Servomex 2700 Combustion Gas Analyser Quick Start Manual

™ 2700 Combustion Gas Analyser Please record your analyser details below Part Number Serial Number Tag Number Blank 2700 Series i Blank ii 2700 Series Blank Servomex 2700 Quickstart Manual 1. INTRODUCTION 1.1 Warnings, Cautions and Notes This manual includes WARNINGS, CAUTIONS and NOTES which provide information relating to the following: WARNINGS Hazards which could result in personal injury or death CAUTIONS Hazards which could result in damage to equipment or property NOTES Alert the user to pertinent facts and conditions 1.2 Scope of this manual This manual describes the operation of the Servomex 2700 Combustion Gas Analyser and details the various options that are available. • For the technical specification, see Section 5 of this manual. • For installation details, see the Installation Manual (part no. 02700005C). • For servicing details, see the Service Manual (part no. 02700002C). This is written for use by suitably qualified personnel. • For the addresses for technical assistance and spares, see the rear cover of this manual. About this manual Reference: 02700/003C/3 Order as part number: 02700003C Servomex 2700 Quickstart Manual 1 Servomex 2700 Quickstart Manual CE Marking The Servomex 2700 analyser carries 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). Servomex 2700 control units are marked in conformity with the Explosive Atmospheres (ATEX) Directive (94/9/EC) when fitted with a European hazardous area certification marking plate. 1.3 Key to Figures on inside of front cover of this manual (Figures 3a and 3b can be found at the end of this manual) Figure 1 Sensor head and control unit 1 Terminal box 6 Control unit 2 Sensor head 7 Wall mounting straps 3 4" mounting flange 8 Display and keypad 4 Sample probe 9 Hinged access door 5 Sample filter Figure 2 Control unit display and keypad layout 1 LCD with measurement display 5 MEASURE key 2 ENTER key 6 QUIT key 3 ARROW keys 7 Alternative main menu display 4 MENU key NOTES As good practice it is recommended that the analyser is checked/validated with check gas every month and then calibrated as required. This period can be extended as a result of operating experience. 2 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual 2. STARTUP AND SHUTDOWN 2.1 Analyser startup CAUTION If the analyser is to be installed in a low temperature environment (-20°C) then it should be powered up for a period of two hours before the compressed air aspirator supply is applied. This prevents corrosive sample gases from condensing inside the sensor head pipe work. If the sensor head and sample probe have been removed from the flue, then refit the sensor head and sample probe to the flue and reconnect any interconnecting wiring (see Installation Manual). Switch on the electrical power to the sensor head and to the control unit. Leave the unit for two hours to warm up and then check that no faults are indicated on the control unit display screen. Connect the aspirator air supply to the sensor head. The correct operating pressure is stated on a label attached to the inside of the terminal enclosure on the side of the sensor head. If necessary, connect calibration gases to the sensor head to verify correct operation. See Section 3.4 for Calibration procedure. NOTES • The analyser should be allowed to stabilise for several hours (typically overnight) before calibration. • It is then recommended that calibration gases be passed through the sensor head to confirm operation of the analyser. Servomex 2700 Quickstart Manual 3 Servomex 2700 Quickstart Manual 2.2 Analyser shutdown WARNING The sensor head is heated and may be attached to a hot flue. The external surfaces will be uncomfortably hot even after power down for several hours. Exercise care when handling the sensor head even when un-powered on a hot flue. CAUTION • The sensor head should always be powered when left on a flue which is in use. If left un-powered, the sensor head can suffer corrosion damage. • If the process is out of service for a short time it is recommended that the analyser sensor head is left powered. It is not essential that the aspirator air is left flowing. • If the analyser has to be switched off for more than 1 week whilst on a flue which is in use, it is recommended that a flow of dry air be connected to the calibration port. Alternatively, the sensor head can be removed from the flue and a blanking plate fitted. This will prevent corrosive gases from entering the sensor head. Attach a dry air supply to the calibration port of the sensor head and purge the sensor head for 5 minutes at 600 ml/min flow rate. The aspirator air supply should be left on at this point. Switch off the aspirator air supply to the sensor head. Switch off the electrical supply at the control unit and then at the sensor head. Leave the sensor head to cool down for a minimum of two hours. If the analyser is to be un-powered for more than 1 week then please note the cautions above. 4 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual 3. OPERATION 3.1 Operating the analyser (Refer to Figure 2) The Servomex 2700 control unit has a tactile 8 button keypad and back lit LCD (2 lines x 16 characters). During normal use the LCD will display either the default measurement display or a menu-based screen editor display. A user can toggle between the menu display and measurement display and access the menu-based screen editor using the keypad. The functions of the keys on the keypad are: MEASURE Returns the analyser to the measurement display. MENU Activates the top level menu of the screen editor. QUIT Aborts the current activity returning the screen editor to the menu level at which the activity was selected. ARROWS Arrow keys select the desired option. When entering numeric information, the left and right arrow keys are used to move between digits and the up and down arrow keys are used to change the value of each digit. The active digit is highlighted by blinking. The user presses the 'ENTER' key to indicate that the numeric input is complete and the data is to be saved. If the 'QUIT' key is pressed then the data is not saved and the input is aborted. Measurement display - Scrolls through alarm and/or fault messages. ENTER Indicates that the menu selection is to be processed or that numerical input is complete. To initiate any menu operation the MENU key should be pressed. The LCD will then present the top level menu, which in turn leads on to other menus. At each menu, the user highlights the desired option using the arrow keys and then presses ENTER. Blinking is used to highlight the selected menu option. During any menu operation, the fundamental measurements are still being made by the analyser and all relevant outputs, alarms and diagnostics remain active. Servomex 2700 Quickstart Manual 5 Servomex 2700 Quickstart Manual The measurement display is shown in Figure 2. The top line of the display shows the current measured value (with its units) for each of the sensors fitted. In normal operation the bottom line of the display labels the gases measured. Should a fault or alarm occur then the lower line of the display will detail the nature of the fault or alarm. Should more than one fault and/or alarm be active then arrow keys on the keypad may be used to scroll through these messages. The fault messages that may appear are as follows: OXYGEN LOW Oxygen too low for reliable COe measurement OXYGEN °C LOW Oxygen sensor temperature too low OXYGEN °C HIGH Oxygen sensor temperature too high COe mV LOW Combustibles sensor output voltage low COe mV HIGH Combustibles sensor output voltage high COe °C LOW Combustibles sensor temperature too low COe °C HIGH Combustibles sensor temperature too high SENSOR °C HIGH Sensor head temperature too high (OPTIONAL) SENSOR °C LOW Sensor head temperature too low (OPTIONAL) AUTO CAL FAIL Autocalibration out of tolerance error COe mV OUTPUT LOW Combustibles sensor sensitivity low (updated after calibration only) COe CONC HI Combustibles sensor has been exposed to very high Coe levels mV OUT OF TOLERANCE Combustibles sensor mV greater than +/-60mV DISPLAY OVER RANGE Measurement is too large to display COe WARMING Combustibles sensor is warming up O2 WARMING Oxygen sensor warming up The MEASURE key may be used to return to the measurement display at any time. 6 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual 3.2 View/Configure functions (Refer to Figures 3a & 3b) The view functions allow the user to interrogate the analyser diagnostics and examine the alarm and fault history logs. No password is required to access the view functions. The view functions are updated dynamically and values may change while they are being viewed. To access this display, press the MENU key and then select VIEW. If the DIAGNOSTICS option is chosen, the diagnostics appear as a scrolling list of values and associated descriptions. There are up to ten diagnostics depending on which sensors are fitted. The ↑ ↓ keys are used to switch between the following diagnostic measurements: Software version Oxygen sensor output voltage in mV Oxygen sensor temperature in °C Oxygen high calibration point in mV Oxygen low calibration point in mV Combustibles sensor output voltage in mV Combustibles sensor temperature in °C Combustibles high calibration point in mV Combustibles low calibration point in mV (Negative values are unfiltered and will differ from those displayed at top level) Probe head temperature in °C (if connected) If the HISTORY option is chosen, either the alarm or fault history logs can be examined. The ↑ ↓ keys are used to scroll through the list of history entries in chronological order. The configure function allows the user to modify and view the analyser settings. These functions are password protected. To access these functions, press the MENU key, select CONFIGURE and then enter a password. There are two passwords that can be entered; a supervisor password (default - 2700) which gives access to CALIBRATE, VIEW, SERVICE & SETUP and an operator password (default - 2000) which gives access to CALIBRATE and VIEW only. Both passwords are factory set and may be changed if required. Servomex 2700 Quickstart Manual 7 Servomex 2700 Quickstart Manual 3.3 Analyser setup (Refer to Figures 3a and 3b) The setup function allows the user to modify and view the analyser configuration (outputs, alarms, blowback, clock and passwords). 3.3.1 Setting up the concentration alarms The control unit has 2 concentration alarms that can be assigned to either of the 2 possible sensors in the sensor head. Each concentration has a user configurable level, hysteresis and polarity (high or low alarm). Each alarm may also be configured to either freeze (remain fixed at the last value) or follow (track the concentration changes) during analyser calibration. The setup process is as follows: 1. Press the MENU key, then select CONFIGURE, enter a valid password, select SETUP and then ASSIGN. 2. Select ALARMS to set up the concentration alarms. 3. Select AL1 or AL2 to specify which alarm is to be set up. 4. Select either NONE, OXYGEN or COe to disable the alarm or to specify the measurement to be the subject of the alarm. 5. Select either FREEZE or FOLLOW to specify if the alarm is to be fixed at its current value or to track the concentration during analyser calibration. 6. Select either LOW or HIGH to specify the alarm as a low alarm or a high alarm. 7. Use the arrow keys followed by the ENTER key to set the concentration level at which the alarm is to be triggered. 8. Use the arrow keys followed by the ENTER key to set the hysteresis on the alarm level. The alarm assignment is now complete and the user is returned to the select alarms display (step 3 above) to allow other alarms to be configured. Use the QUIT or MEASURE key to return to the assign menu or the measure display as required. 8 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual 3.3.2 Setting up the relay outputs The Servomex 2700 analyser is supplied with 4 relay outputs that can be assigned to a number of outputs. Output options include concentration alarms, analyser fault, calibration in progress, blowback in progress, autocalibration solenoid valve control lines and blowback solenoid valve control line. Default relay assignments are: Relay 1 is concentration alarm (AL1), Relay 2 is concentration alarm (AL2), Relay 3 is Analyser Fault (AF) and Relay 4 is the 'IN CALIBRATION' message. The default assignments can be changed as follows: 1. Press the MENU key, then select CONFIGURE, enter a valid password, select SETUP and then ASSIGN. 2. Select RELAYS to set up relay outputs. 3. Select 1, 2, 3 or 4 for the relevant relay number. 4. The available assignments are presented as a scrolling list. Use the ↑ or ↓ keys to select the required assignment and then press the ENTER key. The possible relay assignments are: ALARM 1 ALARM 2 FAULTS IN CALIBRATION IN BLOWBACK GAS 1 GAS 2 GAS 3 BLOWBACK AIR Concentration alarm AL1 Concentration alarm AL2 Analyser fault present AF Calibration in progress Blowback in progress Autocalibration gas 1 solenoid valve Autocalibration gas 2 solenoid valve Autocalibration gas 3 solenoid valve Blowback air solenoid valve 5. The display is returned to the relay number select screen to allow other relays to be assigned. Use the QUIT or MEASURE keys to return to the assign menu or measurement display as required. Servomex 2700 Quickstart Manual 9 Servomex 2700 Quickstart Manual 3.3.3 Setting up the analogue outputs The Servomex 2700 is supplied with one dedicated analogue output for each sensor fitted in the sensor head (maximum of 2 analogue outputs). Each analogue output has a minimum and maximum analogue output range. For the oxygen sensor, 0-1% is the minimum range and 0-25% is the maximum. For a 1750702 combustibles sensor, 0-500ppm is the minimum range and 0-30000ppm is the maximum. Each analogue output can be configured as either 0-20mA or 4-20mA and to either freeze (remain at the last value) or follow (track the concentration changes) during calibration and blowback. The 20mA high point is limited to an over-range of 20.5mA during normal operation. If 4-20mA is selected, then this can also be configured to under-range that can be set down to 3.6mA in 0.1mA increments. An optional "Jam" facility is available to allow the output to set to 0mA (LOW) or 21mA (HIGH) when an analyser fault is detected. The outputs are capped so that their value can not exceed 21mA. The setup process is as follows: 1. Press the MENU key, then select CONFIGURE, enter the supervisor password, select SETUP and then ASSIGN. 2. Select mA OUTPUTS to set up the analogue outputs. 3. If two sensors are fitted then the analyser will prompt the user to select the output to be configured. Select either OXYGEN or COe to specify the output dedicated to the oxygen sensor or combustibles sensor as required. 4. Select the measuring range required, then ENTER. 5. Select either FREEZE (to freeze the output at the last value) or FOLLOW (to follow concentration changes during calibration or blowback). 6. Select either 4-20mA or 0-20mA for the analogue output type. 7. If 4-20mA is selected, set the low limit desired. 8. Select either LOW, HIGH or NONE to specify whether the output should be fixed at 0mA (LOW), 21mA (HIGH) or be unaffected should an analyser fault occur. The analogue output configuration is now complete. The user is returned to the sensor selection display (step 3 above) to allow 10 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual other analogue outputs to be configured. Use the QUIT or MEASURE keys to return to the assign menu or measurement display as required. 3.3.4 Setting up a blowback process The blowback procedure allows the user to apply a burst of a selected gas to the calibration port of the analyser to back flush the sample probe and filter. The blowback gas is controlled via a solenoid valve switched by one of the relay outputs. The required relay output must be assigned before starting a blowback operation. The blowback setup will include a start time and date, a time period between blowback processes, and a duration for the blowback process. A blowback operation may be executed by one of the following means: 1. By timer when the indicated start time and date is reached. 2. By external contact closure between pins 13 and 14 on terminal block TB2 on control unit PCB. 3. From the keypad using the START BLOWBACK entry in the setup blowback menu. The supervisor password will be required and a relay output must be assigned to blowback. If a start date and time is not set then the blowback can only be initiated by contact closure or from the keypad. If the period between blowback processes is set to zero then only a single timed blowback will be executed. The process for setting the blowback parameters is as follows: 1. Press the MENU key, then select CONFIGURE, enter a valid password, select SETUP and then BLOWBACK. 2. Select SET UP BLOWBACK to set the blowback parameters. 3. Use the arrow keys to define the duration in minutes (MM) and seconds (SS) of the blowback. Use the ENTER key to save the value. 4. Use the arrow keys to define the period in days and hours, between successive blowback processes. Use the ENTER key to save the value. Servomex 2700 Quickstart Manual 11 Servomex 2700 Quickstart Manual 5. Use the arrow keys to define the start date for the first blowback. The format will be either day/month/year (DDMMYY) or month/day/year (MMDDYY) as defined in the setup clock procedure (see Section 3.3.5). Use the ENTER key to save the value. 6. Use the arrow keys to define the start time for the first blowback. Use the ENTER key to save the value. Successive blowback operations will start at the time and frequency previously set. NOTE After completion of the BLOWBACK process, if FREEZE has also been selected the analogue outputs remain at freeze and display shows ‘flushing’ for a fixed period of 120 seconds. 3.3.5 Setting up the real time clock and date format The process for changing the time, date and the date display format is as follows: 1. Press the MENU key, then select CONFIGURE, enter a valid password, select SETUP and then UTILITY. 2. Select CLOCK to change the time and date. 3. The current time and date will be shown on the display for 4 seconds before proceeding. Select YES to continue changing the time/date or NO to return to the utility menu. 4. Use the arrow keys to define the new date. The date will be specified either as day/month/year (DDMMYY) or month/day/year (MMDDYY). Press the ENTER key to save the new date. 5. Use the arrow keys to define the new time. The format is hours:minutes (HH:MM). 6. Select either DDMMYY or MMDDYY to specify if dates are to be displayed in day/month/year or month/day/year format. 7. The new time and date will be displayed in the selected format for 4 seconds before returning to the utility menu. 12 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual 3.3.6 Setting a new password Both passwords are factory set and can be changed as follows: 1. Press the MENU key, then select CONFIGURE, enter a valid password, select SETUP and then UTILITY. 2. Select PASSWORD to change the passwords. 3. Select either SUPERVISOR (default - 2700) or OPERATOR (default - 2000) to define which password is to be changed. 4. Use the arrow keys to set a new 4 digit password. Use the ENTER key to save the new password. 5. The new password will be repeated by the analyser. Select either YES or NO to accept or reject the new password value. 3.3.7 Setting the auxiliary air option The auxiliary air is intergrated into the sensor head and therefore this feature must always be set to YES when the combustibles sensor is used 1. Press the MENU key, then select CONFIGURE, enter a vaid password, select SETUP and then UTILITY. 2. Selet AUX AIR to set the auxiliary air status. 3. Select either YES or No to indicate if auxiliary air is applied to sensor head or not. 3.4 Calibration (Refer to Figures 3a & 3b) The operator/supervisor passwords are required to access the calibration functions. The user may either perform a manual calibration, set up the automatic calibration parameters or execute an automatic calibration. Servomex recommend that the oxygen sensor is calibrated every three months and the combustibles sensor every one month. In some applications the calibration interval may be extended as a result of operating experience. During manual calibration, a LOW calibration must be made prior to a HIGH calibration for the combustibles sensor. Servomex 2700 Quickstart Manual 13 Servomex 2700 Quickstart Manual NOTE 1. When a low calibration is performed, the zero may be offset between the limits of -500 and +99ppm which enables the effects of non-CO combustibles to be compensated for. If this is done, the span calibration target value should be adjusted by the same amount in order to maintain accuracy. E.g. if the zero is adjusted by -50ppm then the span should be set to 450ppm when using a 500ppm CO calibration gas. 2. In calibration mode negative ppm combustibles values are unfiltered and will differ from those displayed at top level. 3.4.1 Manual calibration procedure 1. Press the MENU key, then select CONFIGURE, enter a valid password and then select CALIBRATE. 2. If two sensors are fitted in the sensor head then select either OXYGEN or COe for the sensor to be calibrated. 3. Select LOW CAL or HIGH CAL for a low calibration or high calibration measurement. The procedure for performing the low or high calibration of an OXYGEN or COe sensor are the same. 4. Use the arrow keys to set the actual concentration value for the calibration gas used. Press the ENTER key to accept the value. 5. Use the arrow keys to set the required tolerance level. This is the permitted change in the stored calibration value. Press the ENTER key to accept the value. 6. Apply the calibration gas to the sensor head calibration port at a flow of 600ml/min. Note: if autocalibration is selected then the relay outputs will be automatically set to admit the required calibration gas. 7. Wait until the value displayed on the screen is stable. Select Y and the ENTER key to accept the measured value. Note: the displayed value will be calculated using the existing stored calibration value. 8. Should the user accept a value that is outside of the tolerance limits an OUT OF TOLERANCE message will be 14 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual displayed. Select Y or N and press the ENTER key to accept or refuse the new calibration value. 9. Press MEASURE to view and check the actual concentration value and then remove the calibration gas from the analyser. 3.4.2 Automatic calibration The automatic calibration facility allows the Servomex 2700 analyser to perform routine calibrations without user intervention. The calibration procedure to be used is specified by a number of calibration parameters. These parameters must be set up before an autocalibration is started. The autocalibration procedure can perform either a low calibration only or a high and low calibration on either one or both of the possible sensor combinations in the analyser. An automatic calibration may be started in three ways: 1. By timer The automatic calibration will commence when a specified start time and date is reached. If the start time is not specified then the timed start is disabled. The calibration procedure will then be repeated at specified time intervals. If the specified time interval is zero then only one calibration process will be done. 2. By contact closure The automatic calibration will commence when the automatic calibration initiation contacts (TB2 pins 11 and 12) are closed. 3. From the keypad From the CALIBRATE menu, select AUTOCALIBRATE and then START AUTOCAL. In the automatic calibration process the calibration gases are admitted to the sensor head via remotely actuated solenoid valves. These solenoid valves are controlled by the relay outputs on the control unit PCB. If a single sensor is being calibrated then two gases and two relay outputs will be required. If two sensors are being calibrated then three gases and three relay outputs will be required. The relay outputs to be used are configured and assigned by the user in the Setup facility (see Section 3.3). Table 1 specifies the composition and calibration duty for the three calibration gases. Servomex 2700 Quickstart Manual 15 Servomex 2700 Quickstart Manual Table 1: Recommended calibration gas Solenoid number Gas composition Oxygen sensor Combustibles sensor GAS 1 Zero air (20.95%(v) O2) HIGH LOW GAS 2 0.3%(v) O2 balance N2 * LOW N/A * gas composition can be between 0.25% and 2.5% O2 in N2 GAS 3 1000ppm(v) CO balance air** N/A HIGH ** gas composition can be between 500ppm and 1000ppm CO balance air for a 1750702 sensor. The following procedure is executed on automatic calibration. • • • 16 The relay assignments are checked to ensure that the required relay contacts have been assigned as solenoid valve drives. If the relay assignments are incorrect then the autocalibrate will abort with an appropriate error message being displayed for 5 seconds. The required calibration gases will be admitted to the sensor head in turn. When each gas is admitted the process will wait for a user-defined flushing time before recording the calibration response values. Between 1 and 3 gases will be admitted depending on the calibrations to be performed. The new calibration parameters are calculated and compared with the existing stored values. If the change in the calibration parameters is outside of the specified tolerance values then the autocalibration is aborted, a fault is raised and the calibration values are not updated. Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual 3.4.3 Setting up the automatic calibration parameters From the CALIBRATE menu, select AUTO CALIBRATE and then SET UP AUTO CAL. 1. If two sensors are fitted in the sensor head then select OXYGEN, COe or OXYGEN & COe to calibrate either the oxygen sensor only, the combustibles sensor only or both the oxygen and combustibles sensors. 2. Select LOW CAL ONLY to perform a low point only calibration for the selected sensors or LOW AND HIGH CAL to perform both a low point and high point calibration. 3. The user will be prompted to enter a calibration level and tolerance level (see manual calibration procedure, Section 3.4.1) for the low (and, if selected, high) calibration gas for each sensor to be calibrated. 4. Use the arrow keys to select the flushing time to be used. This is the time delay to allow the reading to stabilise after each change of gases. The up/down keys alter the selection by 0.5 minutes over the range 0.5 to 8.0 minutes. 5. Use the arrow keys to set the time period between successive automatic calibrations. The period is specified in days with a range 0 to 999 days. If the period is set as 0 then only the first automatic calibration will be made. 6. The current date and time are displayed for five seconds for reference. Then use the arrow keys to set the start date and start time for the first automatic calibration. The start date and time will then be displayed for five seconds. 7. When the automatic calibration parameters are complete the display will return to the start time entry screen. The user should press the QUIT key if all is satisfactory. 3.5 Service functions (Refer to Figure 3b) The supervisor password is required to access the service functions. The service functions are accessed by pressing the MENU key, then selecting CONFIGURE, enter a valid password and then select SERVICE. Servomex 2700 Quickstart Manual 17 Servomex 2700 Quickstart Manual 3.5.1 Testing the analogue outputs This function allows the user to test and adjust the analogue outputs. Select SET OUTPUTS, then mA OUTPUTS, then 0mA, 4mA or 20mA and then press ENTER to set all the analogue outputs to 0, 4 or 20mA. If the span of the analogue outputs needs adjustment, then potentiometers RV3 and RV4 on the control PCB may be used to set the 20mA point for the combustibles and oxygen sensor outputs. Select QUIT or press the MEASURE key to return to normal measurement. The test function times out after 5 minutes. 3.5.2 Testing the relay outputs CAUTION Do not use this function if autocalibration is assigned to the relays as this could cause damage to the transformer in the utilities unit. This function allows the user to test the operation of the relay outputs. Select SET OUTPUTS, then RELAYS and then SET TO DISABLED or SET TO ENABLED to set all 4 of the relay outputs to enabled or disabled state. Select QUIT or MEASURE to return to normal measurement. The test function times out after 5 minutes. 3.5.3 Delete history Select SERVICE and then HISTORY. The option to delete the alarm and fault history logs is then available. 3.6 Software filtration (Refer to Figure 3b) Due to the fast response of the analyser, it maybe required to 'slow' the measurement signal, allowing it to be integrated into certain control systems more easily. This function allows the user to achieve this by setting a filtration rate for the analyser from 0 to 9, in unit increments; 0 being unfiltered and 9 being the maximum filtration rate. As a default the filtration rate is set to 0. 18 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual The software filter will also progressively reduce the output fluctuation of the instrument as the filter setting is increased from 0 to 9. 1. Press the MENU key, then select CONFIGURE, enter a valid supervisor password, select SETUP. 2. From the SETUP menu, select FILTER. 3. If two sensors are fitted in the sensor head then select OXYGEN or COe. 4. Input a value from 0 to 9, then press the QUIT or MEASURE key when all is satisfactory. The user may need to make several adjustments to optimise the filter settings for their process conditions and control system requirements. 3.7 Language options (Refer to Figure 3b) The user is able to configure the display of the analyser to one of three languages; English, French or German. 1. Press the MENU key, then select CONFIGURE, enter a valid supervisor password and select SETUP. 2. From the SETUP menu, select UTILITY, then LANG and then select ENGLISH, FRANCAIS, or DEUTSCH. 3. Press the QUIT or MEASURE key, when all is satisfactory. Servomex 2700 Quickstart Manual 19 Servomex 2700 Quickstart Manual NOTES 20 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual 4. ROUTINE MAINTENANCE AND SPARES WARNING 2700 spares must be supplied by Servomex 4.1 Spare parts Item Servomex 2700 Control Unit description Spare part number 1 Control Unit PCB O2 only S2710903A 2 Control Unit PCB COe only S2710913A 3 Control Unit PCB O2 & COe S2710923A 4 Transformer 4961-1173 5 Keypad Assembly 02710353 02710353A 6 Display Assembly 2553-9307 7 Mains Protection Cover S2710994 8 Purge Kit S2710995 9 Breather 2371-0052 10 Wall Mounting Kit S2710997 11 Rack Mounting Kit S2710996 12 Enclosure Gasket Kit S2700999 13 Fuse Kit (Control Unit & Sensor Head) S2700998 * * includes: F1.6A HRC (5 x 20mm), F2.5A HRC (5 x 20mm), F3.15A HRC (5 x 20mm) & F6.3A HRC (5 x 20mm) Servomex 2700 Quickstart Manual 21 Servomex 2700 Quickstart Manual Item 22 Servomex 2700 Sensor Head description Spare part number 1 Sensor Head O2 only, 100-120Vac S2720704A 2 Sensor Head Low COe Only, 100-120Vac S2720715A 3 Sensor Head High COe Only, 100-120Vac S2720717A 4 Sensor Head O2 & Low COe, 100-120Vac S2720716A 5 Sensor Head O2 & High COe, 100-120Vac S2720718A 6 Sensor Head O2 only, 220-240Vac S2721704A 7 Sensor Head Low COe only, 220-240Vac S2721715A 8 Sensor Head High COe Only, 220-240Vac S2721717A 9 Sensor Head O2 & Low COe, 220-240Vac S2721716A 10 Sensor Head O2 & High COe, 220-240Vac S2721718A 11 Solenoid Valve Kit S2720993 12 Solid State Relay (SSR) Kit S2720992 13 Sensor Head PCB O2 only S2720902A 14 Sensor Head PCB COe only S2720912A 15 Sensor Head PCB O2 & COe S2720922A 16 Zr 703 Oxygen Cell S2720995 17 Tfx 1750702 Combustibles Cell S1750702 18 ----- --- 19 Cell Connector O2 only S2720991 20 Cell Connector COe only S2720990 21 Cell Connector O2 & COe S2720989 22 Aspirator pipe O2 & O2/COe S2720988 23 Aspirator Kit S2720987 24 Flame Trap Kit 00022907 25 Internal Filter/Flame Arrester Assembly 02720955 26 Thermostat Assembly 02720994 27 Thermistor 2651-7131 28 Band Heater - 120Vac 2653-1825 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual Item Servomex 2700 Sensor Head description Spare part number 29 Band Heater - 240Vac 2653-1832 30 4" Mounting Gasket Kit S2720985 31 4" Weld-On Flange Mounting Kit S2720984 32 Mains Protection Cover S2720983 33 Enclosure Gasket Kit (Control Unit & Sensor Head) S2700999 34 Fuse Kit (Control Unit & Sensor Head) S2700998 * * includes: F1.6A HRC (5 x 20mm), F2.5A HRC (5 x 20mm), F3.15A HRC (5 x 20mm) & F6.3A HRC (5 x 20mm) Item Servomex 2700 Sample Probes description Spare part number 1 Silicon Carbide Filter Kit S2740998 2 Probe Tube Coupling 2344-2294 3 Probe Shroud S2740996A 4 Probe Support Disc* S2740995 5 Thermal Spacer Flange Kit 02750997 6 High Temperature Standoff 02750995 7 Probe Retention Flange Kit 02750998 * Item 4 (Probe Support Disc) is required for Items 13 to 16 when replacing the <700°C filtered probe in a Supported Probe Installation. Sample Probes continued on next page. Servomex 2700 Quickstart Manual 23 Servomex 2700 Quickstart Manual Servomex 2700 Sample Probes continued. Item Servomex 2700 Sample Probes description Spare part number 8 <700°C, Probe, Open-ended, 0.5m S2740701A 9 <700°C, Probe, Open-ended, 1.0m S2740701B 10 <700°C, Probe, Open-ended, 1.5m S2740701C 11 <700°C, Probe, Filtered, 0.5m S2740702A 12 <700°C, Probe, Filtered, 1.0m S2740702B 13 <700°C, Probe, Filtered, 1.5m * S2740702C 14 <700°C, Probe, Filtered, 2.0m * & ** S2740702D 15 <700°C, Probe, Filtered, 2.5m * & ** S2740702E 16 <700°C, Probe, Filtered, 3.0m * & ** S2740702F 17 <1000°C, Probe, Open-ended, 0.5m S2740704A 18 <1000°C, Probe, Open-ended, 1.0m S2740704B 19 <800°C, Probe, Open-ended, 1.5m S2740704C 20 <700°C, Probe, Open-ended, 2.0m S2740704D 21 <1000°C, Probe, Filtered, 0.5m S2740705A 22 <1000°C, Probe, Filtered, 1.0m S2740705B 23 <700°C, Probe Support, 1.5m S2740997C 24 <700°C, Probe Support, 2.0m S2740997D 25 <700°C, Probe Support, 2.5m S2740997E 26 <700°C, Probe Support, 3.0m S2740997F 27 <1750°C, Ceramic Probe, 0.5m 02740707A 28 <1750°C, Ceramic Probe, 1.0m 02740707B 29 <1750°C, Ceramic Probe, 1.5m 02740707C * Item 4 (Probe Support Disc) is required for Items 13 to 16 when replacing the <700°C filtered probe in a Supported Probe Installation. ** Items 14,15 and 16. Filter probes exceeding 1.5m in length are only available as part of a supported probe installation and should not be used alone. 24 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual Item Description Spare part number 1 Quickstart Manual - English 02700003C 2 Quickstart Manual - French 02700013C 3 Quickstart Manual - German 02700023C 4 --- --- 5 --- --- 6 --- --- 7 Installation Manuals - English 02700005C 8 Installation Manuals - French 02700015C 9 Installation Manuals - German 02700025C 10 --- --- 11 --- --- 12 --- --- 13 Service Manual - English 02700002C Servomex 2700 Quickstart Manual 25 Servomex 2700 Quickstart Manual NOTES 26 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual 5. TECHNICAL SPECIFICATION 5.1 Oxygen measurement performance Item Specification Analogue output ranges 0-1 min. to 0-25% max. O2, in 1% steps Display resolution 0.01% O2 Accuracy ±1% of reading or 0.1% O2* Response time (T90), unfiltered software <10 seconds (sensor head only at 300ml/min) * whichever is greater 5.2 Combustibles measurement performance Item Specification Analogue output ranges 1750702 – 0-500 min. to 0-30000ppm max. COe, in 1ppm steps Display resolution 1ppm(v) COe Accuracy ±5% of full scale output range Response time (T90), unfiltered software. <20 seconds (sensor head only at 300ml/min) Servomex 2700 Quickstart Manual 27 Servomex 2700 Quickstart Manual 5.3 General specification Analyser inputs and outputs Digital display 2 line by 16 character back lit LCD. User interface Menu driven with 8 button tactile keypad. Analogue outputs One user-configurable 0-20mA or 4-20mA isolated current output dedicated to each measurement. Maximum load 1 kΩ. Clamped at 21mA. Relay outputs Four SPCO relays. Contact rating 3A/250V AC or 1A/28V DC (non inductive) maximum and 10mA/5V AC or DC minimum. User assigned as concentration (2), fault alarms, calibration in progress, blowback in progress, autocalibration solenoid valves (2/3) and blowback solenoid valve control. Digital inputs Two external digital inputs for autocalibration and auto-blowback initiation. Non-isolated, requiring voltage-free contact closure (or equivalent) to analyser ground to initiate. Physical 28 Size Sensor head 301mm x 330mm x 256mm Control unit 391mm x 167mm x 260mm Weight Sensor head Control unit Power Supply Two voltage ranges are provided: 100-120Vac, 50/60Hz 220-240Vac, 50/60Hz Control unit 250VA Sensor head 600VA Sensor head and control unit are powered separately. Control unit voltage is user set. Sensor head voltage is factory set. <17kg (37.5lbs) <10kg (24.3lbs) Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual Ambient temperature Operating -10°C to +55°C (+14°F to +131°F) Control unit Storage -20°C to +55°C (-4°F to +131°F) Ambient temperature Operating -20°C to +70°C (-4°F to +160°F) Sensor head Storage -30°C to +80°C (-2°F to +176°F) Installation category Category II. Local level power distribution with over voltage withstand up to 2,500V in accordance with IEC 664. Ingress protection IP66 to IEC529:1989 and BS EN60529:1992. Type 4X to NEMA standards publication no. 250. Aspirator air requirements Pressure 0.2 to 0.3 barg (3 to 5 psig). Flow 1.5 litres/min typical. Instrument grade compressed air, free from oil, water and dirt (See ISA-S7.0.01-1996). Materials in contact with sample Oxygen sensor 316 and 310 stainless steel, zirconia, platinum, alumina, Ni/Fe/Cr alloy, high temperature sealing glasses. Combustibles sensor 316 stainless steel, platinum, platinum/iridium, zirconia, alumina, corrosion resistant glass, graphite gasket. Sensor head 316 and 303 stainless steel, gasket sealing material. Sample probes 316 and 310 stainless steel, Haynes alloy 556, silicon carbide, high temperature ceramic. Servomex 2700 Quickstart Manual 29 Servomex 2700 Quickstart Manual Hazardous area classification Sensor head Non hazardous locations. Control unit Approved as Ex ic nA nC IIC T5 Gc, Ex tc IIIB T75°C Dc (Ta = -10°C to +55°C) for ATEX Group II, Category 3, Gas and Dust hazardous atmospheres, certificate number ITS10ATEX47005X. Approved as non-incendive for: Class I, Div. 2, Groups A,B,C & D. Class II, Div. 2, Groups F & G. Class III, Div. 1 & 2. Enclosure Type 4X. T5. Ambient Temperature 55°C max. (Factory Mutual - FMRC) Suitable for use in: Class I, Div. 2, Groups A,B,C & D. Class II, Div. 1, Groups E,F & G. Class III, Div. 1. T5. Ambient Temperature 55°C max. Enclosure Type 4X. (Canadian Standards Association - CSA) WARNING To minimise the risk of propagating brushed discharges, do not install in a high velocity dust laden environment. Design standards Conforms to the following standards: Electromagnetic Compatibility IEC 61326-1: 1997 (BS EN 61326-1: 1997) Control unit - Emission Class B Sensor head - Emission Class A Electrical Safety EN61010-1: 1993 IEC1010-1: 1990: amendments A1:1992 and A2:1995 30 Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual Figure 3a 1 VIEW CONFIGURE 2 VIEW Go to 2 Go to 3 Diagnostics Software Version Oxygen sensor output voltage in mV Oxygen sensor temperature in oC Oxygen Sensor High Cal Point in mV Oxygen Sensor Low Cal Point in mV Combustibles sensor output voltage in mV Combustibles sensor temperature in oC Combustibles Sensor High Cal Point in mV Combustibles Sensor Low Cal Point in mV Sensor Head temperature in oC (if connected) Alarm History Fault History 3 CONFIGURATION ENTER PASSWORD 0000 4 History Operators Password Go to 4 Supervisor Password Go to 5 Operator Password Functions CALIBRATE / VIEW CALIBRATE MANUAL CALIBRATE AUTO CALIBRATE Oxygen COe Calibration Procedure Set Up Oxygen Auto COe Calibrate Oxygen & COe Calibration Procedure Start Auto Calibrate Initiate Automatic Calibration VIEW 5 Low Calibration High Calibration Supervisor Password Functions CALIBRATE / VIEW SERVICE / SET UP Servomex 2700 Quickstart Manual Go to 2 Go to 4 Go to 6 31 Servomex 2700 Quickstart Manual Figure 3b 6 SERVICE Set Outputs History mA Outputs Set 0,4 or 20mA Relays Disabled Enabled Delete History SET-UP Assign AL1 AL2 Alarms Relays None Oxygen COe Freeze Follow High Low R1, R2, R3 & R4 mA Outputs Oxygen Coe Set Range Set Up Procedure Freeze Follow 0-20mA 4.2mA Filter Oxygen Coe Blow Back Set Up Blow Back Blowback Setup Procedure Start Blow Back Initiate Blowback Utility Jam High/Low/None Set Low Jam Point High/Low/None Set Filtration 0-9 Clock Password Clock Setting Procedure Supervisor Operator Password Setting Procedure Yes Auxiliary Air No Language 32 Set Up Procedure (Yes ialways required with combustibles) English/Francais/Deutsch Servomex 2700 Quickstart Manual Servomex 2700 Quickstart Manual It is advised that the parameters for Calibration Tolerances, Combustibles Output Ranges and Filters are set as follows. Figure 3c CONFIGURE ENTER PASSWORD 0000 (supervisor) CALIBRATE MANUAL Oxygen Coe Low Cal High Cal Cal Level Cal Tol Calibration Tolerance Oxygen Low ….0.2% Oxygen High …1.0% 01750/702 Coe Low…. 100ppm Coe High …100ppm AUTO Setup Autocal Oxygen Coe Oxygen & Coe Low Cal Low & High Cal Cal Level Cal Tol. SETUP Minimum Output Ranges ASSIGN FILTER ma Output Oxygen Coe Oxygen Coe Servomex 2700 Quickstart Manual Coe 01750/702 Coe …500ppm Filter Settings Oxygen ….. 4 Coe ……… 5 33 Servomex 2700 Quickstart Manual NOTES 34 Servomex 2700 Quickstart Manual