Servomex User and Installation Manual – Model 2700 Analyzer

COMBUSTION ANALYSERS SERVOTOUGH Fluegas(2700) 2730C Utilities Unit User and Installation Manual Part Number: Revision: Language: 02730001C 1 UK English This page intentionally blank CONTENTS LIST CONTENTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 WARNINGS, CAUTIONS and NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Scope of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2 Air Set (Single and dual sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.3 Air Set and Autocalibration (Single sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.4 Air Set and Autocalibration (Dual sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.5 Air Set with Blowback and Autocalibration (Single sensor) . . . . . . . . . . . . . . . . 16 2.6 Air Set with Blowback and Autocalibration (Dual sensor) . . . . . . . . . . . . . . . . . 18 2.7 Air Set and Manual Calibration (Single and dual sensor) . . . . . . . . . . . . . . . . . . 20 3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3.1 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3.2 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4. TECHNICAL SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Air Set (Single and dual sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Air Set and Manual Calibration (Single and dual sensor) . . . . . . . . . . . . . . . . . . 4.3 Air Set with Autocalibration (Single sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Set with Autocalibration (Dual sensor) Air Set with Blowback and Autocalibration (Single sensor) Air Set with Blowback and Autocalibration (Dual sensor) 29 29 30 31 5. MAINTENANCE AND SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Spare parts for Single and dual sensor air set (02730701) . . . . . . . . . . . . . . . . . . 5.2 Spare parts for Single sensor air set with auto calibration (02730711) . . . . . . . . 5.3 Spare parts for dual sensor air set with auto calibration (02730713C) . . . . . . . . 5.3 Spare parts for dual sensor air set with auto calibration (02730713C) . . . . . . . . 5.4 Spare parts for Single Sensor air set with auto calibration and blowback (02730721) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Spare parts for dual sensor air set with autocalibration and blowback (02730723C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Spare parts for single and dual sensor air set with manual calibration (02730731) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Routine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 33 33 33 33 2730 User and Installation Manual 5 5 5 6 7 34 34 35 35 1 LIST OF FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 2 Single and dual sensor air set flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . .11 Single sensor air set with auto calibration flow diagram. . . . . . . . . . . . . . . . .13 Dual sensor air set with auto calibration flow diagram. . . . . . . . . . . . . . . . . .15 Dual sensor air set with blow back and auto calibration flow diagram. . . . . . .17 Dual sensor air set with blow back and auto calibration flow diagram. . . . . . .19 Single and dual sensor air set with manual calibration flow diagram. . . . . . .20 Single sensor air set installation drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Air set with either auto calibration or blowback installation drawing . . . . . .23 Gland plate details, auto calibration and blowback versions. . . . . . . . . . . . . .24 Manual calibration utility unit version installation drawing. . . . . . . . . . . . . .25 Interconnecting wiring schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 2730 User and Installation Manual Revision History Sheet 02730001C 2730 Operators Manual Ref No. Page(s) Affected 02730/001C/0 – First issue 02730/001C/1 – Filter regulator part number changed except on assembly 02730701 2730 User and Installation Manual Summary of Change Date/ by G.Botting 12.06.06 M. Hubball 4.10.10 3 This page is left intentionally blank. 4 2730 User and Installation Manual 1. INTRODUCTION 1.1 WARNINGS, CAUTIONS and NOTES This manual includes WARNINGS, CAUTIONS and NOTES which provide important information relating to the following: WARNINGS Hazards which could result in personal injury or death. CAUTIONS Hazards which could result in damage to equipment or property. NOTES Alerts the user to pertinent facts and conditions. 1.2 Scope of this Manual This instruction manual describes installation and operation of the 2730 Utilities Units that are available for use with the 2700C combustion gas analyser. • For technical specifications, see section 4 of this manual. • For the addresses for technical assistance and spares, see the rear of this manual. About this Manual Ref.02730/001C/1 Order as Part 02730001C CE Marking Where applicable the 2730 utilities units carry the CE mark which indicates conformity with the European Community Directives on CE Marking (93/68/EEC), Electromagnetic Compatibility (EMC 89/336/EEC) and Low Voltage Directive (LVD 73/23/EEC). 2730 User and Installation Manual 5 1.3 General Safety Information Specific standards of safety are not included in this manual, since requirements of relevant authorities vary widely. The safety precautions described in this manual ensure that the existing safety features are not impaired during normal operation and use. WARNINGS • • • • • • • 6 The electrical power used in this equipment is at a voltage high enough to endanger life. It is essential that only suitably trained and competent personnel are allowed to access hazardous live parts by removing or opening covers of the equipment. The installer must be satisfied that the 2730 installation conforms to the relevant safety requirements, National Electrical Code and any other local regulations, and that the installation is safe for any extremes of conditions which may be experienced in the operating environment of the equipment. This appliance must be connected to a protective earth. The electrical installation must include a means of isolating electrical power by a switch or circuit breaker external to the analyser and within easy reach of the operator. It must be marked as the disconnecting device for the equipment. The 2700 sensor head aspirator supply is suitable for use with compressed air only. Flammable gases must not be used for the aspirator supply. The 2730 Utilities unit is not suitable for use in hazardous areas / locations without the use of appropriate safety purge equipment. The 2730 Utilities unit is only to be used with the gasses specified in the 2700 Quickstart Manual, 2700 Installation Manual and/or this manual. 2730 User and Installation Manual WARNING - GAS HAZARDS If a gas leak occurs within the automatic calibration utilities units, the enclosure may become filled with one or both of the following gaseous hazards. a) 0.3% oxygen in nitrogen which is an asphyxiant. b) Up to 1% carbon monoxide in air which is toxic. Appropriate care must be taken when opening the utilities enclosure for any reason. Automatic calibration units have a breathing device fitted to the enclosure. Ensure that this device is not obstructed or blocked. Manual and Automatic calibration units MUST be located in a freely ventilated area. 1.4 Unpacking WARNING The 2730 Utilities Units supplied with Autocalibration weigh <16Kg (<35lb). Care must be taken when handling. • Remove the 2730 components from their packing and inspect for obvious external damage. • If damage has occurred, inform Servomex or its agent immediately. • Retain all packing and shipping information for future use. 2730 User and Installation Manual 7 This page is left intentionally blank. 8 2730 User and Installation Manual 2. DESCRIPTION AND OPERATION 2.1 Overview The 2700 Combustion Gas Analyser measures the concentrations of oxygen and combustibles present in the sample, this provides the ability to maximise combustion efficiency and reduce emissions. The 2730 Utilities Units provide a convenient package to supply the utility gases required by the 2700 sensor head. The Utilities Unit may provide a number of different gas supplies to the sensor head. For optimum performance, only one analyser should be used in conjunction with an air supply or utilities unit. Aspirator air supply This provides the instrument grade compressed air supply required by the 2700 combustion gas analyser sample aspirator. The aspirator is used to extract the gas sample from the flue into the analyser sensor head. The compressed air supply should be clean, dry, and free from oil and dirt. The aspirator pressure range required is 3 to 5 psig. The flow rate is typically <1.5 l/min under typical flue pressure conditions. Auxiliary air supply The combustibles only and dual sensor versions of the 2700 require auxiliary air to supplement the level of oxygen present in the combustibles sensor. This is derived from the aspirator air supply within the sensor head to give a flow of between 80 to 120 ml/min. Calibration gas supply As good practice, Servomex recommend that the 2700 is checked/validated with check gas every month and then calibrated as required. This period can be extended as a result of operating experience. Calibration can be carried out either automatically or manually. The utility units provide the analyser with a controlled constant flow of the relevant calibration gases. Blowback air supply The blow back utilities units provide a 1 barg pressure compressed air supply to the sensor head calibration port. In extreme conditions blowback may be used to extend the service interval for the external sample probe filter by blowing off any dust coating. The blow back facility is not intended as a replacement for a suitably filtered sampling system. 2730 User and Installation Manual 9 WARNING For the utilities units supplied with either manual or automatic calibration. Do not unscrew the needle valve controlling the calibration gas flow rate by more than 4 turns. Failure to do this may result in the valve assembly becoming detached from the valve body exposing the user to potentially toxic or asphyxiant gases. CAUTIONS All Utilities units are specified to -10°C (+14°F), however, if operated below +2°C (+35.6°F) the instrument grade compressed air and calibration gases used must be free from oil, water, dirt and have a dew point 10°C (18°F) below the ambient temperature, to prevent freezing within the components. Maintenance of the Utilities Units should not be performed at temperatures below 0°C (+32°F). The 2730 utilities unit is designed for use only with the 2700C Series combustion gas analyser and should not be used with any other products or systems. NOTES The (Hoffman/Schroff) enclosure that is supplied with the automatic calibration utilities units requires a special key (which is provided) to gain access for installation and service. All gas pressures stated in this manual are ‘gauge’ pressures unless otherwise specified. 1 barg = 100 kPag 1 barg = 14.696 psig 10 2730 User and Installation Manual 2.2 Air Set (Single and dual sensor) Refer to the flow diagram in figure 1. The single or dual sensor air set (part number 02730701) consists of a filtered pressure regulator supplied complete with gauge, auto drain, inlet and outlet fittings, wall mounting bracket, screws, washers and nuts. The inlet pressure to the air set should be in the range 1 to 5 barg. The outlet pressure from the regulator should be set to the required aspirator inlet pressure as stated in the sensor head terminal box (typically 3.5 psig at a flow rate of <1.5 litres/min). The inlet and outlet fittings are suitable for use with 1/4" OD plastic or metal tubing. Figure 1. Single and dual sensor air set flow diagram Aspirator Air Outlet (3.5 psig <1.5 l/min) typical Air Inlet 1 to 5 barg Auto Drain 2730 User and Installation Manual 11 2.3 Air Set and Autocalibration (Single sensor) Refer to the flow diagram figure 2. The oxygen only air set with autocalibration (part number 02730711) consists of a wall mounted enclosure inside which are fitted the following components: • • • • • A filtered pressure regulator supplied complete with gauge and auto drain fitting. An unfiltered pressure regulator complete with gauge. A multi voltage power supply. Two solenoid valves. A 0-1000 ml/min flow meter and fine control valve. The inlet pressure to the unit should be in the range 1 to 5 barg. The typical flow rate required is <2.5 litres/min. Set the outlet pressure from the filter regulator to 1 barg. The outlet from the aspirator air precision pressure regulator is set to the required aspirator inlet pressure as stated in the sensor head terminal box (typically 3.5 psig at a flow rate of <1.5 litres/min). The pressure of the calibration gases to the autocalibration unit inlet port should be set to 1 barg (flow rate of <1 litre/min). The autocalibration facility consists of two solenoid valves to select the calibration gas required and a flow meter and needle valve to regulate and measure the gas flow rate. The outlet flow rate from the autocalibration unit to the calibration port of the 2700 should be set to 600 ml/min. The inlet and outlet bulkhead fittings are suitable for use with 1/4" NPT or BSPT male fittings and tubing. At the 2700 control unit, to which the utilities unit is attached, configure the relay outputs from the analyser using the ASSIGN RELAYS menu option as described in the 2700 Quickstart Manual. The relays should be set as follows. RELAY 1 RELAY 2 12 GAS 1 GAS 2 2730 User and Installation Manual Figure 2. Single sensor air set with auto calibration flow diagram. Set to 1 barg Air Inlet 1 to 5 barg <2.5 l/min Aspirator Air Outlet (3.5 psig <1.5 l/min typical) Air Inlet 1 to 5 barg <2.5 l/min SV1 Auto Drain SV2 0.3% Oxygen in Nitrogen -OR500ppm Carbon Monoxide in Air Calibration Gas Inlet 1 barg <1 l/min 2730 User and Installation Manual Calibration Gas Outlet 600 ml/min 13 2.4 Air Set and Autocalibration (Dual sensor) Refer to the flow diagram in figure 3. The dual sensor air set with autocalibration (part number 02730713C) consists of a wall mounted enclosure inside which are fitted the following components: • • • • • A filtered pressure regulator supplied complete with gauge and auto drain fitting. A precision pressure regulator complete with gauge. A multi voltage power supply. Three solenoid valves. A 0-1000 ml/min flow meter and fine control valve. The inlet pressure to the unit should be in the range 1 to 5 barg. The typical flow rate required is <2.5 litres/min. Set the outlet pressure from the filter regulator to 1 barg. The outlet from the aspirator air precision pressure regulator is set to the required aspirator inlet pressure as stated in the sensor head terminal box (typically 3.5 psig at a flow rate of <1.5 litres/min). The pressure of the calibration gases to the autocalibration unit inlet ports should be set to 1 barg (flow rate of <1 litre/min). The autocalibration facility consists of three solenoid valves to select the calibration gas required and a flow meter and needle valve to regulate and measure the gas flow rate. The outlet flow rate from the autocalibration unit to the calibration port of the 2700 should be set to 600 ml/min. The inlet and outlet bulkhead fittings are suitable for use with 1/4" NPT or BSPT male fittings and tubing At the 2700 control unit, to which the utilities unit is attached, configure the relay outputs from the analyser using the ASSIGN RELAYS menu option as described in the 2700 Quickstart Manual. The relays should be set as follows. RELAY 1 RELAY 2 RELAY 3 14 GAS 1 GAS 2 GAS 3 2730 User and Installation Manual Figure 3. Dual sensor air set with auto calibration flow diagram. Set to 1 barg Air Inlet 1 to 5 barg <2.5 l/min Aspirator Air Outlet (3.5 psig <1.5 l/min typical) SV1 Auto Drain SV2 0.3% Oxygen in Nitrogen Calibration Gas Inlet 1 barg <1 l/min SV3 Calibration Gas Outlet 600 ml/min 500ppm Carbon Monoxide in Air 2730 User and Installation Manual 15 2.5 Air Set with Blowback and Autocalibration (Single sensor) Refer to the flow diagram in figure 4. The single sensor air set with blowback and autocalibration (part number 02730721) consists of a wall mounted enclosure inside which are fitted the following components: • • • • • A filtered pressure regulator supplied complete with gauge and auto drain fitting. An unfiltered pressure regulator complete with gauge. A multi voltage power supply. Three solenoid valves. A 0-1000 ml/min flow meter and fine control valve. The inlet pressure to the unit should be in the range 1 to 5 barg. The typical flow rate required is <10 litres/min. Set the outlet pressure from the filter regulator to 1 barg. The outlet from the aspirator air precision pressure regulator is set to the required aspirator inlet pressure as stated in the sensor head terminal box (typically 3.5 psig at a flow rate of <1.5 litres/min). The autocalibration facility consists of two solenoid valves to select the calibration gas required and a flow meter and needle valve to regulate and measure the gas flow rate. The pressure of the calibration gases to the autocalibration unit inlet port should be set to 1 barg (flow rate of <1 litre/min). The outlet flow rate from the autocalibration unit to the calibration port of the 2700 should be set to 600 ml/min. The Blowback facility consists of a solenoid valve and bulkhead fitting. The Outlet pressure from the Blowback port is 1 barg. The inlet and outlet bulkhead fittings are suitable for use with 1/4" NPT or BSPT male fittings and tubing. At the 2700 control unit, to which the utilities unit is attached, configure the relay outputs from the analyser using the ASSIGN RELAYS menu option as described in the 2700 Quickstart Manual. The relays should be set as follows. RELAY 1 RELAY 2 RELAY 4 16 GAS 1 GAS 2 BLOWBACK AIR 2730 User and Installation Manual Figure 4. Dual sensor air set with blow back and auto calibration flow diagram. Set to 1 barg Air Inlet 1 to 5 barg <10 l/min Aspirator Air Outlet (3.5 psig <1.5 l/min typical) SV4 Blowback Air Outlet SV1 Calibration Gas Inlet 1 barg <1 l/min Auto Drain SV2 0.3% Oxygen in Nitrogen -OR500ppm Carbon Monoxide in Air Calibration Gas Outlet 600 ml/min 2730 User and Installation Manual 17 2.6 Air Set with Blowback and Autocalibration (Dual sensor) Refer to the flow diagram in figure 5. The dual sensor air set with blowback and autocalibration (part number 02730723C) consists of a wall mounted enclosure inside which are fitted the following components: • • • • • A filtered pressure regulator supplied complete with gauge and auto drain fitting. A precision pressure regulator complete with gauge. A multi voltage power supply. Four solenoid valves. A 0-1000 ml/min flow meter and fine control valve. The inlet pressure to the unit is 1 to 5 barg. The typical flow rate required is<10 litres/min. Set the outlet pressure from the filter regulator to 1 barg. The outlet from the aspirator air precision pressure regulator is set to the required aspirator inlet pressure as stated in the sensor head terminal box (typically 3.5 psig at a flow rate of <1.5 litres/min). The pressure of the calibration gases to the autocalibration unit inlet ports should be set to 1 barg (flow rate of 1 litre/min). The autocalibration facility consists of three solenoid valves to select the calibration gas required and a flow meter and needle valve to regulate and measure the gas flow rate. The outlet flow rate from the autocalibration unit to the calibration port of the 2700 should be set to 600 ml/min. The blowback facility consists of a solenoid valve and bulkhead fitting. The outlet pressure from the blowback port is 1 barg. The inlet and outlet bulkhead fittings are suitable for use with 1/4" NPT or BSPT male fittings and tubing. At the 2700 control unit, to which the utilities unit is attached, configure the relay outputs from the analyser using the ASSIGN RELAYS menu option as described in the 2700 Quickstart Manual. The relays should be set as follows. RELAY 1 RELAY 2 RELAY 3 RELAY 4 18 GAS 1 GAS 2 GAS 3 BLOWBACK AIR 2730 User and Installation Manual Figure 5. Dual sensor air set with blow back and auto calibration flow diagram. Set to 1 barg Air Inlet 1 to 5 barg <10 l/min Aspirator Air Outlet (3.5 psig <1.5 l/min typical) SV4 Blowback Air Outlet SV1 Auto Drain 0.3% Oxygen in Nitrogen Calibration Gas Inlet 1 barg <1 l/min SV2 SV3 Calibration Gas Outlet 600 ml/min 500ppm Carbon Monoxide in Air 2730 User and Installation Manual 19 2.7 Air Set and Manual Calibration (Single and dual sensor) Refer to the flow diagram in figure 6. The single and dual sensor air set with manual calibration (part number 02730731) consists of a wall mounted panel upon which are fitted the following components: • • • A filtered pressure regulator supplied complete with gauge and auto drain fitting. A precision pressure regulator complete with gauge. A 0-1000 ml/min flow meter and fine control valve. The inlet pressure to the unit should be in the range 1 to 5 barg. The typical flow rate required is <2.5 litres/min. Set the outlet pressure from the filter regulator to 1 barg. The outlet from the aspirator air precision pressure regulator is set to the required aspirator inlet pressure as stated in the sensor head terminal box (typically 3.5 psig at a flow rate of <1.5 litres/min). The manual calibration facility consists of a flowmeter and fine flow control valve. The pressure of the calibration gases to the manual calibration unit should be set to 1 barg (flow rate of <1 litre/min). The outlet flow rate from the manual calibration unit to the calibration port of the 2700 should be set to 600 ml/min. The inlet and outlet bulkhead fittings are suitable for use with 1/4" NPT or BSPT male fittings and tubing. Figure 6. Single and dual sensor air set with manual calibration flow diagram. Air Inlet 1 to 5 barg <2.5 l/min Set to 1 barg Aspirator Air Outlet (3.5 psig <1.5 l/min typical) Auto Drain Quick Connect Plug Quick Connect Plug 20 Calibration Gas Outlet 600 ml/min 2730 User and Installation Manual 3. INSTALLATION 3.1 Mechanical Installation Select a location which allows convenient access for installation and maintenance and will minimise ambient temperature fluctuations, vibration and be freely ventilated. The utilities units should be mounted onto a rigid vertical surface capable of supporting the weight of the unit. The aspirator air set and manual calibration versions should be mounted with the filter regulator drain pointing vertically down. The autocalibration versions of the utilities units should be mounted with the electrical entries on the under side. Ensure that the operating ambient temperature is in the range of -10°C to +50°C and that the Utilities Unit is protected from radiant heat sources or from direct sunlight (in ambient temperatures over 30°C). This can be achieved by installing a Heat Shield between the Utilities Unit and the source; a thin metal sheet is usually adequate. All pressure regulators, flow meters and gauges exhibit variations of output with changes in ambient temperature (their temperature coefficient). Although Servomex has chosen products that have good rejection to ambient temperature variation, utility units should be installed in locations with relatively stable ambient conditions. Ideally temperature swings from one extreme to another should be avoided. Instrument air and other gases supplied to the utilities unit must have dew points of at least 10°C less than the minimum anticipated ambient temperature. Table 1 lists the figure numbers that contain the installation drawings for the specific utilities units. Table 1 – Utility Units Installation Drawings Part No. Description Fig. No. 02730701 Air set (single/dual sensor) 02730711 Air set with autocalibration (single sensor) 8, 9 02730713C Air set with autocalibration (dual sensor) 8, 9 02730721 Air set with blowback and autocalibration (single sensor) 8, 9 02730723C Air set with blowback and autocalibration (dual sensor) 8, 9 02730731 Air and manual calibration (single and dual sensor) 10 7 NOTE The liquid that may collect in the filter regulator bowl will be automatically discharged through the drain port. This liquid must be disposed of in an appropriate and safe manner. 2730 User and Installation Manual 21 Figure 7. Single sensor air set installation drawing. f 99mm 32mm 93mm 7 8 8mm 9mm Ø5.5mm 124mm 165mm FLOW 1 2 3 4 5 6 Kit includes two M5 x 12mm mounting bolts, M5 washers and M5 full hex nuts Key to figure 7. 1 2 3 4 5 6 7 8 22 Two off 5.5mm diameter mounting holes for 5mm mounting bolts. Filter drain port (threaded 1/8" NPT male). Filter bowl. Outlet pressure gauge, 0-20 psig (part number 5981-2157). Compressed air inlet (1/4" OD compression fitting). Aspirator air outlet (1/4" OD compression fitting). Mounting bracket. Pressure adjustment control. 2730 User and Installation Manual Figure 8. Air set with either auto calibration or blowback installation drawing 227mm 13 400mm 1 220mm 12 362mm 2 4 593mm TB3 540mm 6 578mm 500mm 5 TB4 SV4 7 SV1 SV2 SV3 TB2 TB1 8 Ø10mm 9 15 10 11 Key to figure 8. 1 2 4 5 6 7 8 9 10 11 12 13 15 Hoffman hinged enclosure. Four off 10mm diameter mounting holes. Filter regulator assembly (part number 5984-4380). Filter regulator output pressure gauge, 0-20 psig (part number 5981-2157). Aspirator air pressure regulator (see spares list for part numbers). Blowback solenoid valve (if required, part number 2372-8040). Calibration gas solenoid valves (2 off for single sensor or 3 off for dual sensor, part number 2372-8033). Gland plate assembly (see figure 14). Enclosure breather fitting (part number 2371-0076). Power supply PCB (part number 02730901) and transparent mains protection cover. Calibration gas flow meter and needle valve (part number 5981-3516). Aspirator air output pressure gauge, 0-20 psig (part number 5981-2157). Adaptor, 1/4" BSPT (M) to 1/4" NPT (F) **. 2730 User and Installation Manual 23 Figure 9. Gland plate details, auto calibration and blowback versions. 10 DRAIN ASP.AIR OUTLET 1 8 9 AIR INLET MAX. 5 BAR CAL GAS (O2 LOW) MAX. 1 BAR CAL GAS/ BLOWBACK 2 3 7 6 CAL GAS (CO HIGH) SIGNAL MAX. 1 BAR MAINS 4 5 Key to figure 9 1 2 3 4 5 6 7 8 9 10 Aspirator air outlet bulkhead fitting **. Calibration and blowback (if fitted) outlet bulkhead fitting **. Unused Enclosure breather fitting (part number 2371-0076). Main power inlet M20 cable gland. Signal connection inlet M20 cable gland. Combustibles sensor high calibration gas inlet bulkhead fitting **. Oxygen sensor low calibration gas inlet bulkhead fitting **. Compressed air inlet bulkhead fitting **. Filter regulator automatic drain outlet **. NOTE ** 24 Gas connections are 1/4" NPT(F) as supplied, 1/4" BSPT (F) is obtained by removal of adaptor item 15 of figure 8 2730 User and Installation Manual Figure 10. Manual calibration utility unit version installation drawing. 16 450mm 173mm 390mm 2 15 360mm 124mm 320mm 3 4 17 14 265mm 238mm 17 41mm 5 6 Ø8.5mm 1 7 8 11 13 17 Key to figure 10 1 2 3 4 5 6 7 8 11 13 14 15 16 17 Mounting bracket. Filter regulator assembly (part number 5984-4380). Four off 8.5mm diameter mounting holes. Compressed air inlet bulkhead fitting **. 6mm OD Quick Connect fitting and tubing (part number 2385-3131). Quick connect socket. Filter regulator output pressure gauge, 0-20 psig (part number 5981-2157). Filter regulator automatic drain outlet. Calibration gas flow meter and needle valve (part number 5981-3516). Calibration gas outlet bulkhead fitting **. Aspirator air outlet bulkhead fitting **. Aspirator air outlet pressure gauge, 0-20 psig (part number 5981-2157). Aspirator air pressure regulator (part number 5984-7016). Adaptor, 1/4" BSPT (M) to 1/4" NPT (F) **. NOTE ** Gas connections are 1/4" NPT(F) as supplied, 1/4" BSPT (F) is obtained by removal of adaptor item 17. - Unit comes with two 1/4" OD compression Quick connect plugs, to fit into external calibration gasses (part number 2385-3100). 2730 User and Installation Manual 25 3.2 Electrical Installation This section defines the electrical interconnection details for the automatic calibration versions of the utilities units. The part numbers for the utility units requiring an electrical power supply are 02730711, 02730713C, 02730721, and 02730723C. WARNING Refer to the warnings and conditions outlined in the “General Safety Information” in section 1.3 of this manual. CAUTIONS • • • • The utilities unit supply voltage is field configurable for either 110 - 120V or 220 - 240V (nominal). Ensure that the rated voltage and frequency is suitable for the installation. Ensure that the link on the PCB has been set to the correct supply voltage. The supply voltage is set by linking together the terminals at terminal block TB2. Ensure that the link setting is correct for the rated supply voltage. The sensor head is intended to be powered from a supply which has the ‘Neutral’ conductor referenced to ground. Where this is unavailable, it is recommended that a suitable isolating transformer is installed and the secondary winding is referenced to ground. Alternatively, the electrical installation must include a fuse rated “F 250 mA HBC” in each supply conductor. The disconnect device (see also section 1.3) must disconnect each supply conductor. The fuses must be marked as being associated with this equipment. Ensure that the installation conforms to the relevant national and local safety requirements. NOTES • • • 26 The conduit or screen (if any) associated with the power supply should be grounded at the cable gland or conduit entry to the enclosure in accordance with local wiring regulations. Fuse F1 located on the PCB is rated F250mA HBC for 110-120V and 220-240V operation. Solenoid valve 4 only must be used for the Blowback facility as it has a larger internal diameter than Solenoid valves 1, 2 & 3. 2730 User and Installation Manual • • • • • • Refer to figure 11 for an interconnection wiring schematic. The 2730 utilities units are rated in accordance with IEC 644 for INSTALLATION CATEGORY II which is characterised as being local level (not distribution level), appliances and portable equipment with over voltage impulse withstand up to 2500V. Electrical terminations are suitable for 20 AWG (0.5 mm2) to 14 AWG (2.5 mm2) solid conductors or 16 AWG (1.5 mm2) stranded conductors. Gland entry sizes and positions are shown in the appropriate installation drawing. Un-used entries should be fitted with appropriate plugs. Ensure that good EMC practices are observed when making connections. Refer also to the 2700 Installation manual. Where a screened cable is specified for the relay connections, in order to avoid ground loops, the screen should be terminated to ‘ground’ only at the Control unit. All electrical connections and access to the fuse, F1, are made to the PCB inside of the unit enclosure. To gain access use the special key provided and open the door. After electrical connections are complete ensure the cover is fitted and the door is locked closed. Figure 11. Interconnecting wiring schematic 2700 Control Unit 2730 Control Unit TB4 Vdc TB4 Solenoid Valve 1 1 N/O 2 N/C 3 COM 4 N/O 5 N/C 6 COM 7 N/O 8 N/C 9 COM 10 N/O 1 RELAY 1 2 Solenoid Valve 2 3 RELAY 2 4 Solenoid Valve 3 5 RELAY 3 6 Solenoid Valve 4 11 N/C 12 COM 7 RELAY 4 8 TB3 TB1 L Live Nl Neutral E Earth L Mains Input Mains Input Nl E 0Vdc 1 Supply 2 220-240Vac 3 110-120Vac 4 100Vac AC Voltage Link Selector. Shown connected for 220-240 Vac operation TB2 Control unit PCB 02710901 / 027109011 / 02710921 2730 User and Installation Manual Utilities Unit PCB 02710901 27 This page is left intentionally blank. 28 2730 User and Installation Manual 4. TECHNICAL SPECIFICATION 4.1 Air Set (Single and dual sensor) Part numbers - 02730701 Dimensions (W x D x H): : 93mm x 99mm x 165mm (3.7" x 3.9" x 6.5") Weight : < 400 gm (< 1.0 lb) Temperature Operating : -10°C to +50°C (+14°F to +122°F) Storage : -20°C to +55°C (-4°F to +131°F) Compressed Air Supply Pressure : 1 to 5 barg (15 to 72 psig) Flowrate : <1.5 litres/min Instrument grade compressed air, free from oil, water and dirt. External connections are suitable for 1/4" OD plastic or metal tubing. Materials of Construction Filtered Pressure Regulator Filter bowl Filter element Regulator body Adjusting knob Elastomers Gauge (0-20 psi / 0-1.6 bar) Body Face Movement Fittings Wall mounting bracket Wall mounting fixings M5x12mm Bolts M5 full hex nut M5 washer 2730 User and Installation Manual : : : : : Polycarbonate to BS 6005 Polypropylene, (40 µm) Zinc alloy Acetal resin Synthetic rubber : : : : : Plastic and steel Plastic Copper/brass Brass (Fibre sealing washer) Mild steel : Stainless steel : Stainless steel : Stainless steel 29 4.2 Air Set and Manual Calibration (Single and dual sensor) Part numbers - 02730731 Dimensions (W x D x H) : 390mm x 174mm x 265mm (15.4" x 6.8" x 10.4") Weight : < 4.5 kg (< 10 lbs) Temperature Operating : -10°C to +50°C (+14°F to +122°F) Storage : -20°C to +55°C (-4°F to +131°F) Compressed Air Supply Pressure : 1 to 5 barg (15 to 72 psig) Flow rate : <2.5 litres/min Instrument grade compressed air, free from oil, water and dirt. Calibration Gas Supply Pressure : 1 barg (15 psig) Flow rate : 1 litre/min Customer connections are brass /nickel plated brass and suitable for use with 1/4" NPT or BSPT male fittings. Materials of Construction Filtered Pressure Regulator Filter bowl Filter element Regulator body Adjusting knob Elastomers Gauge (0-20 psi / 0-1.6 bar) Body Face Movement Precision Pressure Regulator Regulator body Adjusting knob Elastomers Flowmeter & Valve O rings Calibration Quick fit connections Body Seals Wall mounting bracket Bulkhead /Adaptor fittings Fittings Tubing 30 : : : : : Polycarbonate to BS 6005 Polypropylene, (40 µm) Zinc alloy Acetal resin Synthetic rubber : Plastic and steel : Plastic : Copper/brass : Zinc alloy : Acetal resin : Synthetic rubber : Polycarbonate and steel : Neoprene and Buna N : : : : : : Stainless steel and brass Buna Epoxy powder painted mild steel Brass /nickel plated brass Plastic & Steel with NBR packing & ‘O’ rings Polyurethane 2730 User and Installation Manual 4.3 Air Set with Autocalibration (Single sensor) Air Set with Autocalibration (Dual sensor) Air Set with Blowback and Autocalibration (Single sensor) Air Set with Blowback and Autocalibration (Dual sensor) Part numbers - 02730711, 02730713C, 02730721 & 02730723C Dimensions (W x D x H) : 400mm x 220mm x 500mm (16" x 9" x 20") Wall mounting brackets : add an extra 40mm top and bottom Weight : < 16 kg (< 35 lb) Ingress protection : IP65/NEMA 12 Power Supply : 110 - 120 Vac, 50/60 Hz, <20VA (Field configurable) : 220 - 240 Vac, 50/60 Hz, <20VA Installation Category : II Temperature Operating : -10°C to +50°C (+14°F to +122°F) Storage : -20°C to +55°C (-4°F to +131°F) Compressed Air Supply Pressure : 1 to 5 barg (15 to 72 psig) Flow rate : <2.5 litres/min without blowback : <10 litres/min with blowback Instrument grade compressed air, free from oil, water and dirt. Calibration Gas Supply Pressure : 1 barg (15 psig) Flow rate : 1 litre/min Customer connections are nickel plated brass and suitable for use with 1/4" NPT or BSPT male fittings. Materials of Construction Filtered Pressure Regulator Filter bowl Filter element Regulator body Adjusting knob Elastomers Gauge (0-20 psi / 0-1.6 bar) Body Face Movement Precision Pressure Regulator Regulator body Adjusting knob Elastomers Solenoid Valve Body Seal Flowmeter & Valve O rings Enclosure Wall mounting brackets Bulkhead / Adaptor fittings Internal Fittings 2730 User and Installation Manual : : : : : Polycarbonate to BS 6005 Polypropylene, (40 µm) Zinc alloy Acetal resin Synthetic rubber : Plastic and steel : Plastic : Copper/brass : Zinc alloy : Acetal resin : Synthetic rubber : : : : : : : : Stainless steel Viton Polycarbonate and steel Neoprene and Buna N Powder coated steel (RAL7032) Zinc plated steel Nickel plated brass and plastic Plastic & Steel with NBR packing & ‘O’ rings 31 Tubing Venting device : Polyurethane : Stainless steel The four automatic calibration utilities units 02730711, 02730713C, 02730721, & 02730723C comply with the “CE Marking Directive” 93/68/EEC. 32 2730 User and Installation Manual 5. MAINTENANCE AND SPARES 5.1 Spare parts for Single and dual sensor air set (02730701) 5.2 5.3 Part No. Description 5984-4372 Filter regulator <3.5 bar 5981-2157 Pressure gauge 0-20 psig Spare parts for Single sensor air set with auto calibration (02730711) Part No. Description 5984-4380 Filter regulator <7 bar 5984-4295 Aspirator air pressure regulator 5981-2157 Pressure gauge 0-20 psig 2372-8033 Calibration gas solenoid valve 02730901 Power supply PCB 2371-0076 Enclosure breather fitting 5981-3516 Dwyer flow meter 0.2 - 1.0 l/min Spare parts for dual sensor air set with auto calibration (02730713C) Part No. Description 5984-4380 Filter regulator <7 bar 5981-2157 Pressure gauge 0-20 psig 5984-7016 Precision pressure controller 2372-8033 Calibration gas solenoid valve 02730901 Power supply PCB 2371-0076 Enclosure breather fitting 5981-3516 Dwyer flow meter 0.2 - 1.0 l/min 2730 User and Installation Manual 33 5.4 5.5 34 Spare parts for Single Sensor air set with auto calibration and blowback (02730721) Part No. Description 5984-4380 Filter regulator <7 bar 5984-4295 Aspirator air pressure regulator 5981-2157 Pressure gauge 0-20 psig 2372-8033 Calibration gas solenoid valve 2372-8040 Blowback gas solenoid valve 02730901 Power supply PCB 2371-0076 Enclosure breather fitting 5981-3516 Dwyer flow meter 0.2 - 1.0 l/min Spare parts for dual sensor air set with autocalibration and blowback (02730723C) Part No. Description 5984-4380 Filter regulator <7 bar 5981-2157 Pressure gauge 0-20 psig 5984-7016 Precision pressure controller 2372-8033 Calibration gas solenoid valve 2372-8040 Blowback gas solenoid valve 02730901 Power supply PCB 2371-0076 Enclosure breather fitting 5981-3516 Dwyer flow meter 0.2 - 1.0 l/min 2730 User and Installation Manual 5.6 5.7 Spare parts for single and dual sensor air set with manual calibration (02730731) Part No. Description 5984-4380 Filter regulator <7 bar 5981-2157 Pressure gauge 0-20 psig 5984-7016 Precision pressure controller 5981-3516 Dwyer flow meter 0.2 - 1.0 l/min 2385-3100 Quick connect plug (1/4" OD compression) 2385-3131 Quick connect plug (6mm OD compression) Routine maintenance CAUTIONS All Utilities units are specified to -10°C (+14°F), however, if operated below +2°C (+35.6°F) the instrument grade compressed air and calibration gases used must be free from oil, water, dirt and have a dewpoint 10°C (18°F) below the ambient temperature, to prevent freezing within the components. Maintenance of the Utilities Units should not be performed at temperatures below 0°C (+32°F). • On initial installation check the filter regulator bowl monthly for signs of contamination or liquid from the compressed air inlet stream. If required remove and clean the bowl and filter. If no contamination is evident then this time interval can be extended depending on experience. • Every 3 months visually inspect the internal and external pipe work and fittings for signs of leaks or failure. • Every 6 months check and if necessary adjust the aspirator air pressure and calibration gas flow rates. • Autocalibration units in enclosures - ensure that the breather is not obstructed. 2730 User and Installation Manual 35 NOTES 36 2730 User and Installation Manual