Sidel Therm & CO 2 Counter Instruction & Installation Manual

Sidel Therm & CO 2 Counter Instruction & Installation Manual

P.O. Box 1868 Atascadero, CA 93423 800-668-5003 Fax: 805-464-0504 Sid Abma, President www.sidelsystems.com

Table Of Contents System Overview.............................. 4 Theory Of Operation........................... 4 Monitoring The Heat Recovered.................. 5 Installation................................... 8 Mounting The Control Box...................... 8 Thermocouples Installation..................... 9 Flow Meter Installation And Operation........... 11 Controller Settings And Calibration.............. 26 Accessing Parameters......................... 26 Temperature Settings......................... 28 Flow Settings................................ 29 Controller Settings............................ 29 Change Password............................ 30 Setting The Date And The Time................. 30 Schematics................................. 31 Page 3

System Overview Theory of operation The Sidel SRU flue gas recovery unit is designed to recover almost all of the waste exhaust heat and turn it into usable heat. The waste flue gases from the boiler are redirected to the SRU recovery unit, which is placed beside the boiler or alongside the chimney. The Sidel SRU flue gas condenser unit cools the flue gasses to the point where the sensible as well as the latent heat is recovered. The Sidel SRU series is designed so that flue gas temperatures can be lowered well below the dew point temperature of 58 C or 136 F. When the temperature of the waste flue gas is lowered beyond 133 F, condensation starts to occur. Naturally the lower the flue gases can be cooled, the higher the performing efficiency of the waster heat recovery unit. The waste heat recovery unit is designed for natural gas or propane fired equipment only. The vertical construction of the SRU waste heat recovery unit provides for the best possible use of available space. Installation alongside a 110,000 lb/hr boiler Page 4

Monitoring the Heat Recovered In order to quantify the amount of heat recovered, Sidel Systems in conjunction with Helman Automation, has created the Sidel Therm and CO2 Counter. This is an industrial PLC capable of continuously storing data which shows how much energy is being saved by the SRU Flue Gas Condenser. The Therm and CO2 Counter control unit has two major components: the HMI (human machine interface), and the PLC (programmable logic units). The HMI displays all the important information, is the gateway to change parameters, and can communicate collected data to other terminals via the internet. One of the greatest advantages of the system is its capability to be adapted to the monitoring needs of the customer. The system can be programmed to perform all the automation control, data acquisition, and data storage. Page 5

The Sidel Therm and CO2 Counter works in a similar way to any utility meter, with the exception of an additional audible buzzer which sounds in response to any occurring hazard that may occur. The display screen shows the amount of energy being recovered as well as other vital information such as the temperature at several critical points, water flow, chimney valve position, and with it monitor any other information required to protect the SRU from damage. Any data that registers out of normal range will set off an alarm. The HMI used in the Sidel Therm and CO2 Counter has all the latest technology, such as: a high resolution touchscreen, Ethernet, USB and serial port connections. This allows the data collected to be displayed on any computer in the company. The HMI can be customized to display in either Metric units or British units and also can be programmed for Multi languages. This feature is very useful to see graphically how the changes of each parameter affect the heat recovery process Page 6

History Screen Trending Screen Page 7

How the monitor works: From 4 sensors that are inserted into the pipes connected to the Sidel SRU Flue Gas Heat recovery Unit, the Therm and CO2 Counter takes the temperature of: Water flowing into the SRU unit. Water flowing out of the SRU unit. Flue gas flowing into the SRU unit. Flue gas flowing out of the SRU unit. From the water flow sensor inserted into the water intake pipe, the PLC receives the rate of water flowing through the SRU in Gallons per minute (GPM). This data is received by the PLC in 5 second intervals and is displayed on the screen. The PLC calculates the Delta T in BTU s, and the flow rate in GPM and displayes the resulting calculation as BTU s saved every 5 seconds. From these figures it is possible to see, in real time, exactly how the SRU is performing. This information is also saved as history in the PLC memory and can be displayed on the History Screen. By using the touch screen the operator can open and close the Chimney Valve, control the alarm function, set the system, and navigate between the displays. The displayed calculations also can be sent over the internet or intranet to be displayed on any computer within the company. This gives the Sidel SRU a unique advantage in providing real time cost savings analysis that can be used by managers to prove that their company is reducing greenhouse gas emissions and using their energy efficiently. Installation Mounting the Control Box The control box is a NEMA 12 with dimension of 14 x16 x8. The box can be flush mounted to a wall or a post with 4 screws of ¼ diameter. The control box will require power of 120 V ac. To comply with NEC the power shall be supplied with 2 #12 wires and a #14 ground green wire This picture shows the power 120 VAC point of connection. Page 8

run with EMT, or liquid tite conduit. If the unit is equipped with a chimney valve control, the box will require also the installation of a compressed air valve of 80 PSI or more, or wiring to the chimney valve as per actuator requirements. Thermocouples installation Thermocouple probes are the preferred temperature sensor used for the Sidel Therm and CO2 Counter, because they provide a large temperature range and are durable. The probe tip is composed of two alloys welded together which makes them almost indestructible. The Sidel SRU unit provides ½ NPT threaded couplings for therm couple installation. One, for each water inlet and outlet, and one for each flue gas exhaust inlet and outlet. The sensors provided with the unit are made of stainless steel. Make sure to use Teflon tape or pipe sealant for sealing the fitting, especially for the water pipe. In most cases we will provide the NB4 with a sub-miniature aluminum head and a SS ½ NPT thread bushing. It has an internal terminal block for probe connection. The J type thermocouple is composed of two wires; the White wire is the (+) and the Red wire is the (-). Sidel provides 250 ft. of cable to connect the 5 sensors to the controller. This 2 wire shielded cable has one black wire and one red wire. The black wire is to be connected to the white (+) in the probe terminal and the red to the red (-) in the probe terminal. The length of the cable has little effect in the accuracy of the temperature but it is very important to isolate the routing of the cables to the control box from electrical noises to diminish fluctuation on the temperature readings. The probe comes precalibrated. Each probe will be delivered labeled for the port where it will be installed. The following picture depicts the connection to the probe terminal: Page 9

Notice the black wire is connected to the white wire of the thermocouple. The connection to the control box is marked clearly with color terminals. Each thermocouple has red and white terminals. Notice the white terminal is connected to the black wire of the thermocouple probe cable. The terminal connections are organized from right to left; the first is the water inlet, the second is the water outlet, the third is the exhaust inlet and the fourth is the exhaust outlet as shown in the picture. This is for the standard Sidel SRU unit. (The installation of a Sidel SRU Combi will be described in a separate manual.) Page 10

Flow Meter Installation and Operation Operation: The paddle wheel sensor measures the flow at of water in the pipe. Fluid moving in a pipe does not all flow at the same velocity. Toward the center of the pipe, fluid moves faster than at the wall and the relationship between the two changes as the overall flow rate increases. The recommended depth settings have been carefully chosen to minimize this source of error, and should be followed, especially in the smaller pipe sizes. Installation of the sensor: The flow meter IP100/200 series Cold Water Inlet #1 Heated Water Outlet #2 Flue Gas Exhaust Inlet #3 are adjustable depth insertion paddle-wheels. These models are designed to fit 2 to 48 pipe. Installation fittings are standard 1-1/2 or 2 NPT. Ruby bearings and a non-drag hall-effect sensor give these meters the widest flow range of any of the paddle wheel types. A sensor detects the passage of miniature magnets in the six rotor blades. The resulting square wave signal can be sent for hundreds of feet over unshielded cable without the addition of a transmitter. This cable can be connected directly to the PLC (programmable logic controller) for the flow measurement. The hot-tap models (IP115/215) can be installed or serviced without shutting down the line by means of a 2 full-port isolation valve that comes with a nipple for installation on the pipe fitting. In most circumstances, no special tool is required. Flue Gas Exhaust Outlet #4 Page 11

The picture bellow depicts the IP115/215 equipped with the service ball valve. Page 12

Specifications: Piping: For best results, the IP sensor should be installed with at least ten diameters of straight pipe upstream and five downstream. If the installation allows obtaining greater distances, then the result should be optimum. Page 13

See Straight Pipe Recommendations: Page 14

Horizontal is the preferred installation orientation, since it improves lowflow performance and avoids problems with trapped air. Bottom, top, and vertical pipe installation are all acceptable. Page 15

See Full Pipe Recommendations: These are several types of Full Pipe Recommendations: Page 16

Fitting and Meter Installation: The sensor comes with a 1-1/2 male NPT pipe thread adapter fitting. Loosen the compression nut so the adapter slides freely. Pull the meter fully upward and finger-tighten the compression nut. Do not over tighten. Now loosen the compression nut, lower the meter to the appropriate depth setting. The depth setting parameters are given by the combination of the preceding Tables. Be sure flow is in the direction of the arrow on the housing, then tighten compression nut fully. Page 17

Sensor without the service ball valve: Sensor with the service ball valve: Page 18

Sensor Depth Setting: It is important for accuracy that the sensor be inserted to the correct flow direction and depth into the pipe. Page 19

To find the distance D first, find the Dimension C from Table 1 corresponding to the model of sensor and the size of pipe. Then subtract the wall thickness of your corresponding size and type of pipe you use from Table 2. D is the distance measuring from the outside of the pipe to the joint in the housing, as shown in the diagram above. Adjust the sensor to Dimension D and hand-tighten compression nut. Align the strain relief housing with the center line of the pipe where the arrow on the housing points in the direction of the flow as shown in the diagram above. Page 20

Electrical connection: The sensor connection is very simple and straight forward. The IP115/215 come equipped with 18 ft. of cable. The 3 wires cable comes with color coded wires as shown in the picture below: Page 21

The picture above shows the terminal numbers to which each of the flow meter cables needs to be connected: Flow Calibration: In order to properly process pulses from the flow sensor, a number must be enter in the Operator Interface Terminal. This number, is called the K factor, and is the number of pulses the sensor puts out per unit of fluid passing through the pipe. For the sake of practicality the K factor given on Table 3 will be Pulses per Gallons. To set the K factor in the controller follow direction provided in Table 3. Page 22

For example, if 4 copper tubing (type L) is been used, then the K factor to be set is: 17.85 pulse per gallon. This value has to be entered in the Flow Adjustment Menu. The value to be entered should be 1785 without the decimal point. Page 23

Repair and Parts of Sensor: The flow sensor has only one moving part, the rotor. If this is turning properly and there is no signal, the Hall-effect sensor is not operating properly. In order to test the sensor for signal, once the sensor is removed from the pipe for service, gently rotate the paddlewheel. Observe if the input signal X0 in the PLC flicked or goes from turning on and off to see if the Hall Effect changes state. If X0 changes state then the sensor is operating properly. Parts Explosion: Page 24

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Controller Settings and Calibration Accessing Parameters To enter the K factor the user should press the Settings button from the main screen. This will access the flow parameters. Once you press the Settings button the user is required to entered the security Password. This password can be set or changed by the user at any time. Warning!!! any changes made on any category of the setting menu will have a drastic effect in the way the Therm and CO 2 Counter will control or monitor the Sidel Flue Gas Condenser. Only authorized personnel should be accessing this feature of the Therm and CO 2 Counter. Main screen Setting button Page 26

The following is the Password screen where the user will enter the password by touching the green window. After the cursor is active in the Green window the keypad becomes active and a number can be entered. To save the password the ENT key needs to be pressed. To clear press the CR key. The password can be any number between 1111 to 99999999 as shown in the picture below. When the correct password is entered the Setting Menu screen opens as shown in the picture Page 27

Temperature Settings It is important to calibrate all the temperature probes before installation. Since the probes are not perfectly the same when they are shipped from the factory, it is necessary to adjust the temperature offsets of each probe. Helman Automation will calibrate all sensors for all new installations so that recalabration is not required. The adjustment instructions are shown on the screen for convenience. Generally the slope for the J type thermocouples are almost identical, so the only parameters to be calibrated are the Offsets because they might differ a couple of degrees. To accomplish this calibration, the probes must be placed in a container with water at room temperature. This will allow a uniform temperature among the probes. At this point a well calibrated thermometer needs to be used as a reference. Once the temperature is stabilized, then enter the temperature of the reference thermometer in the green window. As the final step press the SINCRONIZE button. Now the program will set all of the probes to the same temperature. Page 28

Flow Settings Once the K factor is obtained from Table 3, enter this number as shown below. In this example the K factor used is for a 4 type L copper pipe which is 17.85 pulse per gallon. The number entered must not have decimal point as shown in the picture. Controller Setting The Therm Counter comes preprogrammed to perform energy monitoring and to automatically control the opening and closing of the chimney valve as well all the safety alarms. This feature must be activated as shown in the picture. After pressing the green button, the message will indicate the Chimney Valve Control is activated. Page 29

Change Password To set a new password the user needs to enter a number that is easy to remember and should be at least 4 digits between 1111 to 99999999. Setting the Date and the Time If the Date and Time shown in the main screen are not correct then they need to be corrected. To correct them select the Setting Date/Time button to access the following screen. Touch any green window to change any parameter and the input keypad will popup then press the appropriate value and press enter. Page 30

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Schematics This system shows an optional diagram with a recirculation pump. Page 33

Notes Page 34

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