comtec 6000

Transcription

comtec 6000

C O M T E C® 6000
O2 / COe* Analyser System
with SME 5 Electronics
Installation & Operating
Manual
Version No. 10
Valid from Software Version 2.29
Revision Date 29 September 2005
* COe is the short cut for COequivalent (For more information see the explanation in chapter 5.1.2 on page 19)
ENOTEC GmbH
Process and Environmental
Measuring Technology
DIN EN ISO 9001
Höher Birken 6
D-51709 Marienheide / Germany
Tel.: +49 (0) 2264 - 4578 - 0
Fax: +49 (0) 2264 - 4578 - 31
Email:
[email protected]
Internet: www.enotec.de
www.enotec.com
Intentionally blank
O2/COe COMTEC® 6000 Analyser System
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Preface
Dear customer,
Thank you for selecting our COMTEC® 6000 as your InSitu Flue Gas Oxygen/Combustibles (COe*)
measuring system.
ENOTEC has been producing its world famous OXITEC® Oxygen Analysers for more than 20
years, and now our COMTEC® Oxygen/Combustibles (COe) measuring system enhances our
product line. ENOTEC are committed to total quality and performance and we have continuously
enhanced our products to integrate various additional features and functions. In this package, the
electronics uses the very latest Microprocessor Technology, making the SME5 electronics one of
the most advanced and up-to-date monitoring units permitting you to reduce your maintenance &
fuel costs to achieve an increased measuring accuracy with more operational reliability due to new
monitoring functions.
In our COMTEC® probes you will find the Zirconium Oxide measuring cell which is gas-tight sealed
in place using a special process and technique developed by our company. This leads to a considerably increased service life as compared to "glued or cemented" measuring cells that have a tendency to leak or crack during operation. The O2 cell is a proven gas-tight design providing greater
measuring accuracy, durability and longer working life with the experience of more than 10,000
installations.
For COe measurement, we have integrated a high temperature Ga2O3 sensor. The conductivity
mechanism of the Ga2O3–sensor is used in the COMTEC® InSitu – high temperature probe to
separate the carrier density and the carrier mobility which both have influence on the overall electronic conductivity and together produce the sensor output signal.
All ENOTEC instruments are thoroughly tested in the factory and are subject to a strict ISO 9001
Quality Assurance procedure. Therefore, with the correct installation, the operation of the
COMTEC® 6000 analyser system is very easy to use and user friendly. It will provide you with
many years of operation with perfect measuring results.
Please read this manual carefully and follow the instructions as directed. If you have any questions, or you are unclear about any aspect of the installation or operation, our Service Department,
regional sales offices or approved distributors will be pleased to assist. The factory contact points
are Tel: +49 2264-45780 or Fax: +49 2264 457831. You may also visit us at our website
http://www.enotec.de or http://www.enotec.com or contact us by e-mail: [email protected] or
[email protected].
Marienheide, 29 September 2005
Dipl.-Ing. Fred Gumprecht
Managing Director
ENOTEC GmbH
* COe is the short cut for COequivalent (For more information see the explanation in chapter 5.1.2 on page 19)
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Table of contents
1
Advice for the Operator
10
1.1
Warranty
10
1.2
Declaration of EC-Conformity
11
1.3
Information on the CE-Certification
12
1.4
Notes on this Document
12
1.5
Symbols used in this Document
13
2
3
4
Intended Use
14
Hazardous Area ATEX Certified Options 15
Safety Instructions for the Operation of
COMTEC® 6000 Analyser System/Probes 16
4.1
General Safety Instructions
16
4.2
Maximum Ambient Temperature
16
4.3
Corrosion
16
4.4
Installation
16
4.5
Safety Hazards
17
5
5.1
General System Description
18
COMTEC® 6000 Measuring Principles
18
5.1.1
Measuring Principle of the ZrO2 Sensor for O2 Measurement
18
5.1.2
Measuring Principle of the Ga2O3 Sensor for COe Measurement
19
Design of the COMTEC® 6000 Analyser
System
Description of the COMTEC® 6000
System Components
6
7
7.1
20
22
Design and Function of the Measuring Probe KES
600x
22
7.2
Special Probe Cable
24
7.3
Special Pneumatic Cable
25
7.4
Design of the Electronics
25
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Installation of the COMTEC® 6000
Analyser System
8
8.1
27
Checking the Location for the Probe Installation at
the Flue Duct Wall
27
8.2
Installing the Probe
27
8.3
Adjusting the Filter Head
29
8.4
Electrical and Pneumatic Connections at the Probe
Terminal Box
30
Installing the SME5 Electronic Unit for COMTEC®
6000
32
8.5
8.6
8.7
8.8
8.9
8.10
9
8.5.1
Requirements on the System Surroundings
32
8.5.2
Requirements on the Connecting Lines
32
Terminal Connections for Electronic COMTEC® 6000
SME5 in the 19” Housing
34
Wiring and Terminal Connection Diagram of
COMTEC® 6000 (Field Housing)
35
Terminal Connector of the COMTEC® 6000 Electronic
Main Board (Field Housing)
36
Attention! Important change of colour code electric
cable FEP-0007
37
Fitting the ferrite sleeves (EMC)
37
Description of the SME 5 Microprocessor
Electronics
38
9.1
38
9.2
Functional Description of the Microprocessor
Electronics
38
Start-up of the COMTEC® 6000 System
10
10.1
COMTEC® 6000 Probe Heating Phase
40
40
Operating Instructions for the COMTEC®
6000 Electronics
43
11
11.1
General operating instructions
43
11.2
Main Window
44
11.3
Actual Value Menu
45
11.3.1
Lambda
46
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11.4
11.5
Parameter Menu
11.4.1
Change of the Parameter O2 Measuring Ranges
49
11.4.2
Altering of a Parameter by the Example of a Limit Value
49
11.4.3
O2 Correction
50
11.4.4
Moisture Content of Test Gas
50
System Menu
52
11.5.1
First Steps for Calibration
53
11.5.2
O2 Single Point Calibration
54
11.5.3
O2 Two Point Calibration
56
11.5.4
COe Single Point Calibration
60
11.5.5
COe Two Point Calibration
62
11.5.6
System Test with Test Gas
67
11.5.7
System Test with Test Air
68
11.5.8
Automatic Calibration (ACAL) of the Oxygen Measurement with
Air (20.95% O2)
69
Measuring Value Memory for the O2 Analyser
71
11.5.9
11.6
12
47
11.5.10 Setting Current Output O2
71
11.5.11 Measuring Range Switching
71
11.5.12 Change Code
71
11.5.13 Damping of O2 mA Output
71
11.5.14 Change Language
71
11.5.15 Service
72
11.5.16 Software
72
Status Messages / Error Messages
System Description / Adjustments
72
75
12.1
In Case of Loss the System Code
75
12.2
Bridge on Back of Display Unit
75
12.3
Adjustment Display Contrast
75
12.4
Relay Outputs / Functions
76
12.5
Digital Inputs
76
12.6
Amounts of Test Air and Reference Air
77
12.7
Stability Criteria for O2 Calibration
77
12.8
Stability Criteria for COe Calibration
77
12.8.1
12.8.2
COe Single Point Calibration and COe Two Point Calibration,
First Point
77
COe Two Point Calibration, Second Point
78
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12.9
Reaction Time of the mA Output
12.10 Extension Modules
78
12.10.1 RS 232 Interface (option)
13
78
Technical Specification
78
85
13.1
Technical Specification Electronic Unit
85
13.2
Technical Specification Probe
86
14
Service and Maintenance
87
14.1
Switching between 230 V and 115 V operation
87
14.2
Replacing the Fuses
88
14.3
Adjusting the Flow Rate of Reference and Test Air
88
14.4
Humidification of the Gas Moisturisation Filter
90
14.5
Replacing the Probe Filter
90
14.6
Exchange of ZrO2 Measuring Cell
91
14.7
Exchange of Probe Inner Parts
94
14.8
15
14.7.1
Exchange of Thermocouple Element
94
14.7.2
Exchange of Heating Element
94
14.7.3
Exchange of Signal Measuring Wire
95
14.7.4
Exchange of 4-Hole Ceramic Rod
95
Exchange of the COe Sensor
Trouble Shooting
15.1
15.2
96
98
O2 Display remains at the End of the Measuring
Range or is higher than expected
98
O2 Display 0 %, although the Operation Mode
indicates a higher O2 Value
99
15.3
Local Displays correct, Output not correct
100
15.4
Unsteady, widely varying Measuring Value (O2)
100
15.5
Unsteady, widely varying Measuring Value (COe), it is
not possible to calibrate the COe Analyser
101
15.6
No COe Measuring Value; empty Bar Diagram
101
15.7
No COe-Measuring Value; black Bar Diagram
101
15.8
No Measuring Value for O2 and COe, black COe Bar
Diagram
101
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15.9
16
O2 reads higher than expected, and COe reads lower
than expected
102
Dimensional Drawings of the Electronics
Unit
103
Dimensional Drawings of the Probes
106
17
17.1
18
Probe Components
Pneumatic Connection and Mounting
Overview
Notes
19
19.1
Carbon Monoxide CO
19.1.1
20
108
114
First Aid
114
Table of Figures
109
114
115
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1
Advice for the Operator
1.1
Warranty
ENOTEC
2 YEAR WARRANTY
ENOTEC warrants that the equipment manufactured and sold by it will, upon
shipment, be free of defects in workmanship or material. Should any failure to
conform to this warranty become apparent during a period of two years after
the date of shipment, ENOTEC shall upon prompt written notice from the purchaser, correct such nonconformity by repair or replacement of the defective
part or parts. The purchaser is not entitled to claim any other legal remedies
on the basis of this warranty. Please refer to the complete ENOTEC warranty
policy for details.
ENOTEC does not warrant equipment supplied by it against normal deterioration. Corrosive gases and solid particles may cause damages and make a repair or a replacement necessary as a consequence of normal wear and tear
during the warranty period. The COe sensor is such a product, with a guarantee limited to one year.
Note: When installing the equipment, the customer must ensure that all necessary supply lines are connected and the operating temperature of the probe
is reached. Experience has shown that products installed but not taken into
operation may be damaged by the process or by external influence. ENOTEC
will not accept any responsibility for such damages.
MANUFACTURER:
ENOTEC GmbH
Höher Birken 6
D-51709 Marienheide
Germany
TEL: +44(0)2264/45780
FAX: +44(0)2264/457831
Email: [email protected] and
[email protected]
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1.2
Declaration of EC-Conformity
ENOTEC GmbH
Höher Birken 6
51709 Marienheide/Rodt
Germany
CE Mark - Conformity
to EC Directive Electromagnetic Compatibility 89/336/EWG
®
We declare that the COMTEC analyser system as detailed below due to its design and construction as well as the type
sold by us complies with the relevant basic safety and health requirements of the EC Directive. This declaration becomes
invalid if the appliance is modified without our prior consent.
Identifier:
Evaluation electronics Type:
Relevant
EC-directives:
Applied
harmonised
generic standards:
Applied
standards and technical
specification, in particular:
Date / Manufacturer’s signature:
Position:
®
COMTEC 6000 Analyser System
......................................................................................
SME 5
......................................................................................
EC Low-voltage Directive (72/23/EWG)
EC Directive Electromagnetic Compatibility (89/336/EWG)
EN 50082-2 1995 Resistance to interference
.....................................................................................
EN 55011 Kl.B 1992 Emission
.....................................................................................
EN 61010-1
2002 Low Voltage Directive
.....................................................................................
EN 61000-4-2 ESD
....................................................................................
EN 61000-4-3 Irradiation E-field
....................................................................................
EN 61000-4-4 Burst
....................................................................................
EN 61000-4-6 Inflow
....................................................................................
EN 61000-3-2 Current Harmonics
....................................................................................
EN 61000-3-3 Flicker
....................................................................................
EN 61326-1 Immunity partly
....................................................................................
29 September 2005 - signed by Fred Gumprecht
.....................................................................................
Managing Director
.....................................................................................
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1.3
Information on the CE-Certification
After having completed and successfully passed EMC-tests, the complete
ENOTEC analyser system - consisting of oxygen measuring probe, electronics
and special probe cable - has a conformity certificate.
If parts of this system are operated with products not supplied or approved by
ENOTEC, the CE-conformity is no longer valid.
Likewise, all warranties are void if the system is operated in a configuration not authorized by ENOTEC!
Note
The enclosed ferrite sleeves must be put over the terminal
leads of the cable (see chapter 8.10 on page 37). The CEconformity is void if these ferrite sleeves are not fitted!
Note
The ground (Earth) connection must be installed thoroughly using the correct cable of at least 1,5mm² minimum.
It is very important that the equipotent bonding is installed
correctly.
Please note that some electrical devices (e.g. frequency
converter etc.) close to the system can create considerable
electrical disturbance and instability. So for normal function
of the COMTEC® 6000 system it is important that these
devices be installed away from the system and in accordance with the manufacturer’s installation notes and guidelines.
Please do not lay the probe cable near power supply cables, or near motors and their cables, as frequency converters control them because this could cause interference
effects. If possible, do not cross the cables because this
could interference effects. However, if this is unavoidable
please make sure that these cables are only crossed at
right angles.
1.4
Notes on this Document
This document describes the design, installation, commissioning, operation,
maintenance and troubleshooting of the COMTEC®6000 InSitu analyser system.
On this equipment only accordingly authorized, qualified personnel may work.
These personnel must be familiar with all warnings, safety references and
maintenance tasks in accordance with this instruction manual. The perfect and
safe enterprise of this equipment presupposes appropriate transport, professional storage and installation as well as careful operation and maintenance.
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1.5
Symbols used in this Document
Important information as well as safety instructions are emphasised by the below-mentioned symbols. Please make sure that all safety advices and warnings are observed at all times.
Note
Exposes important information, which should be pointed
out particularly.
Important
Warns of the risk to destroy the system or parts of it or to
reduce its function.
Warning
Warns of dangers, which result from inappropriate handling, and which can entail death, bodily harm and/or substantial property damage.
Warning – Hot Surface
Warns of the danger from burns, which result from hot system parts.
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2
Intended Use
Note
The COMTEC® 6000 analyser system is a system for
measuring the oxygen concentration and the concentration
of COe in flue gases. For reasons of safety and the possible occurrence of accidents, unauthorized conversions and
modifications of the system are prohibited.
Warning
CO is very dangerous for human, as it is highly toxic, but
invisible and without odour. 1600 ppm (0.16 %) CO in the
air you breathe would lead to death within two hours. It is
absolutely essential to take the greatest care when handling the recommended test gas based on 2.1% O2 and 'X'
ppm CO in N2, where 'X' should correspond to the selected
maximum value of the COe measuring range. When handling the test gas, take special notice of the danger warnings of the test gas manufacturer. In addition, also take
note of the table in chapter 19.1 on page 114, which spells
out the health risks from various CO concentrations.
Warning
The minimum concentration of O2 must amount to at least
1 %. The system may not be used for the determination of
the O2/COe content of gases, whose lower explosion limit
(LEL) can be exceeded. There is danger of explosion,
since the measuring cell temperature of the O2 measuring
cell amounts to 840°C (1544°F).
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3
Hazardous Area ATEX Certified Options
COMTEC® 6000 analyser systems are also currently available in an explosionproof design. Please contact ENOTEC.
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4
Safety Instructions for the Operation of
COMTEC® 6000 Analyser System/Probes
4.1
General Safety Instructions
The COMTEC® 6000 analyser systems may only be operated by authorized
trained skilled persons. For reasons of immunity to interference, it must be ensured that the connection between measuring probe and electronic system is
only made with the special ENOTEC probe cable and pneumatic tubing.
The O2/COe measuring probes supplied by us may only be used with
ENOTEC electronics or with compatible electronics approved by ENOTEC. All
probes are operated at 840°C.
Important
Under no circumstance may the measuring probe be directly connected to the 230V main power, as this will immediately destroy the probe heater element!
4.2
Maximum Ambient Temperature
Important
The maximum ambient temperature for the electronic unit
is 55°C (131°F) and for the probe terminal box 80°C
(176°F). Please ask for other temperatures.
4.3
Corrosion
The probe may only be used in flue gases whose composition is uncritical regarding the corrosive effect on the materials used. With increased risk of corrosion, regular checks at suitably short intervals are necessary.
4.4
Installation
The probe is built into the wall of a flue gas duct. It may protrude into the combustion system up to the probe flange at maximum. Up to the probe flange,
the connection box must remain outside the hot flue gas surroundings. For
high temperature applications, the probe is installed into the outside cold end
of the gas cooling tube.
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4.5
Safety Hazards
During operation, the temperature of the probe filter head
and of all parts exposed to flue gas is 150°C - 840°C
(302°F-1576°F). Direct contact with the hot parts for dismantling or maintenance will cause severe burns! The
probe may only be removed with heat-insulated gloves.
Before removing the probe, always switch off the supply
voltage of the electronic system. After removal, store the
probe in save, protected place and wait until it has cooled
downs below 35°C (95°F).
Warning
CO is very dangerous to human, as it is highly toxic, but
invisible and without odour. 1600 ppm (0.16 %) CO present
in the air you breathe would lead to death within two hours
It is absolutely essential to take the greatest care when
handling the recommended test gas based on 2.1% O2 and
'X' ppm CO in N2, where 'X' should correspond to the selected maximum value of the COe measuring range. When
handling the test gas, take special notice of the danger
warnings of the test gas manufacturer. In addition, also
take note of the table in chapter 19.1 on page 114, which
spells out the health risks from various CO concentrations.
Warning
The minimum concentration of O2 must amount to at least
1 %. The system may not be used for the determination of
the O2/COe content of gases, whose lower explosion limit
(LEL) can be exceeded. There is danger of explosion,
since the measuring cell temperature of the O2 measuring
cell amounts to 840°C (1544°F).
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5
General System Description
5.1
COMTEC® 6000 Measuring Principles
The COMTEC® 6000 measures the net concentration of oxygen and COe
(combustibles) in the flue gas of combustion processes.
5.1.1
Measuring Principle of the ZrO2 Sensor for O2
Measurement
The source voltage Uq (in former times called EMK for “electrical motive
force”) produced by a temperature-stabilised zirconium cell indicates the
amount of oxygen concentration. Measurement is made direct and InSitu, i.e.
the measuring cell is inside the flue gas duct at the end of a probe in the middle third of the gas stream.
The measuring cell consists of a small zirconium-oxide disc about the size of a
penny, which is coated with porous layers of platinum on both sides and soldered with a gas-tight seal into the end of a steel tube cell holder. The temperature of the measuring cell is stabilised by a built-in heater whose
temperature is kept constant by a temperature controller. At a constant temperature the mV-output of the cell is calculated as follows:
Uq =
RT
 P1 
• ln
 + C[ mV ]
4F
 P2 
Where:
P1 =
P2 =
R=
F=
T=
C[mv] =
Uq =
Oxygen partial pressure of the reference gas on the inside of the cell
(e.g. Ref. air)
Oxygen partial pressure of the process gas on the outside of the cell
(Flue gas - O2)
Gas constant
Faraday’s constant
Absolute temperature = (273 + t °C)
Cell constant – millivolt
Source voltage
The reference gas (Instrument Air) is clean, dry and oil-free air (20.95% by
volume O2).
When different oxygen concentrations occur between measuring and reference side of the electrochemical cell, there is a migration of oxygen ions from
the higher to the lower partial pressure side. The mV output signal of the cell is
inversely logarithmically proportional to the oxygen content of the process gas.
With reducing oxygen content in the process gas the mV signal of the measuring cell increases. With air on the process gas side, the ZrO2-cell generates
approx. 0 mV ± 5 mV (cell constant) and with 2.1% O2 approx. + 50 mV (slope
of the characteristic line or decade voltage).
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The water content, existing in any flue gas, and which has an influence on the
actual O2 concentration, is taken into account in this wet measuring process.
The wet process provides a lower measuring value compared to the dry process, because it refers to the total volume. The difference between both values
is in direct proportion to the water content in the flue gas.
5.1.2
Measuring Principle of the Ga2O3 Sensor for COe
Measurement
This kind of semiconductor gas sensor is operated at high temperatures
approx. 710-730°C. Ga2O3 sensors show faster response and recovery times
and lower cross sensitivity to humidity than other sensors.
Additionally, Ga2O3 based sensors show stable long-term sensor properties
and good reproducibility even in flue gases containing sulphur found in fuel oil
burners. Additionally, no pre-ageing is necessary.
In general, the change in resistance of Ga2O3 gas sensor when exposed to different atmospheres is due to a charge carrier exchange of adsorbed gas with
the oxide surface. While the material is exposed to oxygen-containing atmospheres, negatively charged oxygen ions are adsorbed on the semiconductor
surface. Acting as an acceptor, this leads to a depletion region near the surface. The change of resistance is a consequence of the change of free charge
carrier concentration in the depletion region.
The Ga2O3 sensor measures not only CO but also all other combustibles. The
volume of these combustibles is indicated in relation to the value of CO.
Therefore the sensor measures Total Combustibles referred to as COequivalent.
Example:
CO + O → CO2
CH4 + 4O → CO2 + 2 H2O
COMTEC® 6000 measures 1 COe
COMTEC® 6000 measures 4 COe
This means if the flue gas has an actual concentration of 200ppm CH4 (methane), the COMTEC® 6000 analysing system indicates 800ppm COe (4 times
more!).
COe is the short cut for COequivalent.
In the result it does not matter if there are molecules of CO or of any other
combustible (equivalent) gases, important is the volume of lacking oxygen
molecules.
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6
Design of the COMTEC® 6000 Analyser
System
Every COMTEC® 6000 analyser system consists of the measuring probe,
which detects the oxygen partial pressure and the COe content direct in the
flue gas duct, the electrical connection cable, the pneumatic connection cable
and the electronics. The following paragraphs explain the individual components in detail.
®
®
Figure 1 Design of the COMTEC 6000 analyser system with COMTEC O2 /COe probe
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®
Figure 2 Design of the COMTEC analyser system with probe cooling protection tube
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7
Description of the COMTEC® 6000 System
Components
7.1
Design and Function of the Measuring
Probe KES 600x
The probe assembly consists of the connecting box (ASK-...), the inner probe
assembly part (SIK-...) with heater, thermocouple and signal wire, the measuring probe tube (MSR-...) with test gas line, the ZrO2 measuring cell, the COe
sensor, the filter head and the protection tube (optional). Refer to drawing on
page 108.
The connecting box contains the electrical connectors for the measuring cells,
the thermocouple, the probe heater, the solenoid valve and additionally the
pneumatic connector for the reference air.
The probe tube with flange is itself the negative pole and serves as protection
for the positive measuring line and the reference gas line to the reference side
of the measuring cell.
The filter head has a gas deflector plate referred to as v-shield.
The O2 measuring cell itself consists of several layers: platinum, zirconium oxide and platinum with the platinum being applied porously. The measuring cell
with its 4-hole connection flange and gasket seal can be field replaceable by
the customer as required. The COe sensor with its Ga2O3 measuring cell can
be field exchanged as well.
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Figure 3 O2/COe measuring probe KES600x
The test gas or flue gas flows through to the filter and fills the flue gas side of
the filter head. On the probe internal side, reference gas (clean, dry and oilfree instrument air (20.95 percent by volume O2)) continuously flows through
the inner part of the probe to the measuring cell. Because of the two different
gases on each side of the measuring cell, a logarithmic mV output occurs
(high O2-value in the test gas = low voltage (e.g. 21% ≈ 0 mV); low O2-value in
the test gas = high voltage (e.g. 2.1% ≈ 50 mV)). By means of the electronics,
this voltage (mV) is converted into a current 4-20 mA (or 0-20 mA) with a
maximum load of 500 Ohm. The current output is then a direct relationship
with the measured Oxygen value and available as an electrically isolated output signal from the terminals (see Figure 11 on page 34 and also Figure 12 on
page 35).
The temperature of 840°C required for the O2 measuring cell is generated by a
heater element installed inside the probe. To keep the temperature constant, it
is measured by a Type-K (Ni-Cr-Ni) thermocouple and the heater voltage is
controlled by the SME 5 electronic that is equipped with a built-in temperature
reference point to compensate ambient temperature variations (Cold Junction
Compensation).
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The COe sensor is placed under the filter head assembly near the O2-sensor
as well. The dust free flue gas is measured by up to 710-730 °C heated
Ga2O3-cell for COe content at the same time. The Ga2O3 resistance change
due to changes in the COe content of the flue gas and the SME 5 electronic in
a 4-20mA isolated linear output signal converts this resistance change.
7.2
Special Probe Cable
Note
Between the probe and the electronic, the ENOTEC special cable for the O2/CO sensor (FEP-0007 or FEP-0008
(armoured))* is to be used. These contain the conductors
for the heater power, measuring signals, thermocouple,
ground/earth and compensation wire. This cable must not
be longer than 50m (160ft). Other cable length must be
technically approved with ENOTEC in advance.
All ENOTEC special cable must be treated as a measuring signal line.
Important
The shielding of the special probe cable FEP-0007 / FEP0008 must be connected one-end only at the electronic
housing with the earth/ground wire (PE clamp). In no case
the shield of the special probe cable may be connected at
the probe.
All cables have PUR insulation and can be used in ambient temperatures up
to 90°C.
Important
Please do not run the probe cable near power supply cables, or near motors and their cables, as frequency converters control them, because this could cause interference
could also cause interference effects. However, if this is
unavoidable please make sure that these cables are only
crossed at right angles.
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Figure 4 Special cable FEP-0007
7.3
Special Pneumatic Cable
ENOTEC offers a pneumatic cable with 2 tubes for the reference air supply to
the probe (30 l/h continuously) and the test gas supply (150 l/h - 180 l/h) for
the calibration of the O2 and the COe sensor with test gases.
If the pneumatic unit does not use instrument air, but reference air and test air
pumps, the pneumatic cable must not be longer than 50 m (160ft). If larger
lengths are required, an additional external pump must installed upstream, to
ensure a test air flow of min. 150 l/h even under worst conditions.
All cables have PUR insulation and can be used in ambient temperatures up
to 90°C.
7.4
As a standard, the electronics is supplied for a wall mounting housing, with the
pneumatic system built in.
Two different pneumatic systems are available:
An instrument air version requiring the supply of clean, dry, oil-free instrument air at the point of installation.
A pump version using the surrounding ambient air for reference air and test
air.
To recognize the type of pneumatic version please look at the valve for adjusting test air. (For details see page 89).
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Note
To ensure the full functional range of the electronics, one
of the above pneumatic units is required.
The housing has bottom entry electrical cable glands, and compression fittings
for 6 mm or ¼” tubing, as specified, for the pneumatic lines.
Optionally, the electronic unit SME 5 is also available in a 19” rack, in a
weather-resistant glass fibre reinforced plastic housing or in EExd housing for
hazardous areas.
With the EExd housing, the pneumatic unit is mounted in a separate sheet
steel field housing that does not require certification since it only contains the
pneumatic components.
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8
Installation of the COMTEC® 6000 Analyser
System
Note
Only qualified and authorized staff should work with this
instrument. This staff must be familiar with all warnings,
safety instructions and maintenance work in accordance
with these operation instructions. The fault free and safe
operation of this equipment requires proper transportation,
professional storage, set up and installation as well as
careful operation and maintenance.
8.1
Checking the Location for the Probe
Installation at the Flue Duct Wall
Flue gas temperature, pressure and all other process conditions must be in
accordance with the specification. Leave enough space for insertion/removal
of the probe and protection tube (if supplied) and ensure access to the measuring probe and/or connecting box.
Before cutting the hole in the flue gas duct, make sure that the inside of the
duct has enough space for probe installation, and that no soot is blown out
nearby, or any obstacles are in the way.
For probe lengths exceeding 2000 mm, a support must be mounted inside the
duct (every 2 m) to prevent the probe and mounting tube from flexing or bending.
8.2
Installing the Probe
Note
The fastest possible response time is obtained with horizontal installation. We recommend installing the probe in
principle horizontally.
The dimensions for the hole in the flue gas duct and the mounting of the
adapter plate (mounting flange) are shown in the dimensional sheet, page
107. The mounting flange is fitted by the customer and when mounting, ensures an airtight seal.
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Figure 5 Mounting dimensions of the O2/COe measuring probe KES600x
Note
If a cooling protection tube is in use the part of the protection tube projecting from the duct wall must be insulated or
heated, if necessary, to prevent its temperature from dropping below the dew point.
Electrical heaters are available from ENOTEC as accessories. The bolts of the
probe flange must remain accessible.
Figure 6 Mounting dimensions of the O2/COe measuring probe KES6001 with gas cooling tube
The special cables for pneumatic and electronic systems must be left long
enough (coiled up) so that the probe can be removed from the protection tube
without disconnecting it.
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Important
The ground (earth) connection must be installed thoroughly
using the correct cable of at least 1,5mm² minimum. It is
very important that the equipotential bonding is installed
correctly.
Please do not run the probe cable near power supply cables, or near motors and their cables, as frequency converters control them because this could cause interference
Important
The shielding of the special probe cable FEP-0007/FEP0008 must be connected one-end only at the electronic
housing with the ground wire (PE clamp). In no case the
shield of the special probe cable may be connected at the
probe.
8.3
Adjusting the Filter Head
Note
Before installing the probe, the direction of flue gas flow
must be determined and the filter head assembly turned in
such a position, so that the flue gas flow hits the Vdeflector. The filter head can be freely turned a full 360° for
this purpose, by loosening the holding screws and lock
nuts on the filter head, rotating the filter head/V-shield to
the required position, and then tightening both holding
screws and lock nuts.
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Figure 7 Adjusting the filter head
8.4
Electrical and Pneumatic Connections at the
Probe Terminal Box
The special ENOTEC probe cable (FEP-0007 or FEP-0008 (armoured)) and
the pneumatic tubing (FEP-0002) must be connected in accordance with
Figure 1 on page 20 and Figure 8 on page 31. Both cables have PUR sheathing and are designed for a maximum permissible ambient temperature of
+90°C.
Note
All special probe signal cables must be treated as measuring lines. Do not connect the shield of the probe cable at
the probe.
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Figure 8 Probe terminal box
Figure 9 Instruction, how to connect the wires with the terminal board
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8.5
Installing the SME5 Electronic Unit for
COMTEC® 6000
8.5.1
Requirements on the System Surroundings
Note
When installing the electronic unit, please ensure sufficient
air circulation around the electronics housing.
The permissible ambient temperature range for the standard steel box field
housing with instrument air is –20°C to +55°C, and for the unit with built-in reference air and calibration gas pumps -20° to +50°. For the 19” rack mounting
version, the permissible ambient temperature is 0°C to +60°C.
The location of the electronics unit must be chosen so that it is easily accessible ensuring that the door can be fully opened after installation.
The place should be largely weather-protected to enable inspection even under the worst weather conditions.
8.5.2
Requirements on the Connecting Lines
For connection of the supply voltages, it is necessary to use cable of min.
1,5mm².
Before putting the system into operation, it is essential that all electrical connections, supply voltage and pneumatic connections are checked and, if applicable, the instrument air pressure and quality, too.
Special care must be taken not to mix up the connections for test gas and reference air.
Important
The shielding of the special probe cable FEP-0007/FEP0008 must be connected only at the electronic housing with
the ground wire (PE clamp). In no case should the shield of
the special probe cable be connected at the probe.
The enclosed ferrite sleeves must be put over the leads of
the stripped cable (see chapter 8.10 on page 37). CEconformity is invalid if these ferrite sleeves are not fitted!
The ground (earth) connection must be installed thoroughly
using the correct cable size of at least 1,5mm² minimum. It
is very important that the equipotent bonding is installed
correctly.
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Important
Please do not run the probe cable near power supply cables, or near motors and their cables, as frequency converters control them, because this could cause interference
®
Figure 10 Housing versions of the COMTEC 6000 electronic
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8.6
Terminal Connections for Electronic
COMTEC® 6000 SME5 in the 19” Housing
X1
1
2
3
4
5
6
7
8
9
1
0
1
1
1
2
1
3
1
4
X2
Probe solenoid valve L
Probe solenoid valve N
PE
Probe heater L (black)
Probe heater N (blue)
PE
O2 Cellvoltage + (brown)
O2 Cell voltage –
(white/brown)
Thermocouple + (green)
Thermocouple – (white)
O2 output 0/4...20mA +
O2 output 0/4...20mA -
1
X3
1
Maintenance
2
3
2
3
System fault
4
5
4
5
Measure range
6
7
6
7
Limit 1
8
9
1
0
1
1
1
2
1
3
1
4
COe-Sensor measure cell (white)
COe-Sensor measure cell (white)
COe-Sensor heat (red)
COe-Sensor heat (red)
COe Output 4...20mA +
COe Output 4...20mA -
8
9
Limit 2
Dig. Input calibration release 12..24V+
Dig. Input calibration release 12...24VDig. Input measure range switch
12...24V+
Dig. Input measure range switch
12...24V-
1
0
1
1
1
2
1
3
1
4
Figure 11 Terminal connections 19`` housing, back view
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8.7
Wiring and Terminal Connection Diagram of
COMTEC® 6000 (Field Housing)
®
Figure 12 Wiring and terminal connection diagram of COMTEC 6000
Important
The shielding of the special probe cable FEP-0007/FEP0008 must be connected at one end only - in the electronic
housing - with the ground wire (PE clamp). In no case
should the shield of the special probe cable be connected
at the probe.
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8.8
Terminal Connector of the COMTEC® 6000
Electronic Main Board (Field Housing)
®
Figure 13 Terminal connections COMTEC 6000
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8.9
Attention! Important change of colour code
electric cable FEP-0007
Important
The colour codes of the compensation wires for the thermocouple have changed from the old German standard:
(+) red and (-) green to the European standard DIN / IEC
584:
(+) green
Thermocouple (Type K)
(-) white
The result is that there are two white wires in our special cable FEP-0007. Do
not mix up the two white wires. For differentiation one of the white wires is
marked with a brown line, this wire belongs to the ZrO2 oxygen measuring cell.
Example: (+) brown (mV ZrO2 cell signal)
(-) white with brown line (mV ZrO2 cell signal)
Polarity of thermocouple
+
-
DIN IEC 584
green
white
DIN 43710 (old
German)
red
green
ANSI MC 96.1
(US)
yellow
red
Table 1 International colour codes for NiCrNi (Type K) Thermocouple wires
8.10 Fitting the ferrite sleeves (EMC)
Important
Do not connect the cable shield
at the probe.
The enclosed ferrite sleeves
must be put over the leads of the
stripped cable (see Figure 14).
Please use all ferrite sleeves
ENOTEC delivered, because of
their small caliber.
CE-conformity is invalid if these
ferrite sleeves are not fitted!
Figure 14
Ferrite
sleeves
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9
Description of the SME 5 Microprocessor
Electronics
9.1
COMTEC® 6000 is available with a pneumatic system and also as a system
without pneumatics. The standard supply is the electronics in a housing for
wall mounting, with built-in pneumatic system.
Two different pneumatic systems are available:
An instrument-air version requiring the supply of clean, dry, oil-free instrument air at the point of installation
A pump version using the surrounding ambient air

Note
To ensure the full functional range of the electronics, both
versions require a test gas unit with pressure reducer and
flow limiter.
Flow measurement of the test and reference gases is performed electronically
in the SME5 unit, and no manual control or adjustment is required.
The electronics unit has an LED graphic display with back lighting. To operate
the electronics, there are soft keys and a numeric keypad. The entire menu
structure of the electronics is laid out for a simple user-friendly interface.
The bottom of the housing has screw connectors for the cables and pneumatic
lines. Optionally, the SME 5 electronics is also available in a 19” rack or in
EExd housing.
9.2
Functional Description of the
Microprocessor Electronics
The SME 5 electronic unit is designed for connection to one O2/COe measuring probe. The mV signal of the measuring cells are amplified and then converted into a digital signal in the electronics (14 Bit converter). The µprocessor linearises and corrects the signal according to Nernst’s equation of
the O2 measuring cell. The O2 value is then displayed as a percent value and
the mA output has an isolated output, either 0 - 20 mA or 4 - 20 mA keypad
selectable.
The COe measurement is achieved as a resistance measurement of the
heated Ga2O3 cell. The cell temperature is controlled up to 710-730°C. The
sensor resistance output is adjusted for the measuring range from 0 – 2.5 Volt.
The SME 5 microprocessor converts this voltage into a digital signal and displays ppm COe and drives the 4-20 mA output.
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As a standard, the electronics has two O2 measuring ranges and one COe
measuring range. These measuring ranges can be freely defined in their initial
and/or final value (within permissible system-related limits). The second O2
measuring range can be switched on from outside (see chapter 11.5.11
Measuring Range Switching).
To the outside, the second O2 measuring range is signalled by a relay contact.
The electronic is completely self-controlled. Any system errors occurring are
displayed as clear text with an online help function for information.
The COMTEC® user Interface permits intuitive operation by means of a selfexplanatory menu structure. The system is multi-lingual; presently the languages German and English are available. Other languages are available on
request.
Until the COMTEC® probe has reached its operating temperature, the System
Error contact is open and the display shows that the probe is heating up. The
progress of the heating phase is shown by a bar indicating the current probe
temperature. During the heating phase, all system parameters, as well as actual values in the corresponding menus, can be selected on demand from the
keypad.
When the probe has reached its operating temperature and is stable within ±
0.1°C, actual measurements are read, the System Error contact closes and
the standard actual value display appears on the screen. The system is now
ready for O2/COe measurement.
In the following chapters all COMTEC® electronic functions are explained in
detail as well as the menu structure.
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10
Start-up of the COMTEC® 6000 System
Important
Before the COMTEC® 6000 analyser system is powered
on make sure that the conditions comply with the following points:
Does the line voltage correspond with the voltage shown
on the type label of your COMTEC® 6000?
Are all electrical connections made in accordance with the
instructions in this manual?
Is the COMTEC® 6000 probe installed in a flue gas that
corresponds with the probe specification?
Are all pneumatic connections made correctly and gas tight
to prevent the probe from ingress of ambient air?
10.1 COMTEC® 6000 Probe Heating Phase
After switching on the COMTEC® 6000 analyser system, the COMTEC® logo
appears on the display for a short time. During this time, all parameters relevant for a fault-free functioning and start-up are checked automatically.
If during this check any system errors are found, the electronic unit will show
them in clear text. You will find a detailed error and warning description in
chapter 11.6 - Status Messages on page 72.
If the power-on check is finished without any errors the heater window appears as shown in Figure 15. In this heater window the progress of the heating
phase is indicated by a bar in a range of 0°C to 900°C.
®
Figure 15 Display heating phase of COMTEC 6000
When the probe temperature is stable within ± 1.0°C (this should be the case
after approx. 20 to 60 minutes), O2 and COe measurement is released and the
main window appears on the display. If the maximum heating-up time (default
setting: 60 minutes) is exceeded or if such an excess is predictable due to the
heat-up speed, then the heating is turned off and the error message "heating
system don’t work" appears.
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During the heating phase, all actual values can be called up in the corresponding menu window with the soft key [actual]. You can also enter the system
menu and the parameter menu by pressing the corresponding soft keys.
Please note that some functions will not be available in heating phase (e.g.
calibrations).
Note
with these operation instructions.
Note
After switching on the COMTEC® 6000 analysing system,
please wait at least 2 hours before you calibrate the system.
After completion of the heating phase, the main window is been indicated in
the display (see Figure 16).
Note
All process-relevant parameters of the parameter menu
have to be adjusted to the individual process conditions
(see in addition chapters 11.4 on page 47).
Note
Only after both an O2 and a COe single point calibration,
the system is fully operational.
Figure 16 Display during the measuring (main window)
It is however also possible that instead of the COe measured value just underlines are indicated and the respective bar diagram is blank. In this case a COe
single point calibration is necessary. The procedure is described in detail in
chapter 11.5.4 on page 60. After the calibration of the COe sensor the current
COe value is indicated.
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Figure 17 Display of the main widow to show that a COe calibration is necessary
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11
Operating Instructions for the COMTEC® 6000
Electronics
Note
with these operation instructions.
11.1 General operating instructions
The electronics are operated by means of four soft keys and a numeric keypad. The functions of the soft keys always adapt to the current menu window.
The numeric keypad serves only for entering numerical values.
The ENOTEC user interface is designed for intuitive usage of the electronic
unit. This means that as a rule there is no need for the instruction manual during operation.
®
Figure 18 Front panel of the COMTEC 6000 electronic unit
By pressing the soft keys [system], [actual] and [parameter] the respective selection menus can be achieved. In each of this menus various options can be
selected from a list (as shown as an example in Figure 19) with the soft keys
[Ð] and [Ï]. If there are more than 4 options, this is indicated by an arrow on
the right hand side of the menu list. This arrow indicates that there are more
options to follow. The option which can current be selected has a black background and light letters and can be confirmed with the soft key [Enter].
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Figure 19 Display: system menu
11.2 Main Window
In the main window (Figure 20) the currently measured oxygen value and COe
value is displayed. A bar graph shows current value relating to the measuring
range of the output signals.
Figure 20 Display: main window
This main window branches into four menus:
Menu
Status resp.
MR1/2
System
Actual
Parameter
Description
If the Measuring Range Switching is set to “local” and there is no
error or alarm, the measuring range can be selected with this key.
In this case the soft key is marked with "MR1/2". In the case of an
error or alarm this soft key is labelled with "status" and with this soft
key the errors and/or alarms can be called up.
Calls up the system menu, in which you have access to calibration
functions, system settings, system tests etc. For a detailed description see chapter 11.5 on page 52.
Displays all actual values of the system. For a detailed description
see chapter 11.3 on page 45.
Calls the parameter menu, in which several parameters are shown.
These parameters can also be altered. For a detailed description
see chapter 11.4 on page 47.
Table 2 Branching of the main window
After the replacement of the COe sensor or the electronics unit an adjustment
of the parameter values (see test certificate) and a calibration of the COe sensor are required. Depending on the software it is also possible that during the
operation just underlines, instead of a COe value - are indicated and the respective bar graph is blank. In this case the COe sensor is to be calibrated as
well. The procedure is described in detail in chapter 11.5.4 on page 60.
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Figure 21 Display of the main widow to show that a COe calibration is necessary
11.3 Actual Value Menu
Figure 22 Display: actual value menu
In the actual value menu the following current actual values of the electronics
unit can be called up:
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Parameter
O2 Cell Voltage
Unit
mV
Comment
Measured cell voltage of the O2 zirconium oxide cell
Measured cell temperature of the O2 zirconium oxide
O2 Cell Temperature
°C
cell
Calculated O2 value current output dependent on the
O2 range. The O2 range is set and can be changed in
O2 Current Output
mA
the parameter menu (for details see chapter 11.4 on
page 47)
At moisture of > 0% this is the corrected value (for
Oxygen dry
vol % details see chapter 11.4.3 on page 50). This value is
also displayed in the main window.
This is the measured and calculated O2 value based
Oxygen wet
vol %
on the cell voltage.
Lambda is calculated by an approximate equation
Lambda
and is only valid by fuel free of own CO2 or N2 content.
Cold junction temperature of the thermocouple eleCold Junction Tempera°C
ment
ture
Only available on systems with integrated pneumatic
unit. This value shows the measured flow rate of the
Flow Rate Reference
l/h
Gas
reference gas (20.95% O2) used for the zirconium
oxide cell
COe measuring value
ppm Measured COe value
Calculated COe value current output dependent on
the COe range.
The COe range is set and can be changed in the
COe current output
mA
parameter menu (for details see chapter 11.4 on
page 47)
This is the measured resistance value of the COe
COe sensor resistance Ω
sensor in dependence to the temperature
This is the measured resistance value of the COe
COe heater resistance Ω
heater in dependence to the temperature
COe heater power
mW This is the heater power of the COe sensor
COe beta
Calibration constant (just for information)
Table 3 Actual value menu
If instead of a value only underscores are shown, this means that presently no
valid value for this parameter is available.
11.3.1
Lambda
The air ratio factor Lambda describes the relationship of air flow supplied effectively before the combustion to the theoretically amount of air which is necessary for a complete burn. A Lambda value of 1 means the exact relationship
of gaseous fuel and air, needed for a complete combustion, and this mixture is
designated as stoichiometric gas air mixture. With complete combustion of the
fuel also the supplied oxygen is completely used in this stoichiometric point. In
practice this value cannot be attained. Which Lambda value is considered
here as acceptable, depends on respective application.
The value for Lambda (air relationship) is determined by the electronics according to an approximate equation and replaces under no circumstances
one, e.g. in the control room calculated value, which presupposes still further
measured values.
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λ≈
21
21 − O2
Approximate equation for Lambda
As a matter of course this approximate equation is not valid for an understoichiometric combustion. It applies thus only to a combustion with excess
air.
11.4 Parameter Menu
Figure 23 Display: parameter menu
In the parameter menu, the system parameters as shown in Figure 23 can be
displayed and altered.
After having selected a parameter for the first time with the soft key [Enter], a
window appears requesting the entry of a code. If the maintenance code was
not yet changed after the installation, then one confirms the inquiry through
[Enter] without any input of numbers. To change the system code see chapter
11.5.12 on page 71.
After having entered the valid service code, there appears a window where the
corresponding value can be altered.
Note
The system code is factory-set to 0000
Following parameter can be altered in the parameter menu:
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Parameter
Unit
Input-limits
Comment
O2 constant
mV
-50mV up to 10mV
O2 cell constant
Note: a successful O2 single point or two point
calibration will overwrite this zirconium oxide cell
constant.
O2 slope
mV /dec +35mV up to +55mV
O2 cell slope
Note: a successful O2 two point calibration will
overwrite this zirconium oxide cell slope.
O2 test gas
%
O2 concentration of the test gas
0% up to 99%
O2 measuring range
%
1 from
Start value of the O2 measuring range 1
0% to setting of value of “measur(see chapter 11.4.1 on page 49)
ing range 1 to”
Default setting: 0.00%
O2 measuring range
%
1 to
setting of value of “measuring
range 1 from” to 99%
O2 measuring range
%
2 from
within measuring range 1 and not Start value of the O2 measuring range 2
above than “measuring range 2 to” Default setting: 0.00%
O2 measuring range
%
2 to
within measuring range 1 and not
End value of the O2 measuring range 2
below than “measuring range 2
from”
End value of the O2 measuring range 1
O2 limit 1
%
0% up to 99%, min or max
Limit value 1 for O2 min (alarm is set when the O2
concentration falls below the limit value) or max
(alarm is set when the O2 concentration rises above
the limit value) alarm (see chapter 11.4.2 on page
49)
O2 limit 2
%
0% up to 99%, min or max
Limit value 2 for O2 min (alarm is set when the O2
concentration falls below the limit value) or max
(alarm is set when the O2 concentration rises above
the limit value) alarm
O2 correction
%
0% up to 99.9% moisture
Moisture content in the process gas for the calculation of O2 value which would be measured in dried
process gas.
Default setting: 00.0% (no calculation)
(see chapter 11.4.3 on page 50)
COe offset
Ω
090000 up to 500000
COe sensor resistance for 0ppm COe; results from
the calibration with test air and has to be entered
with start up/exchange of the sensor according to
the test certificate.
COe span
Ω
000000 up to 200000
Difference of the COe sensor resistance with 0 ppm
COe and the resistance of the COe sensor at a
measuring with test gas. The value results from a
two point calibration
COe test gas
ppm
100 up to 20000
CO concentration of the test gas
COe measuring
range
ppm
100 up to 20000
Measuring range of COe
Default setting: 1000 ppm
COe correction
%
00.0 % up to 99.9 % moisture
Moisture content of the process gas
COe testgas
%
00.0 % up to 99.9 % moisture
Moisture content of the test gas
(see chapter 11.4.4 on page 50)
COe O2 damp T90
sec
000 - 600
Damping factor; Charging time of the O2 correction
factor for the COe sensor. Please change this value
only after instruction of ENOTEC.
Default setting: 30 seconds
COe calibration time sec
0300 - 1800
Duration of the COe single point calibration or each
single point of the two point calibration
Default setting: 600 seconds
COe alpha
4.00000 - 6.00000
O2 correction factor (can be seen on the test certificate and must be entered here after changing of the
COe sensor)
COe gamma
0.00001 - 9.99999
sensor specific correction factor (can be seen on the
test certificate and must be entered here after
changing of the COe sensor)
Table 4 Parameter menu
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11.4.1
Change of the Parameter O2 Measuring Ranges
The electronics possesses two freely adjustable O2 measuring ranges. The
measuring ranges of electronics can be determined freely. For example one
changes the “O2 Measuring Range 1” as follows:
To reach the menu option "O2 Measuring Range 1" one presses the downward arrow in the parameter menu until the point "O2 measuring range 1 from"
is reached. Then the point is accessed with [Enter], and the maintenance code
has to be inputted and confirmed.
In the menu option "O2 measuring range from" the initial value of the measuring range can be indicated now.
Note
It is to be noted that the initial value of the measuring range
cannot be larger than the final value. Likewise the final
value cannot be selected smaller than the initial value.
Otherwise the electronics does not permit the entered values.
The same rule obtains for the second measuring range,
which has to be within the first measuring range additionally. Therefore, the electronics will not accept such settings, too.
After the input of the initial value this value will be confirmed with [Enter] and
the final value of the measuring range can be keyed in the menu option "O2
measuring range to". As soon as this value is also confirmed through [Enter],
the electronics updates with the new measuring range.
11.4.2
Altering of a Parameter by the Example of a
Limit Value
In this chapter the altering of a parameter will be explained the example of
value “O2 limit 1”. For this purpose the downward arrow in the parameter
menu is to be pressed repeatedly until the point "O2 limit 1" is reached. Then
the point is to be called up with [Enter], and the maintenance code has to be
inputted and confirmed.
Figure 24 Display: parameter input (example)
In the window “Parameter Input”, the parameter to be altered is displayed in
clear text with the current value. If special functions are assigned to this parameter (as like “min/max” as in this example), these are displayed, too.
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Further, the permissible entry limits of this parameter are indicated (as like as
in this example “00.0; 99.0”).
With the numeric keypad, the value can be altered. To correct, the cursor can
be moved back with the [←] key. The sign can be selected independently of
the cursor position with the [±] key.
In this example, the secondary parameter “min/max” can be changed by the
corresponding soft keys.
Note
If a value cannot be entered, it should be checked whether
this value is outside the permitted limits, because in such a
case, the entry of the value is not permitted, but the corresponding limit value is selected.
The altered value has to be confirmed with the soft key [Enter].
Note
When pressing the soft key [Back], the altered value is
cancelled and the old value maintained.
11.4.3
O2 Correction
The design principle of the COMTEC® 6000 oxygen cell measures the wet
oxygen value. In the menu item „O2 correction“, the H2O content of the process gas can be entered. Then the electronic calculates the oxygen value of
the dry process gas (“Oxygen dry”). This value is indicated in the main window.
11.4.4
Moisture Content of Test Gas
Also the moisture content of the test gas is of importance for the COe measurement. The test gas is moistened at the filter at the test gas entry, (see
chapters 14.4 on page 90). As long as a condensation in this filter is visible, it
is to be assumed that the test gas is saturated with H2O. The amount of Vol,%
H2O that the test gas is saturated, depends on the ambient temperature of the
filter. The appropriate values can be inferred from the following table:
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Temperature
in °C
Temperature
in °F
Absolute moisture content at
saturation in Vol.%
0,0
32,0
0,06
2,5
36,5
0,7
5,0
41,0
0,9
7,5
45,5
1,0
10,0
50,0
1,2
12,5
54,5
1,4
15,0
59,0
1,7
16,0
60,8
1,8
17,0
62,6
1,9
18,0
64,4
2,0
19,0
66,2
2,2
20,0
68,0
2,3
21,0
69,8
2,4
22,0
71,6
2,6
23,0
73,4
2,8
24,0
75,2
2,9
25,0
77,0
3,1
26,0
78,8
3,3
27,0
80,6
3,5
28,0
82,4
3,7
29,0
84,2
3,9
30,0
86,0
4,2
31,0
87,8
4,4
32,0
89,6
4,7
33,0
91,4
5,0
34,0
93,2
5,2
35,0
95,0
5,5
36,0
96,8
5,9
37,0
98,6
6,2
38,0
100,4
6,5
39,0
102,2
6,9
40,0
104,0
7,3
41,0
105,8
7,7
42,0
107,6
8,1
43,0
109,4
8,5
44,0
111,2
9,0
45,0
113,0
9,5
46,0
114,8
10,0
47,0
116,6
10,5
48,0
118,4
11,0
49,0
120,2
11,6
50,0
122,0
12,2
52,5
126,5
13,8
55,0
131,0
15,6
57,5
135,5
17,5
60,0
140,0
19,7
62,5
144,5
22,2
65,0
149,0
24,8
67,5
153,5
27,8
70,0
158,0
31,0
Table 5 Moisture content at saturation
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11.5 System Menu
When selecting the system menu with the corresponding soft key, first a code
enquiry appears, where the system code (factory-set to 0000) must be entered and confirmed with [ENTER].
Figure 25 Display: code input
Note
The system code is factory-set to 0000.
After entering the system code, the system selection menu appears (Figure
26).
Figure 26 Display: system menu
In this menu, the following functions can be selected:
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Menu Point
System Test with test gas
System Test with test air
O2 Automatic Calibration
O2 Measured Value Memory
Setting of current output O2
Measured Range Switching
Change Code
Damping of mA Output
Change Language
Service
Description / Remarks
Performs an O2 single point calibration with test air
Performs an O2 two point calibration with test air and test
gas
Performs a COe single point calibration with test air
Performs a COe two point calibration with test air and test
gas
Performs a measuring verification with test gas
Performs a measuring verification with test air
Calls up the menu for the automatic calibration of the O2
measurement. NOTE: An automatic calibration is only
possible if the system has an integrated pneumatic unit.
"Freezes" the last measured value for O2 while calibration
Changes between 0-20mA and 4-20mA output
Sets the operation mode to either "local" or "remote"
Changes the code for the system menu and the parameter menu
Allows to alteration (change) to the damping time of the
mA output for O2
Change language to either "English" or "German"
Calls up the service menu
Shows the software version of the COMTEC® 6000 firmware
Software
Table 6 System menu
A description of the individual functions is given below.
11.5.1
First Steps for Calibration
Before you begin with the calibration, please make sure that the pneumatic
connections are correct (for details see chapter 18 page 109).
The calibration starts from the O2/COe value display (main window).
Note
If the COMTEC® 6000 probe has only just heated up,
please wait at least 2 hours before you go through the next
steps.
Figure 27 Display: main window
Press the soft key [System] to start the System Menu.
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Before you enter the system menu, you are asked to put in the system code
first.
Figure 28 Display: code input
Normally you have only to confirm the factory default code by pressing the soft
key [Enter]. This works only, if the system code has not been changed. Otherwise put in the 4-digit system code using the keypad on the right side of the
display panel, and then press the soft key [Enter].
You enter the system menu. Press the soft key [Ð] several times until the
menu entry of the calibration, which is wanted to, is selected. Confirm with
[Enter].
Figure 29 Display: menu entries for calibration
11.5.2
Please take account to chapter 11.5.1 First Steps for Calibration on page 53,
where it is explained how to get to this calibration point.
Note
If the electronic is connected to a probe without solenoid
valve, the test air valve must be opened first before calibration.
In this menu item, a single point calibration with air can be done. After selecting this menu item, you are requested to begin the calibration with the soft key
[start].
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Figure 30 Request to start the calibration
The single point calibration takes place fully automatically; a manual interference is not necessary.
The horizontal bar of the following indication shows the current value of the
flow rate of test air. If the gas flow corresponds to the requirements, then this
display appears only for a very short time and the calibration starts automatically.
Figure 31 Display: O2 single point calibration, flow rate (appears only if needed)
If this is not the case and the bar ends not on the height of the point marked
by an arrow, please adjust the flow rate accordingly. You have some minutes
to do this before an error message appears. If an error message is shown,
then it must be confirmed and the calibration has to be restarted after setting
the correct flow rate.
If no error message appeared, the single point calibration works fully automatically and starts immediately after pressing the [Start] button (if the flow
rate corresponds with the requirements right from the start) or as soon as the
flow rate is adjusted correctly (if the flow rate had to be adjusted). The progress of the calibration process is represented by a time controlled bar and
takes approx. 2 minutes (see Figure 32).
Figure 32 Display: O2 single point calibration
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During calibration, the cell voltage is checked for stability. This check works
according to the following criteria: The last measured value is always temporarily saved. When the next value is outside the tolerance (±0.5mV), the internal timer is reset and the new value temporarily saved. This means that if the
timer was not reset, the value is stable. In this way, the last measured value
after the timer has lapsed (2 min.) is used to calculate the cell constant or
slope. The moving time bar indicates the internal timer: if the internal timer is
reset also the time bar is also reset.
When the calibration is completed, the display shows a message, which demands an acknowledgement by [ok]. In the case of a successful calibration,
the message will be “Cal. successfully Completed” (see Figure 33); otherwise
it will be “Cell Constant out of Tolerance”. In the latter case the new determined calibration values are not accepted, and the system continues to work
with the old values.
The amount of test air is monitored by the electronics; if it is insufficient, an error message appears (only with integrated pneumatic unit).
Figure 33 Advice for a successfully calibration
During calibration, it is possible to accept the value of the cell voltage with
[Accept] and to calculate the calibration parameters in advance. It should
however be noted that the advance acceptance of the cell voltage is not recommended, because in such case the electronic system does not know if the
output is stable, and therefore the calibration may not be correct.
Note
valve, the test air valve must be closed after finishing the
calibration.
11.5.3
Please take account to chapter 11.5.1 First Steps for Calibration page 53,
In this menu item, a two point calibration with air and with a suitable test gas
concentration can be performed. It should be noted that the concentration of
the test gas must correspond to the value shown in the parameter menu.
Please make also sure that the test gas bottle is connected to the COMTEC®
6000 electronic unit through entry “test gas in” before starting the calibration.
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Note
Note
The value of the test gas used must be set in the parameter menu (see also chapter 11.4 on page 47).
After selecting this menu item, you are requested to begin the calibration with
the soft key [start].
Figure 34 Display: Request to start calibration
The first part of the calibration now takes place fully automatically; a manual
intervention is not necessary.
The quantity of the test gas is supervised by electronics. With insufficient flow
rate the following display appears which indicates the current flow of ambient
air (test air). If the gas flow corresponds to the requirements, then this display
appears only for a very short time and the calibration begins automatically.
Figure 35 Display: O2 two point calibration, first point, adjustment of the flow rate (appears only if needed)
The horizontal bar shows the actual amount of the flow rate. Please make
sure that this bar ends at the point marked by an arrow, otherwise adjust the
flow rate. You have some minutes to do this before an error message appears. If an error message is shown, then it must be confirmed and the calibration has to be restarted after setting up the correct flow rate.
The two point calibration works fully automatically in two steps and starts immediately after pressing the [start] button (if the flow rate corresponds with the
requirements right from the start) or as soon as the flow rate is adjusted correctly (if the flow rate had to be adjusted). The progress of the calibration
process is represented by a time controlled bar and takes approx. 2 minutes
(see Figure 36) for each part of calibration.
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Figure 36 Display: O2 two point calibration, First point
The time-controlled bar is set to zero whenever the input signal of the sensor
is not stable.
The second part of the O2 two point calibration is accomplished with test gas
2. The test gas bottle must be connected to the test gas entry of the electronics housing. After completion of the first part of the calibration an internal solenoid valve switches from test air to test gas and the calibration starts
automatically.
The quantity of test gas is supervised by the electronics. With insufficient flow
rate the following display appears which indicates the current flow of test gas
by a horizontal bar. Please make sure that this bar ends at the point marked
by an arrow, otherwise adjust the flow rate.
Figure 37 Display: O2 two point calibration, second point, adjustment of the flow rate (appears only if
needed)
The second point of the two point calibration works fully automatically also and
starts immediately after the completion of the first point (if the flow rate corresponds with the requirements right from the start) or as soon as the flow rate
is adjusted correctly (if the flow rate had to be adjusted). The progress of the
second calibration process is also represented by a time controlled bar and
takes approx. 2 minutes (see Figure 38).
Figure 38 Display: O2 two point calibration, Second point
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The time-controlled bar is set to the start point whenever the input signal of the
sensor is unstable. If the amount of test gas seems insufficient during calibration, the message “Test gas flow insufficient” appears (only systems with integrated pneumatic unit).
During calibration, the cell voltage is checked for stability. This check works
according to the following criteria. The last measured value is always temporarily saved. When the next value is outside the tolerance (±0.5mV), the internal timer is reset and the new value temporarily saved. This means that if the
timer was not reset, the value is stable. In this way, the last measured value
after the timer has lapsed (2 min.) is used to calculate the cell constant or
slope. The moving time bar indicates the internal timer, if the internal timer is
reset the time bar is also reset.
During the two point calibration, the cell voltage can be accepted in advance
with [accept], but it should be noted that for the two point calibration two cell
voltage values are required. It may therefore occur that after the manual acceptance of a value, the calibration progress bar is reduced to half. This is not
an error, but means that the electronics are now determining the second
value, which can be accepted manually as well.
It should, however, be noted that an advance acceptance of the cell voltage is
not recommended, because in this case the electronic system does not know
if the output is stable and may therefore the result of calibration can be incorrect.
When the calibration is completed the display shows a message, which demands an acknowledgement by pushing [OK]. In the case of a successful calibration, the message will be “Cal. successfully completed”, otherwise it may
be “Cell Constant out of Tolerance” and/or “Slope out of Tolerance”.
Figure 39 Advice for a successfully calibration
If the parameters determined after calibration are outside the plausibility limits,
this is indicated by an error message. In case of errors during calibration, the
electronics will continue to work with the old parameters.
Note
valve, the test air valve must be closed after finishing the
calibration.
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11.5.4
Please take account to chapter 11.5.1 First Steps for Calibration page 53
Note
If the COMTEC® 6000 probe is only just heated up, please
wait at least 2 hours before you go through the next steps.
11.5.4.1 Requirements
Following steps must be checked before the COe sensor can be tested and
calibrated:
1. In the test gas path between the “test gas out” of your COMTEC® 6000
electronic unit housing and the test gas input of the COMTEC® 6000
O2/COe probe (directly at the electronics housing) you will find a filter.
(For details see chapter 18 page 109). Please make sure that the filter
(ENOTEC part no. RLF-0001) in the test gas path is moisturised. THIS
IS VERY IMPORTANT FOR THE ACCURACY OF THE TEST! You
may find a detailed description for the humidification of the filter in
chapters 14.4 on page 90 and as package insert provided to the filter.
2. If you have a probe without solenoid valve please make sure that the
probe valve is also open.
Note
11.5.4.2 Execution of a COe Single Point Calibration
As with the O2 single point calibration, the COe single point calibration has to
be made with air. After selecting this menu item you are shown the following
display:
Figure 40 Request to moisturize the test gas
You will find a detailed description for the moisturizing of the filter in chapter
14.4 on page 90.
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Note
An insufficient humidification of the moisturisation filter results in an incorrect calibration and thus wrong measured
values.
If the test gas is sufficient moistened, please confirm this reminder with [ok].
After which you are requested, to begin the calibration with pressing the soft
key [start].
Figure 41 Requirement to start calibration
The quantity of test air is supervised by the electronics. With insufficient flow
air (test air) (only with the version with integrated pneumatic unit).
Figure 42 Display: Adjustment of flow rate (appears only if needed)
The horizontally bar shows the actual amount of the flow rate. Please make
sure that this bar ends at the point marked by an arrow, otherwise adjust the
flow rate.
The single point calibration works fully automatically and starts immediately after pressing the [start] button (if the flow rate corresponds with the requirements right from the start) or as soon as the flow rate is adjusted correctly (if
the flow rate had to be adjusted). The progress of the calibration process is
represented by a time controlled bar (see Figure 43). The standard calibration
time is 600 seconds and can be seen and changed in the parameter menu.
Figure 43 Display: COe single point calibration
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During the calibration the COe heater resistance is adjusted by means of the
COe sensor resistance (COe Offset). The COe Offset resistance (registered in
the Parameter Menu) is used as reference value.
At the start of the calibration sequence the COe heater resistance is constantly
monitored to ensure that the variance from the Parameter value does not exceed a tolerance of +/- 0.1Ω during the calibration procedure. If the resistance
tolerance is exceeded, the calibration restarts. If a drift of the COe heater resistance during the calibration is determined at expiration of the calibration, then
the timing bar jumps back a short part (1 minute) and the drift condition is examined again. If a stable COe heater resistance is not found after a period of 1
hour, the calibration is aborted and an error message is displayed.
Unlike the Oxygen sensor calibration, a manual keypad acceptance of the COe
heater resistance value is not possible.
The completion of the calibration process is indicated by the ‘On Screen’
message - “Cal. successfully Completed”. This message must be
acknowledged by pressing the Softkey [ok] (see Figure 44).
Figure 44 Completion notice of the single point COe calibration
Note
11.5.5
Please take account to chapter 11.5.1 First Steps for Calibration page 53
Note
If the COMTEC® 6000 probe is only just heated up, please
wait at least 2 hours before you go through the next steps.
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11.5.5.1 Requirements
Following steps must be checked before the COe sensor can be tested and
calibrated:
electronics unit housing and the test gas input of the COMTEC® 6000
IS VERY IMPORTANT FOR THE ACCURACY OF THE TEST! (You
2. Please make also sure that the test gas bottle is connected to the
COMTEC® 6000 electronic unit on entry “test gas in”. We recommend
test gas based on 2.1% O2 and 'X' ppm CO in N2, where 'X' should correspond to the selected maximum value of the COe measuring range.
Otherwise please contact ENOTEC. When handling the test gas,
take special notice of the danger warnings of the test gas manufacturer. In addition, also take note of the table in chapter 19.1 on page
114, which spells out the health risks from various CO concentrations.
The remaining test gas volume must only have the component N2.
IMPORTANT: The minimum requirement of the test gas is at least a
concentration of 1% O2.
3. Please check that the valve of the test gas bottle is open.
Warning
CO is very dangerous to humans, as it is highly toxic, but
in the air you breathe will lead to death within two hours It
is absolutely essential to take the greatest care when handling the recommended test gas based on 2.1% O2 and 'X'
11.5.5.2 Execution of COe Two Point Calibration
In this menu item, a two-point calibration with air (20.95 % O2 und 0 ppm COe)
= test gas 1 and with a suitable test gas concentration (test gas bottle) = test
gas 2 can be performed. It should be noted that the concentration (ppm CO) of
the test gas must correspond to the value shown in the parameter menu.
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ENOTEC recommends test gas based on 2.1% O2 and 'X' ppm CO in N2,
where 'X' should correspond to the selected maximum value of the COe
measuring range. (When handling the test gas, take special notice of the danger warnings of the test gas manufacturer. In addition, also take note of the
table in chapter 19.1 on page 114, which spells out the health risks from various CO concentrations.) The test gas bottle must be connected to the test gas
entry of the electronics unit housing before the start of the calibration, since an
internal single solenoid valve switches automatically from test air to test gas
after completion of the first part of the calibration.
After selecting this menu item you are requested the following display appears:
14.4 on page 90.
Note
An insufficient humidification of the moisturisation filter will
result in an incorrect calibration and thus wrong measured
values.
If the test gas is sufficient moistened, please confirm this reminder with [ok].
Thereupon you are requested, to begin the calibration with pressing the soft
key [start] (see Figure 46).
Figure 46 Display: Request to start the calibration
The quantity of test air is supervised by the electronics. With insufficient flow
air (test air) by a horizontal bar (only with the version with integrated pneumatic unit).
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Please make sure that this bar ends at the point marked by an arrow, otherwise adjust the flow rate.
The two point calibration works fully automatically and starts immediately after
pressing the [start] button (if the flow rate corresponds with the requirements
right from the start) or as soon as the flow rate is adjusted correctly (if the flow
rate had to be adjusted). The operating mode of the first point of the COe two
point calibration corresponds to the COe single point calibration (see chapter
11.5.4.2 on page 60).
Figure 48 Display: COe two point calibration - calibration with test air
The second part of the COe two point calibration is accomplished with test gas
2. The test gas bottle must be connected to the test gas entry of the electronics housing. After completion of the first part of the calibration an internal solenoid valve switches from test air to test gas.
Also in this step the quantity of test gas is supervised by the electronics. With
insufficient flow rate the following display appears which indicates the current
flow of test gas by a horizontal bar (only with the version with integrated
pneumatic unit). Please make sure that this bar ends at the point marked by
an arrow, otherwise adjust the flow rate.
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The second point of the two point calibration also works fully automatically and
starts immediately after the completion of the first point (if the flow rate corresponds with the requirements right from the start) or as soon as the flow rate
is adjusted correctly (if the flow rate had to be adjusted). The progress of the
second calibration process is also represented by a time controlled bar and
takes - if the default value in the parameter menu has not been changed likewise 600 seconds (see Figure 50).
Figure 50 Display: COe two point calibration - calibration test air
The time-controlled bar now starts half a way and is set back to the start point
whenever the input signal of the sensor is unstable. If the amount of test gas
seems insufficient during calibration, the message “Test Gas Flow Insufficient”
appears.
A difference from the O2 sensor calibrations is that it is only possible to accept
the calibration value of the second step of calibration before expiration of the
calibration time.
For this it is to be marked that the manual acceptance of the sensor resistance
is not recommendable, because the compliance of stability condition is not
guaranteed and thus the calibration is possibly not correct, which can lead to a
wrong measured value.
After successful conclusion of calibration the following message appears:
Figure 51 Completion notice of the two point calibration
For the acceptance of the values this message must be confirmed by [ok].
Note
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11.5.6
System Test with Test Gas
In this menu option a system test with test gas can be accomplished. The test
gas has to connect at the test gas entry on the electronic unit.
The following steps must be checked before the System Test with Test Gas
can be started:
3. Before carrying out System Test it should be checked in the Parameter
Menu that the entered values (test gas O2 and test gas CO) agree with
the actual test gas concentrations. If this should not be the case, the
entered values in the Parameter Menu must be changed.
Warning
CO is very dangerous to human, as it is highly toxic, but
in the air you breathe will lead to death within two hours. It
is absolutely essential to take the greatest care when handling the recommended test gas based on 2.1% O2 and 'X'
After selecting this menu item you are requested the following display appears:
You find a detailed description for the moisturizing of the filter in chapter 14.4
on page 90.
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Note
result in an incorrect system test.
If the test gas is sufficiently moistened, please accept this reminder with [ok].
Following which you are requested, to begin the system test by pressing the
soft key [start].
Please control the COe/O2 values in the COMTEC® 6000 display.
Figure 53 Display: system test with test gas
Furthermore, this menu permits adjustment of the correct test gas flow rate
required for two point calibrations. For which the bar for the indication of the
test gas flow rate must end between the two vertical arrows.
Note
If the electronics is not connected to a probe with solenoid
valve, the test gas valve must be opened first before system test and closed after finishing.
11.5.7
System Test with Test Air
In this menu option a System Test with test air can be accomplished. This
serves primarily the verification of the measured values.
Following steps must be checked before the System Test with Test Air can be
started:
After selecting this menu item the following display appears:
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Figure 54 Request to moisturize the test air
14.4 on page 90.
Note
result in an incorrect System Test.
If the test gas is sufficiently moistened, please accept this reminder with [ok].
After which you are requested, to begin the system test by pressing the soft
key [start]. Whereupon the following display appears:
Figure 55 Display: system test with test air
Please control the COe/O2 values in the COMTEC® 6000 display.
Note
If the electronics is not connected to a probe with solenoid
valve, the test gas valve must be opened first before system test and closed after it.
With the soft key [set COeH] the set value of the heater resistance can be
overwritten. The optimal heater resistance results however from the calibration
and should only be manually overwritten after consultation with ENOTEC.
11.5.8
Automatic Calibration (ACAL) of the Oxygen
Measurement with Air (20.95% O2)
COMTEC® 6000 offers the possibility of automatically performing a calibration
at regular intervals.
All settings that are required for an automatic calibration can be made in this
menu.
These are:
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Type of calibration Single Point/Two Point
In this point, the type of calibration can be selected. (Only in systems with
integrated pneumatic)
Automatic calibration On/Off
As a standard, ACAL is off. In this item, ACAL can be activated.
Calibration every xx days (e.g. 90 days)
Indication of the calibration cycle time in days. At a value of 0 days the calibration starts immediately upon release, this is important for a calibration
from the outside.
Release internal/external
If External is selected, a calibration is made only when the digital input
Calibration release has a “high” signal and the cycle time has elapsed. (See
Chapter 12.5 on page 76)
Internal means that independently of the release input status, calibration
will be made when the cycle time has elapsed. If the cycle time has
elapsed, but no release has been given, calibration starts immediately upon
release.
Remaining time xx days
The remaining time until the next calibration is indicated under this item.
Note
For automatic calibration it is essential to connect a probe
with solenoid valve and to ensure that the test gas “air” is
always available and under pressure (instrument air version) or a pneumatic unit with pumps must be installed (for
details see chapter 18 on page 109).
If the test gas flow should be to low, you have 20 seconds time to adjust the
correct flow rate. Otherwise the calibration is stopped and an error message is
indicated, and the main window appears again.
Important
If the calibration time interval in the parameter menu is set
to zero seconds – for example to make a remote calibration – it is very important that the release signal has a
maximum time of 60 seconds. A release signal of more
then 60 seconds could restart the calibration again and
again.
NOTE: There is no "real time" clock in the electronics. It does not know time
of day, month or year. Only a clock counter in electronically used for automatic
calibration purposes.
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11.5.9
Measuring Value Memory for the O2 Analyser
Under this menu item a measuring value memory can be switched on during
calibration. With the measuring value memory on, the last measured value before calibration is saved so that at the current output the measuring value,
which changes because of the calibration, has no effect. The currently measured value is released again after an adjustable delay, when the calibration is
completed.
11.5.10 Setting Current Output O2
Here, the initial value of the current output of the measured O2 value can be
selected with the keys [Ï] and [Ð] (0mA or 4mA).
11.5.11 Measuring Range Switching
The electronics has two measuring ranges. The switching mode of the ranges
can be made manually from the instrument keypad, or by an external remote
12-24 voltage input signal. This microprocessor parameter location is used to
determine which mode of range switching is required - local or remote.
The factory preset default in the electronics is "remote" range switching. This
means that in the case of an open digital input, the measuring range 1 is active. At the modus "local“, the measuring range can be changed in the main
menu with the soft key MR1/2 by hand.
Note
In case of errors and alarms, the soft key MR1/2 in the
main menu is occupied by status information. The status
function has the highest priority, therefore this means in
case of errors the measuring range cannot be changed
manually (by hand).
11.5.12 Change Code
In this menu item, the system code can be changed.
11.5.13 Damping of O2 mA Output
The mA-output can be damped if required. There are optional settings from 0
sec. (without damping) to a maximum of 55 sec. are available.
Damping is useful if the electronics Oxygen output signal is spiky or rough due
to sudden process condition changes. A smooth or damped output can be obtained with the attenuation setting feature.
11.5.14 Change Language
In this menu item the language can be selected.
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11.5.15 Service
This menu item is reserved for ENOTEC service personnel only. It is factorycoded.
11.5.16 Software
This menu item provides information about the software status and the level.
11.6 Status Messages / Error Messages
Figure 56 Display: error messages
If errors or alarms occur during operation, these are displayed as clear text in
the status menu. All errors and alarms must be acknowledged and/or cleared
with the [Enter]-key in this menu display.
A help function for the status messages is available in this menu.
Note
If the electronics is put into operation without a probe connected, some system errors will occur. E.g. heating system
does not work, error cell signal out of range, error wire
breakage thermo element. When the electronics is then
connected to a probe, these errors will be shown again,
because the microprocessor stores the errors as they occur in a permanent memory (EEPROM). After acknowledgement of each of these errors, the system operates
normally.
Following status messages are possible:
1.
cell constant out of tolerance
As the result of a calibration check, the calculated cell constant is
outside of the tolerance range parameters on the microprocessor
settings. Therefore the electronics continues with the previous/former cell constant values. The microprocessor tolerance
range is factory set to: -50mV to +10mV.
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2.
slope out of tolerance
As the result of a calibration check, the calculated mV/Decade
slope is outside of the tolerance range. The electronics therefore
continues with the previous/former slope values. The microprocessor range is factory set to: 35mV to 55mV per decade.
3.
ref.gas flow to low (only with installed pneumatic unit)
The reference gas flow is too low (min. 5 litre-per-hour) Please test
the pressure of the instrument air supply (min. 1 bar) and if necessary, tries to adjust the reference air (see page 77). With the pump
version test the pneumatic tubes for kinks for blockages. If the problem is due to the pump itself, it is possible to change the pump.
Please contact ENOTEC in this instance.
4.
cal. gas flow to low (only at installed pneumatic unit)
The calibration gas flow during the calibration test was too low (min
150 litre-per-hour). Please see point 3 above.
5.
heating system does not work
The probe could not heat to the nominal temperature (840°C). Test
the heater fuses (see page 88), then measure the resistance of the
probe-heater to ensure that it is between 37.5 and 40.0 Ohms.
Warning
Make sure that the power is switched off when doing
this test!
6.
wire breakage thermo element
The electronic unit has detected an error with the thermocouple.
Possible reasons: reverse connection of thermocouple - check wire
connections, wire breakage, faulty thermocouple.
7.
error cell signal out of range
The cell voltage detected by the electronic is out of the input
range (-45mV to +265mV) Possible reasons: wire breakage, extra large amount of combustibles products in the measured flue gas (CO, etc.) or the mechanical breakage cell.
8.
temp. of electronic out of spec
The temperature of the electronic is outside the allowed operating
limits (-20°C to +70°C within its housing)
9.
probe temperature to high
The indicated temperature of the probe is over 890°C. Please test
the temperature of the flue gas (maximum 890°C, without cooling
tube) Please contact ENOTEC.
10.
probe temperature to low
The temperature of the probe was or is too low (<820°C) Please
look at the heater fuse and measure the actual power supply voltage to the electronics unit (230V/115V ±10%).
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11.
alarm limit 1
Oxygen limit 1 out of range.
12.
alarm limit 2
Oxygen limit 2 out of range.
13.
data fault EPROM
A data error has occurred in the microprocessor and the electronics continues with factory default values. Please contact ENOTEC.
14.
measuring value memory active
The measuring value memory is still active.
15.
error by trying ACAL
Automatic Calibration has failed. Possible reasons: mV output
value/signal from probe not stable, cell constant or mV/Dec slope
outside of microprocessor tolerance/range. (Note: the corresponding error is shown on the electronics display), no calibration air (instrument air version only)
16.
COe calibration span to low
COe single-point or COe two-point calibration has failed. Possible
reasons: The calibration time was too short to check the stability of
the calibration value. The calibration was interrupted.
17.
wire breakage COe sensor
The electronic unit has detected an error with the COe sensor Possible reasons: reverse connection - check wire connections, wire
breakage.
18.
wire breakage COe heater
The electronic unit has detected an error with the heater of the COe
sensor. Possible reasons: reverse connection - check wire connections, wire breakage.
19.
short cut COe heater
acknowledge the alarm, in case of recurrence: check the wire,
change sensor
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12
System Description / Adjustments
12.1 In Case of Loss the System Code
In case of loss of the system code, it is possible to reset the code to factory
standard (0000).Therefore, contact to ENOTEC is required.
12.2 Bridge on Back of Display Unit
Important
On the rear of the display board, you will find a closed
jumper connection, which is used only for the first run in
the factory. Do not move or remove this jumper, otherwise
a fault function of the electronic is possible. In this case
contact to ENOTEC is required.
Postion bridge
for working
Figure 57 Back of display unit
12.3 Adjustment Display Contrast
The contrast of the display can be adjusted if necessary. This could be necessary at higher ambient temperatures. The trimming potentiometer is shown on
Figure 58. To adjust the contrast it is necessary to dismount the display board
and power on the system. Now the contrast can be adjust by a small screwdriver (type 2.5).
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Warning
Working under power is only allowed for authorized,
trained skilled persons in keeping to the corresponding
safety instructions (e.g. VDE 0105).
trimming
potentiometer
Adjust contrast
Figure 58 Adjustment display contrast
12.4 Relay Outputs / Functions
The relay contacts are designed for 24V and 1A ~, 1A = (except the relay contacts for the probe valve which is designed for 230V / 1A ~).
Relay
System error
Service
Contact
break contact
make contact
Measuring
range
Probe valve
Limit value 1
Limit value 2
make contact
make contact
break contact
break contact
Function
Signals operation-critical errors
Service code was entered, system is in service
mode
Open: Measuring range 1 active
Closed: Measuring range 2 active
Triggering of the probe valve
Signals a violation of limit value 1
Signals a violation of limit value 2
Table 7 Relay outputs and functions
12.5 Digital Inputs
The digital inputs are designed for a direct voltage of 12 V - 30 V for logical
high. Logical “Low” agrees a voltage less than 1 V.
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Digital input
Calibration release
Measuring range shift
Function
External release for calibration, with ACAL
Switching on the second measuring range
Table 8 Digital inputs and functions
12.6 Amounts of Test Air and Reference Air
As a rule, the systems are factory-set to the correct amounts of test air and/or
reference air.
The instrument air versions are designed for a supply pressure of 1-10 bar.
With a higher supply pressure - say 6 bar - it is necessary to readjust the
amount of reference air and/or test air. (See Chapter 14.3)
The amount of air should be in the following range:
Test air:
Reference air:
150 l/h - 180 l/h
30 l/h - 40 l/h
The amount of reference air can be checked in the actual value menu.
12.7 Stability Criteria for O2 Calibration
During calibration, the cell voltage or rather the zero offsets are checked for
stability. This check works according to the following criteria.
Always the last measured value is always temporarily saved. When the next
value is outside the tolerance, the internal timer is reset and the new value
temporarily saved. This means that if the timer was not reset, the value is stable. In this way, the last measured value after the timer has lapsed (2 min.) is
used to calculate the constant or slope.
12.8 Stability Criteria for COe Calibration
12.8.1
COe Single Point Calibration and COe Two Point
Calibration, First Point
During the calibration the COe heater resistance is adjusted by means of the
COe sensor resistance (COe Offset). The COe Offset resistance (registered in
the Parameter Menu) is used as reference value.
At the start of the calibration sequence the COe heater resistance is constantly
monitored to ensure that the variance from the Parameter value does not exceed a tolerance of +/- 0.1Ω during the calibration procedure. If the resistance
tolerance is exceeded, the calibration restarts. If a drift of the COe heater resistance during the calibration is determined at expiration of the calibration, then
the timing bar jumps back a short part (1 minute) and the drift condition is examined again. If a stable COe heater resistance is not found after a period of 1
hour, the calibration is aborted and an error message is displayed.
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Unlike the Oxygen sensor calibration, a manual keypad acceptance of the COe
heater resistance value is not possible.
12.8.2
COe Two Point Calibration, Second Point
At the start of the Second Point Calibration Procedure, the COe sensor resistance is constantly monitored to ensure that the variance from the Parameter
value does not exceed a tolerance of +/- 5kΩ during the calibration procedure.
If the sensor resistance tolerance is exceeded second calibration point restarts
automatically. The new COe sensor resistance is now the basis for rechecking
for a stable sensor resistance reading within the set tolerance. The default
value of the duration of this calibration procedure is 600 seconds, and can be
changed in the Parameter menu.
If a stable COe sensor resistance is not found after a period of 1 hour, the calibration is aborted and an error message is displayed
12.9 Reaction Time of the mA Output
The reaction time of the mA output to a change of the O2 cell input voltage is
less than 200 ms.
12.10 Extension Modules
As an option, the electronic unit is available with a RS 232 Interface Module.
12.10.1 RS 232 Interface (option)
Via the RS232 (V24) interface cyclically (approx. every 400ms) operational
data are sent.
12.10.1.1 Global Description
The bidirectional OXITEC®/COMTEC® serial interface protocol is used for
value requests, parameters settings and function executions.
The transmission is frame-oriented; it means that each transmission block is
framed by defined control characters. Within the frame only readable characters (ASCII) are allowed. The length of each transmission block is dependant
upon the function and also its assigned data.
The serial communication protocol has no address attribute, therefore it is not
possible to use it for a multi-slave communication bus.
Within each transmission frame there are only ASCII characters allowed but
no control characters. Therefore digits and values are transmitted as text.
Memory dumps are transmitted as HEX character strings.
A CRC8 checksum secures each transmission frame and is placed at the end
of each transmission block as a HEX character string.
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12.10.1.2 Description of the Transmission Block (Frame)
In principle the structures of the transmission blocks of a master request (e.g.
PC) and of a slave answer (e.g. OXITEC or COMTEC) are identical. Additionally the answers of the slave have a leading ACK control character to identify
a successful transmission. The slave transmits a NAK control character on
any transmission faults or unsupported functions.
Each transmission block is framed by the control character STX and ETX.
12.10.1.2.1 Definition of the Control Characters
The control characters are transmitted as 8 bit values and they are defined as
follows:
Control Character
STX
ETX
ACK
NAK
Value (decimal)
2
3
6
21
Value (hexadecimal)
0x02
0x03
0x06
0x15
Table 9 Definition of control characters
12.10.1.2.2 Master Request Î Slave
Any request is defined as follows:
<STX><C><NN><UUUU><F><D....D><HH><ETX>
Definition
Description
<STX>
STX control character
Count of Characters
1
<C>
Operation Mode:
’1’ read operation
’2’ write operation
’3’ execute operation
1
<NN>
Function Number (see also the following chapters)
’00’ to ‘99’
2
<UUUU>
Dimension (Unit) In Clear Text, e.g.:
’ %’
’ mV’
’ mA’
’ °C’
...
4
<F>
Format Character
’A’ ASCII (not used yet)
’F’ floating point, single precision
’D’ floating point, double precision (not used yet)
’I’ 16Bit INTEGER, signed
’U’ 16Bit INTEGER, unsigned
’L’ 32Bit INTEGER, signed
’N’ 32Bit INTEGER, unsigned
1
<D..D>
Values as hex character string (memory dump) or as plain
text (for format ‚A’ only)
0...22
<HH>
CRC8 checksum, hexadecimal character string
e.g. ‚3B’ or ‚04’
2
<ETX>
ETX control character
1
Table 10 Explanation of control characters
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12.10.1.2.3 Answer Slave Î Master
12.10.1.2.3.1 Positive Answer (ACK)
Positive answers will be transmitted to the master if the request block could be
interpreted correctly, and also executed.
The answer transmission block is sent with a leading ACK control character.
<ACK><STX><C><NN><UUUU><F><D....D><HH><ETX>
The description of the transmission format definition is described in Table 10
on page 79.
12.10.1.2.3.2 Negative Answer (NAK)
Negative answers will be sent back to the master, if:
•
•
•
•
•
•
•
more than 32 characters were transmitted by the master within the
STX and ETX control characters
the STX control character is missing
the checksum is not correct
the operation mode is not defined (in general or not for the desired
function, e.g. a write access to a read-only value)
less than required characters were transmitted
invalid characters have been detected within the transmission block
the function number is not supported
12.10.1.2.4 Timing
tA
tD
answer time, min. 0ms, max. 1000ms
delay time to the next request after an answer, min. 0ms
12.10.1.2.5 Checksum Calculation
12.10.1.2.5.1 Specification
The checksum is defined as CRC8 with its polynomial
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C (x ) = x 8 + x 2 + x + 1
The CRC8 calculation includes all characters within the STX and ETX control
character except the two CRC8 checksum characters itself.
12.10.1.2.5.2 C Example
unsigned char stxetx_getcrc8(void *src, int count)
{
unsigned
crc= 0x00;
int
i;
while(count--) {
crc^= *((unsigned char*)src);
((unsigned char*)(src))++;
for(i= 0; i<8; i++) {
if(crc & BIT(7)) {
crc<<= 1;
crc^= 0x07;
} else crc<<= 1;
}
}
return((unsigned char)crc);
}
12.10.1.3 Operation Modes
12.10.1.3.1 Read Operation
The read operation opcode is 1.
The read operation transmission block consists of at least 5 characters:
Request:
Answer :
<STX>1<NN><HH><ETX>
<ACK><STX>1<NN><UUUU><F><D....D><HH><ETX>
12.10.1.3.1.2 Example
Request for an oxygen value:
Request:
Answer :
<STX>100E3<ETX>
<ACK><STX>100
%F9A99A741C8<ETX>
The function returns a floating point (single precision) memory dump which is
interpreted as 20.95% O2.
12.10.1.3.2 Write Operation
The write operation opcode is 2.
The write operation transmission block consists of a format dependent block
length.
Request:
<STX>2<NN><UUUU><F><D....D><HH><ETX>
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Answer:
<ACK><STX>2<NN><UUUU><F><D....D><HH><ETX>
The format characters (<UUUU>) can be set blank on request. The format
character must have the correct function-dependent format. A format character which is not supported by the desired function will be acknowledged by a
NAK control character.
The data which must be transferred are defined as HEX character string of the
memory dump.
12.10.1.3.2.2 Value Limitation
Each data can be limited by a function-dependent minimum and maximum
value. If the value exceeds this limits it will be automatically set to its depended limitation value. In this case the answer contains the new limited
value.
12.10.1.3.2.3 Example
The following example shows how the O2 cell constant can be written. The set
value of 50.00mV exceeds the maximum value of 10.00mV; therefore it is limited to a value of 10.00mV.
Request:
Answer:
<STX>210
F00004842F8<ETX>
<ACK><STX>210mVF000020411A<ETX>
The set value of 50.00mV is limited to 10.00mV, therefor the limited value is
returned.
12.10.1.3.3 Execute Operation
The execute operation opcode is 3.
The execute transmission block consists of at least 5 characters:
Request:
Answer:
<STX>3<NN><HH><ETX>
<ACK><STX>3<NN>
U<DDDD><HH><ETX>
The answer contains the execution status which is defined as follows:
0000
0001
FFFF
normal execution, process running
previous execution process is still running
not supported
12.10.1.3.3.2 Example
The following example executes a single point calibration. The execution
status is directly returned.
Request:
Answer:
<STX>3201F<ETX>
<ACK><STX>320
U0000E3<ETX>
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In this case the execution progress must be requested by a read operation of
the calibration status variable, function number 05.
12.10.1.4 Device Dependent Functions
12.10.1.4.1 Specification
Because of supporting different devices, there are some functions which were
only implemented in COMTEC® and OXITEC® respectively.
If a function is not supported by the device, the return value is always 0. Also
the unit definitions contain only space characters. The device type can be requested by function no. 26.
12.10.1.4.2 Example
The following request asks for the COe value on an OXITEC® system. The
COe value is not supported by OXITEC®.
Request:
Answer:
<STX>106F1<ETX>
<ACK><STX>106
F0000000048<ETX>
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12.10.1.5 Implementation Table
Fn Operation
Description
Format
Dimension (Unit) min
00
read only
oxygen value
F
%
01
read only
O2 cell voltage
F
mV
02
read only
O2 cell termpature
F
°C
03
read only
O2 current output
F
mA
04
read only
status signals
N
05
read only
O2 calibration status
U
0
last calibration successful
1
last calibration fault
2
calibration still active
3
calibration pending
06
read only
COe value
F
ppm
07
read only
COe sensor resistance
F
Ohm
08
read only
COe sensor temperature
F
°C
09
read only
COe heater resistance
F
Ohm
10
read / write
O2 cell constant
F
mV
-50.00
+10.00
11
read / write
O2 cell slope
F
mV
+35.00
+55.00
12
read / write
O2 limit 1
F
%
13
read / write
O2 limit 1 function
N
14
read / write
O2 limit 2
F
15
read / write
O2 limit 2 function
N
16
read / write
O2 lower range
F
17
read / write
O2 upper range
18
read / write
O2 current output average
time
19
read / write
not used
20
execute
single point calibration
U
21
execute
O2 two point calibration
U
22
read
COe current output
F
mA
23
read / write
COe calibration zero offset
F
24
read / write
COe calibration span
25
read / write
26
%
max
+0.00
+21.00
0 (min)
1 (max)
+0.00
+21.00
0 (min)
1 (max)
%
0.00
O2 upper
range
F
%
O2 lower
range
21.00
N
sec
0
55
Ohm
0
999999
F
Ohm
0
999999
COe measuring range
F
ppm
500
10000
read only
device type
0
OXITEC
1
COMTEC
U
27
read only
COe calibration status
U
0
last calibration successful
1
last calibration fault
2
calibration still active
3
calibration pending
28
execute
COe single point calibration
U
29
execute
COe two point calibration
U
Table 11 Description of the function code
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13
Technical Specification
13.1 Technical Specification Electronic Unit
Dimensions:
see dimensional sheets for the different housings
Main voltage:
230 V / 50...60 Hz tolerance
115 V / 50...60 Hz tolerance
Power consumption:
400 VA during start up
100 - 200 VA running
Recommended fuse:
10 A
Ambient temperature:
Version without pneumatic:
-20° C to up +55° C
Version with instrument air:
-20° C up to +55° C
Version with pumps:
-20° C up to +50° C
Version in 19” rack:
0°C up to 60°C
Other temperatures on request
Interference resistance:
Electromagnetic compatibility
(EMC) 89/336/EWG:
EN 50082-2: 1995
EN 55011 KI.B: 1992
EC Low voltage Directive 72/23/EWG:
EN 61010-1: 8 / 2002
Relay outputs, potential-free:
24 V / 1 A
Max. relay output
solenoid valve:
230V ~ 1A
Analog input cell:
±10%
±10%
Re > 9 Meg Ohm
Ue: -45mV to +265mV
for the active measuring range
Resolution of the digitizers in
the active measuring ranges:
14 Bits + sign (O2), 10 Bits (COe)
Analog input thermocouple:
Re: > 900 KOhm
Temperature compensation:
located on the circuit board
Signal output O20/4...20 mA:
max. load 500 Ohm
potential-free:
Current output COe
0/4...20 mA:
max. load 500 Ohm
potential-free
Reaction time of the
mA output:
With a change of 100mV on the cell input <200 ms
Display:
LC, LED-lit 240 x 64 dots graphic display
Measuring accuracy:
Oxygen: ±0.2% of actual measured value
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13.2 Technical Specification Probe
Flue gas temperature:
KES600x:
up to 600°C
up to 1400°C with cooling protection tube
Insertion length:
KES-6001:
KES-6002:
KES-6003:
KES-6004:
KES-6005:
Insertion length
with cooling
protection tube:
470mm
930mm
1850mm
2770mm
3690mm
500/1000mm
Measuring principle:
Zirconium oxide for O2
Gallium oxide for COe
Flue gas pressure:
-50 to +50mbar (-0.725 to +0.725 PSIG)
Flow velocity:
0 to 50m/s
Ambient temperature:
-40°C to +80°C
Response time (lag time):
0,5s (flue gas flowing at > 10m/second)
T90 time:
5s (flue gas flowing at > 10m/second)
Probe material:
V4A (1.4571/316SS) 316L Stainless Steel
Type of protection:
IP65
Voltage supply:
via electronic unit
Dimension:
see types of probes
Probe mounting:
Horizontal – Preferred
Vertical Down – Possible
Important Note: Vertical mounted probes will
generally have slower response time because of
the lower gas exchange dynamic
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14
Service and Maintenance
14.1 Switching between 230 V and 115 V
operation
The working voltage can only be changed after removing the board cover.
Warning
De-energize system first!
The switch for changing the voltage (Figure 59) can be made with a screwdriver and rotating to the voltage required.
selection of
power supply
F3
F1
F2
F4
Figure 59 Switching between 230 V and 115 V operation
Note
It must be noted that the standard pump version of the
COMTEC® 6000 is designed for 50Hz.
For the pump version on 60Hz mains, a special order is
necessary. The mains frequency cannot be changed by the
customer.
The instrument air version is specified for 50-60Hz power
supply.
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14.2 Replacing the Fuses
The electronics has four accessible fuses:
Part
F1
Current
6.3 A
F2
4A
F3
1A
F4
1A
Description
semi time-lag 5x20mm glass tube fuse – to protect the
entire system
probe heater
electronic
electronic
Table 12 Fuses
Important
The fuses on the circuit board below the cover protect the
electronics and should only be replaced by service personnel, because otherwise a damage of the electronics cannot
be excluded.
14.3 Adjusting the Flow Rate of Reference and
Test Air
With a system with a pneumatic unit, it is possible to adjust the reference and
test air.
In this point, the pump and instrumental air versions are different.
In the pump version only the flow rate of test air can be adjusted. (See
Figure 60)
In the instrumental air version both flow rates (test air and reference air)
can be adjusted. (See Figure 61)
The flow rate of reference air can be read in the actual menu (see page 45)
The flow rate of calibration air can be read in the system menu under the
menu point "System Test with test gas" (see page 67).
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Figure 60 Position of valve (pump version)
Figure 61 Position of valves (instrument air version)
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14.4 Humidification of the Gas Moisturisation
Filter
Figure 62 Gas Moisturisation Filter
The filter RLF-0001 is built into the test gas exit of electronics, using a plug-in
connector (0-P-000746). For humidification the filter is to be dismantled at the
plug connector and moistened with the bottle provided (0-U-000173), as
shown in Figure 62. Subsequently, the filter needs to be connected again.
It should be noted, that it has to be pumped not more than the indicated 1-2
times. The intervals of the humidification depend on the frequency of use
through system test and/or calibration. With sufficient humidification a dampness precipitation at the inside of the filter is visible. If such dampness precipitation is not recognisable, a humidification of the filter must be carried out
before the next calibration and/or before the next system test.
14.5 Replacing the Probe Filter
Note
Only ceramic filters / basalt filters can be replaced. Sintered metal filters are welded in place.
a) Loosen both fixing screws at the filter head and pull off the filter head from
the probe.
Probe may be hot!
b) Clamp the filter head into a vice.
c) Remove the old filter completely. Also, clean the grooves in the metal fixing.
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d) Insert new filter with cement as follows:
Mix cement thoroughly and coat both the grooves in the seat and the filter
around the seat at the outside. Press the filter into the seat by turning it.
Wipe the cement between filter and seat and remove excess material inside as well.
Figure 63 Dismantling of filter
Note
The cement dries at room temperature within 24 hours.
Using the cement supplied by ENOTEC, all types of ceramic filters of the ENOTEC product range can be inserted
and fixed.
14.6 Exchange of ZrO2 Measuring Cell
Take the probe out of the protection tube and wait until it has cooled down.
The probe may only be removed with heat-insulated
gloves. Before removing the probe, always switch off the
supply voltage of the electronic system. After removal,
store the probe in a safe, protected place and wait until it
has cooled down below 35°C.
If necessary, clean the probe from dirt and dust etc., after it is cooled down.
Disconnect the wires in the connection head and loose the two screws, which
hold the inner parts of the tube. Pull off the thin transparent reference air pipe
from the wall entrance screwing at the connection cabinet.
Pull out probe internal part (4 hole ceramic rod with signal measuring wire,
thermocouple element and heater) carefully.
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Important
The measuring signal wire may be fixed/fused solid with its
contact net to the inner part of the ZrO2-cell.
Pull off the orange isolation from the measuring signal wire but do not pull out
the signal wire with the probe inner parts, it may be fixed/fused to the internal
cell contact side.
Loosen the four screws at the flange of the measuring cell and remove the
measuring cell from the measuring cell tube (with signal wire, if fixed/fused to
it).
Figure 64 Measuring cell holder tube in cut
Insert a screwdriver or similar tool carefully between the measuring cell holder
tube and the contact net of the measuring signal wire and press the contact
sideways away by turning the screwdriver. Remove the loosened measuring
signal wire. Slide the measuring signal wire back into the 4 hole ceramic rod
and make certain that the round contact net lies in the recess of the heater
support.
Figure 65 Mounting measure cell holder tube
Clean the flange at the probe tube with fine sandpaper. Tighten the new
measuring cell with a new sealing and four new screws at the measuring cell
flange of the probe tube. Insert the probe inner parts and ensure, that the inner parts do not clamp in the probe tube. Press the locking bolt against the
spring, so that the inner parts are pressed against the measuring cell with
enough spring loads.
Version 10.229
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Tighten locking bolt and connect wires as follows:
Terminal
2
3
4
6
7
8
9
10
11
12
13
14
Colour
orange
green
white
black
blue
green/yellow
grey
grey
white
white
red
red
Description
signal wire, oxygen measuring cell
thermocouple element (Type K)
thermocouple element (Type K)
heating element O2
heating element O2
ground/earth
solenoid valve
solenoid valve
COe-sensor measuring value
COe-sensor measuring value
COe-sensor heating element
COe-sensor heating element
Polarity
+
+
-
Unit
mV
mV
mV
Table 13
Polarity of thermocouple
+
-
DIN IEC 584
green
white
DIN 43710 (old
German)
red
green
ANSI MC 96.1 (US)
yellow
red
Table 14 International colour codes for NiCrNi thermocouple wires
In addition, the outside surface of the probe is hot (300°C).
Install the probe and carry out an O2 two point calibration.
Version 10.229
Page 93
Figure 66 Construction of the measure cell holder tube
1. protection cap
2. oxygen cell
3. signal wire pad
4. thermocouple (type K)
5. heater element
6. cell holder tube
7. ceramic rod
8. fixing clamp
9. spacer
10. air connection tube
11. flange gasket
12. measuring probe tube
13. screws M5
14.7 Exchange of Probe Inner Parts
Proceed as described in paragraph 14.6 on page 91 to dismantle the probe
inner part. The exchange of the thermocouple element is an exception, because this can be changed without dismounting the probe inner part as a
whole.
14.7.1
Exchange of Thermocouple Element
The thermocouple element is a covered thermo-couple element with an Inconel-covering and a Ni-Cr-Ni thermocouple.
The thermocouple element is in one hole of the 4-hole-rod. Disconnect the
thermo-couple element at the probe head terminals, pull it out and insert a
new thermocouple element. If the probe is very long, it may be necessary to
pull out the probe inner part completely.
14.7.2
Exchange of Heating Element
Disassemble probe inner part, loosen clamp, pull out signal measuring wire
and pull off heater with support from the 4-hole rod.
Assemble new heater, if necessary with new ceramic support and new 4-hole
ceramic rod.
Insert signal measuring wire and thermocouple element; assemble clamps
and connection sleeves (for long probes).
Version 10.229
Page 94
Important
The heater support has three drillings, which must correspond with three holes of the 4-hole ceramic rod. One hole
is for the reference air, one is for the thermocouple and the
third one is for the signal measuring wire. Make sure that
the grip net lies in the recess of the heating support.
14.7.3
Exchange of Signal Measuring Wire
At the end of the measuring cell, the signal measuring wire has a specially
shaped contact for taking the mV-value of the reference electrode of the ZrO2measuring cell. The contact wire is pressed against the measuring cell by
means of spring load via the 4-hole rod.
If there is not enough spring loads or if the wire is broken, the mV-signal can
no longer be taken, and an error signal will occur.
14.7.4
Exchange of 4-Hole Ceramic Rod
Depending on the length the probe has one or more 4-hole rods. In case of
long probes, you have to ensure during assembling, that the holes fit to another, so that installation can be carried out and the reference air can be lead
to the inner reference airside of the O2-measuring cell.
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14.8 Exchange of the COe Sensor
In addition, at the outside the probe is hot (300°C).
Figure 67 Exchange of the COe sensor
Note
After an exchange of the sensor the values COe Alpha,
COe Gamma and COe Offset must be entered in the parameter menu according to the information on the test certificate, which is delivered with every new sensor. After that
a COe calibration must be made (after a warm up waiting
time of 2 hours).
Version 10.229
Page 96
Figure 68 Retainer ring
Note
Ensure a gas-tight connection using the above assembly.
Version 10.229
Page 97
15
Trouble Shooting
The following information is intended as a key element to assist trouble shooting. It is not a comprehensive list of all possible system errors.
If problems cannot be repaired, please contact the ENOTEC factory, an
ENOTEC subsidiary office or an approved service agent directly:
Manufacturer and Factory
ENOTEC GmbH
Marienheide
Höher Birken 6
D-51709 Marienheide - Rodt
Germany
Phone: +49 (0) 2264 - 4578-0
Fax: +49 (0) 2264 - 4578-31
Email: [email protected]
If the measured O2 value appears doubtful, first check all system parameters.
If all Parameters are correct, check the system with test gas. If the system
works correctly with test gas and there are no leakages in the area of the
probe (flanges, calibration gas connection), then the measurement is correct.
If for instance certain system parameters are wrong, then the measured O2
value cannot be correct. With the following instructions, try to localize or repair
the disorder.
15.1 O2 Display remains at the End of the
Measuring Range or is higher than expected
Steps to localize the problem:
1. All system parameters are correct and the ENOTEC O2 analyser system
shows the correct value with test gas.
Action: Check all flanges and screw connections for tightness.
Result 1: O2 value drops to normal level.
Result 2: O2 value remains high
Cause: Leakages at the measuring probe or at the measuring cell flange seal.
Remedy: Exchange measuring cell or replace measuring cell flange seal. In
case of a leakage in the area of the zirconium oxide measuring cell, this must
be exchanged.
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15.2 O2 Display 0 %, although the Operation
Mode indicates a higher O2 Value
1. Check the measuring cell temperature (set value 840°C general purpose
probe and 800°C for hazardous area probes)
A cell temperature below 600°C may lead to a 0% display.
Result 1: Cell temperature okay, next check.
Result 2: Wrong measuring cell temperature.
Causes:
a) Measuring probe heater defective (resistance must be approx. 35-42 Ohm,
disconnect probe and
check). Note: De-energize probe first.
b) Thermocouple defective (check resistance, approx. 2-80 Ohm)
c) Fuse for heater voltage defective.
d) Transformer (230/115V) defective, check voltages.
e) Triggering for temperature control or electrical load relay defective.
2. Check the mV value of the O2 measuring cell
Result 1:
The mV value is outside the usual range (see characteristic line) e.g. above
267 mV or below - 45 mV.
3. Check the mV value directly on the probe
De-energize electronic system.
Disconnect the probe cable from the probe on terminals 1 + 2 and switch on
the electronic system. After the heating phase measure the cell voltage with a
high-resistance voltmeter on the probe strip terminal.
Result 1:
If on the probe an mV value is measured that according to the characteristic
line and at the right measuring temperature yields a probable O2 value, then
the error is on the way to the electronics.
Possible causes:
a) Cable short circuit
b) Electronics input defective
c) Wire break
Remedies:
a) Check wiring
b) Measure probe cable
Result 2:
On the probe an mV value is measured which is outside the usual range from
-45 mV to 267 mV.
Possible causes:
Version 10.229
Page 99
a) There is no mV tap in the probe (measuring signal wire) or it is interrupted.
b) Combustibles in the flue gas.
c) Measuring cell defective
Remedy: Check whether the probe reacts to test gas. If it does, there may be
a high portion of combustibles in the flue gas. In this case, there are reducing
conditions on the probe cell, which reduce the oxygen content on the cell surface. Caution: Explosion hazard!
If the probe does not react, check the inner part.
15.3 Local Displays correct, Output not correct
1. Check measuring range. Check whether the current value is outside the
measuring range
2. Measure the mA output on the strip terminal.
Result 1: mA value exist, problem is outside the electronics
Result 2: no mA value
Possible causes:
Electronics is defective.
15.4 Unsteady, widely varying Measuring Value
(O2)
1. Check the measuring cell temperature (set value 840°C)
2. Intermittent contact in the probe - internal mV tap.
Action:
Measure the mV value on the terminals on the board.
Result 1: Voltage values jump rapidly like the display
Causes:
a) Intermittent contact caused by wire break.
Remedies:
a) Repair intermittent contact.
Version 10.229
Page 100
15.5 Unsteady, widely varying Measuring Value
(COe), it is not possible to calibrate the COe
Analyser
Causes:
a) The shield/screen of the special probe cable is not connected to a
PE/ground earth clamp at the electronics.
Remedy:
a) The separate shield/screen of the 4 COe wires (black 1-4) must be connected to a PE/ground connection in the electronics.
15.6 No COe Measuring Value; empty Bar
Diagram
Possible reason: The COe Sensor needs a calibration (see chapter 11.5.4 or
chapter 11.5.5 respectively)
15.7 No COe-Measuring Value; black Bar Diagram
Possible reasons:
a) The physical measuring range is exceeded.
b) An error of the COe sensor exists (e.g. wire breakage).
In this case there is also an error message.
15.8 No Measuring Value for O2 and COe, black
COe Bar Diagram
Figure 69 Error O2 and COe Measurement
Possible reasons
a) Breakdown of the O2 measurement
b) O2 value out of the coverage of the electronics, for
example caused by a low O2 concentration in connexion with a high COe concentration.
Version 10.229
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15.9 O2 reads higher than expected, and COe
reads lower than expected
This may be due to a poor seal of the COe sensor coupling located in the terminal box housing. If the nylon nut is not tight enough the O-ring seal will allow
ambient air to enter the COe senor mounting tube and influence the sensors
readings. Tighten or replace the COe sensor coupling assembly.
Version 10.229
Page 102
16
Dimensional Drawings of the Electronics Unit
Figure 70 Field housing IP66
Figure 71 19 inch housing
Version 10.229
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Figure 72 GFK housing (option)
Version 10.229
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Figure 73 EExd housing (option) consisting of 2 EExd housings for the electronic and 1 field housing for the
gas control unit
Version 10.229
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17
Dimensional Drawings of the Probes
Figure 74 Dimension sheet probe KES 600x
Figure 75 Dimension sheet probe KES6001 with cooling protection tube
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Figure 76 Dimension sheet protection tube flanges for KES600X
Figure 77 Adapter plate ADP2000 for flange type A
Version 10.229
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17.1 Probe Components
Figure 78 Probe components with working cycles
Figure 79 Probe inner parts assembly
Version 10.229
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18
Pneumatic Connection and Mounting
Overview
Figure 80 Gas plan pneumatic unit
Version 10.229
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Figure 81 Gas plan test gas and reference gas unit
Version 10.229
Page 110
Parts List
Test gas and reference air unit with two internal
pumps
1
pc DFM-00001
internal flow meter for reference air and test gas SME5
1
pc 0-P-000751
solenoid valve 3/2 ways,
110V/50Hz; G1/8; for SME
5
1
pc 0-P-000757
female elbow fitting G1/8 for
6 mm hose
1
pc 0-P-000755
screw in union G1/8" for 6
mm hose
1
pc 0-P-000658
Miniature filter 9933-05AAQ elimination rate
99,999%
1
pc PLU-0026
Test air pump for SME5
720 l/h 115V/50Hz cable 30
cm
1
pc 0-P-000743
angle fitting 6/6mm LF3000W-STA-6
1
pc PLU-0025
Reference air pump for
SME5 30 l/h, 115V/50Hz
cable 40 cm
5
pc 0-P-000758
plug in connection G1/4 for
6mm hose
5
pc 0-P-000759
fitting G1/4 for 6 mm hose
1
pc 0-P-000763
female elbow fitting M5 for 6
mm hose
Figure 82 Mounting plate 1 1,5 m
0-R-001045
PU-hose 6x4 mm black
(design with pumps)
1
pc 0-P-000777
one-way-restrictor, 6mm, for
6mm hose
Version 10.229
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Parts List
Test gas and reference air unit for instrument air
1
pc DFM-00001
internal flow meter for reference air and test gas SME5
1
pc 0-P-000751
solenoid valve 3/2 ways,
110V/50Hz; G1/8; for SME 5
1
pc 0-P-000757
6 mm hose
1
pc 0-P-000755
screw in union G1/8" for 6
mm hose
4
pc 0-P-000758
plug in connection G1/4 for
6mm hose
4
pc 0-P-000759
fitting G1/4 for 6 mm hose
1
pc 0-P-000753
nut for pressure control
valve
2
pc 0-P-000745
angle screw-in fitting R 1/8"G 1/8"
2
pc 0-P-000760
one-way-restrictor G1/8 for
6mm hose
1
pc 0-P-000757
6 mm hose
1
pc 0-P-000763
female elbow fitting M5 for 6
mm hose
1,5 M 0-R-001045
PU-hose 6x4 mm black
Figure 83 Mounting plate 1
(design with instrument air)
Version 10.229
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Parts List
Mounting plate 2
1 pc 0-A-000155
1 pc 0-L-000047
1 pc 0-L-000080
2 pc 0-P-000658
1 pc 0-X-000351
1 pc 0-X-000353
2 pc 0-X-000352
3 cm 0-X-000355
mounting plate 2
mA output board
power board
miniature filter
micro terminal PE clip
cover for micro terminal
end clip E/MK
mounting rail NS15,
punched
Figure 84 Mounting plate 2
Parts List
Display and microprocessor unit
1
pc 0-L-000073
display and microprocessor
unit
Figure 85 Display and microprocessor unit
Version 10.229
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19
Notes
19.1 Carbon Monoxide CO
CO is very dangerous to humans, as it is highly toxic, but invisible and without
odour. If there is 1600 ppm (0.16 %) CO in the air you breathe, it could to
death within two hours. It is necessary to be very careful when handling the
recommended test gas.
CO concentration in the air Inhalation time and consequences
30 ppm (0.003 %)
Max. allowable concentration on workplace by a
work time of 8 hours
200 ppm
(0.02 %)
Slight headache within 2 or 3 hours
400 ppm
(0.04 %)
Splitting headache within 1 or 2 hours
800 ppm
(0.08 %)
Dizziness, sickness and shaking limbs within 45
minutes, unconsciousness within 2 hours
1600 ppm
(0.16 %)
Headache, sickness, dizziness within 20 minutes,
death within 2 hours
3200 ppm
(0.32 %)
Headache, sickness, dizziness within 5 to 10 minutes, death within 30 minutes
6400 ppm
(0.64 %)
Headache and dizziness within 1 to 2 minutes,
death within 10 to 15 minutes
12800 ppm
(1.28 %)
Death within 1 to 3 minutes
Table 15: Effect of CO in the ambient air to human body
19.1.1
First Aid
CO poisoning begins with sudden tiredness, because of absence of oxygen in
the body. More symptoms are possible like dizziness, sickness and impaired
vision. In this case, act immediately. It is important to cater for fresh air – the
danger area should be vacated immediately. Oxygen therapy should be administered by a qualified first aid or emergency service technician as soon as
possible.
Version 10.229
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20
Table of Figures
Figure 1 Design of the COMTEC® 6000 analyser system with COMTEC® O2 /COe probe ............. 20
Figure 2 Design of the COMTEC® analyser system with probe cooling protection tube................. 21
Figure 3 O2/COe measuring probe KES600x .................................................................................. 23
Figure 4 Special cable FEP-0007 ................................................................................................... 25
Figure 5 Mounting dimensions of the O2/COe measuring probe KES600x ..................................... 28
Figure 6 Mounting dimensions of the O2/COe measuring probe KES6001 with gas cooling
tube ................................................................................................................................. 28
Figure 7 Adjusting the filter head .................................................................................................... 30
Figure 8 Probe terminal box............................................................................................................ 31
Figure 9 Instruction, how to connect the wires with the terminal board .......................................... 31
Figure 10 Housing versions of the COMTEC® 6000 electronic....................................................... 33
Figure 11 Terminal connections 19`` housing, back view............................................................... 34
Figure 12 Wiring and terminal connection diagram of COMTEC® 6000 ......................................... 35
Figure 13 Terminal connections COMTEC®6000 ........................................................................... 36
Figure 14 Ferrite sleeves ................................................................................................................ 37
Figure 15 Display heating phase of COMTEC® 6000 ..................................................................... 40
Figure 16 Display during the measuring (main window) ................................................................. 41
Figure 17 Display of the main widow to show that a COe calibration is necessary......................... 42
Figure 18 Front panel of the COMTEC® 6000 electronic unit ......................................................... 43
Figure 19 Display: system menu..................................................................................................... 44
Figure 20 Display: main window ..................................................................................................... 44
Figure 21 Display of the main widow to show that a COe calibration is necessary......................... 45
Figure 22 Display: actual value menu............................................................................................. 45
Figure 23 Display: parameter menu................................................................................................ 47
Figure 24 Display: parameter input (example)................................................................................ 49
Figure 25 Display: code input ......................................................................................................... 52
Figure 26 Display: system menu..................................................................................................... 52
Figure 27 Display: main window ..................................................................................................... 53
Figure 28 Display: code input ......................................................................................................... 54
Figure 29 Display: menu entries for calibration............................................................................... 54
Figure 30 Request to start the calibration ....................................................................................... 55
Figure 31 Display: O2 single point calibration, flow rate (appears only if needed) .......................... 55
Figure 32 Display: O2 single point calibration ................................................................................. 55
Figure 33 Advice for a successfully calibration ............................................................................... 56
Figure 34 Display: Request to start calibration ............................................................................... 57
Figure 35 Display: O2 two point calibration, first point, adjustment of the flow rate (appears
only if needed) ................................................................................................................ 57
Figure 36 Display: O2 two point calibration, First point ................................................................... 58
Figure 37 Display: O2 two point calibration, second point, adjustment of the flow rate (appears
only if needed) ................................................................................................................ 58
Figure 38 Display: O2 two point calibration, Second point .............................................................. 58
Figure 39 Advice for a successfully calibration ............................................................................... 59
Figure 40 Request to moisturize the test gas ................................................................................. 60
Figure 41 Requirement to start calibration...................................................................................... 61
Figure 42 Display: Adjustment of flow rate (appears only if needed).............................................. 61
Figure 43 Display: COe single point calibration ............................................................................... 61
Figure 44 Completion notice of the single point COe calibration..................................................... 62
Figure 46 Display: Request to start the calibration ......................................................................... 64
Figure 47 Display: Adjustment of flow rate (appears only if needed).............................................. 65
Figure 48 Display: COe two point calibration - calibration with test air............................................ 65
Version 10.229
Page 115
Figure 49 Display: Adjustment of flow rate (appears only if needed)............................................. 65
Figure 50 Display: COe two point calibration - calibration test air .................................................. 66
Figure 51 Completion notice of the two point calibration ................................................................ 66
Figure 53 Display: system test with test gas................................................................................... 68
Figure 54 Request to moisturize the test air ................................................................................... 69
Figure 55 Display: system test with test air..................................................................................... 69
Figure 56 Display: error messages ................................................................................................. 72
Figure 57 Back of display unit......................................................................................................... 75
Figure 58 Adjustment display contrast............................................................................................ 76
Figure 59 Switching between 230 V and 115 V operation .............................................................. 87
Figure 60 Position of valve (pump version)..................................................................................... 89
Figure 61 Position of valves (instrument air version) ...................................................................... 89
Figure 62 Gas Moisturisation Filter ................................................................................................. 90
Figure 63 Dismantling of filter ......................................................................................................... 91
Figure 64 Measuring cell holder tube in cut .................................................................................... 92
Figure 65 Mounting measure cell holder tube................................................................................. 92
Figure 66 Construction of the measure cell holder tube ................................................................. 94
Figure 67 Exchange of the COe sensor........................................................................................... 96
Figure 68 Retainer ring ................................................................................................................... 97
Figure 69 Error O2 and COe Measurement.................................................................................. 101
Figure 70 Field housing IP66 ........................................................................................................ 103
Figure 71 19 inch housing............................................................................................................. 103
Figure 72 GFK housing (option).................................................................................................... 104
Figure 73 EExd housing (option) consisting of 2 EExd housings for the electronic and 1 field
housing for the gas control unit..................................................................................... 105
Figure 74 Dimension sheet probe KES 600x................................................................................ 106
Figure 75 Dimension sheet probe KES6001 with cooling protection tube .................................... 106
Figure 76 Dimension sheet protection tube flanges for KES600X ................................................ 107
Figure 77 Adapter plate ADP2000 for flange type A..................................................................... 107
Figure 78 Probe components with working cycles........................................................................ 108
Figure 79 Probe inner parts assembly .......................................................................................... 108
Figure 80 Gas plan pneumatic unit ............................................................................................... 109
Figure 81 Gas plan test gas and reference gas unit ..................................................................... 110
Figure 82 Mounting plate 1 (design with pumps) ......................................................................... 111
Figure 83 Mounting plate 1 (design with instrument air) .............................................................. 112
Figure 84 Mounting plate 2 ........................................................................................................... 113
Figure 85 Display and microprocessor unit.................................................................................. 113
Version 10.229
Page 116
COMTEC Distribution & Service:
ENOTEC GmbH
Höher Birken 6
D-51709 Marienheide
Germany
Phone: +49 (0) 2264 / 4578-0
Fax: +49 (0) 2264/ 4578-31
Email: [email protected]
ENOTEC UK Limited
PO BOX 9026
DUMFRIES
DG1 3YH
United Kingdom
ENOTEC Inc.
6206 Sandy Ridge Circle NW
North Canton
Ohio 44720
USA
Phone: +44 8703500102
Fax: +44 8703500302
Email:[email protected]
Phone: +1 330 498 0202
Fax: +1 330 497 9802
Email:[email protected]
ENOTEC ASIA PTE. Ltd.
Pasir Panjang Distripark
Block 1
#02-11 Pasir Panjang Road
Singapore 118480
Your Distribution:
Tel :
+65 6100 2188
Fax :
+65 6399 2780
Email : [email protected]
Please contact:
ENOTEC GmbH or your ENOTEC
Regional Office
Version 10.229
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comtec 6000

Transcription

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