation: place spare parts in storage The operator must decide upon suitable storage measures. (2) Spare part for optional components. (3) Available in other lengths (specifications in the price lists or available on request) (1) 11.1 Consumables: • * 1 ZrO2 measuring cell with contact Average service life: 2 to 4 years (depending on fuel) Type 6 57 R 3201 • * 1 heater measuring cell Average service life: 2 to 4 years Type 6 57 R 3203 • * 1 mounting paste (anti-seize paste) (x 5) 6 50 R 1090 • * 1 sampling filter for gas extraction device up to 950 °C (1,740 °F) Type 6 55 R 0028 • * 1 sintered metal filter insert 50 µm (x 10) For sampling filter type 6 55 R 0028, Type 6 55 R 2803 • * 1 filter attachment for probe installation fittings, Type 6 55 R 0212 – filter mesh 20 µm (standard) Type 6 55 R 0211 – filter mesh 10 µm Type 6 55 R 1210 – filter mesh 40 µm Type 6 55 R 0208 – filter mesh 2 µm 121 Spare Parts and Consumables - Spare Parts: 11.2 Spare Parts: • (1) • (1) • (1) • (1) • (1) • (1) • 1 "measuring chamber" repair kit Type 6 57 R 3206 1 "seal set" measuring chamber Type 6 57 R 3212 1 "seal set" measuring cell Type 6 57 R 3213 1 replacement Ejectorpump (complete) with heater Type 6 57 R 3202 1 PT 100 temperature sensor - for probe temperature (capillary) Type 6 57 R 3205 1 gas extraction device with integrated capillary for insertion depth of 500 mm Type 6 57 R 3310 Insertion depth 300 mm (11,8 in) Insertion depth 800 mm (31.5 in) Insertion depth 1,000 mm (39.4 in) Insertion depth 1,400 mm (55.1 in) Insertion depth 1,800 mm (70,9 in) Type 6 57 R 3315 Type 6 57 R 3311 Type 6 57 R 3312 Type 6 57 R 3313 Type 6 57 R 3314 (1) 1 ceramic gas extraction device, insertion depth 500 mm Type 6 57 R 3330 Insertion depth 800 mm (31.5 in) Insertion depth 1,000 mm (39.4 in) Insertion depth 1,400 mm (55.1 in) (1,000 mm ceramic) Insertion depth 1,800 mm (70,9 in) (1,000 mm ceramic) • (1) • (1) • (1) (2) • (1) (2) • (1) (2) Type 6 57 R 3331 Type 6 57 R 3332 Type 6 57 R 3333 Type 6 57 R 3334 1 securing mechanism for protective pipe for gas extraction device Type 6 55 R 0630 1 protective pipe (standard) for gas extraction device, material: 1.4571 (V4A), incl. sintered metal pre-filter, for measuring gas temperatures up to 700 °C (1,290 °F), for the following insertion depths: 500 mm (19.7 in) → 6 57 R 3410 800 mm (31.5 in) → 6 57 R 3411 1,000 mm (39.4 in) → 6 57 R 3412 1,400 mm (55.1 in) → 6 57 R 3413 1,800 mm (70,9 in) → 6 57 R 3414 1 protective pipe (Inconell 600) for gas extraction device, incl. sintered metal pre-filter, for measuring gas temperatures up to 950 °C (1,740 °F), for the following insertion depths: 500 mm (19.7 in) → 6 57 R 3420 800 mm (31.5 in) → 6 57 R 3421 1,000 mm (39.4 in) → 6 57 R 3422 1,400 mm (55.1 in) → 6 57 R 3423 1,800 mm (70,9 in) → 6 57 R 3424 1 protective pipe (ceramic/metal-ceramic version) for gas extraction device for measuring gas temperatures up to 1,400 °C (2,552 °F), incl. pre-filter for the following gas extraction device insertion depths: 500 mm (19.7 in) → 6 57 R 3430 800 mm (31.5 in) → 6 57 R 3431 1,000 mm (39.4 in) → 6 57 R 3432 1,400 mm (55.1 in) → 6 57 R 3433 1,800 mm (70,9 in) → 6 57 R 3434 1 support for gas extraction device (standard) with flange and seal Material: stainless steel 1.4571 (V4A) Type 6 57 R 3510 122 Spare Parts and Consumables - Spare Parts: • • • • • • • • • • • • • • • • • • (1) (2) 1 support for gas extraction device without flange; only in connection with gas extraction device heater Material: stainless steel 1.4571 (V4A) Type 6 57 R 3520 (1) (2) 1 replacement measuring gas sampling heater (complete), with protective pipe, without sintered metal pre-filter for the following insertion depths: Material stainless stell 1.4571 /V4A) 500 mm (19.7 in) → 6 57 P 3450 800 mm (31.5 in) → 6 57 P 3451 1,000 mm (39.4 in) → 6 57 P 3452 1,400 mm (55.1 in) → 6 57 P 3453 1,800 mm (70,9 in) →6 57 P 3454 Type corrosion-resistant steel 1.4539 on request Additional protective pipe polyester on request (1) (2) 1 replacement heater for sintered metal filter attachment for the following insertion depths: 800 mm (31.5 in) → 6 57 R 3471 1,000 mm (39.4 in) → 6 57 R 3472 1,400 mm (55.1 in) → 6 57 R 3473 1,800 mm (70,9 in) → 6 57 R 3474 (1) (2) 1 replacement electronics for gas extraction device and filter heater (complete) 6 57 R 3165 (1) (2) 1 replacement transformer for gas extraction device and filter heater Type 6 57 R 3166 (1) 1 replacement computer electronics Type 6 57 R 1874 (1) 1 replacement base electronics without pressure sensors for LAMBDA TRANSMITTER E in cast-aluminum housing Type 6 57 P 3000 (1) 1 replacement base electronics without pressure sensors for LAMBDA TRANSMITTER E in sheet-steel housing Type 6 57 P 4000 (1) 1 replacement power pack (transformer) Type 6 57 R 3874 (1) 1 replacement display/control unit for LAMBDA TRANSMITTER E in sheet-steel housing Type 6 57 R 4130 (1) 1 differential pressure sensor for LAMBDA TRANSMITTER E in cast-aluminum housing Type 6 57 R 0537 (1) 1 differential pressure sensor for LAMBDA TRANSMITTER E in sheet-steel housing Type 6 57 R 4001 (1) 1 absolute pressure sensor Type 6 57 P 0549 (1) 1 analog output module 0/4-20 mA / 0/2-10 V (floating) max. difference in potential +/-20 V Type 6 57 R 0051 (1) 1 replacement fuse box Type 6 57 R 3102 (1) 1 small accessories kit Type 6 57 R 3250 (1) 1 proportional valve Type 6 57 P 3102 (1) 1 solenoid valve baseplate Type 6 57 R 0402 123 Spare Parts and Consumables - Spare Parts: • (1)(2) • (1)(2) • (1)(2) • (1)(2) • (1)(2) • (1)(2) • (1)(2) • (1) • (1) • (1) • (1) • (1) • (1) 1 replacement external power supply for LSB-module Type 6 57 R 4024 1 replacement LSB-module analog output (voltage), without connection cable Type 6 57 R 4025 1 replacement LSB-module analog output (current), without connection cable Type 6 57 R 4029 1 replacement LSB-module analog input, without connection cable Type 6 57 R 4026 1 replacement LSB-module digital output, without connection cable Type 6 57 R 4027 1 replacement LSB-module digital input, without connection cable Type 6 57 R 4028 Type 6 57 R 4228 (from January 2008) 1 replacement RS422 module, without connection cable Type 6 63 P 0503 1 PUN hose, 6x1 mm, black Type 6 57 P 0547, running meter 1 low-pressure PTFE hose 6 x 4 mm, natural Type 6 50 P 0707, running meter 1 PTFE hose 3 x 0.5 mm Type 6 50 P0228, running meter 1 pre-pressure reducer for 0 to 10 bar, with integrated water separator and drain valve for fully-automatic condensate drainage (complete) Type 6 57 R 3150 1 pressure reducer for Ejectorpump and Calibration (complete) Type 6 57 R 3151 1 serial connection cable, 9-pin Sub D, socket / socket 10 m long (optional) Type 6 63 R 0100 124 Appendix - Technical Specifications 12 Appendix 12.1 Technical Specifications Sheet-steel housing: Cast-aluminum housing: Ambient temperature: Auxiliary voltage: • Painted, stainless steel probe chapter1,4571 (V4A) • Degree of protection in accordance with DIN 40050: IP 65; NEMA 4X • Dimensions (H x W x D): 395 x 330 x 300 mm (15.6 x 13 x 11.8 in) • Color: orange • Weight: 27 kg (24.3 lb) (with 1 m/3.3 ft gas extraction device) • With GED-Heating 500mm/1000mm additional 4kg/6kg • Painted, stainless steel probe chapter1,4571 (V4A) • Degree of protection in accordance with DIN 40050: IP 65; NEMA 4X • Dimensions (H x W x D): 370 x 260 x 280 mm (14.6 x 10.2 x 11 in) • Color: orange • Weight: 22 kg (48.5 lb) (with 1 m/3.3 ft gas extraction device) • With GED-Heating 500mm/1000mm additional 4kg/6kg • Operation: -20 °C to +55 °C (-4 °F to 130 °F). • Transport and storage: -40 °C to +85 °C (-40 to 185 °F) • 230 V AC and 115 V AC, +10% / -15%, 48 Hz to 62 Hz !! To be used only in grounded power line networks !! Power consumption: • (without heater for gas • extraction device and filter) Typical: 160 VA Max: 250 VA Measuring principle: • Zirconium dioxide current probe Operating temperature of measuring cell: • 800 to 1,000 °C (1,470 to 1,830 °F) Sample gas flow rate: • 0.3 to 0.6 l/h (0.8 to 1.6 gal/hr), typ.: 0.5 l/h (0.13 gal/hr) – equal to 500 mA probe current Resolution: • 0.1 vol. % O2 Measurement accuracy: • Better than 0.2 vol. % O2 across the entire range (0 to 25 vol. % O2 ) after previous calibration Detection limit: • 0.1 vol. % O2 Cross-sensitivity: • None vis-à-vis H2O, CO2, SO2, or HCl Signal interference from combustible gases: • At concentrations: ≤ 1,000 ppm CO ≤ -0.05 vol. % O2 ≤ 1,000 ppm NO ≤ -0.05 vol. % O2 ≤ -0.2 vol. % O2 ≤ 1,000 ppm CH4 Interference of all gases: • ≤ +0.2 vol.% O2 Probe current: • 0 to 1,000 mA, typical value for air: 300 to 600 mA, depending on flow rate Maximum permissible duration of flue gas temperature: • Standard gas extraction device 700 °C (1,290 °F) • Inconell gas extraction device 950 °C (1,740 °F) • Ceramic gas extraction device 1,400 °C (2,552 °F) • On request 1,600 °C (2,910 °F) Time-related drift of zero and reference point: • < 0.2 vol. % O2 per maintenance interval Response time (90% time): • < 20 sec (with standard gas extraction device, 1 m/3.3 ft long) 125 Appendix - Technical Specifications Time for ready status: • < 2 hours 126 Appendix - Technical Specifications Analog outputs: • Resolution: Accuracy: Load: Factory setting: 0/4 to 20 mA, 0 to 10 V, (floating) max. diff. in potential ± 20 V 0.01 mA 0.01 mA 800 Ω 4 to 20mA Æ 0 to 21 vol. % O2 Monitor output - Output: - Accuracy: - Resolution: - Factory setting: - Monitor function: Probe voltage US Int. probe (cell) resist. RI 0 to 2.55 V DC, load >10 kW, <100 nF 2% from meas. value, not better than 0.1vol.% O2 10 mV 0 to 2.55 V DC Æ 0 to 25.5 vol. % O2 Can be switched by means of DIP switch to: 0 to 255 mV DC (= 0 to 2.55 V) 0-255 Ω, equal to 0 to 2.55 V • Other analog outputs 0 to 20 mA, 0 to 10 V (via LSB module (see 10.1)) Analog inputs: • Analog inputs 0 to 20 mA, 0 to 10V , PT1000 possible via LSB module (see 10.2) Digital outputs: • Digital outputs possible via LSB module (see 10.3) Digital inputs: • Digital inputs possible via LSB module (see 10.4) Controls: • Display/control unit, multi-function key, maintenance switch and 2 rows of 6 LEDs • Display/control unit (optional) • Analog output • Remote control unit (optional) • Remote display software • LSB bus for connection with other devices with LSB bus (alternative: RS422) • Additional 2nd RS422 (optional) • Field bus interfaces (optional): - Profibus DP - Modbus - Ethernet - CANopen - Interbus S • RS 232 for connecting a PC with remote display software Conformity with following European guidelines: • 89 / 336 / EEC – electromagnetic compatibility • 73 / 23 / EEC – electrical equipment designed for use within certain voltage limits TÜV qualification test: • TÜV qualification tested for emissions measuring devices to Federal German Pollution Control Act (13th and 17th Implementing Ordinance). Proof no.1: 205 155 98 N2-EP GM302 Proof no.2: 936 21203535 / B Interfaces: 127 Appendix - Connection Diagram 12.2 Connection Diagram LAMBDA TRANSMITTER E Base Electronic RS422 / LSB floating Analog output 0/4-20mA 0-10V Monitor output 0 - 2,55V/DC can be switched to: meas. 02 value Probe current Probe voltage Power supply F1- 2,5At at 230V/AC F1- 5At at 115V/AC RS422 LSB (CANopen*) 76 76 GND CAN GND 75 75 TXD- (B) CAN low 74 74 TXD+ (A) CAN high 73 73 RXD+ (A) CAN low 72 72 RXD- (B) CAN high 71 71 GND CAN GND 42- Analog output card (floating) max. posssible difference of floating +/-20V 657R0051 43+ 31- e.g. to connect a multi-meter for servicing purposes (Ri >10kR) 32+ 1 PE 1 PE Grounding 2N 2N Neutral conductor 3L 3L Phase 115V/230V, typ. 160VA, 48...62Hz Connection power max. 250VA F1 To connect the Remote-DisplaySoftware 657R1103 RS232 Interface 9-pole Sub-D male GND Optional 2. RS422Interface (addtitional module) TXTX+ Terminals on additional module RXRX+ Pressure air connectors Pressure air connector with water separator, filter and control valve 0...4 bar (58 psi) onsite *= to be set via parameter 3895 128 Pressure air for ejector pump 2 bar (29 psi) air consumption approx. 1m3/h Pressure air for calibration 2 bar (29 psi) air consumption approx. 1m3/h Appendix - Dimensions 12.3 Dimensions Y 300 180 182 70 395 190 4xM8 16 Fig. 12-1: Dimensions of the LAMBDA TRANSMITTER E X X Insertion depth, dimension X (see table) Insertion depth Dim. X in Y Dimensions with open cover: 630 mm Gas extraction kit Standard up to 700 °C Up to 950 °C (1,740 (1,290 °F) °F) Ceramic 950 °C to 1,400 °C (1,740 to 2,550 °F) Type (order no.) Type (order no.) Type (order no.) 300 mm 657R3015 On request On request 500 mm 657R3010 657R3020 657R3030 800 mm 657R3041 657R3021 657R3031 1,000 mm 657R3042 657R3022 657R3032 1,400 mm 657R3043A 657R3023A 657R3033A 1,800 mm 657R3044A 657R3024A 657R3034A IMPORTANT! When ordering replacement gas extraction devices, bear in mind that the insertion depth is measured from the flange, not across the entire length of the device. 129 Appendix - Base Electronics 12.4 Base Electronics X12 X13 X14 X15 X16 X11 10-15 F1 LED11 LED12 X202 F18 LED10 X203 X204 LED14 LED13 X206 Fig. 12-2: Base electronics Fuses and LED’s LED1 - 9 X205 F10 F11 F12 F13 F14 F15 F16 Fuse Value Monitoring Function F1 T2.5A T5A - Primary line fuse at 230 V AC Primary line fuse at 115 V AC F10 T4A LED1 green Operating voltage +12 V DC heater extract. F11 T2A LED2 green Operating voltage +12 V DC solenoid valve F12 T0.8A LED3 green Operating voltage +12 V DC proportional valves F13 T1.6A LED4 green Operating voltage +6 V DC probe F14 T0.8A LED5 green Operating voltage +24 V DC analog section F15 T1.6A LED6 green LED7 green Operating voltage +5 V DC digital section Operating voltage -5 V DC digital section F16 T4A LED8 green Operating voltage 36 V AC probe heater F17 T4A LED9 green Operating voltage 29 V AC emergency probe heater F18 T375mA LED10 green Operating voltage +5 V DC interface LSB/RS422 - LED11 green RxD LSB interface - LED12 yellow TxD LSB interface - LED13 yellow TxD0 RS232 interface (9-pin Sub D) - LED14 yellow RxD0 RS232 interface (9-pin Sub D) 130 Appendix - Base Electronics Plugs and terminals Designation Function Assignment X11 Power connection 115/230 V, 50/60 Hz 1–L 2–N 3 – PE X12 LSB/RS422 interface Can be set with BR10 – BR15 (Base electronics) and BR12 – BR13 (processor board) LSB RS422 71 – GND 72 – CAN high 73 – CAN low 74 – CAN high 75 – CAN low 76 – GND 71 – GND 72 – RxD73 – RxD+ 74 – TxD+ 75 – TxD– GND See 12.5.1 Analog output 0/4-20 mA 0/2-10 V 4243+ X14 Monitor output 0-2.55 V, for connecting a multi-meter for servicing purposes 3132+ X15 PT100 connection, temperature sensor for capillary temperature 0 - 820 °C (32 – 1,500 °F) 24 X16 Probe connection and extraction device heater 82 – Heater for extraction device 83 – Heater for extraction device 92 – Probe heater 93 – Probe heater 94 – Measured current + 95 – Measured voltage + 96 – Measured voltage 97 – Measured current - X202 Connection of solenoid and proportional valves 1 – MV1 + (Calibration) 2 – MV1 - (Calibration) 3 – PV1 + (Calibration) 4 – MV2 + (cooling) 5 – MV2 - (cooling) 6 – PV1 - (Calibration) 9 – PV2 + (eductor) 12 – PV2 – (eductor) X203 Transformer connection (primary side) for 230 V AC F1 – T2.5A X204 Transformer connection (primary side) for 115 V AC F1 – T5A X205 Transformer connection (secondary side) X206 For LT10P only DS1 Absolute pressure sensor DS2 Differential pressure sensor 25 26 12.4.1 Switching over the line voltage from AC230V to AC115V (if required) 1.) Changing main fuse F1 New value 5A slow-blow 2.) Switch over trafo connector from X203 to X204 131 76 Appendix - Plug-in Jumpers 12.5 Plug-in Jumpers 12.5.1 LSB bus / RS422 Fig. 12-3: Plug-in jumpers on the LAMBDA TRANSMITTER E base electronic 10 11 12 13 14 15 Connector X12 for LSB / CAN / RS422 Fig. 12-4: Plug-in jumpers on the LAMBDA TRANSMITTER E processor board 13 12 Function Board Plug-in jumper Position Activate LSB bus / RS422 base electronic Processor board 10 to 14 12 and 13 CAN * C* Activate RS422 interface base electronic Processor board 10 to 14 12 and 13 RS422 S Test RS422 interface Connect terminal 73 with 74 and 72 with 75. Switch on LAMBDA TRANSMITTER E . LEDs 11 and 12 for RS422 communication begin to pulse at the same speed (approx. 10 ms (msec) pulse). IMPORTANT! This RS422 interface can only be used if it is connected directly to the motherboard at the X12 connector. If you use devices that are connected at the LSB/CAN bus, you cannot use the RS422 interface in this way and must use the optional second RS422 interface (see 10.14) instead. Terminating resistor not activated base electronic 15 CAN * Terminating resistor activated base electronic 15 R * = factory setting 132 Appendix - Plug-in Jumpers 12.5.2 Analog Output card Fig. 12-5: Analog output card on base electronic Fig. 12-6: Plug-in jumpers on analog output card • • • 1 voltage output: 0 to 10 V Parameter 531 setting Type Parameter group Factory setting Output terminals • • • 2 current output: 0/4 to 20 mA Parameter 531 setting 657 R 0051 (floating) 530 - 539 4 - 20 mA => 0-21% O2 42- / 43+ For exchange the analog output card see chapter 8.13. 133 Appendix - Plug-in Jumpers Parameter 530 / 540 / 550 / 560 Here, enter the measured value that is to be output at the analog output. The following settings are possible for each output: • Off • Measured O2 value • Configurable measured value 1 - 6 • Probe temperature • Probe absolute pressure • Probe current • Probe voltage • Internal O2 value Parameter 531 / 541 / 551 / 561 Here, set the measurement range for each analog output. The following settings are possible: • 0-20 mA / 0-10 V (for voltage output) • 4-20 mA • 4-20 mA / error 0 mA • 4-20 mA / error + maintenance 0 mA Parameter 532 / 542 / 552 / 562 Here, set the start of the measurement range for each analog output. • E.g. “0” for 0% O2 Parameter 533 / 543 / 553 / 563 Here, set the end of the measurement range for each analog output. • E.g. “210” for 21% O2 Parameter 534 / 544 / 554 / 564 • Output value for each analog output in “mA” 134 Appendix - Probe Record Pass (Front) 12.6 Probe Record Pass (Front) 135 Appendix - Probe Record Pass (Front) 12.6.1 Probe Record Pass (Back) 136 801027/2012-09 Subject to change without notice ZIRKOR302 E SICK worldwide You will find our local subsidiary or agency at: www.sick.com Your local sales and service partner SICK AG | Waldkirch | Germany | www.sick.com