Installation/Start-up Manual CMB_MAN_ABR_CH88 September CH88 In-Situ Combustion O2. Analyzer System

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Transcription:

CH88 In-Situ Combustion O2 Analyzer System

Section 1: Section 2: Section 3: Section 4: Section 5: Section 6: Contents General Information Essential Instructions... 2 Symbols used... 3 Overview... 4 System Configurations...... 5 Technical Support Hotline...... 5 Typical System Package CH88 In-Situ Combustion O 2 Analyzer System Ordering Information... 6 Specifications System Specifications... 7 CH88 Flue Gas O 2 Probe Specifications... 7 1056 Combustion Electronics Specifications... 7 Installation Mechanical installation... 9 Installation of1056 Combustion Electronics... 9 Installation Specifications - Cable Connecting Probe to Electronics... Probe Installation...... 9 Electrical Installation... 15 Cable Connections... 15 Probe Connections... 16 Power Up Procedure... 16 Calibration...... 19 Manual/Semi-automatic Calibration... 19 Calibration Record... 20 Menu Trees System Menu Tree (English and Chinese)..... 21 Probe Menu Tree (English and Chinese)... 22 Probe Menu Tree (English and Chinese)... 23 Parameters System Parameters... 24 Probe Parameters... 25 CH88 In-Situ Combustion O Analyzer System Alarms... 26 System Alarms... 29 Probe Alarms...... 30 9 Table of Contents

Essential Instructions Section 1: General Information Essential Instructions Read this page before proceeding Emerson Process Management designs, manufactures and tests its Rosemount Analytical to meet many national and international standards. Because these instruments are sophisticated technical products, you MUST properly install, use, and maintain them to ensure they continue to operate with-in their normal specifications. The following instructions MUST be adhered to and integrated into your safety program when installing, using, and maintaining Rosemount Analytical products. Failure to follow the proper instructions may cause any one of the following situations to occur: Loss of life; personal injury; property damage; damage to this instrument; and warranty invalidation. Read all instructions prior to installing, operating, and servicing the product. If you do not understand any of the instructions, contact your Emerson Process Management representative for clarification. Follow all warnings, cautions, and instructions marked on and supplied with the product, including this manual Install your equipment as specified in the Installation Instructions and per applicable local and national codes. Connect all products to the proper electrical and pressure sources. To ensure proper performance; inform, educate and only use qualified personnel to install, operate, update, program, and maintain the product. Use only factory documented components for repair. Tampering or unauthorized substitution of parts and procedures can affect the performance and cause unsafe operation of your process. All equipment doors must be closed and protective covers must be in place unless qualified personnel are performing maintenance. WARNING: RISK OF ELECTRICAL SHOCK 1) Main power wired to separate power source must be disconnected before servicing. 2) Do not operate or energize instrument with case open! 3) Wiring connected in this box must be at least rated 240 VAC and 14 gauge. 4) Non-metallic cable strain reliefs do not provide grounding between conduit connections! Use grounding type bushings and jumper wires. 5) Unused cable conduit entries must be securely sealed by non-flammable closures to provide transmitter's enclosure integrity in compliance with personal safety and environmental protection requirements. 6) Operate only with front panel fastened and in place. 7) Safety and performance require that this system be connected and properly grounded through a three wire power source. 8) Proper use and configuration is the responsibility of the user. 9) Before installing this equipment read the "Safety instructions for the wiring and installation of this apparatus". Failure to follow safety instructions could result in serious injury or death. 10) Install all protective equipment covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death. 11) Local Ground connection shall be provided to CH88 Flue gas O Probe in order to avoid electric shock. The ground conductor should be equal or greater than 16 AWG for a copper conductor in free air or 12 AWG for an enclosed copper conductor. 12) Disconnect and lock out power before connecting the power supply. 13) Install all protective covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death. 14) Disconnect and lock out power before working on any electrical components. There is voltage up to 240 VAC. Verify the reliability and continuity of the grounding of the probe connection before powering the equipment. 15) To meet the Safety Requirements of IEC 61010-1 (EC requirement), and ensure safe operation of this equipment, connection to the main electrical power supply must be made through a circuit breaker (max 10A) which will disconnect all current-carrying conductors during a fault situation. This circuit breaker should also include a mechanically operated isolating switch. If not, then another external means of disconnecting the supply from the equipment should be located close by. Circuit breakers or switches must comply with a recognized standard such as IEC 60947. CAUTION If the ducts will be washed down during outage MAKE SURE to power down the probes and remove them from the wash area. This manual concentrates on the installation, start-up, calibration, and operation of this product. There is also a more comprehensive manual that also covers troubleshooting, maintenance, repair, and spare parts identification. 3 Essential Instructions

Essential Instructions When replacement parts are required, ensure that qualified people use replacement parts specified by Emerson Process Management. Unauthorized parts and procedures can affect the product's performance; place the safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical hazards, or improper operation. Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury. The information contained in this document is subject to change without notice Do not allow the temperature of the CH88 Flue Gas O2 Probe electronics to exceed 85 C (185 F) or damage to the unit may result. Symbols Used on equipment and in instruction manual : EARTH (GROUND) TERMINAL : PROTECTIVE CONDUCTOR TERMINAL : WARNING, RISK OF ELECTRIC SHOCK : : : REFER TO INSTRUCTION MANUAL WARNING, HOT SURFACE EQUIPMENT PROTECTED THROUGHOUT BY DOUBLE INSULATION(APPLIES TO 1056 COMBUSTION ELECTRONICS HOUSING ONLY) Note: If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. Definitions The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this publication. WARNING Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel. CAUTION Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness. Highlights an essential operating procedure, condition, or statement. 4 Essential Instructions

Essential Instructions General Information Overview The CH88 In-Situ Combustion O2 Analyzer System is Rosemount Analytical s latest combustion flue gas oxygen analyzer consisting of 1056 Combustion Electronics and CH88 Flue Gas O2 Probe. This product is intended for measuring the flue gases resulting from any combustion process. It utilizes the same heated sensing technology as the O2 sensors found in most automobiles. Contact Rosemount Analytical s technical support group at 800-433-6076 for any applications other than measuring combustion flue (exhaust) gases. This product utilizes an in situ sensor, i.e. the sensor is placed at the end of a probe, and the probe extends directly into the flue gas duct or stack at a given length. The sensor is like a thermocouple, generating it s own millivolt signal based on the difference between a reference gas (ambient or instrument air always 20.95% O ), and the flue gases being measured. 2 System Configuration CH88 Flue Gas O2 Probe with 1056 Combustion Electronics There are no electronics inside the probe head, so the raw sensor signals for the heater thermocouple and zirconium oxide O sensor 2 are sent to a remote 1056 Combustion electronics. The 1056 Combustion electronics will also directly apply power to the probe heater in order to maintain the correct sensor temperature. This arrangement calls for a 9- conductor cable to carry this power and the sensor signals. Maximum length for this cable is 500 feet. This probe will also operate on previous Westinghouse/Rosemount electronics (World Class and Oxymitter), as well as many competitive electronics. CH88 Flue Gas O2 Probe does not communicate via HART or FOUNDATION Fieldbus communications. Technical Support Hotline For assistance with technical problems, please call the Customer Support Center (CSC). Rosemount Analytical Shanghai Service (086-21-28929294) 1-RAI-AND-U (1-855-724-2638) 1-800-433-6076 In addition to the CSC, you may also contact Field Watch. Field Watch coordinates Emerson Process Management s field service throughout the U.S. and abroad. 1-800-654-RSMT (1-800-654-7768) Emerson Process Management, Rosemount Analytical Inc. may also be reached via the Internet through e-mail and the World Wide Web e-mail: GAS.CSC@emerson.com World Wide Web: www.rosemountanalytical.com 5 General Information

Typical System Package and Ordering Information Section 2: Typical System Package Figure 1 CH88 In-Situ Combustion O2 Analyzer System Ordering Information CH88 Flue Gas O2 Probe Length in Meters inches) Shipping Weight Actual Weight Part Number 0.5 m (19.68 in) 8.6 Kgs (19 lbs) 6.1 Kgs(13.5 lbs) 6A00507G01 1 m (39.37 in) 10.43 Kgs (23 lbs) 7.6 Kgs(16.8 lbs) 6A00507G02 2m (78.74 in) 13.8 Kgs (30.5 lbs) 10.43 Kgs(23 lbs) 6A00507G03 1056 Combustion Electronics dimensions Shipping Weight Actual Weight Part Number in Millimeter(inches) 155 x 155 x 131mm (6.10 x 6.10 x 5.15 in.) 1.8 Kgs(4 lbs) 1.4 Kgs(3 lbs) 24490-00 Accessory Calibration Flowmeter Cal gas adaptor kit to mate to existing tubing arrangement Replacement sensor board Part Number 771B635H01 1A98771H07 6A00493G01 Replacement power supply board 24248-03 Replacement display board 24361-00 6 Typical System Package and Ordering Information

Specifications System Specifications Section 3: Specifications Net O2 Range Variable 0-10% to 0-50% Accuracy Lowest Detectable Limit Process Temperature Effect System Speed of Response to Calibration Gas Calibration Validity Power Reference Air ±1% of full scale for 0-10% ranges and above 0.05% O2 CH88 Flue Gas O2 Probe Specifications Enclosure Process Temperature Limits Output/s Probe Length Mounting Calibration Calibration Gases Calibration Gas Flow Ambient Conditions Storage Conditions 1056 Combustion Electronics Enclosure Less than 0.05% O2 from 100 to 700 C (212 to 1292 F) Initial response in less than 3 seconds T90 in less than 8 seconds. Response to process gas changes will vary depending on process gas velocity and particulate loading of the diffuser Presentation of calibration gases matches the bottle value to within ±0.1% O2 240V ±10%,50/60 Hz, 150 Watts max (during initial warm up) Reference air is ambient air that will passively diffuse into the probe. The ambient air at the installation location must be fresh (20.95% O ). 2 Process-wetted materials are 304 Stainless -40 to 705 C (40 to 1300 F) optional bypass and jacket accessories permit operation to 1050 C (1922 F) One 4-20 ma 0.5, 1, 2 m Vertical or horizontal 2" 150# (4.75" (121mm) bolt circle) and DIN 145 Note: Flanges are flat-faced and for mounting only. Flanges are not pressure-rated. A 2.5" diameter hole in the process is required. Spool piece P/N 3D39761G02 is available to offset probe housing from hot ductwork. Many adapter flanges are available to mate to existing flanges. Manual/Semi-automatic Calibration New calibration values are calculated in the 1056 Combustion electronics. 0.4% O2 and 8% O2, balance N2 recommended. Instrument air may be used as a high cal gas but is not recommended. 100% nitrogen cannot be used as the low cal gas. 2.5-5 l/min. (5-10 scfh) Temperature: -40 to 90 C (-40 to 194 F) Humidity: 5 to 95% RH (non-condensing) Temperature: 0-50 C (32-122 F) Humidity: 5 to 95% RH (non-condensing) Overall 155 x 155 x 131mm (6.10 x 6.10 x 5.15 in.). Cutout: 1/2 DIN 139mm x 139mm (5.45 x 5.45 in.),polycarbonate Material Note: To ensure a water- tight seal, tighten all four front panel screws to 6 in -lbs of torque. Mounting Conduit Openings Ambient Conditions Storage Conditions Pipe, wall, or panel (Refer to drawings) Accepts 1/2 or PG13.5 conduit fittings Temperature: 20 C to 50 C (-4 F to 122 F) Humidity: 5 to 95% RH (non-condensing) Temperature: -20 C to 60 C (-4 F to 140 F Humidity: 5 to 95% RH (non-condensing) 7 Specifications

Specifications Analog Output Alarm Relays Display 4-20 ma, max. load 550 ohms Two (2) SPDT Form C, epoxy sealed contacts rated 5A, 30VDC, 120 VAC, or 230VAC; User configurable to alarm The high-contrast LCD provides live measurement readouts in large digits and shows up to four additional process variables or diagnostic parameters. The display is back-lit and the format can be customized to meet user requirements. 8 Specifications

Installation Section 4: Installation Mechanical Installation Installation of1056 Combustion Electronics The 1056 Combustion Electronics is available in a panel mounting, or wall/pipe mounting configuration. Refer to Figure 5 or Figure 6 for the panel, wall, or pipe mounting details. 1. Ensure all components are available to install the 1056 Combustion Electronics. 2. Select a mounting location near or removed from the O2 Probe. Consider the temperature limitations of the 1056 Combustion Electronics (see "Specifications") when selecting the mounting location. 3. Mount at a height convenient for viewing and operating the interface. Approximately 1.5 m (5 ft) is recommended. 4. The keypad window on the 1056 Combustion Electronics may have an exterior protective membrane. Remove the protective membrane prior to use of the 1056 Combustion Electronics enclosure. Failure to remove the protective membrane may cause the display to appear distorted. The membrane may be difficult or impossible to remove after extended use at elevated temperatures. Installation Specifications - Cable Connecting Probe to Electronics Customer supplied, total of 9 conductors, rated for 105 C or greater, insulation rated for 250V or greater: Heater Power 2 conductors, 12 18 ga. (<200ft.); use 12 ga. for lengths between 200 and 500 ft. Probe sensing 7 conductors (3 twisted pairs plus shield) 16 to 25 ga. (<200 ft.); Use 16ga. for lengths between 200 and 500ft. Shield connected to ground at 1056 Combustion Electronics. All wiring must be rated for 250VAC. Minimum 105 C temperature. CH88 Flue Gas O2 Probe Installation A weld plate for welding to the flue gas duct can be supplied for new installations. 1. Ensure all components are available to install the CH88 Flue Gas O2 probe. Refer to Figure 1. 2. If using the standard square weld plate (Figure 1) or an optional flange mounting plate weld or bolt the plate onto the duct. The through hole diameter in the stack or duct wall and refractory material must be at least 63.5 mm (2-1/2 in). 3. Insert probe through the opening in the mounting flange and bolt through the probe gasket and flange. Grounding screws A Grounding Screw is located on the outside of the CH88 Flue Gas O 2 Probe enclosure. It is intended to provide a local ground. A second Grounding Screw is located inside the probe housing. It is intended to connect the grounding conductor to the control electronics. WARNING: RISK OF ELECTRICAL SHOCK Local Ground connection shall be provided to CH88 Flue Gas O 2 Probe in order to avoid electric shock. The ground conductor should be equal or greater than 16 AWG for a copper conductor in free air or 12 AWG for an enclosed copper conductor. WARNING Before installing this equipment read the "Safety instructions for the wiring and installation of this apparatus" at the front of this Instruction Manual. Failure to follow safety instructions could result in serious injury or death. Install all protective equipment covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death. 9 Installation

Installation CAUTION Do not allow the temperature of the CH88 Flue Gas O2 Probe electronics to exceed 85 C (185 F) or damage to the unit may result. CAUTION If the ducts will be washed down during outage MAKE SURE to power down the probes and remove them from the wash area. Figure 2: CH88 Flue Gas O2 Probe Installation NOTE: ALL DIMENSIONS ARE IN MILLIMETERS WITH INCHES IN PARENTHESES 10 Installation

Installation Figure 3: CH88 Flue Gas O2 Probe Installation NOTE: ALL DIMENSIONS ARE IN MILLIMETERS WITH INCHES IN PARENTHESES 11 Installation

Installation Figure 4: Drip Loop and Insulation Removal Note: Probe installation may be vertical or horizontal. 12 Installation

Installation Figure 5: Wall/Surface and Pipe Mount 13 Installation

Installation Figure 6: Panel Mount 14 Installation

Installation Electrical Installation All wiring must conform to local and national codes. Multiple wiring diagrams are shown in this section. Always refer to the diagrams that apply to your transmitter configuration and disregard all other wiring diagrams. WARNING Disconnect and lock out power before connecting the power supply. Install all protective covers and safety ground leads after installation. Failure to install covers and ground leads could result in serious injury or death. To meet the Safety Requirements of IEC 61010-1 (EC requirement), and ensure safe operation of this equipment, connection to the main electrical power supply must be made through a circuit breaker (max 10A) which will disconnect all current-carrying conductors during a fault situation. This circuit breaker should also include a mechanically operated isolating switch. If not, then another external means of disconnecting the supply from the equipment should be located close by. Circuit breakers or switches must comply with a recognized standard such as IEC 60947. WARNING Before installing this equipment read the "Safety instructions for the wiring and installation of this apparatus" at the front of this Instruction Manual. Failure to follow safety instructions could result in serious injury or death. Note: To maintain proper earth grounding ensure a positive connection exists between the probe terminations housing and earth. The connecting ground wire must be 14 AWG minimum. Note: Line voltage, signal, and relay wiring must be rated for at least 105 C (221 F). Note: If metal conduit is used with the 1056 Combustion the conduit should be reliably bonded to protective earth. The grounding plate inside the 1056 Combustion is not bonded to PE and does not provide adequate grounding. WARNING Disconnect and lock out power before working on any electrical components. There is voltage up to 240 VAC. Verify the reliability and continuity of the grounding of the probe connection before powering the equipment. Cable Connections All electronics are housed inside the 1056 Combustion Electronics. A customer supplied multi-conductor power/signal cable connects between the probe and the 1056 Combustion Electronics. Use the following procedure to connect the probe to the 1056 Combustion Electronics. NOTE: To maintain EMC/EMI noise protection customer supplied 9 conductor cable and cable glands must be properly connected to ground. 1. Run the signal and power cables cable between the probe and the installation site for 1056 Combustion Electronics. Use new cable conduit or trough as needed. 2. Install the cable and lead wires to the probe per manufacturer s instructions. 3. Install the cable at the probe housing and at the 1056 Combustion Electronics enclosure according to the following procedure: a. Unscrew locking nut from gland assembly and slide locking nut back along cable. b. Pull the gland body away from the plastic insert. Use care not to damage the cable shield braid. c. Insert the cable wires into the proper entry ports in the probe and the 1056 Combustion Electronics enclosures. d. At the probe housing, apply Teflon tape or similar sealing compound to the tapered pipe threads. Thread the gland body into the probe housing until properly seated. e. At the 1056 Combustion Electronics enclosure, insert the gland body into the left front cable port from the inside of the enclosure. Use the rubber O-ring provided to seal the cable port. 15 Installation

Installation f. Ensure the cable shield braid is evenly formed over the gray insert. When properly formed, the braid should be evenly spaced around the circumference of the insert and not extend beyond the narrow diameter portion. g. Carefully press the gray insert into the gland body. The grooves on the insert should align with similar grooves inside the gland body. Press the insert in until it bottoms out in the gland body. h. Slide the locking nut up and thread it onto the gland body. Tighten the locking nut so the rubber grommet inside the plastic insert compresses against the cable wall to provide an environmental seal. 4. At the 1056 Combustion Electronics, connect the cable leads to the connectors on the sensor I/O board as indicated in Figure 7. Probe Connections There are no electronics inside the probe head, so the raw sensor signals for the heater thermocouple and zirconium oxide O 2 sensor are sent to a remote 1056 Combustion Electronics. The 1056 Combustion Electronics will also directly apply power to the probe heater in order to maintain the correct sensor temperature. This arrangement calls for a 9- conductor cable to carry this power and the sensor signals. Maximum length for this cable is 500 feet (see specifications). 1. Remove cover from probe. 2. Feed all probe wiring through the conduit port of probe. 3. Refer to figure 7. Connect probe heater power leads to probe connector. 4. Connect O signal, thermocouple, and cold Junction (CJC) wires from probe to 1056 Combustion Electronics 2 Power-Up Procedure 1. Apply AC line power to 1056 Combustion Electronics. 2. The probe will take approximately 45 minutes to warm up to the 736 C heater setpoint. The 4-20 ma signal will remain at a default value of 3.5 ma and the O2 reading will remain at 0% through this warm-up period. After warm up, the probe will begin reading oxygen and the 4-20 ma output will be based on the default range of 0-10% O2. 3. If there is an error condition at startup, an alarm message will be displayed on the 1056 Combustion Electronics. Refer to full instruction manual for troubleshooting alarms. 16 Installation

Installation Figure 7: Wiring Diagram 17 Installation

Installation Figure 8: Wiring Diagram 18 Installation

Calibration Calibration The CH88 In-Situ Combustion O2 Analyzer System can be calibrated in the installed condition without removing the instrument from the process duct and also while the combustion process is on-line. A stainless steel tube runs the length of the probe, and delivers the calibration gasses into the cell area. Factory calibration will usually be satisfactory for initial start-up and operation, but most accurate measurement is gained by executing a calibration under normal operating conditions. Recommended calibration gases are 0.4% O and 8% O, with the balance of nitrogen in the gas bottles, but other values 2 2 can be used as long as the electronics are configured identically. Instrument air or pure nitrogen are not recommended as calibration gas values. A two-stage pressure regulator should be used to establish a pressure of 20 PSI, from the bottles, and the flowmeter should be set to 5 SCFH flow rate. Manual/Semi-automatic Calibration The CH88 Flue Gas O2 Probe with the standard housing can be calibrated in a semi-automatic fashion, with a technician following prompts via the display of the 1056 Combustion Electronics. The technician will need to manually switch the gases based upon these prompts. Recommended calibration gases are 0.4% O2 and 8% O2, balance nitrogen. A two-stage pressure regulator should always be used, set to 20 PSI. The calibration gas flowmeter should be set for 5 SCFH, with the cal gas fitting removed from the probe. A diffuser/filter that is plugged over time may cause the flowmeter to deliver less flow to the sensing cell, but the flow rate should never be readjusted until a new diffuser is installed. Readjusting the flowmeter back up to the 5 SCFH level could pressurize the cell during calibration, and cause the O2 reading to shift downwards. The electronics will determine if the calibration was successful, and calculate new calibration values. New calibration values are automatically loaded into the electronics after a successful calibration. Record the calibration data on the log provided (cell slope, constant, and impedance, as well as the speed of response data). 19 Calibration

Calibration Records Probe Serial Number: Probe Tag Number: Probe Location: Date Placed Into Service: Calibration Record For Rosemount Analytical In-Situ O2 Probe Notes: Response initial When the second calibration gas is turned off, note the number of seconds Response final required for the O value to begin migrating back to the process value. 2 When the second calibration gas is turned off, note the number of seconds required for the O value to settle out at the process value. 2 CAUTION Make sure that the calibration gas cap is replaced tightly after calibration is complete. Many combustion processes operate at a slight negative pressure (draft pressure), and can draw ambient air down the cal gas lines and into the sensing cell, causing a false elevated O reading. This same phenomenon is possible if the calibration gas hoses are permitted to become degraded or 2 loose. 20 Calibration Records

CH88 In-Situ Combustion O2 Analyzer System Menu Trees Section 5: Menu Trees CH88 In-Situ Combustion O2 Analyzer System Menu Trees System Menu Tree (English) System Menu Tree (Chinese) 21 CH88 Menu Trees

CH88 In-Situ Combustion O2 Analyzer System Menu Trees Probe Menu Tree (English) Probe Menu Tree (Chinese) 22 CH88 Menu Trees

CH88 In-Situ Combustion O2 Analyzer System Menu Trees CH88 In-Situ Combustion O2 Analyzer System Menu Trees Menu Trees Probe Menu Tree (English) Probe Menu Tree (Chinese) 23 CH88 Menu Trees

Parameters Section 6: Parameters CH88 In-Situ Combustion O2 Analyzer System Parameters System Parameters 24 Parameters

Parameters Probe Parameters 25 Parameters

Parameters Probe Parameters (continued) 26 Parameters

Parameters Probe Parameters (continued) 27 Parameters

Parameters Probe Parameters (continued) 28 Parameters

Parameters CH88 In-Situ Combustion O2 Analyzer System Alarms System Alarms 29 CH88 Alarms

Parameters Probe Alarms 30 CH88 Alarms

Parameters Probe Alarms 31 CH88 Alarms

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